What's New in Food Technology Jul/Aug 2013 by Westwick-Farrow Media

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contents

food for thought

bakery, cereals and grain

July/August 2013

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processing

21 Cutting CCA’s carbon 10 Streamlining breakfast footprint cereal processing 26 Reducing energy and water usage in 15 MicroZap, macro effect continuous-process 18 Minimising unplanned cooking and cooling downtime, acoustically 30 Humidity reduces carcass weight loss 36 Creating high-value products from leftovers 44 From concept to reality: the Little Creatures story

48 53 66 testing

packaging

55 Chilling out on the shelf 65 Smart bottle ignites beer packaging world

bulk handling, storage & logistics 68 Weighing up quality and quantity 76 Meat wholesaler dehumidifies to cut ice and cost

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Jul/Aug 2013

Okay, I admit it - I don’t get it. I just don’t understand this emissions trading stuff. I actually thought the carbon tax was a good idea - it made sense to me. Highly polluting companies have to pay - that seems fair. Lower income end consumers receive compensation so they don’t end up out of pocket - that also seems fair. Assistance is available to help companies lower their carbon tax liability - great idea. If companies improve their efficiency and reduce their emissions they reduce their carbon tax liability - a win, win, win. Bindaree Beef is a classic example of a gross emitter which invested its own and the government’s money to improve its efficiency and lower its emissions. When Tony Windsor supported the introduction of the carbon tax scheme, Bindaree Beef was the only company in his New England electorate that was to be affected. Now, with the help of a government grant of nearly $23 million and at an overall cost of $46 million, the family-owned company is slashing its carbon emissions and operating costs and eliminating its carbon tax liability. In 2011-12, Bindaree’s total taxable carbon emissions were listed at 28,345 tonnes - which is above the government’s 25,000-tonne direct carbon tax threshold. The company could have made some cheap changes and just snuck in under the threshold, but instead the owners, the McDonald family, spent two years and up to $2 million researching and developing a much more significant approach that will reduce the company’s carbon emissions by a staggering 95.58%. An on-site pilot plant has established that the proposed system is viable and now Bindaree is installing a more energy-efficient rendering plant and directing all of its organic waste through a digester. The company will cut its electricity consumption by up to 50% by using the biogas from the digester to generate clean energy. This will allow Bindaree to replace a coal-fired boiler and reduce its coal consumption by 7200 tonnes each year. The abattoir currently processes around 1100 head per day and these changes will reduce the utility cost of processing each head of cattle by more than one third. At the same time, carbon emissions will be cut by 95.58% and the company will not be liable to pay any carbon tax. The digester will also produce high-quality recycled water for irrigation and organic fertiliser for sale. It is anticipated that the project will deliver annual operating cost savings of $2.44 million to the business and projected income from fertiliser sales of $1.8 million. As an added benefit, the fertiliser sales will create 10 new jobs. This is a really great story - a success story that has resulted in lower emissions, improved efficiency, extra jobs … so what is with this emissions trading stuff? It may prove profitable for investment traders but as far as the real world goes, I repeat - I just don’t get it.

Jul/Aug 2013

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I just don’t get it

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

Fo d

Foods labelled sugar free, fat free or whole wheat might not be as healthy as they seem, according to a registered dietician at The Methodist Hospital in Houston. According to Kari Kooi, recent studies show people tend to let their guard down and eat twice as much - or even more - of these foods because they are marketed as healthy food products. “Consumer food marketing can be extremely persuasive and the right buzzword on a package can lure a shopper into making an unwise purchase,” said Kooi. “We need to educate consumers on how to read nutrition labels so they can avoid falling prey to the ‘health halo’ effect.” Kooi has outlined the top five ‘health’ foods to avoid: • Vegetable chips: often marketed as a healthy substitute for potato chips, vegetable chips have a similar nutritional profile to regular potato chips. You’re better off eating vegetables, Kooi says. Vegetable chips contain vegetable powders and, once a vegetable is processed into a chip, many of the nutrients are lost. Calories also increase because fat is added.

FOR

thought

• Nutrient-enhanced waters: these are little more than coloured sugar water loaded with empty calories, Kooi says. A better option is to simply take a daily multivitamin with a glass of water. • Muffins: while a sprinkling of oats and a few blueberries might make muffins appear healthier than doughnuts, muffins are nothing more than cupcakes without icing, Kooi says. Made with refined white flour, plenty of oil and refined sugar, mega-sized coffee shop muffins can easily top 600 calories. • Pre-made smoothies: Kooi says these are syrupy concoctions loaded with calories and sugar. Homemade smoothies with yoghurt, milk and fresh or frozen fruits are a much healthier option, Kooi said. • Frozen yoghurt: while this treat can be made with low-fat or fat-free dairy ingredients, it’s far from being calorie free. Many of the live and active cultures added to frozen yoghurt are not able to survive freezing, so don’t count on any probiotic benefits, Kooi warns. They also often contain a hefty amount of added sugar.

SA to develop free-range egg standard

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image©iStockphoto.com

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Five common foods with the ‘health halo’ effect

Jul/Aug 2013

South Australia is proposing a new industry code to define the stocking density of hens for producing ‘free-range’ labelled eggs. John Rau, the South Australian Minister for Business Services and Consumers, said the government is proposing a voluntary industry code that will allow those who adhere to it to display a ‘South Australian Laid, Free Range Egg Code Compliant’ label. Animal welfare group Humane Choice welcomed Rau’s actions. “I believe this industry code will actually bring clarity to the free-range confusion and those producers that are meeting consumer expectation will stand out from the crowd,” said Lee McCosker, the Chief Operating Officer of Humane Choice. “Consumers will then be able to decide if they are willing to pay a little more for what they want or accept eggs grown under a more intensive operation. The choice will be made a lot clearer.” Currently, there is no federal legislative or regulatory definition to control the free-range egg market. Queensland is the only state to have passed a law setting a stocking density of 1500 birds per hectare in the outdoor area of a free-range system for eggs labelled as free-range. According to Rau, “such an individual state approach exposes a state’s industry, as an individual state cannot restrict producers from other states (who are not required to adhere to the same rules) from selling eggs in their state”. The South Australian Government has called for submissions on the proposed standard. Submissions can be emailed to AGDCBSReforms@agd.sa.gov.au. The closing date for submissions in Friday 19 July 2013.

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Calls for gingko ban following cancer study results A report from the US National Toxicology Program (NTP) has found “clear evidence” that Gingko biloba caused liver cancer in mice, and “some evidence” that gingko caused thyroid cancer in rats. In the high-dose groups of mice, the results were significant: gingko caused hepatocellular carcinomas in 94% of male mice (compared to 44% of controls) and 96% of female mice (compared to 34% of controls). Researchers from the NTP reportedly told the New York Times that, in some instances, the number of cancers exceeded the numbers ever seen in mice in the lab. While the supplement industry argued that the NTP used an extract of gingko not used in supplements sold in the US, the NTP says the composition of the extract it tested falls within the range of what is sold. In light of these findings, the Center for Science in the Public Interest (CSPI) is urging the Food and Drug Administration (FDA) to prohibit the use of gingko in foods and dietary supplements. The CSPI has recommended the FDA give companies 30 days to recall products containing gingko, and then “seize whatever products remain on shelves to protect consumers”. “It used to be the case that the only problems associated with gingko were the unfounded and deceptive claims by manufacturers that it helped memory,” said CSPI executive director Michael F Jacobson. “Now we know these make-believe benefits are far outweighed by a real risk of cancer.”

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Jul/Aug 2013

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The latest generation of tubular drag cable conveyors provides critical process and product quality benefits for breakfast cereal processors. Minimised product damage, improved product safety, reduced clean-up and faster changeovers are key advantages over traditional conveying systems.

hatever the food item - from frozen pizzas to fresh burritos, baked goods to candy, health bars to processed cheese - the need for transporting food products through each process stage in the food production line with high throughput, minimised product damage and a high level of product safety is of critical importance. Regardless of the quality of processing and packaging machinery, if the material handling system being used is inefficient then the finished products and throughput volume will be compromised. Yet, too many food manufacturers are plagued with conveying equipment that is not suited to the needs of their particular processing and packaging applications. One industry that is heavily reliant on conveying systems is breakfast cereal manufacturing, where a variety of different conveyor applications have traditionally been used to transport cereal products between sequences of processes.

Critical conveying challenges in breakfast cereal production Breakfast cereal processing plants often face several critical conveying challenges. One of the most important is ensuring that the product emerges undamaged before its final packaging. However, keeping the clusters, loops, puffs and flakes whole can be a significant challenge, given that at the end of most machine processing steps the product is dropped down onto a conveyor system before being taken to the next process. The ideal outcome is to transfer the product through the processes and into the packaging as gently as possible to avoid breakage. Breakfast cereal plant managers and plant engineers know that the way their product is conveyed during the manufacturing process plays an important role in ensuring minimum waste. Product contamination is another issue. In every step of the process, precluding any foreign matter from entering the 10

Jul/Aug 2013

Jim McMahon

process stream is a critical objective. Traditionally used in cereal processing, bucket elevators and belt conveyors not only permit the entry of cereal dust and foreign particles into the food stream, but their exposed format means they can spread dust. This opens the door to contamination and the spread of allergens. This problem is particularly evident during product transfer between the coating, drying and packaging operations, where there is exposure to a combination of different ingredients. Line changeovers have become a focal issue in breakfast cereal plants in terms of cleanliness and speed. Companies increasingly aim to run different product lines within a shift or day. Despite these changeovers, processing plants are expected to maintain stringent levels of sanitary operation. Cleaning conveying systems can be a time-consuming challenge. Every minute spent disassembling a conveyor system for cleaning consumes valuable production time. Yet, if not cleaned properly, product may need to be discarded in-process because of contamination. Worse, consumers could be negatively impacted, resulting in potential injury, costly recalls and impacted brand reputation. To resolve these issues, cereal processors are charged with administering changeovers as quickly as possible while maintaining 100% system cleanliness.

Traditional systems for conveying breakfast cereal For decades, open conveyors have been the predominant systems used to transport breakfast cereal products through the manufacturing process. But because of the limitations of these open conveying systems, cereal processors have gradually moved to other conveyor types, particularly closed-system tube conveyors. Like open conveyors, they each have design strengths and weaknesses. Below is an assessment of the major types of systems used in breakfast cereal processing:

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BAKERY, CEREALS & GRAIN

Streamlining breakfast cereal processing

Flat-belt conveyors Although this type of conveyor handles cereal products gently, the product is exposed to ambient contamination unless covered. The cover, however, collects cereal residue and must be removed and cleaned between runs to reduce crosscontamination risk. When introduced onto the conveyor, the cereal product is dropped from the processing machine, which produces dust and can cause product damage.

Pneumatic conveyors These systems use air to move cereal from extruder to packaging by generating air pressure levels that are either above or below the atmospheric pressure. Pneumatic conveyors enable flexibility, allowing products to reach multiple destinations with one system. They can also convey cereal at high rates without product breakage and with minimal dust dissemination. Pneumatic conveying is the most expensive method for moving cereals due to its high power consumption. Auger conveyors Known as flexible screw conveyors, auger conveyors can transport cereals vertically, horizontally and at any angle. They consist of a stainless steel flexible screw enclosed in a rigid steel tube or flexible plastic tube driven by a motor. These conveyors have a throughput of up to 45,000 kg/h. However, they are limited in how much product they can transport before effecting product breakage. Also, internal cleanliness can be an issue, with the unit having to be dissembled regularly for cleaning. Aeromechanical conveyors These completely enclosed, high-capacity mechanical conveyors can move breakfast cereal vertically, horizontally and at varying angles. Within a stainless steel tube, a wire rope with evenly spaced discs travels at high speeds, running in sprockets at each end of the conveyor. The high-speed action generates an internal air stream travelling at the same high velocity as the discs. As the cereal is fed in, the air stream aerates, or fluidises, it and carries it to the packaging outlet, where it is discharged by centrifugal force. The system can move up to 100,000 kg/h of cereal. One drawback is that the flow of product can easily become inhibited, causing the conveyor to run without transporting cereal at expected throughput volumes. Downtime is also a factor because the tension on the wire rope needs to be adjusted at regular intervals. Tubular drag chain conveyors This conveyor gently moves breakfast cereal through a sealed tube with a drag chain pulled through it on a loop. Solid circular discs (flights) are attached to the chain, which push

the cereal through the tube. This system can move up to 36,000 kg/h of cereal and can run under either pressure or vacuum modes. The chain tends to accumulate cereal debris build-up, which poses a cross-contamination risk, so it needs to be regularly removed. Also, the chain-drive components need to be regularly adjusted to keep the system in registration, which increases downtime. Such traditional conveying systems have struggled to keep pace with the increasingly challenging requirements that breakfast cereal processors face - not to mention corporationsâ&#x20AC;&#x2122; continued push for more cost-efficiency and higher throughput on their processing lines, which is also driving the need for system upgrades in breakfast cereal processing worldwide. Conveying systems installed 10-15 years ago incorporating the above systems may have been adequate at that time. But now better technology in conveying system design, controls and automation has brought in a new generation of conveyors. Safer, cleaner processes that reduce waste and deliver cost, labour and energy savings are increasingly being factored into equipment selection. Such conveying systems have critical impact on cereal processorsâ&#x20AC;&#x2122; operational costs and plant ROI.

Tubular drag cable conveyors - a more efficient lean-process conveying solution The tubular drag cable conveyor, developed by Cablevey Conveyors, is fast becoming the conveying system of choice for breakfast cereal production. The system gently moves friable cereals through an enclosed tube without the use of air. This generation of tubular drag cable conveyors can transport up to 22,000 kg of breakfast cereal product per hour, at low speed and with virtually no product degradation. Similar to tubular drag chain conveyors, tubular drag cable conveyors gently move product through a sealed tube, but instead using a patented, coated, flexible stainless steel drag cable. Solid circular discs (flights) are attached to the cable, which push the cereal through the tube. The coated cable ensures that no debris accumulates within the stands of the cable, as the cable is totally sealed. Designed for quick cleaning, quick line changeovers and maximised system uptime, the tubular drag cable conveyor system employs cleaning mechanisms that reduce debris buildup. The completely enclosed system keeps contamination out, but can be cleaned-in-place at multiple points. For example,

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Bucket elevators Bucket elevators use a continuous line of buckets, either attached to each other on a rubber belt or attached by pins to two endless chains running over tracks and driven by sprockets. Centrifugal force throws the cereal out of the buckets into a discharge spout as the buckets pass. This type of conveyor can transport fragile materials with minimal product damage. However, the system can be very dusty, as dust is generated when cereal is loaded into the buckets and while the product is being conveyed. The excessive dust produced can also open the door for dust explosions.

Tubular drag conveyors are ideal systems for moving

BAKERY, CEREALS & GRAIN

product between the extrusion, forming, tempering, flaking and toasting processes, and on through to the coating process.

an air knife at the product discharge locations in the system automatically releases food particles from the discs and cable. Also, urethane wiper discs attached to the cable eliminate any residual debris from the conveyor system while in progress. The system is equipped with a cable self-tensioning device. The tubular drag cable conveyor operates on low horsepower, using energy-efficient variable-speed motors of less than 5 HP each, consuming minimal power compared to other conveyor systems. The system’s production flow can be adjusted to variable speeds.

Versatile integration throughout all breakfast cereal production processes This tubular drag conveyor system has the unique flexibility to integrate with any processes in cereal production. The conveyor can be integrated into all processing areas, such as: receipt, weighing and mixing of raw materials; preconditioning and extrusion; drying, tempering, flaking and toasting; and coating, drying, cooling and packaging. Tubular drag conveyors are ideal systems for moving product between the extrusion, forming, tempering, flaking and toasting processes, and on through to the coating process. The system is critically applicable where product can become particularly damaged, where contamination would be

prevalent or where dust accumulation can be excessive, such as end-of-line processing from coating through packaging. These areas would include the coating process to the dryer, from the dryer to the weigh-filler, from the dryer to the holding silo, then from these processes to packaging. “In the cereal production marketplace, quality and product safety are very high-profile issues,” said Gary Schliebs, Process Engineer with Plus One-Percent Engineered Solutions, engineering implementers to the food industry. “More and more breakfast cereal processors are looking at using this tubular drag conveyor technology right from the initial mixing phase to the blender, then into an extruder. Some major manufacturers are also implementing the system even further downstream, from their extruder to their coating system and through to their packing line. Here is a system that they can go with all the way - an end-to-end package solution that fits perfectly from a cleaning perspective and from an enclosed system point of view, and the risk is absolutely minimal from a contamination or hygiene issue.” The tubular drag conveyor truly embodies a new generation of conveying solution for breakfast cereal processors. plus one percent Contact info and more items like this at wf.net.au/U626

Rotary filling and sealing machine The RP-8TZ Rotary Filling and Sealing machine is suitable for packaging loose produce such as cereals, muesli, coffee and dried fruits into pre-made bags and pouches, both with and without a zip. The machine consists of eight stations and a user-friendly interface. It is modular in design, with operating, adjusting and fault indication shown via touch screen. It has been hygienically constructed to allow for easy cleaning, with high quality and long-life machine parts. Integration of various fillers such as augers, multihead weighing machines, volumetric fillers, liquid fillers, paste fillers and other special fillers is possible with the machine. Perfect Packaging Contact info and more items like this at wf.net.au/U289 12

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Colour coding keeps company clean

up, while quick-drying plastics have been selected for their resistance to bacterial growth. The Ferguson Plarre Bakehouses facility has been colour zoned by Vikan. Each production zone uses a different colour, and currently six colours of tools are in use. Tools are stored within the zoned areas on brackets of the same colour, ensuring staff always have the right tools to hand and reducing the risk of microorganisms being transferred from one part of the facility to another. “We run lean management systems at our bakery, which Vikan’s products fit in with perfectly,” said Raymond Holder, Food Safety Manager at the Ferguson Plarre Bakehouses production facility. “With the Vikan colour-coded products, we are able to control tool use in each area and, in this way, reduce the risk of cross-contamination. “Vikan’s system has helped us progress even further towards our hygienic cleaning goal, which is of extreme importance to us as we put great effort into maintaining the highest standards of product quality.”

BAKERY, CEREALS & GRAIN

Established in 1901, Ferguson Plarre Bakehouses is a familyowned and operated business. The Victorian company produces desserts, pasties, cakes and pies in one central baking facility daily and dispatches products to about 50 franchised stores across the country. Working with a range of ingredients that includes eggs and raw meats means the avoidance of crosscontamination and bacterial control is a key business driver. The company says one of its most challenging tasks is to continuously keep the bakery clean and organised so it is always prepared for health inspections. To achieve its stated aim of becoming “one of the most hygienically clean and professional working bakeries in the world,” Ferguson Plarre Bakehouses has implemented Vikan’s colourcoded cleaning hygiene system in its production facility. The system fully supports HACCP requirements, making it easier to ensure product safety and document the company’s internal hygiene control. Vikan’s tool range is made from FDA-approved raw materials that are suitable for use in the food industry. The smooth, fully moulded components make them easy to clean and prevent bacteria build-

WR&D Wells Pty Ltd Contact info and more items like this at wf.net.au/U453

DESIGN

Lightweight hinged bakery boxes

PTY LTD

LINPAC Packaging has developed a range of hinged bakery

Sp Specialising in Stainless Steel Conveying Systems and Co Manufacturing Stainless Steel M an and Aluminium Products

boxes for morning goods which are lighter than previous designs. The company says the range will ease the eco-tax burden on retailers and manufacturers across Europe. The LeanBake range, which comprises both hermetic (airtight) and semi-hermetic boxes, offers good product protection and

Stainless steel conveying systems and equipment for the food industry:

is suitable for manufacturers looking for a packaging solution with a low carbon footprint. Suitable for croissants, Danish pastries, tarts and muffins, the LeanBake range is available in a variety of sizes that can

• Boning line conveyors

be easily displayed on-shelf. According to the company, the

• Product carousel conveyors

containers’ premium appearance enhances product value

• Incline, decline and bend conveyors

through better presentation while keeping products fresh.

• Box and package handling conveyors

The hermetic boxes have been developed for sponge-based

• Non-powered roller conveyors

products, keeping moisture within the pack so products stay

• Stainless steel bin tippers

fresher for longer. The standard boxes are slightly vented on

• Sanitation wash stations

three sides to allow air to circulate and ensure that pastry products such as croissants and Danish pastries retain their

“Our commitment to continuous improvement and technological innovation is driven by our team of talented and experienced staff”

crispness. The boxes stack easily and uniformly to assist in the production process. The PET construction ensures good visibility, which is required to encourage consumers to purchase. The design of the corner radius is such that it assists with

16 Glennie Street West, North Gosford NSW 2250 Australia Phone: 02 4323 2755 Fax: 02 4323 664 Email: enquiries@proali.com.au

opening, improving ease of use for the consumer. The external dimensions of the boxes have been adapted so they fit on the standard European pallet.

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Jul/Aug 2013

Clean-label improvers The Nutrilac Natural Improvers range from Arla Ingredients offers targeted benefits for producers of bread, cakes, biscuits, cookies and bakery fillings. All are made from natural and functional proteins derived exclusively from milk and can be listed on-pack simply as â&#x20AC;&#x2DC;milk proteinâ&#x20AC;&#x2122;. The ingredients are designed to provide industrial bakers with smoother and more efficient processes, which make handling of dough, batters and fillings easier. They also provide good

BAKERY, CEREALS & GRAIN

stability, locking in the air whipped into batters and the water kneaded into dough, resulting in good freshness, texture and resilience throughout a productâ&#x20AC;&#x2122;s shelf life. According to the company, the improvers can also extend shelf life as they help a product maintain sensory properties for longer, cutting down on waste and increasing profit margins. The ingredients can also improve the nutritional profile of a baked product by reducing fat content. Nutrilac CH-4650 ensures a more stable batter with better mixing tolerance, enhances cake surfaces by reducing stickiness, improves colour and appearance in cakes and optimises creaminess by imitating fat in custard cream and other types of filling. A high-gelling protein designed to create structure and strength in baked goods, Nutrilac IM-8027 provides optimum viscosity in most batter systems, greater water retention and good emulsification. Nutrilac IM-5566 provides softness in bread without reducing crumb resilience or elasticity, offers increased strength in cakes for better slicing quality and stabilises aerated batter systems for higher volume and stability. Nutrilac IM-7042 offers improved mixing tolerance, produces a more stable batter and provides good emulsification properties in a whole range of wheat-based baked goods, including bread. Arla Foods Ingredients www.arla.com

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MicroZap macro effect Microwave technology advances global food safety and security What if zapping food in the microwave was the key to food safety? While it might sound too simple to work effectively, a group of scientists at Texas Tech University are developing a new food purifying technology using electromagnetic radiation - better known as microwaves.

hile there’s no denying that microwaves can make life easier for the consumer, they could have a greater impact than we realise. Texas Tech University scientists have formed MicroZap, a technology company that will commercialise the scientists’ microwave and food safety research. MicroZap technology has been used to extend the shelf life of fresh bread to 60 days - a result that could have positive implications for global food waste and food safety. “We use electromagnetic radiation (microwaves) which interact with the molecules in the product or sample and will affect pathogens, bacteria and mould in the different products we treat,” said Andreas Neuber, Associate Director of the Center for Pulsed Power and Power Electronics at Texas Tech. “The unit has levels on the outside similar to those produced when people use their microwave oven in the home. MicroZap technology is very similar, except that we work with much higher fields on the inside. We have been extremely successful treating mould in bread products and have extended the shelf life of bread to 60 days.”

Slow burner Overnight successes rarely happen overnight. “It’s been almost nine years since we’ve started this process,” said Mindy Brashears, Texas Tech Professor of food microbiology and food safety and director of the International Center for Food Industry Excellence (ICFIE). “By the time you start having success and you start hearing about it, and it starts to hit the media, there already has been a lot of background that has gone into that technology.

“We’ve spent a lot of time doing research, writing manuscripts, publishing, working very hard building the company to get to this point today where we’re close to commercialisation.” Texas Tech was invited to Italy to learn more about the MicroZap technology, which was originally invented by a group of scientists in Italy. The Texas Tech scientists discovered many applications and found many ways they could modify the technology to take it to the next level, Brashears said. “As we scientists started going through this process, the university realised that this could actually move ahead to a company. They wanted us to go out and really form on which is something that most scientists don’t really enjoy doing. But we did, and we formed an LLC, and the university helped us find investors. “Through those investors we were able to come up with a business plan; we have a CEO, a board of directors, stocks and shares - a really legitimate company for this process. The technology and all the intellectual property rights were transferred from the Italian group to Texas Tech, and the patents were filed either through the university of through the company.” MicroZap has expanded the technology to other food products, including peanuts, fresh produce and pet food, as well as non-food products such as mould on wine corks. “We’ve also broadened our ability to treat other dangerous pathogens such as Listeria and E. coli, as well as the capability of killing the deadly superbug MRSA in homes and healthcare facilities,” said Don Stull, CEO of MicroZap.

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We have been extremely successful treating mould in bread products and have extended the shelf life of bread to 60 days.

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Zapping the world The technology could have a huge impact on global food security, according to Brashears. “The technology is very good at killing moulds,” Brashears said. “A lot of our product is thrown away - in the US, 40% of all food is thrown away. When you relate that to a developing country, and we’re trying to ship grains overseas to these countries that need it, a lot of the loss comes from moulding. If we can treat the grains before they’re shipped, then ultimately there would be more product to feed those communities.” In many areas of the world, waterborne diseases cause a considerable burden. Brashears says water is the most easily treated product in the microwave, as microwaves excite the water molecules more easily than other substances. “One of our goals at MZ is to develop a unit that is fully solar powered and put this in a developing country with central location sites that could be run by citizens of that country as a source of income,” Brashears said. “People could bring their grain - and also water - there for treatment. People could put it through the process and come out with water that’s safe and drinkable and won’t cause illness.”

Closer to home In addition to treating food, MicroZap has also modified devices for treating towels and linens for viruses such as MRSA, which could be commercialised for businesses like hospitals and gyms. The company also aims to develop a household unit or a small unit that could be used in restaurants or at the grocery store. “We’ve also looked at pet food, which is becoming a huge source of pathogens in the US. And it not only makes the animals sick potentially, but it can also cause the animal to make the human sick. Or, there are children who will try the pet food and it will make them sick directly. Animal foods have the same standards as human foods in regards to pathogens. “We’ve done everything from spices to beef jerky, nutrition bars - all sorts of items that have been successfully treated to kill pathogens or kill moulds or other spoilage bacteria to increase the shelf life.” The team has also trialled rockmelons and other fruits and vegetables. “We get a good surface sterilisation on the outside with the microwave process. We have to be very careful because these are very delicate, and different fruits and vegetables have different reactions; a cantaloupe has very thick skin so you can treat it longer, but with something like a tomato, if you treat it too long, you run the risk of sensory changes.” According to Brashears, about 150 companies are interested in the microwave technology - and that is just for food-based products. With continued industry interest and positive research results, MicroZap could have a macro effect on the future of food.

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Using NIRS to determine shelf life

In Vitro Technologies Pty Ltd Contact info and more items like this at wf.net.au/U490

The micro-doughLAB from Perten Instruments is a small-scale (4 g) dough mixer and analysis system used to determine the quality and processing characteristics of flour and dough. A mixing stage develops the dough to measure absorption (amount of water required for a dough to reach a defined consistency) and dough mixing profile (development time, stability, softening and other quality parameters), and two elasticity stages determine elasticity of dough at optimum and overmixed consistencies. The system can be used to predict the processing characteristics and breadmaking potential of wheat flour for straight dough bulk fermentation, sponge and dough, rapid processing and Chorleywood Bread Process or other mechanical dough development, different recipes and different final bread qualities and characteristics. Integrated temperature control, variable temperature and energy input rates and high torque make the system versatile enough to test wheat meal, flour, semolina, rye, durum, triticale, other grains and flours, additives and full formulations for milling, baking, pasta and Asian products. The small sample size makes it suitable for researchers, wheat breeders, grain handlers, millers and bakers with limited sample and/or valuable samples. It can be used to screen breeder lines, develop rapid and small-scale methods and to establish the performance, specification, water and mixing requirements of flour. It enables users to save time and money by accurately and quickly identifying the best flour for their application. Perten Instruments Contact info and more items like this at wf.net.au/U059

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Jul/Aug 2013

BAKERY, CEREALS & GRAIN

Near infrared spectroscopy (NIRS) is a solution that enables the fast screening of bakery products. Food technologists use water activity to formulate products that are shelf stable. Below certain values, mould growth is inhibited, resulting in a longer shelf life. Ethanol, an approved food additive, is used as a flavour carrier and to enhance the shelf life of bakery products. As part of a feasibility study, Barilla tested NIRS from BUCHI as a screening technology to quickly measure total moisture, water activity and ethanol content. These parameters were selected as indicators of shelf stability for bakery products such as industrial breads, cakes, mini cakes and snacks. Positive results from the feasibility study led Barilla Bakery plants in both Italy and France to develop dedicated NIRS calibrations. This robust method is now used as an internal screening method for routine daily analysis. Another molecule which occurs most commonly as cellulose in plants, the bran of cereal grains or the cell wall of baker’s yeast is β-Glucan. Barilla Central Labs evaluated the possibility of using NIRS from BUCHI as a fast technology to quantify β-Glucan content. The final results obtained indicated that NIRS can be used successfully to quantify the content of β-Glucans in the premixes used for industrial bakery productions, as long as the moisture content variation is taken into account. Some Italian bakery plants of the Barilla Group have started to use NIRS as a routine screening tool for β-Glucan content. The BUCHI NIR system can also simultaneously measure protein, fat, ash, starch and fibre.

Dough mixer and analysis system

Minimising unplanned downtime, acoustically

BAKERY, CEREALS & GRAIN

Established in 1886, Whitworth Bros Ltd (WBL) supplies flour to the UK’s largest food manufacturers. Operating from production sites in Wellingborough, Northamptonshire and Peterborough, the company supplies flour in bulk loads, as well as bag deliveries. Looking to minimise the potential for unplanned plant downtime, WBL devised a proactive condition monitoring (CM) strategy. After considering various monitoring options such as vibration and temperature - the company discovered the MHC range of instruments from Holroyd, part of Parker Kittiwake. In 2009, WBL invested in the MHC-Memo Pro acoustic monitoring system. Part of the investment involved employing a condition monitoring technician to roll out the system across all three sites. WBL started collating data capture routes across all WBL sites and, within a short time, commenced data acquisition and analysis. This enabled WBL to take a proactive approach to monitoring and maintenance of the equipment at the company’s Wellingborough and Peterborough sites. The MHC-Memo Pro identified which machines were in need of remedial action and appropriate preventive maintenance was undertaken as required. Machines that were considered to be beyond routine servicing were withdrawn from service as part of planned maintenance activity. WBL devised a cost metric calculation to assess the savings to the company off the back of the newly implemented CM activity. The company has found this approach to be beneficial in helping justify the expenditure and resource costs allocated to this particular CM strategy as well as balancing the CM approach against that of machinery failure. Data collection takes place on a regular basis for all critical plant and machinery. This allows engineering resources to be directed to the plant in need of maintenance and this is

organised as part of planned, proactive activity, rather than as a result of a machinery breakdown. WBL uses a suite of sensors that are compatible with the MHC-Memo Pro system. The standard magnetic mounted sensor is used to collect the majority of information with the handheld, extended probe allowing data capture in hard-to-reach areas. Low-profile sensors have also been installed to allow critical plant data to be gathered. All three sensors are readily connected to the MHCMemo Pro and data can be captured almost instantaneously. “The hardware and software associated with the Memo Pro system has been very well designed and constructed,” a WBL representative said. “This functionality is mirrored with the analysis software, which allows new data to be quickly downloaded and compared against historic data for all machines detailed for each production area.” Currently, WBL carries out routine monthly data capture, supplemented with weekly collections for machines suspected of having an underlying bearing issue. The Memo Pro is also used for one-off readings to help diagnose individual machine issues as they arise. At the Wellingborough site, data is collected from 2500 separate data points, ensuring a comprehensive dataset that allows machine condition trending. Existing coverage sees the majority of the Wellingborough site plant captured using the range of standard sensor products, so WBL is now looking at monitoring challenges it faces with oscillatory equipment such as flour sifters. In collaboration with Holroyd, WBL continues to keep abreast of further advances in condition monitoring technology with a view to further minimising future plant breakdown and maximising production efficiency across all its sites. Pulse Technologies Pty Ltd Contact info and more items like this at wf.net.au/U472

Advanced batch control white paper Effective batch control ensures that products ranging from bread loaves to cookies are uniformly consistent. Manufacturers have a number of options to consider when selecting a batching solution to optimise throughput and ensure product consistency. Mettler-Toledo details the benefits of a dedicated batch controller in its Advanced Batch Control white paper. Manufacturers rely on batch control to manage different types of materials and transfer them onto weigh platforms as well as weigh each ingredient. A weighing system that accurately and reliably measures ingredients and transfers them to batches is a critical part of the manufacturing process, and it can be automated, manual or a combination of both. Manufacturers have traditionally relied on batch solutions based on a programmable logic controller (PLC) or a distributed control system (DCS). While these systems are suitable for processes in which end-products are fixed, they lack flexibility in instances of ingredient switches or recipe changes. Introducing such changes requires new code writing and additional start-up time, and this can tax the limited resources of small to mid-size operations. Manufacturers can simplify batching by choosing a dedicated controller that combines both weighing and transferring functions within a single unit. A stand-alone batch solution with built-in industry control standards allows for modular production across multiple locations and plants. It also simplifies user interfaces and minimises operator training requirements. To download a copy of the white paper, visit: www.mt.com/ind-wp-advanced-batch-control. Mettler Toledo Contact info and more items like this at wf.net.au/U220 18

Jul/Aug 2013

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Cutting CCA’s carbon footprint

PROCESSING

Innovation in process technology and the successful application of stainless steel has led to efficiency gains and sustainable outcomes for one of the world’s most recognised brands in the food and beverage industry. In 2011, Coca-Cola Amatil (CCA) announced a $450 million investment in PET bottle self-manufacture, or ‘blow-fill’ technology, at its production facilities across Australia, New Zealand, Indonesia, Papua New Guinea and Fiji. Blow-fill technology is a manufacturing technique that allows companies to produce their own polyethylene terephthalate (PET) bottles within their own facility. It allows manufacturers to form, fill and seal bottles in one continuous process at the one location without human intervention. Blow-fill has enabled CCA to make its PET bottles using significantly less PET resin, resulting in production of the lightest-weight bottles in the global Coca-Cola system. Previously, CCA would buy blow-moulded bottles from a third-party supplier, transporting them to its own facility to sterilise and fill with product. CCA’s integration of these three steps into one operation has automated its production lines, creating economies of scale and optimising efficiencies of operation. CCA’s Kewdale facility in Perth is one packaging line that recently completed its installation of blow-fill equipment, procured from Krones AG, a German-based process manufacturer. CCA engaged ASSDA (Australian Stainless Steel Development Association) member and Accredited Fabricator TFG Pty Ltd for the installation and fabrication of the stainless steel interconnecting pipework for the facility’s new blow-fill equipment. Sydney-based ME Engineering detailed the scope of works, and coordinated the process engineering and installation of the new equipment. Over 6 km of 304 and 316L AS1528 standard-grade stainless steel tube was supplied by ASSDA sponsor Prochem Pipeline Products, ranging in size from 25 to 200 mm diameter. The TFG team purge TIG welded all stainless steel components on-site and internally passivated the stainless steel using citric acid. ME Engineering’s Project Manager Andrew Meagher said grade 316L was specified for CCA’s Kewdale facility because of the highchloride content of the water supply in Perth. continued ▶ www.foodprocessing.com.au

Jul/Aug 2013

continued ▶

PROCESSING

With spring water one of CCA’s main products, sanitation is key to avoiding microbiologically influenced corrosion. Tom Moultrie, General Manager of TFG, said that, while there are other materials that can be specified for equipment using compressed air, stainless steel provides aesthetic appeal, trusted hygiene and longer life span. The use of stainless steel has been successful in the output of this project, with CCA’s State Projects Engineer Simon Wall stating, “as a beverage manufacturer, food safety aspects of our processes and equipment are critical to ensuring the integrity and quality of our products - an area that stainless steel ensures.” Kewdale’s new blow-fill line commenced operation in June 2012. It features 14 blowing stations, 108 filling nozzles and 18 capping stations, and has the capacity to produce 26,000 bottles per hour. Wall said the investment in PET bottle self-manufacture will continue to deliver savings in raw materials - bottles are made using less PET resin and less water is used in the bottling process - and meet future consumer growth and demand. CCA’s ongoing commitment to innovation and sustainability has maximised production capabilities while minimising the use of resources. By the end of 2012, 10 blow-fill lines will have been deployed across CCA’s production facilities in Australia, bringing self-sufficiency to over 70%. Once all 26 production lines are implemented, CCA estimates a saving of 7000 tonnes of PET resin per year, a 15% reduction in bottle weight and 50,000 truck movements eliminated per year. Overall, this is reducing the carbon footprint of every 600 mL bottle by an average of 22%. Australian Stainless Steel Development Association Contact info and more items like this at wf.net.au/U627

This article is featured in issue 52 of Australian Stainless magazine, published by the Australian Stainless Steel Development Association (ASSDA). Images courtesy of TFG Pty Ltd.

Cleaning brushes Vikan has improved its EDGE range of cleaning brushes, which are designed for efficiency and functionality in food production, retail and municipal environments. The brushes’ smooth dynamic profile and multifunctional grip points aid handling and application by offering a more comfortable and efficient grip. The non-symmetrical head includes shorter and stiffer filaments to deliver a scrubbing action and longer, angled filaments to reach into corners. The externally angled and faceted design minimises flat surfaces where liquids can lie

Centrifugal coating system Uniformly coat virtually any tree nut, seed, coffee bean - and many other products - with Spray Dynamics’ Centrifugal Coating System.

and minimises dirt traps. The redesigned hang-

The system enables processors to apply dough and tamari coatings,

ing hole provides better access for cleaning

topical oil and dry seasoning and other flavourings. A variety of sizes are

and encourages users to place the tool on

available for a wide range of capacities, including three production models

a hook for storage.

and a centrifugal coater designed for laboratory and R&D applications. Spray Dynamics food coating systems are available from Heat and Control.

WR&D Wells Pty Ltd Contact info and more items like this at wf.net.au/U345 22

Jul/Aug 2013

Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U122 www.foodprocessing.com.au

Cooking oil filter Using no additives, paper or consumable filter media, the Micron-Pro cooking oil filter can filter particles down to submicron size at rates up to 125 gallons/min (approx 473 litres/min) of hot oil.

PROCESSING

The filter is suitable for plants producing meatballs, potato chips, batter-breaded foods and other products. Up to 98% of the oil can be recovered from filtered particles, depending on debris types. Fines are quickly removed from the oil and filter to minimise burning and free fatty acid formation. Fines are automatically discharged from the filter with no operator intervention. Low-pressure operation assures safety. The filter has minimal moving parts and requires no costly centrifuge, bellows or conveyorised screens. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U155

Software for dynamic packing lines The Marel GEBA SC 125 V dynamic packing line can now be used with Marelâ&#x20AC;&#x2122;s Innova software, which monitors all key positions in the line and enables users to control processing. Marel says its standard slicing and packing lines for salmon retail packing have undergone development and improvement to meet demands for better quality, yield and capacity. Using the Marel Vision scanning system, the GEBA SC 125 V slicer, for example, is capable of cutting fillets in such a way as to ensure full utilisation of the raw material. The Innova Production Monitoring software option makes the dynamic packing line smarter and more efficient. All data on fillets,

Polyurethane boots

pieces, weight, trim, etc are registered and used for creating reports,

Made in Belgium, Bekina polyurethane boots have been designed for use in general industry, the food processing industry and agriculture. The boots offer three main advantages: they are on average much lighter than PVC boots; they are thermoinsulated, remaining flexible and pleasant to wear even under extreme temperatures of -20Â°C; and they last much longer than PVC boots. The Steplite X is Bekinaâ&#x20AC;&#x2122;s answer to increasingly higher standards thanks to its three key features: an even broader instep for enhanced wearing comfort; the integration of the highest steel toecap for increased safety; and a specially designed sole profile for an even better grip. For the food processing industry, slip-resistant boots are a necessity. The Bekina Steplite X boot has a specially developed sole profile which is SRC approved, thus complying with the European Standard Mechanical slip-resistance test for footwear. They ensure workers can walk confidently, minimising the risk of slips, trips and falls. The boots also comply with the requirements of the Austral-

or for traceability by logging historical data. Production line weaknesses and strengths can be more easily identified and rectified. Various solutions are available for either fixed weight or maximum capacity, depending on the slicer. The SC 125 V slicer cuts fixed weight slices, which enables the production of fixed weight boards with high accuracy. This slicer utilises each fillet well, with minimum off-cut in head and tail. The SC 250 double lane slicer is suitable for high throughput requirements. For producing retail packs, all Marel slicers can be delivered with different packing line set-ups, as required. A dynamic packing line with synchronised feed belt speed is available for both the GEBA SC 125 V and GEBA SC 250 slicers. This packing solution is in sync with the out-feed belt of the slicer, regardless of which slicing program is being used. The dynamic packing line makes it possible to exploit the product spacing feature to the full, creating an efficient flow for retail packing. Marel New Zealand Ltd Contact info and more items like this at wf.net.au/S712

ian standard. Bekina Contact info and more items like this at wf.net.au/T986 24

Jul/Aug 2013

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PROCESSING

Reducing energy and water usage in continuous-process cooking and cooling Jim McMahon

Recent developments in heat and water recovery in continuous-process cooking have provided critical reductions in energy use. Capable of being integrated into existing rotary drum systems, these heat and water recovery systems are helping food processors realise significant cost savings.

here are many processes in food manufacturing that can be addressed to reduce operating costs while also improving sustainability. One of the most critical objectives to achieving this is reducing process energy and water consumption. Implementing energy- and water-efficient practices and technologies should be a priority in food manufacturing plants. With the continual increase in energy and water costs, optimising energy and water usage in food processing has never been a stronger issue. The continuous-process cooking and cooling method for pasta, rice and vegetables has experienced continual improvements over the past four decades in the reduction of energy consumption, through improved system designs and streamlined automation. Recent technological advances have made significant improvements in reaching critical energy- and water-efficiency levels.

products separated during the cook and chill processes, which facilitates consistent product temperatures.

Continuous-process cooking and cooling

These improvements have ensured more uniform processes and allowed cookers and coolers to handle higher throughputs. Step-blanching, for example, enables incremental temperature increases throughout the process. Gentle mechanical agitation occurs as the food products progress through the cook and chill processes. A system called Hydro-Flow applies a combination of air and water injection which physically and

Continuous-process cooking and cooling evolved from the batch method, which has been a standard in commercial cooking and cooling systems. But the batch method has its drawbacks. It is limited in maintaining precise temperature and time parameters in the cooking and cooling process. The batch process is also limited in its capability to keep these 26

Jul/Aug 2013

The first generation of continuous-process cooking/cooling systems used conveyors to move food products through the processes. Cookers and coolers are only as good as their ability to precisely control the productâ&#x20AC;&#x2122;s exposure to time and temperature parameters throughout the processes. Conveyorbased systems, however, are prone to variable production rates, which introduces variations in product temperature resulting in inconsistent product quality. These conveyor-based systems have been superseded by rotary drum continuous-process cooker/coolers, which use an auger method to move food products through a water-filled drum. Considered the industry standard for continuous-process cook and chill methods, rotary drum cooker/coolers have significantly improved the processing of pasta, rice and vegetables.

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Recapturing heat and water from cooker overflow With conventional rotary drum continuous-process cooking, the cooker is filled with ambient-temperature (approximately 18°C) water and heated to 93-96°C. In the processing of pasta, rice or vegetables, the water needs to be continually heated to compensate for the constant addition of ambient-temperature product. This requires energy. Additionally, because water is absorbed into pasta and rice during cooking, ambient-temperature make-up water needs to continually be added into the rotary drum. This adds to the heat load requirements of the cooker. This also requires energy. During a process run of pasta, rice or starchy vegetables, which may continue for 20 continuous hours, as much as 37 litres of water can be overflowed per minute to reduce the build-up of starch in the water. This means an equal amount of make-up water needs to be added. The volume of overflow and make-up water varies depending on the size of the cooker, and the type and volume of pasta, rice or vegetables being run. The overflow water is discarded as wastewater and takes the 93-96°C heat energy out along with it. For every litre that comes out of the cooker at 93-96°C as overflow, a litre of make-up tap water at approximately 18°C needs to be added. The cooker, then, has to heat that water back up to 93-96°C to continue the cook process. This, too, requires energy. In essence, not only is the overflow heat energy from the cooker being wasted, new energy now has to be added to reheat the water in the cooker to 93-96°C. The latest technology in continuous-process rotary drum cooking is now capturing and re-using the heat from the overflow water. Instead of being put down the drain, the overflow water is moved to an adjacent storage tank where it is pumped through a heat exchanger. The heat is transferred from the hot overflow water to a reservoir of ambient-temperature make-up water before it is put into the cooker.

Using this process, the make-up water can reach 51°C, considerably higher than the 18°C tap-originated make-up water used in all prior continuous-process cooker systems. This significantly reduces the heating load requirements of the cooker. A sizable difference in energy savings can be realised when heating water to 93°C from a starting point of 51°C, rather than from 18°C. Additionally, the starch-laden overflow water, which has previously been discarded, is then screened to remove the particulates and re-used as make-up water to compensate for product absorption, providing significant water savings. This system was developed by Lyco Manufacturing, a leader in the manufacture of commercial rotary drum continuousprocess cooking and cooling equipment. The new technology can be integrated into existing rotary drum continuous-process cooking lines. The upgrade can pay for itself, in energy savings alone, within a six-month timeframe.

Energy recuperation from the quench system In rotary drum cooking and cooling, the pasta, rice or vegetables come out of the cooker at 93-96°C. The product then immediately goes into a chiller where it is cooled in 1-4°C water. Initially, the water put into the chiller is tap water with a temperature of about 18°C. To bring the chiller’s water temperature down to the range needed for cooling product, energy has to be expended. As hot food products are released into the chiller, the water has to be continually cooled to take the heat out of the product and bring its temperature down to a safe range quickly, to reduce the potential of bacterial growth. This requires energy. Bacteria predominantly grow in an environment that is between 5°C and 60°C. During the cooking process, raw ingredients are brought up past 60°C as quickly as possible to the final cooking temperature, thus minimising the time that food products can be influenced by bacterial growth. The same is true on the other end of the process line, with the cooling of the product - reducing its temperature as quickly as possible to below 5°C is essential. The energy usage in this cook-and-cool process can be considerably improved with the addition of a mid-process quench step, adding a small reservoir between the cooker and the cooler. Instead of moving the product directly from the 93-96°C water temperature of the cooker and into the 1-4°C chiller water, a mid-process quench cycle with unheated ambient-

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Jul/Aug 2013

PROCESSING

buoyantly supports heavier loads, evenly distributing food products in cookers and coolers. Controls automation integrated into rotary drum continuousprocess cooker and cooler systems has largely made these improvements possible. Their programmable logic controllers (PLCs) provide precise automated control of process functions, including recipe management, and enable uniform cooking temperatures and control of water flow, achieving a totally consistent end process. These control systems minimise the time required to perform complex tasks and increase efficiency in cooking and cooling process operations. They reduce operator error and process cycle times, enable improvement in product quality and consistency, and increase production throughput and equipment ROI. The benefits from these automated process technologies have also minimised energy and water consumption. Compared to batch systems and conveyor-based cooker/coolers, the latest improvements in rotary drum continuous-process cooker/ coolers enable them to process the same volume of pasta, rice or vegetables in less time, using significantly less energy to heat the water required for the processes. Monitoring energy and water usage and managing process systems in these rotary drum cookers and coolers has played an important role supporting sustainability efforts in food processing plants.

When recapturing heat and water from cooker overflow, British thermal units (BTUs) can be reduced by 60%, kilowatt hours (kWh) can be reduced by 72%

PROCESSING

and water usage can be reduced by 25%.

temperature tap water can capture much of the product’s heat before it enters the primary chill cycle. Since the quench tap water is not preheated, it requires no energy input. Quenching reduces the temperature of the pasta, rice or vegetables down to 43-48°C, capturing 45-50% of the cooked product’s heat energy in the quench water. The quench water can then be used in the cooker for make-up water to rehydrate the product, instead of bringing in the usual 18°C tap water to reach the 93-96°C temperature cooking range. This sizably reduces the energy draw normally needed to heat the cooker water. The quench then releases the product into the chiller, which now only has to bring the product temperature down 39-44°C to reach the targeted 4°C, instead of needing to bring the temperature down 89-95°C if the quench cycle was not in place. The energy savings in the chiller from the reduced refrigeration load is significant. The quench system, called Easy-Flow, also developed by Lyco Manufacturing, maintains 100% uniform product cooling with less than 1% product damage. Rice, most varieties of pasta and select vegetables can be cooled in the quench to 43-48°C before entering the chilled water cooler. Easy-Flow uses a patented plenum technology to achieve its high-speed cooling without damaging the product. The pasta, rice or vegetables are pulled through the cooling plenum at the bottom of the tank by Venturi effect, which increases the velocity of the fluid without pump impeller contact.

The Venturi effect creates a pressure differential that pulls the water and product through at a high speed with the capability of moving 1100 litres of water and product through the plenum per minute.

Reduced energy and water consumption Compared to conventional rotary drum continuous-process cooking, recapturing heat and water from cooker overflow and quench systems can result in considerable savings. When recapturing heat and water from cooker overflow, British thermal units (BTUs) can be reduced by 60%, kilowatt hours (kWh) can be reduced by 72% and water usage can be reduced by 25%. With the quench system in place, for a continuous-process rotary tank cooker, BTUs and kilowatt hours can be reduced by 35% compared to an identical rotary tank cooker without the quench system. For the chiller under the same conditions, with the quench system in place, BTUs, tons of cooling required per hour, and kilowatt hours can be reduced by 41%. These recent technological advances in continuous-process cooking and cooling have allowed food processors to significantly reduce their energy and water consumption, while achieving improved equipment and process ROI.

Lyco Manufacturing http://www.lycomfg.com

Food-grade lubricant range FUCHS has improved the packaging of its food-grade lubricant range, Cassida. The benefits of using synthetic fluids and greases in food production machinery have been proven and documented, the company says. However, the risk of contamination from the incorrect use of application-specific lubricants can cost the food and beverage industries millions of dollars in expensive product recalls and irrevocable damage to brand reputations. Misuse of lubricants in a food or beverage manufacturing environment due to human error can be common, even with good engineering and operational practices. The use of non-food-grade lubricants in these environments causes additional unnecessary risk. The renewed packaging of the Cassida range of food-grade lubricants is designed to reduce the risk of contamination due to human error. A clean white appearance differentiates the range from other non-food-grade products. The products are also colour-coded based on applications. Cassida grease cartridges and aerosols are colour-coded to ensure there is no cross-contamination, as users can rely on matching colours for different applications instead of only numbers and words. According to FUCHS, this simplifies the process and can help eliminate human error. Fuchs Lubricants Contact info and more items like this at wf.net.au/U033 28

Jul/Aug 2013

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PROCESSING

Humidity reduces carcass weight loss Simply increasing humidity in an abattoir chill-down area can reduce carcass moisture loss from 2.5% to less than 1%. Abattoir equipment specialist GM Steel has found that using the JetSpray humidifier from JS Humidifiers reduces carcass moisture loss after slaughter. “A carcass coming from the slaughter line is wet and warm,” said Robert Ten Cate, consultant at GM Steel. “When it is introduced to the chill store, the cold dry air strips moisture from its exposed surface. The amount depends on the abattoir’s cooling technology but it can be anywhere between 1.2-2.5% of its total weight, and sometimes even more. “By maintaining a high humidity in the chill store with a JetSpray humidifier during the initial cooling, moisture loss from the carcass is inhibited and can be reduced to less than 1%.” With the average cost of beef at $4/kg, an abattoir processing 3500 carcasses a week could increase profits by more than $2 million each year by preventing 500,000 kg of beef weight evaporating into the chill store atmosphere. The JetSpray humidifier comprises rows of precisionengineered nozzles combining compressed air and water to produce a spray with a droplet size of just 7.5 microns. When mounted directly in front of the evaporator coils of the refrigeration system, the nozzle line introduces moisture to the airstream as it enters the chill store. The spray is so fine that the moisture is absorbed by the atmosphere, preventing wetting inside the room. Its hygienic design makes it suitable for use in food processing facilities. A reverse osmosis water filter removes all minerals from the supply water before it is treated with ultraviolet sterilisation to kill any remaining microorganisms. In addition, the system regularly runs purge and flush cycles to ensure water cannot stagnate in the humidifier. “Independent testing has shown that by maintaining the optimum humidity during cooling, carcass weight loss is reduced without any condensation forming inside the chill store or on the meat. Humidification of the air does not introduce moisture to the surface of the carcass or increase microbial growth,” said Ten Cate. “In fact, client tests showed that the high humidity actually reduced microbial growth rather than promote it. The higher

humidity improved the conductivity of the air and consequently increased heat transfer from the carcass. Some installations have seen a significant reduction of their chill cycle to reach the required carcass core temperature. As the carcass temperature is reduced more rapidly the microbial growth is inhibited. “Another significant benefit of a quicker cooling cycle is the reduction in energy consumption of the cooling system. Clients have seen energy bills reduced by as much as 10% when maintaining an optimum humidity in the chill-down area due to improved heat transfer efficiency from the carcasses.” Aireven Pty Ltd Contact info and more items like this at wf.net.au/U340

Alert24+ rodent traps are a pesticide-free system for remote monitoring and

High-resolution absolute encoders

control of rodent pests. The traps communicate via an on-site base station to

ELAP high-resolution absolute encoders provide actual posi-

Adams Pest Control’s secure Alert24+ servers and give an immediate warning

tion data at power on. Despite possible shaft rotations, there

of rodent presence. The servers store the data, analyse it and present it on

is no need to reset to the zero position after a power down.

Rodent monitoring system

dedicated, password-protected web pages for each installation. Messages are sent by email when activity is detected or service required. Due to the 24/7 monitoring, only active stations need checking, saving technicians time. The system’s full audit trail shows protection and activity, proving

The single- and multi-turn absolute encoders are suitable for any machine in all industrial fields. The wide choice of mechanical solutions available will fulfil most application requirements.

due diligence. The data analysis shows trends for site, zones and traps. The

Different available output signals and voltage supply

battery-powered remote units are easy to install and the batteries are claimed

range make it possible to interface ELAP absolute rotary

to last at least 12 months. A variety of remote units is available: mouse and rat

encoders to any counting system or PLC controller. The

snap traps, electronic mouse traps and monitors. Repeater units are available

encoders’ high resolution values allow them to be used in

to extend communication in larger installations.

applications requiring a high degree of accuracy.

Adams Pest Control

Motion Technologies Pty Ltd

Contact info and more items like this at wf.net.au/U310

Contact info and more items like this at wf.net.au/U316

Jul/Aug 2013

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Rheometer Rheology Solutionsâ&#x20AC;&#x2122; OnLine Rheometer (OLR) uses a multifrequency squeeze flow technique that allows the viscoelastic flow properties of a material to be measured in a short time. The measured rheological parameters can be used for process monitoring, and in a feedback

PROCESSING

system used to control the process and therefore the quality of the final product. During the OLR measurement cycle, the plates close, trapping a sample of the product and making a measurement. When the measurement is completed the top plate retracts, allowing the

HACCP and hygiene monitoring system

product flowing through the OLR to remove the

Australasian Medical & Scientific has announced the Lightning MVP ICON

measured sample before the cycle begins again.

from Biocontrol, an instrument and software platform that combines HACCP

The OLR offers fast and reliable real-time results,

and hygiene monitoring with powerful program management capabilities.

out-of-specification diagnosis and plug-and-play

MVP ICON measures ATP, which is an indicator of hygiene as it is present

installation. It is used in conjunction with software

in most food residues and microorganisms. Other key HACCP parameters

developed specifically for the OLR. The SOLR

measured include pH, temperature, conductivity and chemical concentration.

software provides flexibility: the user takes data

The MVP ICON Dashboard software provides key program analytics,

from their own product to decide what they want

updated in real time, that provide performance data critical to managing a

to continuously measure, plot and report.

quality program. The Dashboard software serves as a control panel, providing

Out-of-specification product diagnoses allow

quality assurance professionals with a quick overview of key control metrics,

plant engineers to compare the out-of-specification

assuring their HACCP plans and sanitation protocols are being followed and

material with in-specification data to diagnose why

properly executed.

there is a change in the product quality.

The dashboard provides insight into criteria for a sanitation program, such

The OLR is suitable for manufacturers of food,

as the amount of ATP swabs used in comparison to a set target, whether

cosmetics and personal care products, as well as

failed results have been adequately re-cleaned and retested, and when the

manufacturers of household chemicals.

MVP ICONâ&#x20AC;&#x2122;s next calibration is due. The software also features original print-

Rheology Solutions Pty Ltd

and-present HACCP reports to reduce the amount of time quality managers

Contact info and more items like this at wf.net.au/T074

spend analysing HACCP trending data and preparing for audits. The instrument has a lightweight design and touch screen. Test points can be organised into sample plans to efficiently conduct testing throughout a facility, and retest tracking ensures testing complies with standard operating procedures. The ability to randomise test points eliminates testing bias and adds another management tool for ensuring program compliance. Australasian Medical & Scientific Ltd Contact info and more items like this at wf.net.au/U393

Carrot-polishing machine With more than 1000 Wyma customised polishing brushes and a capacity of up to 20 t/h, the Wyma Mega-Polisher is claimed to be the largest carrot-polishing machine available. The machine has two 3.0 m long drums connected by a sliding transition, reducing footprint and allowing efficient and gentle produce flow. Polishing intensity is easy to control with an optional human interface panel which includes gate position and brush and barrel speed dials. Reduced water consumption is achieved with the addition of an integrated water recycling system to filter and recirculate water used in the machine. The system includes a Mega-Polisher frame with catchment tray, sedimentation and recirculation tanks, a flume and a rotary filter screen. Gentle handling is improved with the addition of an adjustable elevator to minimise produce drop at the out-feed end. Wyma Engineering (NZ) Ltd Contact info and more items like this at wf.net.au/U095 32

Jul/Aug 2013

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Ex i isolator range R. Stahl has extended its ISpac family of Ex i isolators with the 9147 series. The transmitter supply units

Intelligent portion loading robot

PROCESSING

Marel has produced a high-performance

enable the use of vibration sensors in hazardous areas. These sensors for condition monitoring of plants and machines allow users to detect any damage at an early stage.

intelligent portion loading (IPL) Robot that

Most vibration sensors are designed with the

can be configured to virtually any applica-

protection class Intrinsic Safety (Ex i) and require the

tion in the protein sector.

use of isolators. The 9147-type supply units support

The universal graphical interface makes

a wide range of these sensors and transmitters.

the systemâ&#x20AC;&#x2122;s controls straightforward and

An easily accessible rotary switch allows for quick

easy to use. Remote access to custom-

and easy configuration. Two versions are available:

ersâ&#x20AC;&#x2122; installations is possible, enabling fault

a one- and a two-channel version. The two-channel

diagnosis and performance monitoring.

version requires 50% less space in the switching

The robot picks and places at speeds of up to 80 picks/min and has a reach of

cabinet, which may reduce indirect installation costs. An optimal signal-to-noise ratio ensures precise signal transmission.

up to 1250 mm. The gripper technology

Like all ISpac isolators, the modules are available as single units on a DIN rail, with a

enables most products - even those that

common power supply and collective error message via the pac-Bus, or in pac-Carriers.

are delicate - to be lifted and placed, at

The pac-Carriers enable factory prewiring of plants, thus facilitating final mounting or

speed, into a tray or thermoformer in a

retrofitting at a later date and ensuring error-free installation of the isolators. The detection of problematic vibrations is important in condition monitoring of pro-

variety of configurations. Examples of products include bacon, cooked deli meats, fish and cheese. The IPL Robot vision system can rec-

cess plants with rotating parts. By diagnosing danger before a failure could happen, it helps prevent plant shutdowns. Generally, vibration detection is successful earlier than temperature, speed or acoustic measuring. Complete condition monitoring for machines

ognise product characteristics such as

also includes temperature sensors, discrete signals and 4-20 mA signals.

size or shape and can be programmed

R. STAHL Australia Pty Ltd

to place or divert products according to

Contact info and more items like this at wf.net.au/R554

requirements. Marel New Zealand Ltd Contact info and more items like this at wf.net.au/U118

Solution for treatment of production wastewater Aerofloat has launched a product to meet wastewater treatment needs in the food industry. The Aerofloat unit is compact, easy to maintain, has low power requirements and produces a high-quality effluent to meet regulatory standards. The Aerofloat unit is suitable for companies consistently exceeding their trade waste licence. It provides an affordable solution to comply with the regulatory requirements. The Aerofloat product uses a version of the wellknown water treatment process called dissolved air floatation (or DAF). Unlike traditional DAF systems which use large and expensive mechanical scrapers to remove solids, Aerofloatâ&#x20AC;&#x2122;s patent-pending technology hydraulically raises the water level in the sealed, odourless DAF tank, pushing the floated pollutants off the top of the tank via a pipeline into the waste holding tank. Pre-treatment of trade wastewater by a system based on the DAF principle is a commonly used best practice option where grease arrestors or other simple passive pre-treatment devices are inadequate. Aerofloat (Australia) Pty Ltd Contact info and more items like this at wf.net.au/T298

Jul/Aug 2013

www.foodprocessing.com.au

For around every 4 L of olive oil that’s pressed from the ripe fruit, about 17 kg of olive skins, pulp and pits are left behind. Known as pomace, these leftovers typically have low-value uses. But US Department of Agriculture (USDA) agricultural engineer Rebecca R Milczarek and her colleagues are working with olive growers and olive-oil processors in California - where most of the US’s commercial olives are grown - to find new, environmentally friendly and profitable uses for pomace. According to Milczarek, pomace from California mills is usually a wet, heavy goulash that ranges in colour from green to brown to black to purple, and has an aroma somewhat like that of olive tapenade, a flavourful spread made of finely chopped or puréed olives, anchovies, capers, garlic and olive oil. Milczarek notes that one key to creating higher-value uses for pomace is to develop techniques that millers can use to quickly and affordably dry it on-site. That would make the pomace lighter and easier and less expensive to ship to, for example, a centralised processing plant. There, specialised equipment could be used to extract additional oil or perhaps compounds for use in new foods, pharmaceuticals, cosmetics or other products. In her research, Milczarek is investigating the dynamics of drying pomace. The goal of these studies is to determine precisely how long it would take for water to diffuse from the pomace under specific conditions. In preliminary experiments,

documented in a 2011 peer-reviewed article in the Journal of Food Engineering, Milczarek’s team dried small batches of fresh pomace, using a combination of microwave and convection (hot forced air) heating. The drying rates for the four internal temperatures studied - 40, 50, 60 and 70°C - averaged about 28% lower than those reported in some studies conducted by other scientists. Lower drying rates mean more drying time is needed in order for the pomace to dry sufficiently. For commercial drying, pomace would be carried on a conveyor belt through a ‘drying tunnel’. With the drying rates in mind, the tunnel could be lengthened, or the conveyor belt could be slowed, to ensure that pomace emerging from the tunnel isn’t damp and prone to mould. Of course, drying adds to mills’ energy costs. However, the combination of microwave and convection drying that Milczarek tested is inherently more energy-efficient than drying options that are based solely on convection, she points out. Two features of Milczarek’s study - keeping the pomace’s internal temperature steady when testing each temperature regimen and taking pomace shrinkage into account - likely made the research unique among olive-pomace-drying experiments and contributed to the accuracy of her results. Milczarek is with the USDA Agricultural Research Service (ARS) Western Regional Research Center in Albany, Calif. ARS is the USDA’s chief intramural scientific research agency. © www.sxc.hu/helenej

PROCESSING

Creating high-value products from leftovers

Belt cutting machine The Kronen GS 20 belt cutting machine has been designed and built for the large industrial food processor to cut leafy products, vegetables, herbs and whole heads of lettuce and cabbage. The machine is equipped with a 250 mm wide

Adhesive-coated mat

conveyor belt with a product down-holder that

The VWR PureStep multilayered, ad-

applies pressure to the product, holding and

hesive-coated mat removes dirt and

controlling it up to the point of cutting.

dust from foot traffic and wheels prior

Individually definable programs can be stored

to entry into a critical manufacturing

and selected with simple-to-use control buttons

environment. A consistent coat weight of

and features digital in-motion cutting size adjust-

adhesive produces a higher performing mat

ment from 1 to 50 mm using a knife with three

without excessive tack issues.

blades. The knife cover has been optimised to allow gentle product handling, and a locking system combined with a new belt cover creates additional safety around the knife. The machine has a capacity of between 500 and 4000 kg/h, depending on the product. To ensure

The mats are produced in an ISO 9000 factory with QC test data and reports available for each case. Each layer is fully coated with a particle grabbing adhesive and constructed of 1.8 m/45 µm low-density polyethylene film. The mats can be applied directly to the floor or used with frames where direct adhesion is not possible.

hygiene, the GS 20 has inclined surfaces, stain-

The mats are available in 30 or 60 layers, in multiple sizes and with

less steel shaft seals and a seamless knife edge.

various frame options. Low-profile, numbered tabs indicate how many layers are remaining and ensure that only one layer is removed at a time.

Reactive Engineering Pty Ltd Contact info and more items like this at wf.net.au/U110 36

Jul/Aug 2013

VWR International Pty Ltd Contact info and more items like this at wf.net.au/U410 www.foodprocessing.com.au

HAPPY MACHINES FOR SAFER FOOD

Improving Efficiency, Performance and Quality â&#x20AC;&#x201C; Safer Food with CASSIDA food grade lubricants The CASSIDA portfolio covers a full range of food grade lubricants including speciality oils and greases. Our products fulfil the highest safety and quality standards and are registered by NSF International and certified according to ISO, Halal and Kosher standards. The performance of CASSIDA lubricants, coupled with FUCHSâ&#x20AC;&#x2DC; expert knowledge and service support, allows plant efficiency to be increased, maintenance costs to be reduced and the level of food safety to be improved. Get to know the CASSIDA food grade lubricants for Happy Machines at fuchs.com.au or Free Call Australia 1800 1800 13.

Refrigerated storage sampling kit Refrigerated storage facilities are challenging environments for any smoke-detection system, as

PROCESSING

ice tends to form on ceiling-mounted equipment and structures are generally within close proximity to the entry points. The Xtralis Refrigerated Storage Sampling Kit has been designed for existing and new refrigerated storage facilities that require an effective, easy to install and maintain ASD sampling arrangement.

Compact torque sensor series With the compact 8661 series of torque sensors, burster is extending its portfolio of products to include static and rotating torques over the range from 0.05 to 200 Nm. In addition to its accurate measurements - down to 0.05% of full scale - this development offers a high level of reliability and security. An optional, integrated USB interface also provides the travelling user with easy mobile display and documentation of the measured values. It is suitable for a range of possible applications in industrial automation and in the laboratory. The torque sensor comes into its own in fields such as precision and micro mechanics, test bed equipment for electric motors or in the automobile industry, where torque and the associated angular position and rotation speed are important process magnitudes. It is also at home in laboratory research and development projects in medical technology, in the chemical industry and in quality control. ADM Instrument Engineering Group

The kit enables the ASD pipe to be installed, inspected and maintained outside the refrigerated storage facility - such as within the roof space - which enables contractors to work in ambient conditions at all times, safely. It eliminates the need for costly access equipment hire for service and maintenance and is less prone to blockage due to icing. The kit eliminates the need for heat tracing and expensive and complex HDPE continuous pipe. The kit minimises the need for a â&#x20AC;&#x2DC;back-flushâ&#x20AC;&#x2122; system. According to the company, it provides a generally more robust ASD installation for these unique environments.

Contact info and more items like this at wf.net.au/T391

Xtralis Pty Ltd Contact info and more items like this at wf.net.au/U061

Photoelectric sensors The ifm efector O6 wetline series photoelectric sensors are diffuse reflection sensors that provide noiseimmune background suppression. Even highly reflective backgrounds, such as stainless steel, do not affect the background suppression, according to the company. The sensing range is independent of the type and colour of the object to be detected. The sensorsâ&#x20AC;&#x2122; automatic sensitivity adjustment is said to guarantee safe functioning even in the case of vapour, smoke and strongly reflective environments. The clearly defined round light spot in the operating area provides consistent light intensity in the light cone. Scattered light around the light spot that could disturb other sensors by reflections is avoided. The compact O6 is perfectly sealed and the two setting potentiometers have a double sealing. The stainless steel housing provides the high protection rating IP68/IP69 K. The transparent black housing cover provides good contrast for the integrated LEDs (operating state, switch point) so that they are clearly visible even in bright environments. The coated front lens consists of resistant, splinter-free plastic. In addition to the diffuse reflection sensor, through-beam and retroreflective sensors in the same hygienic design are also available. ifm efector pty ltd Contact info and more items like this at wf.net.au/T983

Jul/Aug 2013

www.foodprocessing.com.au

Sweet Only Wonderware MES software provides dependable consistent quality and safety without sacrificing flexibility. For more information, visit wonderware.com/MESQuality and get a free whitepaper called “Be ready for changing tastes, a new approach to plant software”.

Avantis

Eurotherm

Foxboro

IMServ

InFusion

SimSci-Esscor

Skelta

Triconex

Wonderware

Real Collaboration. Real-Time Results.

© Copyright 2012. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.

PROCESSING

Kerry Ingredients, the largest division of Ireland-based Kerry Group, produces more than 9000 food ingredients products from more than 70 manufacturing sites across five continents, including Australia. The company’s Victorian plant, near Altona, produces a range of ingredients from savoury through to sweet products for the food processor and food service markets. Recently, it installed a Grundfos NOVAlobe 50 to pump various products at up to 50,000 cP viscosity. Kerry Ingredients Project Engineer Geoff Walker says he knew what he required and believed the Grundfos NOVAlobe was the right pump to use. “We designed a clean rectangular hollow support frame for it, and this, the pump and other parts of the assembly were put together locally by Doyle Pump and Engineering in conjunction with Grundfos,” Walker said. “It sits on its frame beneath a homogeniser which is directly below an 1800-litre stainless steel tank, operates up to half a dozen times per shift and has been working faultlessly since its installation. “It pumps a variety of liquids from mayonnaise through to chocolate and strawberry sauces, and - of course - hot cleaning water. It transfers our products to portable tanks and fillers, or whatever else is required to move the product around the factory. “The pump operates at temperatures ranging from 15 to 90°C and has tremendous flexibility because of its clean-in-place attributes. “We have been very pleased with its performance. While it is not a new installation, it replaces an existing pump and is doing a great job.”

©iStockphoto.com/Eli Asenova

Pump proves its worth

Stainless steel panel PC Wincomm has introduced the WTP-8866-19, a 19″ IP65-compliant ruggedised panel PC with stainless steel construction that offers wear and corrosion resistance. The selection of material and design concept provides extended service life under harsh environments faced in industrial control environments, particularly the food processing industry. Equipment cleanliness and disinfection are critical components in food processing environments. The corrosion resistance of stainless steel is essential in harsh environments due to the constant exposure to the caustic chemicals used during cleaning and sterilisation. The WTP-8866-19 was designed for continuous long-term exposure to these environments. The PC incorporates the Intel Atom N270 1.6 GHz CPU and Wincomm’s Smart Fan thermal management design protecting the motherboard and components against overheating even when running 24/7 in challenging ambient temperatures. The company’s

Grundfos Pumps Pty Ltd

heat dissipation technology also incorporates

Contact info and more items like this at wf.net.au/T275

anticondensation properties, which ensures an internal dry environment, especially in humid or cold exposure common in food

Cheese dicer

processing and industrial facilities.

The Affinity dicer is the largest cheese dicer

The WTP-8866-19 is equipped with a 350-

Urschel Laboratories manufactures and was

bit LCD panel and has full IP65 certification.

developed from dairy industry requests for a

IP65 cables for USB, COM, LAN and DC-in

large, heavy-duty and sanitary cheese dicer.

are also available. For user convenience,

The heavy-duty dicer delivers a sanitary

all I/Os are located on the back of the

design, optimal high-capacity output and

panel PC enclosure. Apart from providing

precision cuts. The maximum in-feed is

four USB ports, Wincomm has also added

178 mm in any dimension. Cuts types include

power/reset switches to make the PC easier

dice and strip. The dicer is also suitable for

to control and use.

ham and salami products.

A waterproof antenna and antenna

The dicer’s sanitary, highly polished stainless steel surfaces deter bacterial growth, and

socket provide overall waterproofing of the

the food zone is completely separate from the drive train. Hinged swing-away panels and

system and protect the computer against

sloped surfaces simplify maintenance and washdown procedures. The machine has been

the frequent washdowns mandatory in food

designed for continuous operation, allowing uninterrupted production. Slice thicknesses

processing facilities.

of 3.2 to 19.1 mm are possible with the dicer.

Soanar Limited

Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U384

Jul/Aug 2013

www.foodprocessing.com.au

Contact info and more items like this at wf.net.au/T268

Compressed air products catalogue

Stainless steel panel PC

Exair’s Catalogue 26 is a full-colour technical

The Aplex APC-3782T rugged touch panel computer

guide offering solutions to common industrial

is housed in a fanless stainless steel chassis that pro-

cooling, drying, conveying, blowoff, cleaning,

vides an IP65 front panel and sides. An optional IP42

coating and static electricity problems.

waterproof kit protects the I/O connectors and cables,

This expanded 168-page catalogue in-

allowing the panel computer to be easily cleaned.

cludes many products that can help com-

The panel computer is supplied with a 17″ SXGA

PROCESSING

panies conserve compressed air and reduce

1280 x 1024 resolution LCD and a resistive USB touch

dangerous noise levels. Featured products include the Heavy Dutry HEPA Vac

screen, making it suitable for operator panel and HMI

and No Drip Atomizing Nozzles, as well as an expanded selection of Super Air

control applications. It features a built-in energy-efficient

Nozzles, Safety Air Guns, Chip Shields and Digital Flowmeters.

Intel Atom D525 1.8 GHz processor with 2 GB of DDR3

Detailed technical explanations, performance data, application photos and

memory. A 2.5″ hard-drive bay and internal and external

dimensional drawings are provided for each product. The electronic ver-

CompactFlash slots are provided for system and data

sion is available to download from the Compressed Air Australia website:

storage. I/O connections include two COM ports, four

www.caasafety.com.au/request-a-catalogue.

USB 2.0 ports, two gigabit ethernet ports and a 3-pin

Compressed Air Australia Pty Ltd

terminal block connector for 11-32 VDC power. VESA

Contact info and more items like this at wf.net.au/U079

75 x 75 rear-mounting holes allow the panel PC to be securely wall or arm mounted. The panel computer is compatible with Windows XP Pro, XP Embedded and Windows Embedded 7 operating

Heater catalogue

systems, allowing it to support a wide range of off-the-

The Watlow Heating Solutions catalogue

self and custom-developed industrial applications. For

highlights the company’s full product of-

applications requiring a smaller screen resolution, the

fering with descriptions, specifications,

APC-3582T with a 15″ LCD or the APC-3282T series

applications, line drawings and photos.

with a 12″ LCD are also available.

A description of the company’s lead-

Interworld Electronics&Computer Ind

time options is featured at the begin-

Contact info and more items like this at wf.net.au/T383

ning of the book. These options allow high-demand products to be expedited, reaching customers quickly and reducing potential downtime. An easy-to-read table of contents with bold section headings makes it simple for customers to find the information they need as quickly as possible. A selection matrix describing different heater types and their applications is also included.

Machine-mountable remote display for noise-immune monitoring

The heater catalogue is available in several formats, including printed

Banner Engineering has added the Machine-Mountable Remote

book form, PDF file from Watlow’s website (www.watlow.com), on CD and

Display to its line of iVu Vision products. The remote display

as a flip book, which is more user-friendly on smartphones and tablets.

enables users to view the iVu sensor image remotely and serves

Watlow Australia Pty Ltd

as a constant monitoring and user programming interface,

Contact info and more items like this at wf.net.au/U014

without interference from electrical noise. The remote display has metal housing to shield the display from electrical noise, while its cabled connector provides a

Control & Power Switches

secure, dependable connection, which further enhances the device’s electrical noise immunity.

Extensive Range of

The rugged stationary remote display has an 89 mm colour

Stainless Steel & Insulated Enclosures

flat-panel touch screen LCD and a wide viewing angle - 60° left and right, 50° up and 55° down. Two LEDs on the remote display provide feedback of the remote sensor location - one for power/error, and the other indicating inspection pass/fail. The device is available in five cordset lengths, which can be ordered separately. Mounting brackets and a stylus are

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

Jul/Aug 2013

included with the cordset kit. The remote display is compatible with all Banner iVu sensors. Micromax Pty Ltd Contact info and more items like this at wf.net.au/T107

www.foodprocessing.com.au

Are you looking to gain back sensing control over harsh applications?

Simply easy!TM Then look no further than the food & beverage sensor offer from Telemecanique Sensors. With innovative designs, the latest technology, IP69K, stainless steel construction and ECOLAB® certification, our food & beverage sensor offer delivers on sensing control in both harsh conditions and wash-down applications. Our extensive offer covers:

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PROCESSING

From concept to reality: the Little Creatures story A handful of friends got together at the end of the 20th century, among them a brewer, a winemaker and a beer marketer. Inspired by the vibrant beer culture in northwestern USA, they had the idea of brewing a beer with a distinctive taste: hoppy, unpasteurised and inspired by the US Pale Ale beer category. They aimed to release the brewing process from its exile behind factory walls to render the art of brewing transparent. In Fremantle, the group found the ideal property, which had previously been used as a crocodile farm. The location was spectacular: directly next to the fishing harbour and marina. This was where the beer buffs translated their idea into corporate reality, supported by Lion Group, which took a 20% stake. They called their brewery Little Creatures, a nickname for the yeast cells that transform a brew into a beer. At the end of 2000, they were serving their first guests Little Creatures Pale Ale. The bartender doesn’t have to worry about the beer taps running dry: behind the bar are four 40- and 70-hectolitre tanks. The brewery produces Little Creatures Pale Ale, Bright Ale, a pilsner and the Rogers mid-strength. Six times a year, specialty beers are brewed, like Bock, Spicy Christmas Beer and Belgian Beer, each in a 400-hectolitre batch. Little Creatures now produces over 100,000 hectolitres of beer annually at the Fremantle facility. In the early years, the brewers used a 50-hectolitre brewhouse, but this quickly became too small as demand increased. In 2006, Little Creatures requested quotes from three German brewhouse manufacturers. “Krones was the right choice for our brewhouse,” said Brewmaster Russell Gosling. “We had already been quite impressed with a Krones bottling line back then. “The guys from Steinecker were the ones who best understood our concept of integrating the entire process technology into the restaurant and the beer hall,” said Daniel Heary, who served a brewer’s apprenticeship at Little Creatures before studying at the Institute of Brewing & Distilling. “The brewhouse is very easy to operate, since everything has been automated using Botec F1. And if we do have a question, we just log in to the Krones hotline. After all, we’re a bit cut off from the rest of the world here, and not so easy to reach. That’s why the service hotline is all the more important to us.” In 2008, the brewhouse was installed, rated at 100 hectolitres of cold cast wort and designed for 10 brews a day. It is composed of a Variomill wet mill, a mash tun, a lauter tun, a heat-holding tank, a Stromboli wort boiler with a vapour condenser and an energy storage tank, warm and cold water tanks, plus a whirlpool. One special feature is a hopbag, in which natural hops are added. The hot wort then flows from the whirlpool via the hopbag directly to the cooling system and into the fermentation tanks. The old English method of the hopbag, which brewers affectionately refer to as the ‘toilet seat’, because of its shape, is used for all the beer varieties except the pilsner.

Jul/Aug 2013

The brewhouse is in the second hall next to the restaurant on the first floor, with the kit underneath. From the wort boiler, through the glass facade, the brewers enjoy a view of the harbour. Together with the brewhouse, Krones supplied nine cylindro-conical fermentation tanks (holding 400 hectolitres each), the yeast propagator, the entire piping and a CIP system. To help shoulder the costs, Lion increased its stake in Little Creatures to 34%. In 2010, Little Creatures added a TFS filter to the process technology, plus a buffer tank, a cooling system and a carbonator from Krones. The kegging and bottling operations have been relocated to a hall a few kilometres away. A Krones line rated at 12,000 bottles/h runs in two-shift operation, with a Kosme bulk glass depalletiser, a Krones Mecafill filler monobloc-synchronised with a rinser and a closer, a Kosme labeller with a cold-glue station for body and neck labels, and a cluster packer, a Kosme carton erector, a Krones Blitzpac packer and a Kosme palletiser. “The Mecafill filler was particularly important for us, since we don’t put our beers through a tunnel or flash pasteuriser, which means we have to be particularly careful to ensure microbiological safety during filling,” explained Heary.

www.foodprocessing.com.au

PROCESSING

In 2011, Little Creatures placed an order with Krones to build a complete brewery, including all utilities, in Geelong. In 2012, this project was given a boost when Lion acquired 100% of Little Creatures. The brewery is designed for an annual capacity of 250,000 hectolitres, with an option for upsizing to 400,000 hectolitres. The 200-hectolitre Steinecker brewhouse features the latest technology, including the EquiTherm energy storage system, combined with a unit-type cogeneration plant. The process technology is supplemented by a Krones bottling line. As of mid2013, Little Creatures has been able to brew its beers in eastern Australia as well, putting it closer to the nation’s consumers, who can’t get enough of Little Creatures’ distinctive taste. JL Lennard Pty Ltd Contact info and more items like this at wf.net.au/U153

E X M 0 0 6 1 _ 1 3 5 x 1 8 0 WN F T

2 0 1 3 - 0 4 - 2 9 T1 2 : 0 6 : 3 2 + 1 0 : 0 0

www.foodprocessing.com.au

Jul/Aug 2013

Productivity software gives insight into filling-line efficiency

Tank cleaner Designed to comply with sanitation and hygiene standards, the Sanitor Tank Cleaner from Tecpro Australia is constructed completely from 100% AISI 316 stainless steel. The company

the food, beverage, pharmaceutical, chemical, coatings and transport industries, or

Operations Feedback Systems (OFS), a leading provider of real-time productivity improvement software products, has been selected by Kyvalley Dairy for the provision of the core OFS suite at its processing facility in Kyabram, Victoria. Kyvalley Dairy is one of the largest dairy farm operations in Victoria, producing 25 million litres of milk annually. The company’s product range includes full cream milk, reduced fat milk, no fat milk, frothing milk and flavoured milk ranging from 250 mL to 3 L. “We realise that investing in technology solutions is a must-have for our business, and if we don’t we face the risk of being left behind,” said Wayne Mulcahy, CEO of Kyvalley Dairy. “OFS is going to provide us with an invaluable insight into the efficiency of our filling line via several OFS monitors. We will also get a precise understanding of the performance of crucial elements in the production process such as our labeller, packer and robot/palletiser.”

wherever rigorous standards of hygiene and product purity are essential.

OFS - Operations Feedback Systems

Tecpro Australia

Contact info and more items like this at wf.net.au/T261

says the streamlined external design ensures no residue can build up and contaminate the wash. The Sanitor’s design also eliminates the need for ball bearings, which increases unit life while preventing the possibility of contamination associated with bearing degradation.

PROCESSING

The tank cleaner’s pressure regulation system ensures constant, slow rotation at pressures ranging from 2 to 20 bar, with flow rates from 24 L/min. This low-jet peripheral velocity is optimised to maintain high impingement and allow longer chemical dwell times for improved cleaning efficiency. It is suitable for burst rinsing or prolonged washing, with the precision slots in the rotating barrel producing strong impact fan jets that scrub the vessel in a 360° wash pattern. The wide operating pressure band makes the unit suitable for a variety of small to medium-sized vessels, including food and beverage storage tanks, transport containers and chemical reactors. Lightweight and compact, the low-wear design requires minimal maintenance. It has a 3/8″ BSP connection and requires a minimum opening of 32 mm for unit insertion. At a pressure of 10 bar, the tank cleaner has a cleaning radius of 2.4 m and wetting radius of 3.6 m. It is suitable for working temperatures up to 95°C and ambient temperatures of up to 140°C. The flexible and durable Sanitor is a suitable tank-cleaning solution for

Contact info and more items like this at wf.net.au/T980

Jul/Aug 2013

www.foodprocessing.com.au

Metal-detectable products CK Safety, sister company to Spray Nozzle Engineering, has introduced a line of metal-detectable products to reduce the risk of product contamination during production. Within the food and pharmaceutical industries, there is the danger of

PROCESSING

contamination from protective clothing and other articles accidentally breaking and entering the production line. Undetected contaminants can result in costly product recalls, damage to equipment, harm to a company’s reputation or, worse still, serious injury if the contamination is consumed. To reduce this risk, there are two options: use only metal implements or use CK Safety metal-detectable products during the production process. Detectamet products can be detected by conventional X-ray systems (dependent on detection sensitivity), inline metal detectors and magnetic extraction systems. Because of this, any product supplied by CK Safety will be detected by these systems and be automatically rejected. CK Safety products can be used in conjunction with the HACCP benchmark. Selected metal-detectable products can be ordered with Microban antibacterial protection, to reduce possible food poisoning, fungi and bacteria contamination from Detectamet product exposure. The company has available a range of cost-effective, metal-detectable products such as pens, cable ties, earplugs, beard snoods, spatulas, safety knives, wound dressing and a full list of stationery. CK Safety Contact info and more items like this at wf.net.au/U319

Served up on a plate Using AirLINE Quick manifolds, Bürkert is able to assemble control cabinets extremely qickly, inexpensively, and to a very high standard (IP66). Introducing Smart Panel, with systems typically despatching within 48 hours. Bürkert. We make ideas flow.

Pneumatics - AirLINE Quick HP.indd 1

www.foodprocessing.com.au

Jul/Aug 2013

www.burkert.com.au 1300 888 868 www.burkert.co.nz 0800 BURKERT (287 537)

20/05/2013 3:50:07 PM

Wireless standard photoelectric sensor Micromax Sensors & Automation has announced the Banner Engineering SureCross Q45, a self-contained, wireless standard photoelectric sensor designed for control and monitoring applications.

TESTING

The company claims that, when traditional solutions are costly due to infrastructure requirements, operators can use the sensor to quickly integrate a scalable, wireless sensor network to improve efficiency by monitoring and coordinating multiple machines and processes.

Microplate reader for antioxidant assay

It allows users to easily add a single photoelectric sensor in minutes

Everyday metabolism, as well as stress and environmental pollutants, causes cells in the human body to produce molecules that are collectively known as reactive oxygen species (ROS). ROS can be either free radicals or can form free radicals through their interaction with biological molecules (ie, proteins, DNA/RNA and lipids). Too many free radicals are thought to play a role in cancer, ageing and other degenerative diseases, such as cardiovascular, Alzheimer’s and Parkinson’s. A method was needed that could measure the antioxidant capacity of a substance, either directly from the food or indirectly in the blood after being consumed. The oxygen radical absorbance capacity (ORAC) assay is such a method, and can be conducted using the PHERAstar FS microplate

without pulling cables. Offering a turnkey wireless photoelectric solution, the sensor’s power management gives extended battery life of up to five years on two replaceable AA lithium batteries, depending on sensor and application. It has a real-time response of less than 250 ms. The sensor allows long-range communication of up to 1 km line-ofsight minimum. It has multiple I/Os with support of a wireless network of up to 47 Q45 sensors per gateway. It has built-in site survey capabilities and offers robust IP67/NEMA 6P protection against liquids and debris common to industrial environments. The sensor is suitable for a range of applications, including cable replacement, moving applications, remote applications and productivity solutions. Four models are available: Polarized Retroreflective, Convergent Visible, Remote Device Interface and Fiber Optic. Micromax Pty Ltd Contact info and more items like this at wf.net.au/R272

reader from BMG Labtech. It is suitable for food manufacturers wishing to market their products as high in antioxidants. BMG LabTech Pty Ltd Contact info and more items like this at wf.net.au/U457

Food analyser for moisture, fat and protein measurements The NDC InfraLab food analyser has been developed for the food industry and provides rapid and accurate moisture, fat and protein measurements. NDC, a UK-based manufacturer and world leader in NIR technology, designed the InfraLab to enable instantaneous, simple and ‘on-site’ fast measurements in powder products, cheese products, dry foods, biscuits and snacks. The instrument provides analysis results in less than 10 seconds and avoids having to wait hours for results of traditional laboratory methods. It saves time, money and enables tighter process control and a higher volume of tests. The InfraLab is designed to operate ‘at-line’ in harsh and hygienic processing environments and requires no special operator skills. It provides automatic data recording. The InfraLab provides Ethernet and LIMS connectivity and interfaces with clients’ IT systems to enable automatic data recording. A barcode reader assists in product recognition without the need for manual data entry. B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/S289 48

Jul/Aug 2013

www.foodprocessing.com.au

Haze meter for beer quality analysis The HI 847493 haze meter from Hanna Instruments is designed in accordance with the MEBAK (Central European Brewing Com-

TESTING

mission) standard requirements for haze in beer measurements. The instrument compensates for beer colour to guarantee accurate readings during the brewing process. The optical system consists of an LED and multiple detectors. A two-, three- or four-point calibration can be easily performed at any time using the supplied or user-prepared standards. Features include a real-time clock, log on demand (up to 200 measurements) and Fast Tracker tag identification system. The haze meter also incorporates a continuous measurement mode to measure the settling rate of suspended matter and a signal average (AVG) mode to accumulate multiple readings giving a final average value. The average mode is particularly useful to measure samples with suspended particles with different dimensions. The device features a user-friendly interface with a large backlit LCD. Acoustic signals and display codes guide the user step by step through routine operations. Hanna Instruments Pty Ltd Contact info and more items like this at wf.net.au/T790

There is more to food safety than meets the eye. Pathogen Testing by Merck Millipore • Dehydrated Culture Media Merck Millipore is the largest provider of granulated media for pre-enrichment and selective enrichment of pathogenic organisms from numerous food matrices.

• Sample Preparation Kits Easy to use products to generate pure, inhibitor-free DNA and RNA for fast molecular detection

• Real-Time PCR Kits A range of simple, yet sophisticated kits that offer the highest sensitivity and specificity with results in just 24 hours

• Lateral Flow Tests Immunological detection that supplies swift presence/absence in one easy step and delivers results in 24 to 48hrs filtered liquids directly to waste

Contact Merck Millipore: Australia Ph: 1800 335 571 www.merckmillipore.com

New Zealand Ph: 0800 46 3725

Merck Millipore is a division of

www.foodprocessing.com.au

Jul/Aug 2013

TESTING

Rapid detection system, manifold for filtration and sterile membrane dispenser Merck Millipore has added three products to its EZ-product family, which is designed to facilitate microbiology workflow in quality-assurance and quality-control (QA/QC) laboratories. The EZ-product family now includes: the EZ-Fluo rapid detection system, the EZ-fit Manifold and the EZ-Pak Dispenser Curve. The EZ-Fluo rapid detection system is claimed to reduce time to result by approximately 2/3rds of that required by traditional methods, allowing contamination events to be identified sooner. The system uses standard membrane filtration to detect viable and culturable bacteria, yeasts and moulds down to 1 CFU per sample. EZ-Fluo test results are easily comparable to compendial method test results, which facilitates validation and integration of the system in any laboratory. The EZ-Fluo method is non-destructive, allowing growth of microorganisms after they have been stained in order to identify them using any standard identification technology. The EZ-Fit Manifold filtration system enables universal laboratory filtration while minimising contamination risks. Traditional filtration equipment contains non-accessible areas where biofilms can form, increasing the risk of contamination. The EZ-Fit Manifold enables access to clean all internal areas in order to ensure the filtration process is contamination free. The EZ-Pak Dispenser Curve provides high-speed sterile membrane dispensing with no-touch operation. The dispenser design allows for quick and easy membrane loading in less than 30 s. Merck Pty Limited Contact info and more items like this at wf.net.au/T044

Packaging leak detection system How do you guarantee to your customers that your packaging system is dependable once it leaves your facility? This is a complex question. Issues such as packaging material compatibility, sealing machine set-up and seal reliability in airfreight are just some of the production variables that need to be taken into account. The manufacturing considerations are countless. A systematic package testing system that incorporates the Pack-Vac Leak Detector will allow users to quickly and reliably set up packaging lines, resulting in less downtime for machinery adjustments. Additionally, continual process monitoring with the Pack-Vac Leak Detector will detect sealing problems before they snowball and catch defects before they get to customers. The Pack-Vac is simple to set up and operate. A range of tests can be performed either underwater or in the dry chamber. The most common test performed is the bubble emission test. The chamber is filled with water, submerging your package when the lid is down. Opening the ball valve will apply a vacuum to the package causing it to expand and put pressure on the seams. A successful test will maintain the integrity of the package; a failure will be easily identified by the stream of bubbles rising to the surface from the leak. Pack-Vac can also be used to test rigid trays, tubs, cups and packaging containing liquid with some headspace. An altitude simulation test is also possible. Niche Gas Products Contact info and more items like this at wf.net.au/U050 50

Jul/Aug 2013

www.foodprocessing.com.au

Preventing sulfide contamination in the brewery to continuously measure concentrations of hydrogen sulfide (H2S) and dimethyl sulfide in the fermentation by-product gas. This system uses a full-spectrum UV-vis spectrophotometer to detect the absorbance of sulfides in the reclaimed CO2 stream, an ideal method as CO 2 has zero absorbance in the UV spectrum. The OMA provides fast-response alarms to high-concentration threshold, which allows immediate diversion of contaminated CO2. For this application, the OMA is typically multiplexed to automatically cycle analysis between multiple sampling points. This maximises system value by allowing one unit to monitor the raw fermentation gas entering the reclamation system, gas coming off the acid aldehyde scrubbers and the bottling gas coming off of the sulfur removal beds - all with sample stream switching at user-defined intervals. Using the OMA system, a brewery enables intelligent CO2 reclamation which continuously prevents sulfide contamination of the beer product.

â&#x20AC;˘ Powerful Customisation â&#x20AC;˘ Accurate Analysis

HI902C Automatic Titration System HI902C automatic titrator can perform acid/base, potentiometric, ORP, complexometric, precipitation, back titrations and titre determinations. This versatile titrator supports up to 100 methods, has a large colour LCD screen and a real time titration curve amongst a host of other useful features. Contact Hanna Instruments to learn more about this powerful automatic titrator.

Tel: 03 9769 0666

Fax: 03 9769 0699 Email: sales@hannainst.com.au

www.hannainst.com.au

www.foodprocessing.com.au

Jul/Aug 2013

TESTING

Prior to filling, beer bottles are purged with CO2 to remove air and protect the taste against oxidation. In the fermentation process, yeast consumes sugar and expels a large amount of CO2, which can be reclaimed and used for this bottle purging purpose. Unfortunately, fermentation often also produces toxic, odorous sulfides that can foam up into the piping and contaminate the reclaimed CO2. In order to continue using the great resource of CO2 by-product yet avoid contaminating the bottled beer with foul-smelling toxins, the reclaimed gas is run through sulfide removal skids. However, sulfide breakthrough can occur if the gas does not spend enough time in the scrubber. Employees are sometimes tasked with sniff-testing the reclaimed CO2, but this is an unhealthy practice and is too discrete to vigilantly prevent product contamination. An automatic, continuous analysis solution is required in order to immediately divert contaminated CO2 from use in bottling as well as provide feedback control for the sulfur removal processing time. The Applied Analytics OMA Process Analyzer can be used

Optical oxygen measurement for beer If large amounts of dissolved oxygen are present in finished beer, oxidation processes take place. These oxidation processes negatively affect the beer’s flavour and cause premature product ageing. To ensure the best product quality, taste and a long shelf life, the amount of the dissolved oxygen must be minimised. This requires considerable technical effort and a continuous oxygen content monitoring. The monitoring of dissolved oxygen content has traditionally been

TESTING

done with amperometric sensors. Amperometric monitoring is done with the help of electrochemical sensors according to the Clark Principle: the content of dissolved oxygen is determined by means

Oil-in-water analyser

of a current flow in the sensor’s measuring chamber. However, this

With the invention of mid-infrared quantum cascade

amperometric method has known limitations, such as a difficulty with

lasers (QCL), a new form of liquid spectroscopy

inline measurements typical of large filling lines due to Clark sensors’

became possible. The EraCheck uses this portable

susceptibility to breaking down and requiring a lot of maintenance.

and field-proven technology to enable fast, easy

Hamilton has developed an alternative to the amperometric method.

and reliable measurements in harsh environments.

Claimed to be the first standardised 12 mm sensor, the VisiFerm

The eco-friendly analyser features QCL-IR

DO measures dissolved oxygen optically using a method based on

technology allowing an extraction with the CFC-

oxygen-dependent luminescence.

free solvent cyclohexane. With high speed and precision, the product will detect even sub-ppm concentrations of total petroleum hydrocarbons (TPH) or total oil and grease (TOG) in water in full compliance with ASTM D7678. The analyser is suitable for the following applications: the prevention of hydrocarbons in discharged water; process control in the petrochemical industry for upstream oil recovery; downstream process water monitoring; purity control in the chemical and energy industries; environmental

VisiFerm DO optical sensors optimise the brewing process in several

testing such as testing for compliance with envi-

ways. After CIP cleaning, the optical sensors can be re-used faster

ronmental regulations, bilge water monitoring in

than with an amperometric sensor. As a result of this, the quantity

marine transportation and the contamination of

of rinsing product used and afterwards discarded can be reduced.

surface soils by various types of crude oils and

Moreover, the VisiFerm DO sensors are also less susceptible to break-

their products.

down and need less maintenance than amperometric sensors, as they

Crea Laboratory Technologies Pty Ltd

have only one part subject to wear: the sensor cap. The sensor cap

Contact info and more items like this at wf.net.au/U174

must be changed every four to eight months, and the replacement and recalibration only takes a few minutes. Grace Davison Discovery Sciences Contact info and more items like this at wf.net.au/T407

Jul/Aug 2013

www.foodprocessing.com.au

General system Pack offers innovation and many years of experience, with a range of affordable flow-wrappers all designed and manufactured in-house using italian engineering. stand-alone or together with a wide range of automatic feeding systems, GsP offers complete turnkey solutions for many industries.

DistriButiON sYstEMs

Product range Flow wrappers tray denesters Product distribution systems top loaders robotic pick & place

Packaging Materials Heat & cold sealable films

tOPlOAD sYstEMs

Poly films Modified atmosphere packaging

Food chocolate Biscuits & snacks cakes & pastries Frozen & fresh foods salad in trays

rOBOtiC PiCK AND PlACE

Fruit & veg Meat, poultry & fish cheese

non Food automotive parts M A DE IN I TALY

industrial components Medical & hygiene

AustrAliA 1800 777 440 www.jllennard.com.au

©iStockphoto.com/Dieter Spears ©iStockphoto.com/Joe Gough

PACKAGING

Chilling out on the shelf Latest ready-meal technology doubles shelf life Martin Bevis*

The latest European innovation for chilled ready meals is manufactured on a continuous production line and claims it can extend shelf life up to 45 days. If this seems a little hard to believe, then read on.

n the supermarket ready-meals section, the consumer has the choice between a fully frozen product or a chilled product. Presently, the chilled meal generally commands a premium consumer perception over the frozen range for several reasons: • The freezing process can damage the product quality, for example, rendering crisp vegetables into a mush when reheated. • The factory freezing process will dehydrate the meal, and storage in a domestic freezer will continue to dehydrate it. This affects the final quality and eating experience. • The chilled product has greater visual appeal on the supermarket shelf than a frozen meal as its display appearance is identical to the reheated meal, and the packaging is generally designed to show this off. • The chilled meal is perceived as fresh and healthy. That frozen dinner could be up to 12 months old! The chilled product also commands a premium market price, and so its popularity amongst manufacturers is increasing.

The primary challenge for chilled ready-meals manufacturers is the limited shelf life of the product, requiring a flexible production process and slick logistics to optimise the time the product is present on supermarket shelves. There are two main methods used exclusively to extend chilled meal shelf life and still retain that ‘just made’ appeal. For retailers, wastage rates and discounts are high due to the pressure to sell within the product’s limited shelf life and the inevitable loss of any product that remains unsold once it has passed its use-by date. Methodology

Process

Shelf life of product

Pasteurisation

Heating up of product post -production to ensure sterility

Up to 14 days

Modified atmosphere packaging (MAP)

Displacement of air in Up to 10 days pack with CO2, nitrogen, or a mixture of both

www.foodprocessing.com.au

Jul/Aug 2013

PACKAGING

©iStockphoto.com/John Gollop

Innovation There is now a process on the market which claims to extend the shelf life of these meals by 30-45 days (under industrystandard chilled storage conditions), while maintaining the quality of their pasteurised equivalents. The technology was invented in Sweden by a company called Micvac. A range of ready-meals products using this process is already being manufactured and sold in one of Australia’s leading supermarket chains. Firstly, the Micvac process is designed to fully cook the product in the plant, by the use of a continuous industrial microwave tunnel, instead of alternatives such as a spiral oven. This renders segregated high-risk/low-risk divisions within the plant unnecessary, as the raw ingredients can be assembled into the tray. The tray is then sealed and the contents fully cooked within the microwave tunnel. All product leaving the plant has therefore been fully cooked in a sealed tray, and is sterile. The microwave oven provides a rapid and thorough cook within a small footprint, the cooking performance of which cannot be matched by a spiral oven. It should be noted that some hydrated products such as rice and pasta require partial cooking prior to assembly due to the differing cooking characteristics of the components of the meal. This is more than just another microwave cooking technology, the company says. The new element in this process is the patented Micvac one-way valve that is attached to the film that seals the top of every meal. This valve allows the cooking steam to escape from the pack during the rapid microwave cooking process and therefore prevents the pack from exploding. Once the meal is cooked, the valve closes during cooling to ensure the pack remains fully purged and no exterior air is allowed back in. The novel, multi-purpose nature of this valve allows it to serve, firstly, as described above in the initial cooking process, and then as a cooking tool for the consumer when they reheat the meal in their microwave oven. Once heated, the Micvac valve emits a loud whistling noise to indicate that the meal is ready. This is due to the passage of hot steam through the valve exactly as it occurred during the factory cooking process.

Build it and they will come Micvac’s innovation is smart in more ways than just how it cooks and reheats food. The company makes and supplies a number of the unique elements of this new technology, all of which can be implemented into any standard ready-meal manufacturing process. These features will be of great interest to the rest of the ready-meal industry. The film that covers the meals and the valves are each supplied in roll form by Micvac. A purpose-built Micvac Valve Unit (MVU) module is integrated into an existing tray sealer and applies the valve and the seal while the sealer is running. Micvac manufactures the valves itself to ensure they all meet the required quality standards. The microwave tunnels are supplied and supported by Micvac from its Swedish base. The special microwaveable Flextray trays are manufactured under licence at various sites but can be obtained through Micvac directly. Outside of these 56

Jul/Aug 2013

Ready-meal packaging with the Micvac Valve Unit.

The Micvac Valve Unit. process particulars, any standard ready-meals plant would already have the necessary equipment in use to manufacture this product.

Conclusion The appeal of chilled ready meals is their quality and authenticity to restaurant-quality food. There are other life-extending methodologies which will take the product life well beyond six months, such as deep freezing or retorting, but products preserved by these methods cannot match the fresh appeal of the chilled product and are proving hard to market to the consumer. The growth area in the supermarket aisles is in fresh and chilled foods. This sector will grow significantly over the next five years and is predicted to outperform the overall growth in supermarket sales, displacing tinned and boxed foods from the shelves. Retailers will be looking for ways to maximise their displays of chilled foods and reduce wastage in this high-margin sector. Extending shelf life while maintaining quality is the sure-fire way of ensuring a product ends up on consumers’ shopping lists. Wiley & Co Pty Ltd Contact info and more items like this at wf.net.au/U628

*Martin Bevis is one of Wiley’s Senior Process Engineers and has worked on a range of food manufacturing projects in the United Kingdom, Europe and Australia.

www.foodprocessing.com.au

the seasoning

REVOLUTION CONTINUES

introducing the new the ultimate on-machine seasoning (OMS) system that delivers consistent coverage and flavour for both wet and dry applications.

simplicity

performance

flexibility

Improved modular design that is

Tighter standard deviations on

The ultimate in OMS seasoning

fully enclosed for a more hygienic

seasoning performance through scarf

that is fully integrated with both

and quick to clean system. Pivoting

position. Loss-In-Weight powder

oil spray and flavour injection in

drum that improves accessibility for

feeder technology improves accuracy

one system for total control of

hard to reach areas to simplify day

of seasoning application. Vacuum

adhesion. Capable of quick

to day operation.

fill provides cleaner operation.

flavour changes.

paul webster » regional sales manager » tna australia pty ltd » p: +61 2 9714 2300 » m: +61 (0) 451 631 293 » f: +61 2 9748 2970 » info@tnasolutions.com

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PACKAGING

NEWS

Packaging Organic ‘health halo’ changes consumer perceptions The word ‘organic’ can mean many things to consumers. Even so, the power of an organic label can be very strong: studies have shown that this simple label can lead us to think that a food is healthier, through what is known as the ‘health halo effect’. But can this bias go further? A study by Cornell University’s Food and Brand Lab researchers Jenny Lee, Mitsuru Shimizu, Kevin M Kniffin and Brian Wansink set out to answer this question. Their study shows that an organic label can influence much more than health views: perceptions of taste, calories and value can be significantly altered when a food is labelled ‘organic’. Certain people also appear to be more susceptible to this health halo effect than others. Researchers recruited 115 people from a shopping mall in Ithaca, New York, to participate in this study. Participants were asked to evaluate three pairs of products: two yoghurts, two cookies and two potato chip portions. One item from each food pair was labelled ‘organic’, while the other was labelled ‘regular’. However, each product pair was identical - and organic. Participants were asked to rate the taste and caloric content of each item and how much they would be willing to pay for the items. A questionnaire also enquired about their environmental and shopping habits. Even though these foods were all the same, the organic label greatly influenced people’s perceptions. The cookies and yoghurt were estimated to have significantly fewer calories when labelled organic and people were willing to pay up to 23.4% more for them. The nutritional aspects of these foods were also greatly biased by the health halo effect. The organic cookies and yoghurt were said to taste lower in fat than the regular variety and the organic cookies and chips were thought to be more nutritious. The label even tricked people’s taste buds: when perceived as organic, chips seemed more appetising and yoghurt was judged to be more flavourful. Regular cookies were reported to taste better - possibly because people often believe healthy foods are not tasty. All of these foods were exactly the same, but a simple organic label made all the difference. This study found that people who regularly read nutrition labels, those who regularly buy organic food and those who exhibit pro-environmental behaviours (such as recycling or hiking) are less susceptible to the organic health halo effect. So, if you do not consider yourself in one these groups, take a closer look when shopping for cookies and chips that are labelled organic - they are, after all, still cookies and chips!

Jul/Aug 2013

Sirane increases mushroom shelf life Sirane has reportedly increased the shelf life of mushrooms by seven days by using its Sira-Flex Resolve range of bags and films. Mushrooms packed with the company’s film showed no browning and no condensation following the trial, the company said. “The films worked well in the trials with the breathable pulp-tray punnets that mushrooms are often packed in. There was absolutely no browning, no condensation, and the mushrooms touching the film was not a problem, which it is using other types of film,” said Sandra Evans, sales manager for fresh produce. “We also have a new product coming soon which could extend this shelf life even further. A new pad is about to be launched by Sirane which will inhibit bacteria growth. These two solutions could help retailers keep their mushrooms fresher for longer.” Sira-Flex Resolve has been designed to strike a balance between humidity control and O2 and CO2 permeability. The permeability is temperature dependent so that the ideal atmosphere is maintained inside the pack, even if the storage temperature is variable. The product is suitable for all types of vegetables, including salads, as well as many types of fresh fruit. The fully compostable film is a natural, plant-derived polymer. The company had good results with brassicas in trials conducted in 2012. Shelf-life extension is a hot topic in the UK, especially in light of the Courtauld Commitment - Phase 3, which aims to reduce waste in the grocery supply chain by 3%, as well as household food and drink waste by 5%. “Courtauld 3 wants retailers to ensure packaging develops and evolves,” said Simon Balderson, MD of Sirane. “Not only is it possible to reduce packaging waste significantly, but it’s also possible to reduce food waste significantly with more advanced packaging. “Many companies may look at Courtauld 3 and think it will cost them more money, but using more advanced technology can actually save companies money in the long run, as they’ll get money back from reduced discounting, wastage and returns.”

www.foodprocessing.com.au

Bulk cheese packaging Until now, the process of opening and stripping bulk cheese blocks has required sharp knives and physical force due to the skintight package, puncture-resistant film and heavy weight of the product itself. Curwood’s EZ Open Block-Tite bulk cheese packaging transforms the opening and stripping process with easy-open, peel-away film.

PACKAGING

Claimed to be the first bulk cheese package to incorporate an easy-peel feature, EZ Open Block-Tite packaging brings together high-abuse Block-Tite barrier bulk film and Curwood’s EZ Peel opening feature. With the EZ Peel feature, processors simply lift the flap on the block’s back seal using special grasp notches, then peel the package open for clean, fast, complete film removal. The opening initiates an easy linear tear, which allows the film to pull away effortlessly and cleanly in a straight line, following the block shape of the cheese. While the opening feature adds to convenience and efficiency, it also improves safety. The peel-away feature eliminates personal safety hazards associated with using sharp knives to cut and remove the film, reduces the potential for cross-contamination of cheeses via non-sterile knives and removes the potential for film shards left on the cheese, which could then be ground or sliced into the product. The product’s format allows original cheese manufacturers to add the integrated peel-open feature without sacrificing machine speeds or package integrity. The EZ Open Block-Tite film machines like non-peelable films - no machine or speed adjustments are required. Bemis Flexible Packaging Australasia Contact info and more items like this at wf.net.au/T975

www.foodprocessing.com.au

Jul/Aug 2013

Aseptic blow fill machine for milk products GEA Procomacâ&#x20AC;&#x2122;s ABF (Aseptic Blow Fill) machine has successfully passed the LA (low acid) microbiological validation, making it suitable to fill milk and milk-based products.

PACKAGING

The ABF consists of a traditional oven, a preform steriliser, a sterile blower and an aseptic filler. The preforms are warmed in the oven so they arrive hot in the steriliser, where they are sterilised internally and externally with hydrogen peroxide. Once sterile, they enter the sterile area of the blower, are stretch-blown

Label printer applicator Using LightSmart technology, the Avery Dennison 81x Label Printer Applicator (LPA) uses a backing-paper-free label material, reducing energy and material use, and therefore waste, for carton, tray and pallet labelling - at a lower total applied cost. The LightSmart label material does not need backing paper, which traditional pressuresensitive labels do. Coated on the reverse with a non-tack adhesive, LightSmart labels become sticky through heat activation after the print and cut. The material can even withstand high-temperature warehousing; it only activates in the 81x LPA. The machine gives manufacturers the flexibility to print differentlength labels, because the material is on one roll that can be cut to the desired length, thus maximising material use. This also lets manufacturers change message lengths â&#x20AC;&#x2DC;on the flyâ&#x20AC;&#x2122; so they can create marketing messages or simply change label formats without needing to change the label stock. It also reduces supply SKUs, as only one roll is needed for different label lengths. Being backing paper free eliminates an entire waste stream - and associated disposal costs - as well as expensive silicones and liner materials, energy and assets from traditional labelling. The LPA is suitable for secondary packaging such as cartons and shrink trays with content and shipping labels.

into bottles and then filled. The blower is sterilised using hydrogen peroxide and the sterile environment inside the microbiological isolator is maintained with an overpressure of sterile air. The high- and low-pressure pipelines that supply blowing air to each mould are also sterilised, maintaining sterility throughout the system. During operation, a standard stretch rod moves up and down in a non-sterile environment entering the moulds and touching the preform/bottles. The ABF system includes a magnetic joint that allows movement inside the aseptic housing and ensures the stretch rod remains sterile. Preforms are thicker and more heat resistant than bottles. Once they are sterile they can be blown without the need for further sterilisation, which means lighter bottles and reduced PET consumption. One key feature of the ABF is the simultaneous internal and external sterilisation treatment of the preforms, with no risk of contamination. The ABF is validated in low acid conditions for products with a pH >4.5.

Matthews Intelligent Identification Pty Ltd

GEA Process Engineering Australia Pty Ltd

Contact info and more items like this at wf.net.au/T992

Contact info and more items like this at wf.net.au/U026

Jul/Aug 2013

www.foodprocessing.com.au

Blown extrusion bottle machinery range MAER has restyled its TC-10-8-8 range of machinery. The range, now renamed the SB5 Series, is suitable for the

PACKAGING

production of plastic bottles made by blown extrusion for use with foodstuffs such as milk and dairy products, whether in the blowing phase or integrated into the packaging line itself before the bottling machine. The principal change made has been the minimisation of the structure or main chassis of the device, with a cubic or cabin-type shape, which gives it a more aesthetic design, according to the company. The restyling of the structure in cabin form also reduces the machine’s footprint and gives greater accessibility from either side of the machine to the interior of the cabin where the moving parts are situated. This allows a greater degree of control and visual inspection of the bottles through their route due to the fully open design of the cabin. The bottle conveyor has also been improved with a ‘flat-end’ finish or design, reducing the risk of bottles falling through a possible gap or space in the bottle transfer zone from or to the conveyors of other devices in the line. Lighter format-change parts have been developed for the machine. The machine now has improved ergonomics when changing formats, making adjustments or replacing the cutting blade. The range includes the SB520 model, with a speed of 20,000 bph, and the SB510 and SB525 models, with speed ranges from 12,000 to 25,000 bph. HBM Packaging Technologies Contact info and more items like this at wf.net.au/T912

Void-fill and protective packaging systems and materials Automated Packaging Systems has introduced its line of AirPouch void-fill and protective packaging systems and materials. AirPouch systems deliver on-demand, inflatable air pillows, bubbles and tubes used for void-fill, protective wrapping, blocking, bracing and packing applications. Preformed material is shipped in boxes and inflated on demand at the packing station for maximum production efficiency. These compact units are portable and require only electricity for operation. The AirPouch Express 3 system will produce void-fill air pillows at the rate of 15 m/min. The AirPouch FastWrap system produces cellular cushioning wrap at 20 m/min. Both product lines include EZ-Tear perforations for operator speed and convenience. Void-fill pillows offer advantages over traditional packing materials because they are cleaner, lighter, more user friendly and increase product visibility over EPS peanuts and paper. Shipping, storage and handling costs are claimed to be less than conventional packing materials because one standard box includes more than 1200 linear metres of material. EarthAware recycled and biodegradable materials are available in a tinted green colour to demonstrate environmentally friendly options. MPI Australia Pty Ltd Contact info and more items like this at wf.net.au/T977

www.foodprocessing.com.au

Jul/Aug 2013

Multifunction top-loading case packer Cermex has expanded its product range with the Flexicase multifunction toploading case packer, which forms, loads and seals. The company claims its case packer is one of the most efficient solutions on the market, when speed, footprint and packaging size range are taken into account.

PACKAGING

With a speed of 40 cases/min, a 20 m2 footprint and good scope in products/ cases handled, the case packer is suitable for the packing of plastic bottles of all sizes, shapes and strength in to RSCs (regular slotted containers). Seventeen servomotors for the various functions ensure fluidity and accuracy. Several product collating modules can be associated with the FlexiCase, with the choice of either stop and go or continuous technology, according to speed and bottle criteria.

Bag packaging systems

The machineâ&#x20AC;&#x2122;s footprint is a third smaller

Automated Packaging Systems has introduced several

than a traditional horizontal forming solution.

bag packaging systems, including the Autobag AB

The cases are extracted vertically and descend

180 Print-n-Pack and the Pacesetter PS 125 OneStep.

positively via a chute to be opened and then

The Autobag AB 180 Print-n-Pack is a high-speed

transferred to the lower flap sealing station.

bagger with an incline thermal transfer printer for

Six servomotors hold and guide the cases to

applying high-resolution graphics, text and barcodes

safeguard the process. At a level of 900 mm,

directly onto the bag. The system operates at speeds

the case magazine is ergonomic in order to

up to 80 bags/min and is suitable for small to me-

facilitate reloading by the operator.

dium products in bags up to 28 x 56 cm. The AB

The FlexiCase is equipped with a Cermex

180 bagger also integrates with automatic infeeds

numerical axis gantry, associated with a simple,

such as the Autobag Acc-Count 200 high-speed

lightweight gripping tool. Modular in design,

automatic counter.

the machine offers the possibility of integrating

The Pacesetter PS 125 OneStep is an all-electric

third-party polyarticulated robots.

tabletop bagger that packages up to 25 bags/min

Three servomotors and a positive lateral-

in low- to medium-volume hand-load operations. Ap-

band drive facilitate the kinematics of the hot

plications include bag packaging for a wide range of

melt glueing operating to create accurate case

hardware, electronics, plumbing, crafts, automotive,

folding, squaring and pressing while eliminating

medical and kit components.

bumping. A sealing alternative using adhesive

Genuine Autobag and SidePouch materials are

tape is also available.

system matched for guaranteed reliability. Bags are

The packer has a cantilever structure enabling walk-in access to the heart

available in many different material types, sizes and

of the machine. Developed in compliance with OMAC (Organization for Ma-

features, such as reclosable zippers, flaps, tapes,

chine Automation and Control) standard, all of the functions making up the

hanger holes and more. Printing in up to 10 colours

packer are broken down into autonomous subprograms to facilitate machine

enables high-impact graphics for greater customer

operation and maintenance.

appeal.

Allied Industries Pty Ltd

MPI Australia Pty Ltd

Contact info and more items like this at wf.net.au/S480

Contact info and more items like this at wf.net.au/T978

Jul/Aug 2013

www.foodprocessing.com.au

Industrial label printer The Zebra ZT230 Series industrial label printer stands out from the rest when it comes to easy set-up, intuitive user operation, space-saving design and

Rotating filling machine

ease of service and maintenance. Find out how

BEUMER has expanded its product portfolio with the rotating filling machine

this industrial label printer from insignia is a good

BEUMER fillpac R. This machine, designed for capacities of 300 to 6000 bags per

fit for a business’s requirements. inventory and asset management and tracking, mak-

by a calibratable weighing unit. Together with a bag placer, the fillpac R can fill even woven polypropylene bags.

ing it a good fit for warehouse, shipping and logistics

The three-position cylinder that regulates the coarse and fine flow is protected

labelling. The Zebra ZT230’s rugged all-metal frame

from dust, because it is positioned vertically and outside of the dirty area.

suits the most demanding of applications.

The cylinder for bag discharging is also located in the dust-free zone above the

Larger roll capacity sees increased uptime with

filling spout. This solution minimises wear and tear on both cylinders and therefore

fewer ribbon changes necessary. The Zebra ZT230’s

ensures longer service life. The machine is also equipped with an automatic bag

space-saving design includes a unique bi-fold

weight correcting device, which automatically adjusts the weight of subsequent bags.

door that fits easily into tight spaces, maximising

The system is designed so that it is easily accessible for maintenance. The

work space. The Zebra ZT230 offers fast installation, multiple

generously dimensioned filling impeller reduces fill times and therefore increases throughput without impairing weight accuracy, according to the company. The system is also equipped with an ergonomic control panel. The improved human-machine interface concept makes work simple and intuitive.

connectivity options and high print quality. insignia Pty Ltd Contact info and more items like this at wf.net.au/U171

BEUMER Group Australia Pty Ltd Contact info and more items like this at wf.net.au/U042

Sauce Applicator

Waterfall Applicator

Pepperoni Slicing

DFC can supply you with all of your Packaging and Processing Machinery needs, whether it is Cooking, Topping or Packaging your goods, DFC can help. Shrink Wrapping Machinery

Call us today. C t TTaping, Check Weighing, Carton Metal Detecting & Pallet Wrapping Machinery Cook Quench Chill Machinery

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

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

www.foodprocessing.com.au

Jul/Aug 2013

PACKAGING

The Zebra ZT230 is a suitable solution for asset

hour, can fill all types of valve bags. The weight accuracy of the bags is provided

>>> Guide to Life Cycle Inventory

PACKAGING

Life Cycle Inventory (LCI) identifies and quantifies energy and resource use and environmental discharges through the entire product life cycle, from cradle to grave. Resource inputs, energy requirements and releases to air, water and land for each step in the manufacture of a product or process are quantified, from extraction of the raw materials to disposal of waste. LCI studies are usually comparative analyses in which two or more packages are compared on the basis of providing equivalent function, with the results giving an environmental profile of the systems studied. The LCI identifies those system components or life cycle steps that are the main contributors to environmental burdens such as energy use, solid waste and atmospheric and waterborne emissions, enabling companies to effectively target environmental improvement efforts. Despite the increasing popularity of LCIs in both industry and government, the technique’s limitations are often overlooked. LCIs are not able to assess the actual environmental effects of emissions and wastes from the product because these will depend on when, where and how they are released into the environment. Secondly, LCIs do not consider the various functions a package performs. Thus, when comparing several different packages for the same product, an LCI takes no account of the convenience function such as whether or not the package is reclosable, easy to pour from, etc. A third limitation is that LCIs do not consider costs. The carbon footprint is a small excerpt from an LCI and includes only the greenhouse gas (GHG) emissions that are released as part of the processes of creating, modifying, transporting, storing, using, providing, recycling or disposing of goods and services. The Publicly Available Specification 2050:2010 Specification for the assessment of the life cycle greenhouse gas emissions of goods and services has been developed by the British Standards Institution (BSI) in response to calls for a consistent method for assessing the life cycle GHG emissions of goods and services. The Carbon Reduction Label was launched in the UK in 2007 and has appeared on more than 5000 individual product lines. The Carbon Reduction Label was launched in Australia in 2010 but to date take-up has been very limited and publicity about it almost non-existent. Professor Gordon Robertson FAIP info@aipack.com.au www.aipack.com.au

Electric heat sealing machine Sonoco Alloyd, a unit of Sonoco, has introduced what is claimed to be its industry’s first 100% electric ergonomic heat sealing machine. A fully electronic rotary machine, the NFPA79-compliant Aergo 6E is equipped with one heat seal station, one eject station (both standard) and two additional open load stations that can be used to accommodate up to two feeders for versatile package styles. All machine movements of the Aergo 6E are electrically controlled, eliminating the need for compressed air. The Aergo 6E has been improved with a heating plate mounting system. Operators simply insert the heating element into a guided shelf where it is locked into place. The heating plate can later be removed easily, allowing for faster changeovers and safer operation. Additional features include an overload alert system, redundant safety switches, touch-screen controls, and adjustable speed drive and a 36″ load height for operator convenience. Despite its 12 x 16″ seal area, the machine has a small footprint, making it suitable for small production floors or cleanroom facilities that may not have compressed air hook-up capabilities. It is suitable for a range of market segments, including retail, automotive, HBA, hardware, medical, electronics and others requiring high-volume capacity and frequent changeovers. Package applications include face seal blister-to-card, card-tocard and trapped packaging (two cards and a blister). Sonoco Australia Pty Ltd Contact info and more items like this at wf.net.au/U308

Injection-moulding resin NatureWorks’ Ingeo biopolymer is a low-carbon-footprint polymer made from renewable plant material, not oil. Plastics and packaging applications for Ingeo include food-service ware, rigid packaging, films, durables and fibres. The company has introduced high-performance Ingeo injectionmoulding resin grades. Grades 2500HP, 3100HP and 3260HP are designed for use in medium- and high-flow nucleated formulations. They are claimed to provide a good balance of mechanical and thermal properties while delivering up to 75% cycle-time savings based on current Ingeo grades. Heat distortion temperatures (at 66 psig) are in the range of 15°C higher than previous-generation solutions. NatureWorks LLC Contact info and more items like this at wf.net.au/T981

Jul/Aug 2013

www.foodprocessing.com.au

Smart bottle ignites beer packaging world

PACKAGING

Dutch brewer Heineken has launched Ignite, the world’s first smart beer bottle, which can interact with other Ignite bottles, its environment and the people around it. The interactive bottle uses microsensors and wireless networking technology to sense the moment when a bottle is being used to say ‘cheers’. The bottle can also actively respond to the music and the output of specific audio and data cues. For example, it can detect various motion types such as toasting, drinking and sitting idle on the bar top. The motions trigger certain light effects lighting up the complete bottle, enhanced by the swirls of beer, carbon dioxide and oxygen. In addition, the bottle lights can be remotely activated, so that each bottle becomes an active light source controlled by specially developed VJ software, allowing synchronisation of bottles to music. The housing under the bottle holds a custom-designed circuit board based around the open source Arduino hard- and software platform. It features eight bright LEDs, an efficient 8-bit microprocessor, an accelerometer to detect various motion types and a wireless network transceiver to communicate with the outside world. The 3D printed housing (designed and developed by product design firm C10) is made of two parts, allowing the unit to be re-used on multiple bottles of beer. The Heineken Ignite project aimed to develop an idea that would create a memorable Heineken experience that unlocks the power and possibilities of mobile innovation and technology. Heineken believes that mobile innovation could offer a much more rewarding experience than just an app and embraced the challenge to think about how the product could be leveraged as an interface to the brand experience. A prototype of the product was revealed 9 April at Milan Design Week as part of Heineken’s Lounge of the Future concept. The first prototype was clunky and still separate from the bottle itself, but it was used to demonstrate that the basic idea works. The next challenge was to minimise the hardware. Fifty individual components needed to seamlessly work together. With a custom-designed board, the tech team managed to reduce the size of the whole board to just larger than a €2 coin.

The boards need their own custom casing, so the team from C10 started developing 3D printed designs that would hold the boards. The casing had to meet a host of requirements - it should be unobtrusive and stylish, made from a material that allows rapid manufacturing, should withstand cooling and house both board and battery. The team figured out a way to split the case design into two parts, one dummy part which is attached to the bottle and is disposable, and another which can be screwed on that holds all the electronics and the battery. This needs to be done just prior to serving because the cooling in the refrigerator plays havoc with battery life. The team eventually decided to hide the battery underneath the board, making the packaging less obtrusive due to the design, shape and colour. Several prototypes later - when software, hardware and casing design come together - Heineken had the final prototype of the world’s first interactive bottle ready. The launch in Milan provided Heineken with information on how the prototype would perform in a real-life environment. The concept is being optimised and, based on the success of the prototype launch, Heineken is now rolling it out in nightclubs in seven of its top 25 markets before the end of the year. The 2.0 version of Ignite has also already been identified and worked on for 2014.

Robot hardware platform and software controller Bosch Packaging Technology has launched Gemini 4, a Delta robot

updated hardware, manufacturers no longer need to use multipicking

hardware platform and software controller. Bosch says the platform

heads to enhance performance. Regardless of pack size or style, the

allows manufacturers to reduce the total cost of ownership of their

same head is used, eliminating downtime for changeovers. Bosch

automated production lines as it offers increased speed and lower

claims these gains in productivity mean a reduction in cost per pick.

changeover time.

In addition, due to its higher pick density in comparison with previous

The hardware component of Gemini 4 has a streamlined architecture

versions, the controller has a smaller footprint.

and integrates standardised industry equipment from Bosch Rexroth and

The controller offers easy set-up and operation. Its human machine

Beckhoff. Operators can run up to eight Delta robots and 16 conveyors

interface (HMI) can store instructions for multiple products, which

through the simplified controller.

speeds initial set-up and reduces changeover time from 20 min to

The streamlined design of the controller and its software are op-

1 min (including gripper changeover). The software utilises a user in-

timised for the control of Delta robots, helping increase acceleration

terface similar to previous Gemini iterations, ensuring operators familiar

and pick rates. This may enable manufacturers to enhance accuracy

with the system need only minimal training.

and raise production line speeds by up to 25% (product dependent), while maintaining gentle product handling, process reliability and qual-

Nupac Industries Pty Ltd

ity. With the Gemini 4 controller and the gains in speed inherent to the

Contact info and more items like this at wf.net.au/T796

www.foodprocessing.com.au

Jul/Aug 2013

Antimicrobial wall cladding Dotmar EPP has available the RĂśchling TroBloc F antimicrobial wall cladding that prevents microbes, bacteria, viruses and moulds from proliferating on its surface. It does not use any toxins to achieve this antimicrobial effect. The E. coli organism has a tendency to move towards the accumulation of nutrients and avoid acids and high concentrations of salts, which could cause damage to the organism. TroBloc F is claimed to prevent this process.

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The claddingâ&#x20AC;&#x2122;s effectiveness against the Escherichia coli bacteria has been verified by a series of tests conducted by the laboratories of Ciba SpezialitĂ¤tenchemie AG, Basel/Schweiz. The surface of the TroBloc F is scratch resistant and can be cleaned easily. It has a constant, long-lasting effect because the active ingredient does not migrate. It is suitable for use in the food processing and packaging industry, meat and poultry processing, the beverage industry, catering and the dairy industry.

Automated storage and handling systems Dematic RapidStore Mini Load (ML) systems provide increased performance for automated storage and handling of prod-

Dotmar EPP Pty Ltd

ucts such as cartons, cases, totes and trays weighing up to

Contact info and more items like this at wf.net.au/U127

450 kg. Uses include kitting, buffering, staging and sequencing stock in manufacturing and distribution applications. Dematic RapidStore ML and ML+ Storage & Retrieval Machines (SRMs) provide a suitable interface between bulk reserve stock and online stock in picking and assembly applications. They can be designed to meet height and throughput constraints, and tailored to meet storage and handling requirements. ML and ML+ systems can be integrated with a comprehensive range of conveyors, diverts, merges and accumulation conveyors, as well as a range of conveyor sorting systems, to transport stock to and from the system in the right sequence to meet the needs of high-speed kitting and order fulfilment applications. Single-masted SRMs can handle up to four loads at a time. Clever design minimises the distance between storage systems and the load, providing better overall space utilisation. There are six models in the RapidStore ML family. The ML10 and ML14 are designed for dual handling of totes,

Tracking and recipe control system

trays, cartons and cases weighing up to 50 kg, to heights of 10 and 14 m respectively. Lightweight aluminium masts

Matcon has launched Track-Record, an intermediate bulk container (IBC) tracking and recipe control system for use in powder processing.

The lightweight aluminium double-masted ML20 ensures stability and safe operation up to 20 m high. The ML20

Traceability and quality assurance is becoming increasingly

can carry one, two or three LHDs in single or double deep

crucial for manufacturers of food and other high-value processed

configurations, meaning it can handle and transfer up to six

ingredients. The number of recipes, ingredients and particularly

loads at a time.

allergen concerns are increasing. When combined, this results

The ML+300 is a heavy-duty, double-masted ASRS made

in new manufacturing challenges in ensuring brand names are

from lightweight, high-strength steel. It can handle loads of

not at risk due to manufacturing methods or human errors.

340 kg to heights up to 20 m. It is suitable for use with single

Matcon has developed Track-Record, a purpose-made soft-

ensure rapid acceleration and travel speed.

and double deep telescopic tables with grippers and extractors.

ware package, which it says has the sole purpose of providing

The single-masted ML+350 and ML+450 are suitable

total control of operations in powder processing systems. Apart

for use with a range of specialised LHDs in applications as

from offering quality assurance, the software may also provide

diverse as spare parts stores, machine assembly centres

improved plant output and efficiency by structuring workflow

and libraries, where heavy loads are typically carried in steel

and optimally utilising people and machinery.

bins or crates.

Matcon Pacific Pty Ltd

Dematic Pty Ltd

Contact info and more items like this at wf.net.au/U123

Contact info and more items like this at wf.net.au/T628

Jul/Aug 2013

www.foodprocessing.com.au

Weighing up quality and quantity

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Short batch runs and strict hygiene can hinder high manufacturing efficiency. In a conventional pharmaceutical plant, for example, one batch per shift is typical. However, at its dry powder blending and packing facility in Suzhou, China, Stern Ingredients is able to change recipes in less than an hour - without any hygienic compromise. This results in very low processing cost per kilogram. Stern achieves these results by harnessing smart design features combined with the ‘parallel processing’ concept. Matcon assisted Stern with an initial concept design for its facility, as well as providing all handling and processing equipment. In China, demand is growing for flour standardisation and fortification as the downstream market, such as bakeries and biscuit producers, is evolving from artisanal towards industrial ventures, where reliable and predictable behaviour of raw materials is a necessity. Consumers are also increasing their demands for increased safety and transparency, especially staple foods like noodles and bread. Stern opted to establish a local operation in China, as importing ingredients and compounds from Germany was not viable and a local production facility was considered essential. With this, Stern Ingredients (Suzhou) Co., Ltd was born. Stern wanted to assure the highest possible quality by installing state-of-the-art equipment and solutions for operations at the Suzhou facility. It was, however, a tough compromise between quality and investment, since initial production volumes were forecast to be low. Local and global equipment suppliers were evaluated, with the final decision in favour of UK-based Matcon, which has a local team in Shanghai. Matcon’s powder handling system had a higher capital cost than local alternatives but its ‘lean manufacturing’ philosophy not only meant that plant efficiency would be high, it also allowed Stern to begin with a moderate initial investment and add further process modules as demands increased.

Stern offers a variety of proprietary compounds as well as contract manufacturing, involving an almost endless number of ingredients. Strict operator procedures combined with accurate weighing equipment assure a ‘right first time’ approach. The formulated ingredients are placed on a batch pallet and taken to a dedicated tipping room. The batch is transferred into an intermediate bulk container (IBC) which is check-weighed to confirm that all ingredients are present. For quality assurance purposes, all ingredients are sieved and passed through a metal detector during the IBC Filling operation. The facility uses the IBC Blending concept, which ensures the powder stays inside the IBC during the blending cycle - no transfer is required. Once the 360° tumble mixing operation is complete, the IBC is unloaded from the mixing cage and moved to the packing area in its entirety. There is nothing to clean in relation to the mixer, which is immediately ready to process the next batch - even if it contains a totally different batch recipe. Matcon says this can be done with absolutely no risk of cross-contamination from the mixer. The building design, combined with equipment choice and operator procedures, results in a plant that meets stringent food and pharmaceutical production legislation. Stern was amongst the first to receive the highest credits in China’s new and demanding hygiene audits. Still in the first year of operation, Stern has started production with a focus on specific key accounts, as well as emphasis on product quality over quantity. Hence, production volumes will stay below 1000 MT pa. Due to rapid growth, capacity utilisation is increasing fast. Fortunately, the nature of the IBC Blending concept and parallel processing philosophy means that the system is easy and cost-effective to scale up. Additional packing suites may be employed, while still using the existing IBC Blender to produce up to four batches per hour. Stern is therefore well prepared to fulfil orders from the most demanding Chinese customers, as well as international companies aiming to ease their way into the market using contract manufacturing. Matcon has supplied numerous systems of varying sizes to different manufacturing industries in China in recent years. Armed with these references and a local qualified and dedicated team, Matcon expects China will become its largest market in the coming years. Matcon Pacific Pty Ltd Contact info and more items like this at wf.net.au/U146

Jul/Aug 2013

www.foodprocessing.com.au

Tubular cable conveyors Flexicon has introduced the Flexi-Disc line of tubular cable conveyors for the gentle transfer of friable food products. The conveyor moves material using high-strength polymer discs affixed to a stainless steel or galvanised cable that slide within smooth stainless steel tubing, moving fragile food products gently, quietly and dust free. The system can have single or multiple inlets and outlets, and convey

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over short distances or hundreds of metres. It can move products horizontally, vertically or at any angle, and through small holes in walls or ceilings. The conveyor is suitable for food products that are prone to breakage or degradation, including: cereals, coffees, teas, dried fruits, frozen vegetables, grains, nuts, peas, pet foods, seeds, snack foods and spices. Modular system components in 304 or 316 stainless steel include tubing, drive wheel housings, tension wheel housings, metered and non-metered inlets and discharges with and without valves, as well as accessories for wet or dry cleaning, including CIP sanitising. Available in unlimited configurations, the conveyor is offered as a stand-alone system, or fully integrated with upstream and downstream equipment such as inlet hoppers, bag dump stations, bulk bag dischargers, bulk bag fillers, drum/box/container tippers, weigh batching/blending systems, screeners, filling machines and storage vessels manufactured by Flexicon and others. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/U312

Complete Range of High Performance Doors www.assaabloy.com

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www.foodprocessing.com.au

Jul/Aug 2013

Automatic articulated palletising robot BEUMERâ&#x20AC;&#x2122;s robotpac, a space-saving, fully automatic articulated robot, is able to perform even complex palletising and de-palletising tasks reliably and efficiently. For each type of packaged good, the company has designed a suitable gripping system that can be changed flexibly. An additional tool changer allows the fully automatic use of multiple gripping systems that can be operated from a single robot working area. Grippers include: a fork gripper for palletising bagged goods and cardboard boxes; a finger gripper for palletising bagged goods; a parallel gripper for palletising cardboard boxes and other dimensionally stable containers with parallel side walls; and a suction gripper

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that handles all goods with suctionable surfaces.

The robotpac offers precision and availability, as well as gentle product handling. An ultrasonic system provides accurate measures of the stacking height, making it possible to calculate the exact placing position of the packaged goods and stack these precisely and carefully for optimal stack configuration. Regulated by complex control mechanisms, the robotpac can stack packaged goods of variable dimensions on one pallet. Individual programs cover all packing patterns. According to the company, the machine is easy to maintain and very quiet. Equipped with an additional drive axle and an integrated motor connected to the control system, the robotpac is freely movable on a guide rail. Consequently, it can be used in distribution centres for order picking tasks. The robotpac is claimed to be reliable even in dusty environments typical of packing plants and of the building material industry. BEUMER Group Australia Pty Ltd Contact info and more items like this at wf.net.au/U047

Hygienic powder bin aerators Tetra Pakâ&#x20AC;&#x2122;s Hygienic Powder Bin Aerators can be installed on powder bins, silos and batch hoppers to promote powder flow during discharge and prevent powder compaction during long-term storage. The working principle is based on introducing food-grade compressed air between the bin wall and the powder. Fluidising with compressed air loosens powder inside the bin and reduces the friction angle between the product and bin surface. The aerators eliminate the risk of valve rubber parts falling inside the hopper. The flush poppet-style valve head avoids the retention of powder particles between the valve parts and the inside of the hopper walls, preventing product cross-contamination and microbial growth inside the powder storage plant. The Retrofit Hygienic Powder Bin Aerator M25 is supplied fully assembled and allows easy installation in new and existing plants, with no additional work to retrofit the bins with previously installed fluidisers of other brands. The Externally Fitted Hygienic Powder Bin Aerator M50 allows mounting of the aeration points from outside of the bin, making it suitable for aeration of small vessels, vessels with difficult internal access or when handling difficult powders. It enables fast valve replacement and gives easy access to the product inside the hopper during inspections or maintenance. The Hygienic Powder Bin Aerator M75 for powder handling systems with cleaning in place (CIP) delivers compressed air, CIP fluid or drying air via the hygienic aerator valve inlets. It can be installed on a new plant or retrofitted onto powder vessels as part of an existing CIP system. Hygienic Powder Bin Aerators are air activated and controlled via pilot solenoid valves. They have a sanitary design, are fabricated from stainless steel or food-grade plastics, and require minimal maintenance. Tetra Pak New Zealand Ltd Contact info and more items like this at wf.net.au/U441 70

Jul/Aug 2013

www.foodprocessing.com.au

Track and trace system Authenticateit has launched a track and trace system to help stop manufacturers, retailer and shoppers unwittingly buying and selling counterfeit goods. The system allows brands to track and trace their products throughout the supply chain and prevent unauthorised distribution and grey im-

Aluminium two-stage helical bevel gear units

porting. It allows retailers to verify authenticity of

For hygienically demanding applications, NORD Drivesystems supplies aluminium two-stage helical

goods received from their suppliers.

bevel gear units in five sizes with a maximum torque of 660 Nm that are easy to clean. The washdown design is based on smooth inclined surfaces, and has transitions with large

Authenticateit smartphone application to check

radii without dead spaces and requires no assembly covers. Cleaning liquids wash off easily and

an item’s authenticity before purchase. Authen-

completely from the surfaces, which also remain cooler than those of conventional drives due to

ticateit’s system is fully compatible with GS1

the special construction. The design is suitable for use in the food industry and complies with

global standards, making it easy for brands to

international guidelines and standards such as EHEDG, ANSI/BISSC and ANSI/NSF. If required,

implement Authenticateit without the cost and

the gear units can be fitted with double shaft seals. They can be ordered as open or closed

hassle of adding additional identifiers.

frame versions with hollow or solid shafts. Designed according to the proven Unicase principle, the

The GS1 Databar was selected as the unique

housings are torsion resistant and withstand high mechanical stress. With the optional NSD tupH

product identifier (UPI), allowing consumers to

surface treatment, they become highly resistant to corrosion as well as acids and alkaline solutions.

scan it as a barcode to verify product authen-

NORD’s NSD tupH sealed surface conversion system is not a coating, which means that no

ticity and as a product barcode to be used by

layers can peel. Instead, the process transforms surfaces with up to seven times the hardness of

retailers at the point of sale.

the base aluminium material. Thereby, the housings acquire robustness and durability qualities that

Authenticateit enables brands to take imme-

are similar to stainless steel versions, while remaining lighter and more economic.

diate action to recall, bar, disable or neutralise

In addition to food industry processes, the gear units are also suited to conveyor systems and

unauthorised sales or imports. The Authenticateit

hoists, especially in applications where geared motors have to be moved and their light weight

smartphone app is available to consumers for free

becomes essential. All gear units can be combined with suitable smooth-surface motors from

download from the App Store and Google Play.

NORD or other manufacturers.

Authenticateit

NORD Drivesystems (Aust) Pty Ltd

www.authenticateit.com

Contact info and more items like this at wf.net.au/U124

Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

www.foodprocessing.com.au

Jul/Aug 2013

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Consumers can simultaneously use the free

$30 million facility to keep Adelaide cool

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Automotive Holding Group (AHG) has appointed Vaughan Constructions to deliver and leaseback a new temperature-controlled storage facility in Adelaide. The facility is for Rand Transport, a leading national refrigerated transport, cold storage and distribution services provider specialising in the transportation of temperature-controlled and frozen goods. The $30 million facility will feature a 15,000 m2 office space, 7500 2 m of chiller and annex at 4°C, 500 m2 of racked freezer area at -22°C, smart lighting, a specialised plant and equipment to run refrigeration. “Vaughan’s reputation for quality and detail, and their understanding of our unique needs, is what won them the project,” said AHG’s Phil Oates. “We’re confident they’ll deliver an exceptional result for Rand.” While Vaughan continues to focus its core business of building for owner-occupiers and directly for developers, its financial capacity and flexibility as a private company has allowed it to undertake some prelease deals as the opportunities arise. “Our preference is always to wear the D&C builder’s hat but occasionally we are not partnered with any of the key developers and are forced to go it alone,” said Vaughan Constructions Joint Managing Director Ken Vaughan. Construction commenced in February and is expected to be completed by late November 2013.

NEWS

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Maersk teams up with UN to combat global food waste To combat global food waste, Maersk Container Industry (MCI) has joined the United Nations’ SAVE FOOD initiative to help make international food logistics more efficient. Food losses in industrialised countries are as high as in developing countries, but in developing countries more than 40% of food loss occurs at postharvest and processing levels, while in industrialised countries, more than 40% of food loss occurs at retail and consumer levels, the UN Food and Agriculture Organisation says. As part of SAVE FOOD, MCI and other companies will share their expertise to reduce food waste. “Food is lost or wasted in all links of the food value chain, including transport and distribution,” said Robert van Otterdijk from UN SAVE FOOD. “One way to improve is to share knowledge across all links in the food value chain.” To date, MCI has hosted a refrigeration expert conference on optimal handling of fruit and vegetables and signed a memorandum of understanding with Chilean fruit exporters’ association ASOEX to exchange knowledge and optimise the use of technologies that can extend shipments of fruit and vegetables.

UV light could double shelf life of strawberries Strawberry lovers rejoice: the days of unpacking your luscious berries from the refrigerator only to find them sprouting wispy goatees of mould may be numbered. US researchers have demonstrated that low irradiance ultraviolet (UV) light directed at strawberries over long exposure periods at low temperature and high humidity - typical household refrigerator conditions - delays spoilage. A research team from the USDA’s Food Components and Health Laboratory and Sensor Electronic Technology, Inc (SETi) used a novel device incorporating LEDs that emit UV at wavelengths found in sunlight transmitted through earth’s atmosphere. The results are reported to be significant because previous attempts using traditional UV light sources for produce storage resulted in severe drying, and it was unknown if the advantages of long exposure to low-level UV light would be effective against rot. While LEDs have the ability to span the wavelength range from near UV to infrared, the full UV spectrum had presented challenges for LED manufacturers. SETi developed a special technology to fabricate UV LEDs across the entire UV spectrum from UVA to UVC. This flexibility allowed them to tune the emitted light to the wavelengths most effective for this application. “UV-LEDs presented the opportunity to try low-

Jul/Aug 2013

power devices that work well in the cold and can be engineered to work in small spaces such as refrigerator compartments,” said lead USDA researcher Steven Britz. To test the LEDs, the researchers placed one batch of strawberries in a dark refrigerator and another in a refrigerator exposed to UV-LEDs. The UV-treated strawberries stayed mouldfree for nine days - a twofold shelf-life extension. The extended shelf life was judged by weight, moisture content, concentration of select phytochemicals, visible damage and mould growth. The team is working to commercialise the technology for home refrigerators. “These findings are expected to have a major impact on the appliance business to extend the shelf life and preserve nutritional value of fresh produce while reducing waste and saving money for every household,” said Remis Gaska, president and CEO of SETi. The research results were presented at the Conference on Lasers and Electro-Optics (CLEO:2013).

www.foodprocessing.com.au

NEWS

Bulk

Program available for Queensland Supply Chain & Logistics Conference

Fonterra has announced a further $30 million investment to expand its dry distribution centre at its Whareroa site in Taranaki. This follows a $23 million upgrade of the Whareroa coolstores last year, bringing the total capital investment in the logistics infrastructure on site to more than $50 million since 2011. Director of Logistics Mark Leslie says the project is part of Fonterra’s overall drive to simplify their supply chain and reduce the associated costs. “These investments are part of a strategy to deliver more products, more directly to ports for export. “Our capacity to process milk continues to increase, which means that our storage capacity must grow to meet this. Where possible we want to store product at the point of manufacture to reduce costs,” says Leslie. Fonterra has steadily increased on-site storage capacity building four distribution centres since 2008 at Crawford Street in the Waikato, Mosgiel near Dunedin, Kauri in Whangarei and Darfield in Canterbury. “This investment at our Whareroa facility will improve our logistics network’s storage capacity and address existing capacity constraints in the region. “This means we are able to reduce the number of freight movements from where a product is manufactured through to delivery to the customer, which reduces our carbon footprint and ultimately saves on transport costs,” says Leslie. Construction is expected to be complete by August 2014.

Fish shipment fresh after 33-day sea journey Global Fresh Foods has sent its first commercial sea shipment of fresh fish to Tokyo from Talcahuano, Chile, using its fuel-cell based oxygen management system. The shipment of salmon will spend up to 33 days at sea before being sold at Tsukiji Fish market, the world’s largest wholesale fish and seafood market. GFF’s technology completely removes oxygen from the shipment, which the company says means the fish will arrive at its destination as fresh as the day it was packed. It eliminates the need for ice, polystyrene packaging and air freight. “We have been working with our partners in Japan to completely transform what is now a largely frozen trade route for Chilean salmon into a market for fresh fish,” said Mark Barnekow, CEO of GFF. In May 2013, the company successfully freighted more 18,000 kg of fresh salmon from Chile to Long Beach, California, without polystyrene or ice.

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Jul/Aug 2013

BULK

The program for the 14th annual Queensland Supply Chain & Logistics Conference is now available. This year’s event has the theme of ‘Supply Chain Sustainability: Exploring its impact on you and your business’. The conference’s extensive line-up of guest speakers includes: Robert Allan, CEO, Royal Wolf Holdings; David Overall, CEO, Downer EDI Mining; Phillip Di Bella, Managing Director, DiBella Coffee; and Richard Hancock, CEO, National Heavy Vehicle Regulator. To be held on Thursday 29 and Friday 30 August at the Sofitel Brisbane Hotel, the Queensland Supply Chain & Logistic Conference is the largest event of its kind in the state and is suitable for supply chain, logistics, transport and procurement professionals and practitioners. Day two of the conference will involve three Advanced Workshops for high-end, hands-on personal and professional development. Delegates can choose one of three sessions: Procurement; Change; and Supply Chain Collaboration. For more information and to register for the 2013 Queensland Supply Chain & Logistics Conference, visit www.qldscc.com or email info@qldscc.com.

Fonterra invests another $30 million at Whareroa in Taranaki

Inline postgasser Modified atmosphere packaging (MAP) is used for replacing ambient atmospheric air with inert gas in fat-containing powders during hygienic packaging. This prevents powder products from deteriorating and prolongs shelf life. Historically known as Bulkpak 25, the Inline Postgasser by Tetra Pak is used for fat-containing powders packed into 25 kg powder

BULK

bags or cartons with plastic inner liner. The postgasser offers safe operation and can be integrated into new or existing filling lines with different levels of automation. It is installed immediately before airtight

Pick-and-place robot

bag closing stations. The order of operation is as follows: the line conveyor

To extend the usefulness of

transports the bag to the postgassing station, and the

the IRB 360 FlexPicker, ABB

bag is locked in place by the front and rear clamp plates.

has increased its top payload

Postgasser probes go down into the powder; a plastic

from 3 to 8 kg. Designed for

cover plate protects powder from external contamination

both picking and packing ap-

and minimises powder exposure to the atmospheric

plications, the robot can pick

air. Ambient air present in powder is evacuated

up heavier items, handling up

by vacuum and replaced with an inert gas. The

to 100 cycles/min. Its average

probes are then removed from the powder, the

throughput capacity has also

clamping plates are released and the bag can be

been increased.

transported to the airtight closing. The postgasser has a minimal

The robot’s 1130 mm work-

footprint and high throughput rate, and offers savings of inert gas and consistently low residual

ing range has been optimised

oxygen levels. It is claimed to eliminate the need for filter or valve attachments in the barrier

for packing and is claimed to

liners. With all parts fabricated in stainless steel and food-grade materials, the postgasser is

have the smallest footprint of all

suitable for operation in cleanroom environments.

delta robots handling more than

The postgasser can be installed in combination with one of the company’s Bulkpak Heat

3 kg. Advanced motion control

Sealers or any similar bag-closing equipment.

simplifies the frame design

Tetra Pak New Zealand Ltd

and the tool flange has been

Contact info and more items like this at wf.net.au/U442

re-engineered to accommodate larger grippers. These larger and heavier

Heavy-duty HEPA vacuum

grippers make the robot suit-

Exair’s Heavy Duty HEPA Vac attaches to a 205 L

able for handling flow-wrapped

open-top drum to turn it into a powerful HEPA-

products, giving the FlexPicker

quality industrial vacuum cleaner.

the ability to pick up as many

The vacuum has been engineered to filter

as 500 products/min directly

contaminants to HEPA requirements in dusty

from an indexing belt.

environments requiring frequent cleaning.

In addition, a mounting in-

The compressed air-powered vacuum is

terface has been added to

quiet at 82 dBA, half the noise of electric

the robot’s moving plate. The

vacuums, making it suitable for a variety of

upgraded model has the same

environments. An easily maintained pre-filter

features as the original, such as

stops larger particles, while the HEPA filter handles

a hygienic design for washdown

the smaller matter.

applications, good tracking

All filters are tested for minimum 99.97% filtration

performance and integrated

at the 0.3 micron level to meet HEPA standards in strict

control of indexing belts.

accordance to IEST-RP-CC-007.

ABB Australia Pty Ltd

The vacuum is supplied with the Heavy Duty Dry Vac, lever lock drum lid, shut-off valve,

Contact info and more items like this at wf.net.au/U290

pre-filter, HEPA filter, 3 m static resistant hose, hose hanger, ½″ quick connects coupling, 6 m compressed air hose, pressure gauge, and aluminium chip wand (drum not included). Deluxe systems that include a drum dolly are available. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/U255

Jul/Aug 2013

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Bulk bag filling systems National Bulk Equipment (NBE) bulk bag filling systems are engineered, fabricated and constructed to speed inspections, simplify integration and ensure qualification for

These sanitary bulk bag filler systems also support process practice protocols where 3-A Accepted Practices or other cGMPs are necessary. The systems include features such as: 32 Ra surface finishes to simplify cleaning; tool-less, demountable assemblies to speed inspection; 3-A compliant components to aid in sanitary standards conformance; HEPA air filtration for sanitary bag inflation; and a structural framework leak test system to facilitate clean-in-place (CIP) procedures. These sanitary bulk bag fillers also offer NTEPcertified weigh devices to assure certified weight accuracy to ±.01%, to a 2000 kg bag weight. The integrated automation of NBE sanitary bulk bag fillers standardises controls programming and expands controls functionality to include legacy systems. System-wide automation of process operations, diagnostics and reporting are controlled through a single HMI. NBE integrated automation is claimed to improve equipment performance, optimise throughput and increase operator safety. National Bulk Equipment Contact info and more items like this at wf.net.au/U403

Experts in product movement Eye-Flex®

CCure Edge™

Wirebelt is the leading manufacturer of stainless steel conveyor belts for product handling and processing. Manufacturing range includes Flat-Flex , Eye-Flex , Compact Grid™, Honeycomb and Spiral Woven Mesh. Wirebelt - for conveying, cooking, cooling, covering, drainage, heating and drying applications. ®

Flat-Flex®

Compact Grid™

Richard Foot Pty Ltd. Unit 14, 2 Apollo Street, Warriewood NSW Australia 2102 Tel: +61 2 9979 8311 Fax: +61 2 9979 8098 Email: sales@rfoot.com.au www.rfoot.com.au

www.foodprocessing.com.au

Jul/Aug 2013

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start-up into food processing and packaging operations. The systems are 3-A, USDA, FDA and BISSC compliant.

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Meat wholesaler dehumidifies to cut ice and cost In South Africa, Durban’s moist and warm climate is an attraction for tourists but caused problems at Chester Wholesale Meat. The moist tropical air kept moving inwards from the truck loading area and condensing in the holding dispatch section, which is kept at 10°C. In addition to blinding mist, large amounts of condensation on the meat product, walls and floor caused a slippery build-up of water and provided a potential hazard for the workforce. This became so problematic that the area earned the nickname ‘the fish tank’. Beyond the holding area, moist air made its way to the cold store, which, at -25°C, caused it to cool and flow downwards to the store floor. The result was considerable formation of frost on the freezer coils as well as the freezer entrance, walls, floors and on product. Not only was this energy-inefficient, requiring multiple defrost cycles per day and high refrigeration plant load, but the formation of frost was destructive to product packaging and to the Chester product itself. For the client to be more efficient and successful, a moisture-free holding area and frost-free cold stores were needed. Controlled climate - key to success In order to alleviate the problem, Chester Wholesale Meat contacted Munters, with whom they had a four-year working partnership. Munters recommended the installation of IceDry MX2700 Desiccant dehumidifiers - one to be used in the holding area and one in the cold store. Payback was immediate. By means of the dehumidification process, the IceDry application enabled Chester Wholesale Meat to reduce the refrigeration plant load 11 times more effectively by using the MX2700 units, rather than allowing the plant itself to dehumidify the air. This resulted in significant savings and an environmentally friendly reduction in power usage.Because of the insulation barrier formed by the build-up of ice in the past, refrigeration had had to run longer in order to obtain heat transfer through the ice. Defrosting was necessary on a more regular basis - which utilised more expensive energy. Ice also caused forklifts to slip, resulting in repair to fridge panels, shelving and racking systems and damage to the

forklifts themselves. The dangers of water or ice slippage and injury provided a significant occupational safety concern. In addition, temperature fluctuations affected the longevity of the product. Frozen moisture in and on the product caused damage to product packaging, thus affecting product presentation. What does the dehumidifier do? Munters IceDry application uses desiccant drying technology to absorb moisture from the air on a molecular level, using high-performance silica gel in a patented rotor technology. Because moisture is removed using the sorption process, the energy consumption is fractional. Typically the energy used for a Munters MX system to remove moisture is 11 times cheaper than for the ammonia plant to remove the same moisture at -25°C. Range of dehumidification products The MX2700 (2700 m3 of air/hour) unit used at Chester Wholesale Meat removes as much as 25 kg of water/hour in this cold environment, with an extremely small energy footprint. The MX2700 is the smallest of the MX range of units, ranging from 2700 to 9000 m3/hour. The MXs are the largest stand-alone dehumidifiers in the Munters range, while the MDU, Modular Dehumidification Units, process as much as 80,000 m3/hour. Chester’s Operations Manager Steven Shrewsbury says that while he had had great expectations before the Munters system was installed, the impact of the system has actually exceeded his expectations. He says the cleanliness of the plant now, with the absence of water and ice, is great for hygiene and provides a good working environment. Corrosion and maintenance costs have come down, which has had a positive effect on the attitude to housekeeping. The maintenance costs on forklifts in the plant have been reduced, while the shelf life of product and packaging in the freezers has increased. Benefits of dehumidification at Chester Wholesale Meat • Reduced energy consumption • No frost and ice build-up at cold store entrances • No or very few defrost cycles • Dry floor in the holding area • Prevention of ice build-up on coils • Guaranteed meat product temperature and quality prior to transportation • Improved staff and equipment safety (no slippery floors, no mist) • Reduced refrigeration load up to 11 times Munters Australia Contact info and more items like this at wf.net.au/U318

Jul/Aug 2013

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Inventory control white paper Aggressive, hot, frozen and non-free-flowing or nonmeasure. When it comes to managing the inventory of

Multi-axis motion system

high-value solids, liquids and gases, gravimetric level

Complex motion-control applications of-

control offers inherent flexibility and accuracy.

ten require the design of custom systems

self-levelling materials can be challenging to accurately

Mettler Toledo has published a white paper, Inven-

- a process that can be expensive and time consuming for the project developers.

the benefits of tank and silo weighing as well as

The Technosoft iPOS360x SX multi-axis mo-

gravimetric level control.

tion system makes this phase faster and easier,

This addition to the companyâ&#x20AC;&#x2122;s collection of industry resources gives an expert overview of how businesses

giving the designer a compact (100 x 98 x 37 mm) ready-to-run solution based on the family of Technosoft iPOS drives.

can obtain accurate results for materials stored in tanks

iPOS360x SX allows users to plug in up to four iPOS3602 VX or iPOS3604

and silos while reducing the potential for contamination.

VX intelligent drives and provides all the necessary connectors (motor, encoder

The white paper also details the advantages of

feedback and I/O signal) for each drive. The drives are connected through a

gravimetric control, including effective inventory manage-

CANbus link. Two CANbus connectors plus an optionally connectable termi-

ment and production flexibility. It explains how weigh

nal resistor ensure a rapid connection to any CANbus network configuration.

modules can easily convert nearly any tank, hopper or

An RS232 link offers easy access to all drives for set-up and testing, using a

silo into a scale, as well as looking at how tank scale

standard PC.

installation impacts accuracy and safety.

Using iPOS drives, the system offers a solution for controlling up to four

Finally, it describes the importance of weighing

DC brushed, (rotary or linear) brushless or step motors (4 x 144 W, 4 x 36 V).

terminals and transmitters to tank and silo weighing

Each drive has a built-in motion controller and provides PLC features. Each can

and provides important maintenance information, ex-

operate as a standard CiA402 CANopen slave drive or can be programmed

plaining the predictive maintenance features on certain

to execute complex motion programs directly at drive level, using Technosoft

weighing equipment. According to the company, this

Motion Language (TML).

is important because well-designed, properly installed systems guarantee a long life. The white paper further explains the benefits of tank and silo weighing and provides expert advice on optimising these systems. For a copy of the white paper, visit:www.mt.com/

The TML language programming allows each drive to execute complex motion sequences including setting of various motion modes, I/O signals handling, arithmetic and logic operations, conditional jumps and calls or data transfers between axes. The motion system enables users to implement a multi-axis system by configuring any drive as master: the application master drive will call each axis to

ind-wp-inventory-control.

execute and confirm complex TML functions.

Mettler Toledo

Technosoft

Contact info and more items like this at wf.net.au/U320

www.technosoftmotion.com

www.foodprocessing.com.au

Jul/Aug 2013

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tory Control: Tank and Silo Weighing, which explores

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Albany provides Primo door solution

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, Jeanette Teuma, Colleen Sam Packaging Section Editor: Alice Richard Assistant Editor: Alice Richard Circulation Manager: Sue Lavery circulation@westwick-farrow.com.au Copy Control: Mitchie Mullins copy@westwick-farrow.com.au Advertising Sales National Sales Manager - Nicola Fender-Fox Ph: 0414 703 780 nfender-fox@westwick-farrow.com.au 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

Primo Smallgoods is the largest producer of ham, bacon and smallgoods in Australia. Founded in 1985, the company began with just 38 employees and one manufacturing facility in Homebush, Sydney. Now, the company has in excess of 4000 employees and has constructed Australia’s largest food manufacturing plant in the Brisbane suburb of Wacol. The new state-of-the-art modern facility consolidates three separate plants under one roof on an 8.6 hectare greenfield site and will almost double Primo Smallgoods’ production capacity and markedly boost efficiency. Stage one of the Wacol project involved the construction of a raw material freezer and distribution chiller. Stage two will involve the construction of a smallgoods, value-added meats, ham, bacon and salami processing operation as well as corporate offices. Primo continues to stay ahead of its competitors with investments in new high-tech machinery, including the use of the Albany Doors’ range of highperformance doors. Through consultation with construction company Wiley, Albany was able to provide high-performance door solutions for Primo’s freezer, processing and distribution areas. Models such as the RapidRoll 660 and Envico Igloo were used to cope with the busy demands of Australia’s largest production facility and ensure reliability in even the harshest environments.

Contact info and more items like this at wf.net.au/U144

Jul/Aug 2013

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March 2013 total CAB audited circulation (Aust + NZ): 6501 readers (81% personally requested)

Albany Doors Systems

NZ - Gemma Burr Ph: 0800 44 2529 Fax: +61 2 9489 1265 gburr@westwick-farrow.com.au

Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP100007395 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.

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