What’s New in Food Technology Mar/Apr 2012 by Westwick-Farrow Media

food for thought 10 Test tube hamburgers 14 Australia and New Zealand on display

24 Processing and filling technology for liquid-food beverages

37 Megatrends in the beverage industry

packaging

beverages

©iStockphoto.com/Tom Young

©iStockphoto.com/Yulia Saponova

contents

March/April 2012

40 53 74 bulk handling, storage & logistics

45 Safety in Action and Melbourne Materials Handling trade shows 47 Changing refrigeration lighting could save millions 50 Cleanroom technology ensures longer-lasting produce

processing 55

The 19 best new products and technologies for food processors

testing and quality assurance 78 Pill to prevent listeriosis may be on the horizon

67 Processed food gets real with advanced thermal heating technologies 72 Confectionery leads product launch activity

www.foodprocessing.com.au

March/April 2012

©iStockphoto.com/Cathleen A Clapper

Did you like the purple colour on the cover of this issue of What’s New in Food Technology & Manufacturing? In the original image, the bottle furthest to the right contained a red drink but we have had so many red- and orange-themed covers on the magazine lately that our designer cleverly recoloured the drink purple. Selecting images for the cover of this magazine is trickier than you may think. When we had food on the cover everyone assumed we were full of recipes. Largescale food processing images are quite hard to come by and there are really only so many pictures of food on a conveyor that can be countenanced. Even when we do come across a good image, the problems don’t stop. One cover image from Belarus a couple of years ago included so many safety glitches that a company we know of uses it as a ‘Find the mistakes’ quiz in its food and personnel safety training. Compounding the difficulties of finding the ‘right’ cover is the number of people involved, all of whom think their opinion is the most valid! The publisher, the art director and the entire editorial department put in their 20c worth and they never all agree. As the editor, I think I should get what I want - but this is not easy. I can’t see why I can’t have cows on every cover. Cows are lovely. But no - everyone painfully points out that the magazine covers the whole of food processing in Australia and New Zealand and that cows on every cover would send the wrong message. Really? I argue that just because you manufacture biscuits or soft drinks doesn’t mean you feel excluded if there are cows on every cover of the magazine. Isn’t this true? Let’s face it, no one ever complained when, for a couple of years in the early 2000s, I used cows as the story stop at the end of every article. No one ever said they felt excluded. But this was considered irrelevant as I lost the battle to have a drawing of a cow reclining in an easy chair and drinking grass juice on the cover of this issue of the magazine. But keep an eye on future covers - this rather glorious cow will get her day in the sun yet! If you are doing something rather interesting in the food processing arena and want to tell the world, please send the details to me. And please include some high-resolution images (cows given extra points). Actually, cows and stainless steel - now there’s a combo!

©iStockphoto.com/Smokeyjo

Crumbs from my table

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

March/April 2012

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

Are your service suppliers FOOD SAFE and HACCP compliant?

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

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

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CSIRO’s FIESTA 2012 workshop CSIRO is once again hosting the International Nonthermal Food Processing Workshop - FIESTA 2012, supported by the Nonthermal Processing Division of the Institute of Food Technologists (IFT) and the European Federation of Food Science and Technology (EFFoST). The workshop will be held in Melbourne’s Bayview Eden Hotel from 16 to 17 October. In addition, a focused short course on innovative food processing technologies will be run on 15 October. The course will include a tour of CSIRO’s $40m food processing pilot plant. The workshop’s theme this year will be ‘Innovative Processes for Sustainable, Safe and Healthy Foods’.

The workshop offers opportunities for nonthermal and other innovative technologies in adding value to foods and enabling the sustainable manufacture of healthier food products, such as reduced salt, fat and sugar, that benefit the Australian and international markets. To reflect the year’s theme, sessions will address innovative technologies for such topics as: a sustainable future; a safe supply chain; sensory aspects, human health and nutrition; and processing and commercial development challenges. Travel assistance grants are available. Applications for these grants are now open. For more information, see the workshop’s website: www.innovativefoods2012.com.

thought

The Australian Food and Grocery Council (AFGC) has established an SME forum to cater for small-to-medium enterprises (SMEs) in Australia’s $10 billion food and grocery manufacturing sector. The Forum is intended to serve the needs of smaller food and grocery manufacturers and explore the issues that affect SMEs. A changing membership base has led the AFGC to turn its attention to smaller businesses. “AFGC has an increasing number of SMEs joining our industry organisation, which has been strongly and effectively advocating on behalf of food and grocery manufacturers since 1995,” AFGC Chief Executive Kate Carnell said in a media release. “AFGC has also updated its membership fees to reflect the capacity of smaller manufacturers and is encouraging more SME CEOs to serve on AFGC’s Board.” The AFGC held its first SME Forum on March 15 in Sydney, featuring guest speaker Coles Group General Manager Supply Chain George Dymond, who provided an overview of Coles’ strategy, engaging with Coles, innovation and Active Retail Collaboration (ARC). The Forum is open to full AFGC members.

Salt may be linked to gastric cancer risk Food processors could experience increased pressure to reduce salt in food products, following the publication of a study linking salt intake with gastric cancer. The study, published in Clinical Nutrition, was a meta-analysis of previous research published in the journal to examine the possible link between salt intake and the risk of gastric cancer. The research team from the University of Naples Federico II drew on data from seven previous studies of nearly 270,000 people to make its conclusions. The study found that those who have a high or moderately high salt intake have a 68% or 41% greater risk of gastric cancer respectively than those whose salt intake is low. Professor Graham MacGregor, chairperson of CASH

March/April 2012

(Consensus Action on Salt & Health), said in a media release that this study provides “strong evidence that we need to reduce salt intake around the world”. “It is time that all countries around the world follow this lead to reduce salt intake to less than 5 g per person per day as recommended by the World Health Organisation in order to save the maximum number of lives,” he commented. However, reducing salt content presents a range of difficulties, including consumer acceptance and food safety and shelf life. These factors could make reducing salt content difficult for food manufacturers, but consumer awareness of salt intake may force the industry to change its approach to salt in food products.

www.foodprocessing.com.au

©iStockphoto.com/Sean Locke

Fo d FOR

image©iStockphoto.com

AFGC establishes SME Forum

New ISO standard means safer radiation Food irradiation could be made safer with the introduction of a new ISO standard, ISO 14470:2011. In a statement on its website, ISO said that the new standard will benefit those involved in food processing, from manufacturers through to consumers. Ultimately, ISO hopes the standard will lead to greater confidence in and transparency between food regulators and consumer representatives. Food irradiation involves exposing food to ionising radiation to improve its safety and quality. It can control pathogenic microorganisms and parasites, reduce the

number of microorganisms that lead to spoilage and extend a product’s shelf life. Irradiating bulbs, tubers and root crops can even prevent them from sprouting. Irradiation is only suitable for food that has been produced under what ISO calls good manufacturing practice (GMP) principles. ISO 1470:2011 has several objectives. It aims to provide directions for an agreement between customers and irradiator operators, as well as establishing a system of documentation to support the controls on the food irradiation process.

Self-chilling beverage can launched in US Californian beverage group Joseph Company International is launching its self-chilling beverage can in the US in March 2012. The self-chilling can will contain the company’s energy drink, West Coast Chill, which is reportedly based on natural ingredients and contains no sugar or caffeine. In research and development for over 18 years, Joseph Company’s Microcool technology has received multiple awards for its design. Despite initial environmental issues - the original technology contained the CFC Freon HFC134A - the technology is now “ecofriendly”, according to the company, using “CO2 reclaimed from the atmosphere and activated carbon ascertained from a renewable vegetable source.” To initiate cooling, consumers press a button on the base of the can, and within 3 minutes the temperature will drop by 30˚F, according to a press release issued by the company. Promoted under the catch-phrase “The Ice Age is Over”, the company claims this technology will revolutionise the beverage industry. Joseph Company claims it will provide recycling bins specifically for West Coast Chill cans so they can be re-used.

Juicy happenings Down Under As news of FSANZ’s response to the carbendazim situation in the US reached the Australian media, sensationalist headlines abounded. “Toxic orange juice alert follows US warning of fungicide,” wrote the Courier-Mail. A Current Affair published an article beginning with the alarming sentence, “It is unlabeled [sic], dangerous and on our supermarket shelves.” Even the Sydney Morning Herald jumped on the bandwagon: “Chemical scare sparks call for juice import tests.” FSANZ was roundly criticised for not recommending increased testing of imported orange juice. One vocal critic of FSANZ’s response was Citrus Australia, the peak body for citrus growers in Australia. It issued a media release on 13 January calling for increased testing. On 18 January, FSANZ issued a statement advising that “oranges and orange juice sold in Australia will not be permitted to contain any carbendazim after the existing permissions are revoked in the first quarter of 2012”. The statement stressed that the levels found in the US were well within internationally accepted limits and that consumers should not be concerned about carbendazim levels in juice. Citrus Australia’s Chief Executive Judith Damiani used both the organisation’s first press release and its second, “welcoming” the news that testing is being increased, as platforms from which to promote Australian citrus. Both press releases urge consumers to buy Australian oranges and orange juice in order to avoid contact with carbendazim. Damiani even attempted to harness Australian patriotism to plug the industry: “Make sure you buy Aussie juice or Aussie Valencia oranges for your breakfast or BBQ on

Australia Day!” Fruit Juice Australia issued a media release in October 2011 mentioning a shopper survey that “found that price is a more determining factor than origin” and “around half of Australian grocery buyers (47%) don’t care where food comes from as long as it is good quality and reasonably priced and 56% think imported food keeps Australian prices competitive”. In a consumer climate such as this, is it any wonder the citrus industry is seizing any opportunity to promote Australian produce? Both of Citrus Australia’s press releases had the feel of marketing material, each concluding with a list of recommended brands that use the Aussie Grown endorsement logo - supported by Citrus Australia, of course. Despite the changes to testing of imported orange juice concentrate in Australia, FSANZ continues to argue that carbendazim levels in orange juice don’t pose a risk to consumers’ health. “A 70 kg adult would have to drink around 150 litres of orange juice in a day before going over the safe level,” a media release on FSANZ’s website declared. The changes to Australian standards mean that now no oranges or orange juice sold in Australia will be permitted to contain carbendazim. So why does FSANZ continue to insist on the safety of current carbendazim levels in juice? Surely if they were acceptable, current standards would not need to be altered. Is this a case of FSANZ attempting to save face? Or should the EPA’s assessment that the levels found in US juice are non-threatening be enough to convince consumers that the old Australian standards were sufficient?

www.foodprocessing.com.au

March/April 2012

Crown Prince Frederik inspects Jasol system at Don KRC

Draft standards for probiotics Probiotics are finding their way into a wide variety of food products as a result of consumer interest and manufacturing innovations. In response to the increase in probiotic food ingredients, the forthcoming Food Chemicals Codex (FCC) will include draft standards intended to ensure quality in these ingredients. The latest FCC Forum will contain the proposed standards, which are available for public review and comment. The standards include quality specifications such as identification and enumeration (microbe count), as well as intended uses in food, safety, regulatory status and purity of probiotics and other microbial food cultures. They also offer information on probiotics, including testing to assess product safety and health claims of probiotic ingredients. The FCC Forum is a free-access online vehicle through which proposed FCC standards are published for public review and comment. It is published by the US Pharmacopeial Convention (USP).

Happy birthday tna This year, the Australian packaging company tna is celebrating its 30th birthday. Starting from scratch in 1982, the company has now installed more than 6000 production lines in 120 countries and has an annual turnover in excess of $45 million. Its iconic product, the tna robag vertical form, fill and seal bagger was conceived as two circles and a dot on the back of a serviette in 1983. The bagger used continuous rotary motion, all servo controls and rotary continuous motion jaws with a stripping action to achieve snack food pack rates only previously dreamed of. Following the first installation in 1986 at the Smiths Snack Foods plant in Sydney, continuous improvement has meant that by 2004 the robag 3 VFFS was packing an astonishing 220 bags/min. International interest in robag Interpack at 1991 resulted in tna’s expansion

March/April 2012

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all around the world and currently it generates 95% of its annual revenue from overseas. At Cirque du tna, the company’s 30th birthday party, tna’s founder Alf Taylor paid tribute to his wife Nadia, his family, his employees, suppliers and clients. He also announced an anniversary competition where winners will join tna at PackExpo in Chicago and potentially take home a $5000 diamond (visit www.tnasolutions.com). While tna also supplies the roflo product conveying and distribution system, seasoning systems, multihead scales, checkweighers, date coders, metal detectors, case packers, palletisers, fully automated multipacking and complete processing equipment, the robag must have a special place in the hearts of Alf and Nadia because the family dog’s name is robag!

©iStockphoto.com/Joe Biafore

thought

and the Danish Trade Minister toured the plant and saw a demonstration of the Jasol cleaning system in operation. “Jasol and Systems Cleaners have worked together to install a market-leading cleaning system that sets a benchmark for the cleaning of food processing sites,” said Anthony Symons. “It’s great recognition for Jasol and Systems Cleaners to have the Crown Prince and Danish Business Delegation come all this way and learn about the cleaning system utilised in the very large KR Castlemaine Plant in Victoria.”

©iStockphoto.com/Diane Diederich

Fo d FOR

image©iStockphoto.com

Don KRC recently received a special visitor to its Castlemaine plant in Victoria. As part of his visit to Australia, Crown Prince Frederik of Denmark inspected Jasol’s ‘smarter way’ system for cleaning Don KRC’s Castlemaine plant. Sporting a hair net, apron and disinfected boots, the Crown Prince spent time with Jasol’s National Market Manager of Food, Anthony Symons, and Systems Cleaners Managing Director, Peter Jessen. The Prince

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Test tube hamburgers Instead of paddock to plate, your hamburger could soon be making a journey from the test tube. Two scientists outlined their research into meat substitutes grown in the lab at the AAAS (American Association for the Advancement of Science) annual meeting on 19 February, revealing new possibilities for more sustainable meat production to feed the world’s growing population.

ark Post, a scientist at Maastricht University, is using cow stem cells to create tissues that “resemble the skeletal muscle that makes up steak or hamburger,” according to a report on the AAAS’s Annual Meeting. According to the BBC, Post has grown pieces of muscle 20 x 10 x 1 mm that resemble calamari. He hopes to make a hamburger composed entirely of created meat by October this year, which will cost around €250,000. Costs should decrease once the technology is established. Post is hoping celebrity chef Heston Blumenthal will agree to cook the first hamburger in the European Autumn. Stanford University biochemist Patrick Brown is creating meat from plant materials. He anticipates his technique will be used not only to create meat, but also dairy and other products and claims his products will appeal to even “the hardcore meat and cheese lovers who can’t imagine giving all this up.” Brown told the AAAS meeting that using plant materials will be a cheaper and more sustainable way to produce meat. The consensus at the AAAS meeting was that current techniques for producing meat are inefficient and environmentally disastrous. Brown explained that only 4% of the 10

March/April 2012

world’s land surface is used to grow crops for human consumption, compared with 30% that is used for grazing and growing crops for livestock feed. Post told the BBC that it takes 100 g of vegetable protein to produce 15 g of animal protein - a low 15% efficiency. His synthetic meat could have an efficiency of up to 50%. Possibilities also exist for making meat healthier when it’s produced synthetically. At the inaugural If Conference in London in November 2011, Post said that there is a possibility to change the lipid composition of synthetic meats so they include more polyunsaturated fatty acids. Global meat consumption is a hot topic at the moment, with the WHO saying that meat consumption is set to double by 2050. One solution is for more people to become vegetarian, but Post acknowledges that’s unlikely to happen. However, with meat production as inefficient as it is, Post said, “a vegetarian in a Hummer is much less damaging for the environment than a meat eater on a bicycle.” Post’s lab has thus far only produced small strips of tissue, thousands of which will be needed to make a single hamburger. Synthetic meat production has a long way to go, but it looks like it’s off to a strong start.

www.foodprocessing.com.au

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Reaping the rewards 45th annual AIFST convention 15-18 July, Adelaide Convention Centre, Adelaide The Australian Institute of Food Science and Technology Incorporated has held an annual convention for the past 44 years. In 2012 the 45th Annual Convention will be held in Adelaide with the theme of ‘Reaping the rewards’. We invest considerable time in education, science, research, development, agriculture and production, so how do we reap the rewards for the future of food, science, technology and industry from the seeds we sow? Keynote speakers include: • M alcolm Bourne, Cornell University, USA Preserving food after harvest is an integral component of food security. • Geoff Fincher, University of Adelaide - Plant cell walls in cereals: technical applications in human health and biofuel production. • Patrick Wall, University College of Dublin, Ireland - Challenges delivering food safety in a global food chain. • John Kerin, ACT - If I knew then what I know now - a retrospective on agri-food policy. • Senator Nick Xenophon, Martin Hamilton-Smith MP - Food politics - a political perspective. There are sessions on: safe and sustainable food supply, supply chain excellence, best practice processing, consumer sensory, consumer marketing, consumer packaging, biotechnology, gut microbiome, prebiotics/probiotics, microbiology - man vs germ, babies and beyond, global opportunities, cook chill, IP capture and national food and nutrition development and technology transfer. The convention will also feature separate bookable interactive workshops on the 18 July and a trade exhibition with 30 stands. Registrations are now open. To view the program and to register visit www.aifst.asn.au/convention. All enquiries to Julie Bennett, tel (02) 8399 3996 or email julie@aifst.com.au.

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March/April 2012

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Australia and New Zealand on display

Anuga FoodTec is the premier international food processing equipment and technology exhibition. At this year's event, four Australian/New Zealand companies will show the international food processing community their wares. Heat and Control

Benefits: • Increase product pack depth • Reduce fryer size and floor space requirement • Reduce oil volume and oil turnover rate • Integrated de-oiling capabilities • Increase operating efficiency • Reduce system cost • Modular design for reduced installation costs

Founded in the back corner of a garage in 1950, Heat and Control has transformed the food processing industry by pioneering continuous cooking equipment. The company’s innovations include pioneering the external heat exchanger for industrial frying systems, high-speed processing equipment for potato chips and other snacks and the invention of the multipurpose oven, the MPO Cooking System. More recent innovations include the HeatWave fryer, FastBack conveyor, Revolution Seasoning System and Revolution Proportional Gate and the KleenHeat heat exchanger. The company is still privately owned and its second-generation management has expanded the portfolio into packaging systems and Heat and Control, in close partnership with Ishida, has become a full service provider of food processing technologies. Continuing its pioneering tradition of food processing technology development, Heat and Control is exhibiting four of its latest innovations at Anuga FoodTec. French fry system The next generation French Fry System is designed to improve finished product consistency and frying quality. Users have total control of product quality, providing an efficient solution estimating up to 25% reduced equipment costs. 14

March/April 2012

French fry system

On-machine seasoning system The FastBack Revolution On-Machine seasoning system delivers high efficiency by operating as an integrated system with bagmakers, weighers and product delivery conveyors.

www.foodprocessing.com.au

On-machine seasoning system Users can accurately and uniformly apply different seasonings at the point-of-packaging and use less seasoning. The on-machine seasoning system (OMS) can be used for: • Potato, batch and baked chips • Extruded products - slurry applied - topical seasoning OMS • Tortilla chips - both with and without pre-oiling • Nuts, crackers, grain chips, popcorn and mini rice cakes Slurry spray system Spray Dynamics is a Heat and Control company that began in 1970 by developing a bread pan oiler. The system addressed the need for a faster, cleaner, more efficient method for commercial bakeries to apply release agents to their bread pans. Since then, Spray Dynamics has become a world-recognised supplier of efficient, high quality and innovative equipment for the controlled application of liquid and dry ingredients. The company’s slurry spray system can be used to spray virtually any pumpable slurry, including sugar, syrup, chocolate, oil or emulsions. It has been engineered for cereal, snack and pet food applications to maximise coverage and Slurry Spray System minimise waste. The clogfree spray station design prevents nozzle plugging. It is available for use in coating drum and conveyor belt applications. Coating drums Every coating drum manufactured by Spray Dynamics is designed and engineered specifically to meet the requirements of the product. The Soft Flight Coating Drum features a shell-in-shell design that provides sanitary operation and simple cleaning for meat, dairy and other process-specific applications. The variable tilt frame assembly and product flight design exposes each piece of product to the application of liquid and dry coatings. This custom product flight configuration reduces breakage. Soft Flight coating drums are available in a variety of sizes and configurations. Heat and Control (www.heatandcontrol.com)

Coating drums

Goldpeg International Gold Peg specialises in direct steam injection (DSI) continuous cooking systems for pasteurisation, UHT/sterilisation and aseptic cooking and processing. The company provides industrial food equipment for the production of processed cheese, mozzarella, desserts, rendered meat products, pet food, taco meat, sauces, soups and dips, baby food and infirmed food, fruit and vegetables and more. The RotaTherm Direct Steam Injection Continuous Cooking System has been designed so that users can set the heating and processing parameters such as cooking temperature, heating profile, shear, pressure, mixing as well as various other settings - all with a precise level of control. The latest release, the RotaTherm CUBE System delivers flexibility and accurate control for throughputs up to 1,000 kg/h. Gold Peg also offers ancillary equipment including feed systems, auger feed hoppers, direct cooling using vacuum de-aeration flash vessel, indirect cooling, surge vessels, creaming tanks, conveyors, blenders, temperature probes, control systems and CIP systems. Gold Peg International (www.goldpeg.com.au)

Gold peg international Cavitus Pty Ltd Cavitus focusses on high power ultrasound (HPU) - an emerging technology that is clean and green and adds to the sustainability efforts of the businesses who embrace it. Ultrasonic sound waves, as emitted by Cavitus systems, cause the creation of sub-microscopic vapour bubbles in the liquid phase, which expand and contract thousands of times per second. The collapse or implosion (cavitation) of the vapour bubble creates localised high temperature (up to 5000+ K) and pressure (of 2000+ atmospheres) and the creation of a fast moving high-shear energy wave (570 km/h). The high-shear energy created by the cavitation effect can be focused and used in a range of applications such as the modification of particles in a liquid, the breakdown of cellular and molecular structures, de-aeration of liquids and surfaces. Currently the company offers 5 HPU application families which cover extraction, temporary viscosity reduction, density enhancement, de-foaming and cleaning and sanitation. Cavitus (www.cavitus.com) GEA Avapac GEA Avapac's core business is the design and manufacture of a range of bag filling machines and hygienic packing systems for a wide variety of powders. In 1994 the GEA group recognised the potential of NZ company, Avalon Engineering and acquired the company. Founded in the mid-70s, Avalon Engineering focused on the design and production of hygienic packaging components and systems for the NZ dairy industry. GEA Avapak (www.avapac.com) www.foodprocessing.com.au

March/April 2012

Packaging PACKAGING

NEWS Rebrand makes self-heating can sizzle on the outside

Glass container plant opens in Vietnam A state-of-the-art glass container manufacturing plant has opened in Vietnam. Joint venture partners Owens-Illinois (O-I), Berli Jucker Public Company Limited (BJC) and Saigon Beer Alcohol Beverage Company (SABECO) opened the US$47 million factory on 7 February. The factory will initially produce 75,000 tonnes a year of mainly returnable premium glass containers for Vietnam’s alcohol, soft drink and pharmaceutical markets. The plant has the capacity to produce 84,000 tonnes of glass each year to adapt to market trends. Employing nearly 450 people, mainly from the Ba Ria region, the plant uses natural gas for improved sustainability. It replaces an existing facility in Ho Chi Minh City that was vacated to accommodate the city’s urban development plans. The plant has opened in response to Vietnam’s recent strong economic growth and regional need for economical and sustainable packaging. 16

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Design Futures has given a self-heating canned food product a complete rebrand, bringing it into the 21st century and making it more appealing to consumers. The in-house design consultancy, based at Sheffield Hallam University, redesigned the product titles, strapline and logo while revamping the design of the HOTCAN brand of tinned food, which is produced by Heat Food & Drink. “The old design was quite busy and we wanted to make sure the main message was as prominent as possible. We also wanted to create a sense of character and tone for the range that would appeal to the target audience,” said John Kirkby, Creative Director of Design Futures at Sheffield Hallam. “The previous product titles were very straightforward, so we’ve used more informal titles wherever possible to demonstrate the fun element of the product. For the new logo we kept the wording bold and clear, adding a ‘degree’ symbol to the letter ‘C’ to highlight the self-heating element of the product along with the new strapline, ‘No microwave. No kettle. Just HOTCAN’.” Design Futures realised that not all consumers will appreciate the bright new packaging. The HOTCAN is also used by the emergency services, Disaster Management Agency and the military, so the design team also produced camouflage versions of the products for uses where high visibility is a disadvantage. The HOTCAN works using a self-contained heating mechanism that is activated by piercing the rim of the can with the provided key, setting off a completely safe exothermic reaction. It heats the contents of the can in 10-12 minutes, keeping it hot for up to 45 minutes. Mark Taylor, Managing Director of Heat Food & Drink, said: “HOTCANs have been produced for over 30 years but in 2010 we took over the product, so it was certainly time to revisit the packaging. We were looking for a distinctive, timeless identity that would really stand out on the shelf and we knew instantly that Design Futures had hit the nail on the head when we saw the proposals. “We’re really happy with the redesign - it gives the product a really new vibrant image. It’s been part of a complete revamp for the product, which has also included upgrading the heating mechanism, developing a new range of high-quality food, and we’ve even reduced prices to make the product more cost-effective for our customers.”

Innovative bottle for VB’s new beer

PACKAGING

Owens-Illinois (O-I) has helped Carlton United Brewers (CUB) introduce an innovative bottle for its new Victoria Pale Lager. Manufactured by O-I at its Sydney plant, the Victoria Pale Lager bottle is claimed as Australia’s only beer bottle with a fully embossed label panel. The classic green stubby bottle’s design was developed by CUB’s brand design agency Cowan, drawing on the masculine shape of the traditional Victoria Bitter stubby. The design was developed for manufacturing by O-I to align with Victoria Bitter’s existing secondary packaging and filling lines. “We’ve achieved a contemporary, premium-looking bottle well suited to the new lager without needing to make any changes to existing production and filling lines,” said Peter Sexton-Bruce, Business Manager, Beer, O-I Australia. Using its local, regional and global expertise with additional market research insights, O-I presented CUB with a range of packaging solutions for the lager designed to appeal to its target demographic. “We produced six fully embossed glass models and presented them to CUB’s marketing team to highlight the bottle’s true impact.” Craig MacLean, Group Marketing Manager - VB, said the Victoria Pale Lager’s package design was critical in creating interest from existing and new VB customers. “O-I’s expertise in glass manufacturing helped us turn a great-looking concept into a reality that will appeal to a new generation of VB drinkers,” said MacLean. “We’ve been working with O-I on a range of new packaging innovations and this bottle is a true reflection on the range of services, beyond glass manufacturing, that O-I can offer its customers.” The bottle also features a small neck label which has been added to provide additional information on the beer, complementing the overall design. Victoria Pale Lager is brewed using 100% pale malt, a variety known for producing fine lagers, combined with fresh green hop characters and subtle aromas, to deliver a quality flavour. O-I Asia Pacific Analytical Services Contact info and more items like this at wf.net.au/M137

March/April 2012

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Liquid filler The new models in the Masterfil range of liquid fillers are claimed to provide many advantages over standard piston fillers, including double-acting pistons to eliminate recharge time - 6 x 10 L/min for a twin head unit which is double a normal twin head unit; PLC control of settings with quick recall of up to 99 products and settings; multispeed filling to minimise splash at start and end of fill cycle; multiple filling heads from 1 to 12 heads; CIP adaptors; multi-stroking to fill from 500 mL - 20 L; and specialised flowmeter controlled units are available. Widely used for industrial and food applications in the UK, Europe and the Middle East, the Masterfil units are made to UK and European standards. Integrating the Masterfil units with conveyors etc is said to maximise the benefits available. The units are suitable for filling a range of products including cleaning products, lubricants, paint and food products. Australian Filling & Packaging Machines Contact info and more items like this at wf.net.au/M894

Laser-activated material for labels

Metal detection for plastic products

The Herma LAM laser-activata-

metal detectors for metal detection in plastic products.

Perfect Packaging has available a range of Mesutronic

ble material is a label paper that

The single-surface metal detectors are coil-under-belt

has been specifically developed

design and are available in a variety of models. They are

for use with CO2 laser inscription.

suitable for examining relatively flat and blow-moulded

When the laser makes contact

products such as bottles and fuel tanks for vehicles.

with the material, its specialised

The SL model does not require a metal-free zone,

coating changes from white to

making it suitable for installation in existing conveyors.

black. There is no damage to the label itself and the inscription won’t smudge or scratch

Perfect Packaging

FlexiFruit, What‘s New in Food Technology, 150 x 195 mm, CC-en24-AZ013_02_12 Contact info and more items like this at wf.net.au/M391

off, making it suitable for use in dusty or harsh environments, as well as for standard food, beverage or pharmaceutical application. The label material, coupled with CO2 laser technology, is suitable for high-resolution text, graphics and barcodes and can be used on all print orientations. Depending on the print size, it can deliver up to 200 labels per minute, is said to be more robust than thermal transfer and UV and temperature resistant. There is no need for thermal transfer ribbons or replacement of thermal printheads, which provides a saving on consumables. The system is fast and accurate with sharp, precise edges (high-resolution is available even in small fonts) which gives greater flexibility for customised printing - on or off the production line - before or after label application. The REA-JET CL laser coding system integrated with the HERMA 400 compact label applicator becomes an all-in-one print and application system.The Herma LAM self-adhesive material is smudge-proof, scratch-proof and resistant to solvents and grease, making it suitable for a range of applications.

Result Packaging Pty Ltd Contact info and more items like this at wf.net.au/M867

krones FlexiFruit – doses fruit

chunks as if they’re hand-picked. www.krones.com

PACKAGING

Label applicator system keeps the brew flowing at CUB Yatala With five breweries in Australia and others in Fiji and Samoa, Carlton & United Breweries (CUB) is Australia’s - and Fiji’s - largest brewer. Its Yatala Brewery in Queensland produces 450 million litres of beer each year, satisfying approximately one quarter of the nation’s thirst for beer. With advanced brewing and packaging technology, the stateof-the-art Yatala brewery has no room for inaccurate, incomplete or illegible pallet labels that slow output and raise production costs. Australia’s major retailers require logistics labels with unique serial shipping container codes (SSCCs) to be applied to pallets delivered to their distribution centres so they can be scanned on receipt. To ensure the production line continued to meet industry standards for pallet labelling, CUB needed a time-saving and robust solution that could withstand a 24/7 production schedule. The solution also needed to apply labels at multiple heights while complying with trading partner requirements, including the GS1 barcoding standards for pallet labelling. CUB turned to insignia, a strategic alliance partner of GS1 Australia. Working closely with CUB personnel, insignia developed a unique solution: the Domino printand-apply label applicator system. C U B ’s n e w p a l l e t labelling system has been running like clockwork since installation. The Domino applicator has reduced system downtime, lowered maintenance costs and increased production throughput for CUB, while meeting all of its customers’ changing technology requirements. The applicator sits within a sealed cabinet with a pneumatic door that opens only when a label is to be applied. The cabinet is designed to keep dust out, providing the Domino M-Series printer with an optimum operating environment. This ensures the printer and the printhead are not degraded by dust and other materials commonly found in warehouse and production environments - a fully functional printhead is vital for printing barcodes to GS1 standards. The Domino M-Series pallet applicator at CUB comes with a standard check-scanner feature mounted to the tamp pad and protected via a sensor system to ensure it is not damaged during operation. The check scanner scans the barcodes on the label to ensure that they are applied correctly and the barcodes are readable. It then verifies that the correct label and related GTIN and SSCC are applied to the correct pallet and in the correct position. The plant’s new Domino M-Series print engine operates with a 300 dpi printhead. This high-resolution printhead provides more options for the maximum magnification of the barcodes within the standards for the specific label size used. The scanner monitors the

March/April 2012

performance of the printhead. The quality of the printhead and the media management of the print engine ensure a quality barcode is produced even when printing a barcode in ladder format. This has allowed insignia to deploy a 4″ 300 dpi printhead at CUB and print the label in ladder format. Unique tamp-pad and tamp-arm cylinder technology within the system allows the label to be rotated 90° once on the tamp pad and applied in the correct orientation to the pallet. This means that if a pixel in the printhead does blow and a line is created in the print, it will not lead to an unreadable barcode as it will cut across the barcode bars leaving a legible barcode. A key feature of the CUB Domino M-Series SSCC palletlabelling system is its automatic height adjustment capability. CUB has a core need to meet an industry requirement of applying a GS1 logistics label to unwrapped pallets. In this case they need to apply the label to the side of one carton only on the pallet - not overlapping another carton. The Domino M-Series SSCC palletlabelling system’s automatic height-adjustment technology means that once a label is printed onto the tamp pad, the tamp arm will then drop to the requisite height for the specific pallet configuration for the product on the pallet and apply the label to a single carton. As only the lightweight tamp arm is moving to meet these differing height requirements, there is less wear and tear on the system and the arm can move quickly to apply the label in the shortest time possible. This feature can also be used to apply labels to part pallets within an operation. With this system in place, the label is applied in the correct position according to GS1 standards so the pallet can be scanned on receipt at the retailers’ distribution centres. The Swedish-made Domino M-Series has the highest quality boards and components. The simplicity of the applicators’ design makes it easy to use and to maintain. This has resulted in very high levels of up-time performance or OEE (overall equipment effectiveness) of the system. As a proactive business, CUB saw the potential supply chain benefits of implementing this system and the flow-on effects of this quality practice throughout their supply chain. Once a quality, readable GS1 logistics label is applied in the right location to the right pallet, products can be traced through the supply chain. To ensure consistent barcode quality, CUB Yatala has a comprehensive service contract with insignia that covers preventative maintenance and breakdowns. This means that their pallets continue to go out the door meeting GS1 standards. insignia Pty Ltd Contact info and more items like this at wf.net.au/M925

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PACKAGING

Versatile closure design for spice package Consumers don’t like being told what to do. Some prefer to pour their spices; others prefer to use a spoon. McCormick’s packaging engineers in France took their consumers’ needs into consideration when they were designing a new spice package with a wider neck and wider access. The engineers chose the Wetherchem FlapMate closure as the traditional single-method sift cap on the package wouldn’t truly satisfy all of their customers. “Weatherchem’s FlapMate closure not only fit the dimensions on our new wider bottle, but its design allows a customer to either pour [from or] put a teaspoon inside our glass container,” explained Natalie Jacqmin of McCormick, who’s part of the package development team in France working on the project. FlapMate closures provide a good solution for spice manufacturers, appealing to consumer interest in convenience and food safety. The butterfly hinge design allows for easy opening and closing with one hand. Some closures allow the hinge to flap down during dispensing, making it more difficult to control during pouring and creating spills. FlapMate’s lid provides good flow because it is specially engineered to stay in the full, open position providing greater control over product dispensing. With a tight close that’s sift-resistant, the closure provides an audible ‘snap’, confirming for the consumer the product is safe and fresh. The raised deck dispensing platform keeps the surface clean, and its one-piece design is simple for the manufacturer to use as there are no detached parts to track or assemble during capping operations. Jacqmin, who said McCormick is creating the new package as part of a private label project for the UK, noted that the FlapMate’s 43 mm dimension was important to the project, as most spice bottles in France are typically 38 mm. “We considered creating a mould to manufacture the new closure ourselves,” she noted, “but the quantities and time-to-market didn’t really allow for that decision. We knew Weatherchem had a product that would suit our needs immediately, with the right dimensions, finish and colours, and we didn’t want to delay the project by 12 months by bringing it in-house.” In fact, Jacqmin’s team asked Weatherchem to create customised colours - brown, blue, orange, green and pink - on the closure to accommodate their branding objectives. After initial test runs and customer approvals, the colours were approved as a good quality match and the project received official approval to move forward. FlapMate is part of Weatherchem’s improved sustainability solutions for customers. The cap is an unlined closure that is 100% recyclable and manufactured with fewer materials and has a lighter weight than other alternatives, which saves on shipping costs. Cormack Packaging Contact info and more items like this at wf.net.au/M712

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March/April 2012

Taping machine The EXC103SD Side Drive Uniform Taping Machine is used for the fast sealing

Code reader The Cognex DataMan 300 series of readers was developed to handle the difficult-to-read DPM (Direct Part Mark) codes as well as provide high read

of cartons. The machine can be designed to cater for a variety of different sized boxes, with no tool adjustment required by the operator. The taping machine can be fitted into most existing packaging lines without any major changes. It features an easy-to-use control panel, wheels for mobility and steel construction.

rates for challenging 1-D barcodes

Australian Warehouse Solutions Pty Ltd

and 2-D data matrix codes.

Contact info and more items like this at wf.net.au/M159

The 1DMax+ with Hotbars tech-

PACKAGING

nology provides high read rates of damaged 1-D linear barcodes. The controllable, field-interchangeable lighting modules allow users to create good lighting for achieving high read rates. Intelligent tuning automatically adjusts the settings of the integrated lighting to find the optimal light set-up for the part. Additional features and benefits include: enhanced 1DMax+ and 2DMax+ code-reading algorithms for reading the most challenging 1-D and 2-D codes; flexible lens options C-mount lens, S-mount or a variable focus liquid lens to provide maximum depth of field flexibility; and Cognex Connect communications suite supports industrial protocols as well as RS232 connectivity for integration into legacy systems. The series is available in two base models: the DataMan 300 (800 x 600 pixels); and the DataMan 302 (1280 x 1024 pixels) which is suitable for reading small DPM codes in a large field of view or on small components. Cognex Australia Contact info and more items like this at wf.net.au/M732

Shrink tightening film wraps chocolates Innovia Films’ shrink-tightening BOPP substrate, Propafilm OS, has been selected by global confectionery manufacturer Ferrero to overwrap boxes of its Rondnoir chocolates. Propafilm OS is a high-speed, transparent, overwrapping film manufactured using Innovia Films’ unique bubble process. It has balanced shrink-tightening properties and offers a sparkling pack appearance. The film is also said to be able to significantly increase product shelf life due to its water vapour, flavour and aroma barrier properties. “We are pleased to supply Propafilm OS to Ferrero. The outstanding sparkle and gloss of the film are important factors in the confectionery market, where shelf appeal and pack wrap tightness can influence purchasing decisions,” said Steve Langstaff, BOPP Product Manager, Innovia Films. Ferrero Rondnoir is mild, dark chocolate with delicate wafer, smooth chocolate cream and an almond pearl hidden within. The BOPP overwrapped chocolates are available in two box sizes - 12s and 24s. Innovia Films Pty Ltd Contact info and more items like this at wf.net.au/M713

March/April 2012

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Capper machines installed at healthcare plant PACKAGING

Kompass Milan has successfully installed three of its PF 6-head capper machines for plastic pre-threaded and plastic pressure caps at the Sydney plant of Sanofi Aventis, a specialist in pharmaceuticals, consumer healthcare products and vaccines. The Kompass PF pre-threaded capping machines are suitable for treating all types of screw caps. The pick-and-place distribution systems on the machines have positive grippers which make them suitable for even the most difficult closures. The machines installed at Sanofi Aventis have a line speed of 7200 bph and were integrated onto their existing production lines. The pre-threaded capping machines are equipped with adjustable heads with magnetic clutches that allow the customers to vary the torque during tightening and are a popular choice of machine in the beverage and pharmaceutical industries. Kompass has capping machines in both free-standing and turret versions which are suitable for a range of closures such as pressure, plastic screw, aluminium and crown caps. The range is divided into single-head and multihead versions and uses brushless motors which permit total control via touch screen and are suitable for use within sterile environments as they contain laminar flows, UV lamps and H O Â˛ Â˛ sanitising systems. HBM Packaging Technologies Contact info and more items like this at wf.net.au/M138

Gas displacement pycnometer Micromeritics AccuPyc II 1340 Series pycnometers are available through Particle & Surface Sciences. The company claims the fully automatic pycnometers provide rapid, precise volume measurements and density calculations on a wide variety of powders, solids and slurry shaving volumes from 0.01 to 350 cm3. The instruments claim to accurately complete most sample analyses in less than 3 mins. Suitable for analysing a limited amount of material, Micromeriticsâ&#x20AC;&#x2122; AccuPyc II 1340 1 cm 3 gas displacement pycnometer performs fully automatic, high-speed, high-precision volume measurements and density calculations on a variety of powders and solids. The pycnometer has a design that allows the volume of small amounts of sample to be accurately detected and measured with reliability to within a fraction of a microlitre. Its manifold design uses reliable, high-precision valves that seal securely so that small leaks do not contribute to variability of results. High-compression, minimum-volume seals around the pressure transducer minimise helium storage and leakage. This shortens the time to complete a run cycle and reduces the development of temperature gradients that may otherwise compromise results. The pycnometer also features a low-noise transducer amplifier that can result in faster equilibration. The instrument can be operated with a keypad or an optional Windows interface that provides good reporting and archiving capability. Both versions include direct sample mass input from a balance and cycle-based displacement volume reporting. The Windows interface also includes time-based pressure equilibration, percent solids content and total pore volume reports. For users requiring high throughput, an integrated control and analysis module can control up to five additional external analysis modules of the same or different volume capacities. A glove box model is also available for analyses in applications where the control module and analysis module must be in separate environments. Particle & Surface Sciences Pty Ltd Contact info and more items like this at wf.net.au/M421 www.foodprocessing.com.au

March/April 2012

PACKAGING

Processing and filling BIG (Bottling Investment Group), the production firm of The Coca-Cola Company, has gained a foothold in Malaysia with a greenfield facility serving as a showcase for bottlers in the entire region. The plant was designed to meet the needs of Coca-Cola’s move into the liquid-food beverage market. The plant has a number of sustainability features and innovations including the twin-flow filler in monobloc design from

Krones, with separate pre-dosing of pulp and subsequent filling of juice on a PET hotfill line.

n a 120,000 m2 site surrounded by oil palm plantations in Enstek, Kuala Lumpur, BIG built a hall 20,000 m2 in size. Up till the start of production in 2011, the hall has seen three complete Krones lines commissioned: a PET bottling line for carbonated soft drinks (CSDs) rated at 43,200 bottles an hour, on which Coca-Cola’s entire range of carbonated products is filled, plus Schweppes and the alcohol-free root beer A&W Sarsaparilla; secondly, a canning line rated at 90,000 cans an hour; and thirdly, a PET hotfill line rated at 36,000 bottles an hour. According to Krones, this is the first line anywhere in the world to feature a Modulfill Flexifruit (Sensometic VP-GW) filler with a pulp pre-dosing starwheel. Fruit juices with a pulp content have recently gained in popularity, particularly in Asia markets. The Minute Maid Pulpy product has now become Coca-Cola’s 14th brand with a billion-dollar turnover. “We will be transferring the successes achieved with these liquid-food beverages to other countries as well, with the wave currently rolling west from Asia,” said the Engineering Director at BIG, John Holzemer. “So far, there hadn’t been any in-house-produced Coca-Cola fruit juices with a pulp content in Malaysia - we imported Minute Maid Pulpy from China. So Malaysia was, in fact, the perfect location for the new process and filling technology.” At present, there are three products being handled on the hotfill PET line in Kuala Lumpur: Minute Maid Pulpy Orange, Minute Maid Pulpy Lemon and Minute Maid Pulpy Tropical in 350 mL and 1 L containers.

Pre-dosing starwheel and juice filler Separation of pulp and fruit juice is meticulously observed throughout the whole production and filling process for the Minute Maid products: this begins in the syrup kitchen where the freeze-concentrated pulp and the fruit-juice concentrate are handled separately and is continued in the newly developed filler. Krones had been working on the technical concept for the twin-flow-filling process since 2008, in close cooperation with and following specific stipulations laid down by Coca-Cola. Among the goals involved was not only high dosing accuracy, but also very gentle product handling. The Contiform H24 blow-moulding machine is monobloc-synchronised with the filler. The freshly 24

March/April 2012

blow-moulded containers are first passed to a pre-dosing starwheel with 40 filling units, each featuring five valves: one main valve with a large diameter for filling the viscous slurry (this is the part of the juice containing fruit fibres and/or fruit chunks, which is prepared and dosed separately), with fibre sizes up to 10 mm, a second valve for returning and circulating the product for heat-holding purposes, plus another two valves for setting the slurry pressure, and a fifth one for CIP cleaning. Depending on the product’s consistency, the dosing speed in the system can be adjusted to suit the product currently being handled. As a rule, 10% of the finished beverage is dosed as slurry, which has pre-mixed with water in a ratio of 1:1, so that the end product contains 5% pulp. The mixing ratios can, however, be varied as needed. The bottles containing the slurry are now passed to the main filler via Monotec starwheels featuring servodrive technology. But firstly, a weighing cell in the main filler verifies whether the preset slurry quantity has in fact been accurately dosed in. Signals are exchanged between the pre-filler and the main filler to ensure automatic slurry-dosage correction in the event of doubt. In the 70 filling units of the main filler, the fruit juice is passed from the central bowl through the filling valve into the bottle in a pressureless process, with a second valve regulating the speed of the filling function. Here, a heat-holding valve and automatic CIP cups have additionally been installed. If necessary, the main filler can, of course, also operate without pre-dosing.

Combining process engineering and filling technology The process technology required for juice production (which was supplied by another manufacturer) features separation of pulp and juice throughout. The deep-frozen pulp is crushed in the syrup kitchen with the addition of water, while juice concentrate and water are mixed in the blender. There are no longer any mixers in the bottling hall. The pulp and the fruit juice are then bottled separately, the first in the pre-dosing starwheel and the latter in the main filler. “The filling technology alone, though, is not the key to this concept, it’s the combination of process engineering and filling technology,” explains John Holzemer. “Only with the entire process can we guarantee a quality that so far had never been achieved. The crucial factor is that the raw materials are crushed here in the plant at Enstek, and not macerated as is otherwise the practice.”

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A ‘green’ plant The new facility was built in Enstek, a newly created cybercity, about 40 km to the south of the metropolis Kuala Lumpur, close to the international airport and the Sepang Formula 1 Racetrack. The building is currently undergoing certification by the US organisation LEED (Leadership in Environmental and Energy Design). “The principal focus when erecting this facility was on designing as ‘green’ a plant as possible. Malaysia Enstek is our model, which we intend to use for all new BIG plants that will be built over the next few years,” explains John Holzemer. BIG was keen to minimise its water consumption. A filling facility usually needs two litres of water for making one litre of finished product. “We try to consume only 1.5 litres per litre of product, which means we’re saving 25%,” says Project Manager Wim Vermeulen, who has been involved in the construction project right from its start three years ago. Filling the products at ambient temperature, for example, instead of cold-filling them, saves on cooling water. The 20,000 m2 roof surface is used for collecting rainwater. That definitely makes sense, given the average rainfall every year is 2500 mm per square metre. Two tanks each holding 300 m3 collect the rainwater, which is treated and then used as product water, covering about 15% of the total requirement. Treated wastewater is recycled as process water as is the backwash water from the membrane filters. Also, filter backwashing procedures are not controlled by time but by the degree of turbidity in the backwash water as measured by a turbidity meter, which means backwashing can be finished earlier. The treated wastewater is used for secondary purposes like toilet flushing, watering the gardens or in the cooling towers. No fewer than eight cooling towers each consuming 2000 L an hour have to be supplied with process water. For water treatment, BIG uses a reverse osmosis system rated at 150 m3 an hour and featuring the very latest membrane technology from Germany, which operates in two stages at low pressures of just seven bar, thus requiring less energy and achieving a high efficiency of 92%. Dry lubrication is used for the conveyors in the Krones lines; this, too, saves precious water. Electrochemically activated (ECA) water serves for CIP cleaning of the CSD line and the canning line, thus enabling BIG to do without chemicals here. This kind of CIP cleaning is said to be faster and reduces water consumption by about 30%. BIG had already gained encouraging feedback from this process at

other plants.The building systems have been entirely automated, including monitoring, and temperature and humidity measurements. Both fresh and recirculated air are adjusted in accordance with the CO2 content in the air. When there is nobody in the offices, the air conditioning switches itself off. For its PET filling operation, BIG opted for monobloc configurations comprising blow-moulder and filler for the CSD and hotfill lines, thus enabling it to dispense with the ‘energy-gobbling’ air conveyor. The fillers are enclosed, instead of being accommodated in large cleanrooms, which saves in sterile-air treatment. Cans are rinsed not with water, but with air. In BIG’s hotfill operation, there is an option for dosing in nitrogen, which means lighter containers can be used. What’s more, the oven in the Contiform H24 has been prepared not only for 28 mm closures but for 38 mm wide-neck ones as well. All motors and pumps are fitted with servodrives, with the drives for the conveyors being run in low-energy mode. For cooling purposes, cascade-type compressors are used, and ecofriendly ammonia as the refrigerant. The two Contiform blow-moulding machines operate with recovery of the high-pressure air.

Innovations in packaging In terms of product packaging, BIG has also taken some innovative steps. For CSD products in PET containers, a heightreduced bottle neck with 1881 closure makes for lower-weight preforms. For hotfill containers, BIG intends to test this variant as well. CSD preforms are made of non-crystallised PET, which have a lower weight and are said to use less energy during the production process. For end-of-the-line packaging on the total of five Variopac Pro packers, BIG does without trays and pads: the packs are merely stabilised with shrink-film. Thanks to the option for warm-filling at just 70°C instead of hot-filling at 82°C on the hotfill line or filling at ambient temperature instead of cold-filling on the CSD lines, a lot of energy can saved. BIG also chose to fill its CSDs without preservatives in Enstek, into PET bottles, cans and in future also returnable bottles, to pasteurise them in a flash pasteuriser instead, and then to carbonate them upstream of the filler. The German BIG facilities are already operating with preservative-free bottling of CSDs. Coca-Cola’s goal is to be able to produce carbonated soft drinks all over the world without using any preservatives. By pre-pasteurising CSDs before the filling process, Malaysia, for the first time, is also producing CSDs that contain no preservatives. Krones (Thailand) Co Ltd Contact info and more items like this at wf.net.au/M891 www.foodprocessing.com.au

March/April 2012

PACKAGING

technology for liquid-food beverages

Gas mixer with digital MFCs Wittâ&#x20AC;&#x2122;s KM-Flow is a gas mixer with digital mass flow controllers (MFC) for packaging using a protective atmosphere in the food industry. The KM-Flow mixes two or three gases for all types of packaging machines, whether vacuum, thermoforming, pillow bags or manually sealed compartments. The digital

PACKAGING

MFCs assume the function of the proportional valves and pressure regulators in standard mixing systems. The gas mixer is certified according to ISO 22000 for food safety. The operation is performed by touch screen instead of the control dial commonly used in other models. Programmable gas mixtures can be selected by button or by barcode reader. The company claims the digital data bus makes evaluation of the measuring data easier. The MFC technology is technically precise and reliable when metering and retaining the selected mixing ratio. MFC devices are suitable for users wanting a fully automatic inert gas packaging process with permanent monitoring and fault correction. Used in combination with an analysis instrument that continually measures the gas concentration in the package during the packaging process, the gas mixer can adjust the gas ratio and gas mixture volume. This can minimise gas consumption and uncontrolled escape of CO2. Niche Gas Products Contact info and more items like this at wf.net.au/M715

MAP laser system for perforating plastic film PerfoTec, a laser-based modified atmosphere packaging (MAP) system, is available from Raymax Applications. The company claims the system lowers the rate of respiration of fresh and cut produce, thereby reducing the rate of depletion. Developed in a research environment in the Netherlands, the system is suitable for suppliers of fresh fruit and vegetable packaged goods to supermarkets. Many consumers are choosing ready meals and ready cut produce. After being harvested, fruit and vegetables still respire, consuming oxygen and emitting carbon dioxide. This can reduce shelf or fridge life. MAP systems are designed so that the amount of oxygen in the pack meets the requirements of the produce, while dispersing the carbon dioxide it generates. The system has automatic oxygen transmission rate (OTR) control software that allocates the number and size of perforations made by the laser according to the requirements of the produce being packaged. Also included is a respiration meter that calculates the physiological parameters of the produce within four hours. When combined with the OTR reading, the system determines the number and size of perforations. The company claims this system improves shelf and fridge life of packaged fresh produce. Raymax Applications Pty Ltd Contact info and more items like this at wf.net.au/M512 26

March/April 2012

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VFFS bagger The tna robag 3ci vertical form fill seal (VFFS) bagger is an upgrade on the existing model. The new bagger has improved speed and precision, with other features to maximise plant productivity and waste reduction. With improved modularity and core component capability, the bagger offers good performance with throughput rates of graphical user interface (GUI) screen. The bagger is suitable for production lines of high volumes of sweet and savoury snacks, confections, cereals, pasta, powders, meat and poultry and fresh and frozen produce. Also available with the companyâ&#x20AC;&#x2122;s smartdate 5 date coders and intelli-detect 5 metal detectors, the bagger can be fully integrated up- and downstream onto existing lines and in synergy with other products from the companyâ&#x20AC;&#x2122;s portfolio, such as intelli-weigh multi-head scales for precise and efficient weighing. Further up the production line, the roflo VM 3 series of vibratory and horizontal motion distribution solutions transport product so breakages or loss of flavours are minimal, while eliminating the risk of cross-contamination. Efficient and accurate seasoning is achieved with the intelli-flav OMS 3, which applies a proportional amount of seasoning to the product, while multiple conveyors allow for variable infeed of product. For wet applications, the intelli-flav CLO features a true mass flow control system which ensures even coating and flavour distribution, proportionate to volume and speed of product throughput. Recirculation and a unique purging solution for clearing stoppages in pipe work mean that production demands remain unaffected. TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/M727

The Tobii system from Arrow Scientific uses eye tracking to quantify the time consumers spend looking at product labels or planograms, as well as where they are looking. It is designed to help users determine which package design or shelf placement is most effective in attracting consumer attention. Eye tracking provides details of what the consumer is looking at and complements consumer feedback in evaluating product impact. The eye tracker measures the elements consumers observe, such as brand, pictures and captions. This may help increase understanding of how consumers decipher a visual stimulus and the way they search for information on packaging. The system provides heat maps that indicate the longest period of gazing in red, showing which products receive the most amount of consumer attention. As well as measuring how long people look at labels, the system monitors where they are looking. The information the Tobii system supplies can provide information on how a package design or planogram can be improved to increase its appeal to consumers. Arrow Scientific Contact info and more items like this at wf.net.au/M681

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March/April 2012

PACKAGING

250 bpm, and improved visibility of operation with the new

Eye tracking system

>>> Embossed wine bottles Glass container maker Owens-

Importance of a packaging department

Illinois has launched internally embossed wine bottles, providing Australian and New Zealand

Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale and end use. It is often an agglomeration of conflicting and competitive business groups, comprising large numbers of individual enterprises, all motivated by the need to provide goods and services for customers and at the same time generating profit. Making all this work well often lies in the hands of the packaging engineer or technologist. The success of packaging is often how well the technologist combines his or her understanding of the raw materials, packaging material, converters, equipment suppliers and suppliers of ancillary materials and services, and the distribution supply chain. He or she needs to comprehend the totality of packaging and steer all those involved in a particular packaging project towards a successful outcome. The user of packaging materials is not the consumer of the product, but it is the food, confectionery, pharmaceutical, cosmetic, hardware, furniture or appliance manufacturer who intends to protect their product. The packaging technologist needs to have a sound understanding of the raw materials and what type of packaging can be used for each type of products, always considering the commercial, economic and environmental aspects of each material and at the same time seriously considering the marketing desires and needs to ultimately make the sale. A good knowledge is required on what equipment is suitable for which type of packaging; for example, canning, bottling, pouching, filling or wrapping, or for that matter, a combination of any of the aforementioned disciplines of packaging. The packaging technologist must have a sound knowledge on the country’s governing packaging-related laws and rules, trade association requirements, or simply the user’s specific requirements relating to packaging. Aspects of distribution, supply chain and distribution are an integral part of the design of the packaging as they directly relate to how well the package fits on a pallet or a container in this country or any other country, as many countries have different size pallets. Then, ancillary materials need to be considered, eg, decoration, coatings, pigments, solvents, lacquers, primers, binders, adhesives, plasticisers, inks, dyes, resins, starch, tapes, closures, sealing devices, dispensers, barcoding, and the list goes on. Bearing in mind that each of the above is a science of its own.

PROCESSING PACKAGING

winemakers with striking glass packaging design alternatives. O-I’s internal embossing technology enables grooves on the inside of bottles, creating distinctive decoration while providing a smooth exterior for easy labelling. O-I has manufactured two concepts at its Adelaide plant featuring standout swirl and dot patterns. Other designs are available to customers wishing to explore this branding opportunity. The internally embossed wine bottles also provide consumers with a reveal effect as designs are revealed when wine is poured from a bottle. Internal embossing of wine bottles follows O-I’s recent use of the technology in the beer segment. Western Australia’s Gage Roads Brewing Co launched Australia’s first application of internal embossing in the beer market in June last year. O-I Asia Pacific Analytical Services Contact info and more items like this at wf.net.au/M816

Control & Power Switches Extensive Range of

Stainless Steel & Insulated Enclosures

www.krausnaimer.com 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

March/April 2012

www.foodprocessing.com.au

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

Handheld barcode reader The Intermec SG10T is a simple, affordable and reliable handheld barcode

SIPA of Italy, a specialist in stretch blowmould-

reader designed for small to

ing machines for the production of PET bottles,

medium-sized businesses. Provid-

has developed large 40 L plus size containers

ing good performance in a stylish

for a range of applications such as water, beer,

point-and-shoot form factor, the device uses

oils, detergents and chemicals.The large PET

solid-state imaging technology to read all com-

containers can handle the rigorous top-load

mon 1D barcodes with ease and is suitable for

requirements for transporting large packs. SIPA

entry-level countertop reading needs.

engineers can also suggest subtle changes

Enabling businesses to achieve greater ac-

that can enable more containers to fit on a

curacy and efficiency in tracking the storage,

pallet and reduce distribution costs for the user.

movement, accounting and sales of inventory

A Malaysian manufacturer of palm oil ‘Able Perfect’ is using a SIPA

and assets, the device is suitable for a range of

stretch blowmoulding machine to create square, stackable containers in

environments. The barcode imager is also able to

10, 20 and 25 L sizes. The container preforms were designed to optimise

be used right out of the box, providing intuitive

the blowing process, as well as the cooling of the unique base, which

point and shoot trigger ergonomics to eliminate

was critical in ensuring the stackability of the containers. SIPA was also

the need for training.

able to integrate its machinery into the customer’s existing production facility, which was a key customer requirement.

As a simple plug-and-play scanner, the device is available with either a USB or keyboard wedge

Another application is at a site in South Asia where a PPS 300/12 L

interface. It is also compatible with Intermec’s

preform injection-moulding machine and a SFL 2/2 stretch blowmoulding

EasySe PC programming tool, meaning that

machine manufacture 10 L hot-fill bottles that will be filled with soy sauce.

in a few clicks, the Windows-based utility will

SIPA engineers spent eight months perfecting the preform and bottle

produce the programming barcodes necessary

design to ensure its solution met the user’s expectations. The system is

for custom applications

now producing 1100 x 10 L containers per hour. HBM Packaging Technologies Contact info and more items like this at wf.net.au/M725

Intermec Technologies Aust Pty Ltd Contact info and more items like this at wf.net.au/M143

Australian Made Label Applicators

www.foodprocessing.com.au

March/April 2012

PACKAGING

Large PET containers

Packaging for the microwave market NorAbsorbit is a flexible microwave packaging that allows greasy, breaded or bread-like foods to be prepared in the microwave so that they are crisp and tasty. The packaging absorbs both moisture and

PACKAGING

grease during cooking in the microwave and the food is thus cooked directly in the sales packaging until it is crispy. Preparation is therefore more

Corner wrap applicator Suitable for moving cases, the Corner Wrap Applicator from Markem-Imaje enables users to apply a label on the front and side, or the front and top, of outer case packages and boxes. The applicator has been designed to complement the existing applicator range available with the 2000 Series print-and-apply systems. The applicator enables more label data on a single large label or the same data visible from two sides of the box. The device is used to meet the demands of retailers and supermarkets who require a single label across the two faces of trays and boxes to be visible. The corner wrap applicator is also recommended for cases or products that demand higher volumes of data, such as ingredients lists or language variants, on the same label. It is capable of applying a range of label sizes from 200 to 400 mm long. Features include: high speed, capable of applying a 200 mm label around the corner of a case at 30 products per minute; label application range: between 50 and 120 mm high and 200 and 400 mm long; robust industrial design; few moving or serviceable parts; label present detector to ensure that the label is correctly fed and applied; non-stick pad surface for simple cleaning and continued operation; low resistance of applicator provides support for low-weight cases. The applicator has been designed and tested to comply with all current safety standards.

convenient, shorter and cleaner than conventional frying in a pan. The moisture and grease that develop during microwave cooking pass through a perforated sealing layer and are absorbed and retained by the packaging’s inner layer. Even unbreaded foods such as bacon are said to become much crispier than with conventional microwave technology. In contrast to the frying of bacon and similar foods in the pan, no preparation is necessary; time-consuming washing and cleaning afterwards are also eliminated. NorAbsorbit also has insulating thermal properties that reduce the outside temperature of the packaging after microwave cooking, making it possible to touch the bag after cooking. Combined with easy-opening features that can be integrated, this ensures quick and easy removal of the cooked food and makes it suitable for ‘to-go’ applications for snack food items. An additional steam venting label can also be integrated - this allows for especially gentle steam cooking of the food, preserving the natural flavour and the vitamins. In addition, the entire surface of the packaging can be printed and it has an appealing design - for example, a window that allows the consumer to view the food.

Markem-Imaje

Nordenia (Australia) Pty Ltd

Contact info and more items like this at wf.net.au/M134

Contact info and more items like this at wf.net.au/M988

inn vate Packaging

The most advanced scale on the market!

Learn how the PrimoWeigher 360 reduces washdown time by 50% and servicing costs by 80% to dramatically improve your bottom line.

www.innovatepackaging.net.au 30

March/April 2012

www.foodprocessing.com.au

• • • • • • • •

Filling Equipment Bagging Machines Palletisers Packaging Supplies Weighing Equipment Carton Erectors Pallet Wrappers Complete Systems

Ph: 1300 664 955

Single-wrap die-fold package with hermetic seals Bosch has introduced its single-wrap die-fold package with hermetic seals. It is machine designed for gentle product handling and heat minimisation. The company claims its precise fold achieves a premium package look and that it can improve shelf life. The pack style is produced by the Starpac 600 HL and is compatible to run polypropylene film (OPP). The heat-sealed and airtight hermetic seals may maintain product freshness for increased shelf preserving original aromas and flavours.

Horizontal casepacker

The machine automatically applies tear tape to the packaging

The Econocaser horizontal casepacker has been designed to handle a

material to create a tamperproof package.

variety of case styles. Its solid construction accommodates corrugated

The machine wraps small to medium-sized chocolates with

and folding board materials including full flap, economy flap and butting

an output of up to 600 pieces per minute. The machine uses a

end flap case constructions.

folding box to create all folds at once for symmetrical side and

The horizontal casepacker operates by automatically pulling cases

longitudinal seals. This is achieved by the folding boxâ&#x20AC;&#x2122;s ability to

from the supply magazine and erecting them onto a single load station.

maintain the position of wrapping materials with elastic properties

Product may then be manually or automatically loaded. Following load-

which, according to the company, cannot always be ensured with multistation folding.

ing, the machine cycle begins and the loaded case is transported to the

Bosch Rexroth Pty Ltd

Perfect Packaging

Contact info and more items like this at wf.net.au/M552

Contact info and more items like this at wf.net.au/M225

closure section for either gluing or taping.

Recyclable carton The Bosch Packaging Technology Eco|Save|Pack packaging is a safe and ecofriendly tray carton for the packaging of fragile products. The package will be produced on the CUT 120 horizontal cartoning machine that has production rates up to 120 pieces/min. The pack style was created by Bosch in cooperation with the carton manufacturer Faller. The packaging protects the contents from transport damage caused by impact, falls or pressure due to storage in multipacks or on pallets. The inlay provides optimal protection due to its chambered design; the product is locked in place, which prevents shifting and mutual contact, thus preventing damage to the product. The reclosable, folded carton and the easy removal of the product from the inlay make the packaging easy to use. Additionally, supplements such as usage information in the form of booklets, outserts or pre-folded inserts from a roll or from a sheet can be inserted into the packaging. The packaging can also be used for syringes, needles and pipettes. The monopackaging material used for the tray carton makes the usage of plastics obsolete and therefore saves additional process steps and machinery. The CUT 120 horizontal cartoning machine erects the tray carton, fills it and then closes it. Depending on the project, single, multiple or combination packaging can be processed. The machine can also be easily retrofitted for new applications. Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/L440

Ask us today about our Innovative Ready Meal Systems and Supplies

Unit 6/30 Park Road, Mulgrave NSW 2756 Tel: 02 4577 3641

www.extremeautomation.com.au

www.foodprocessing.com.au

March/April 2012

PACKAGING

life while protecting the product against insects and moisture and

Gas mixer and analyser for MAP The MAP Mix Provectus from PBI-Dansensor is a ‘smart’ gas mixer for modified atmosphere packaging (MAP). It can be coupled to the company’s gas analyser, MAP Check 3, to provide constant monitoring and automatic adjustment of mixture and flow to achieve maximum efficiency. The mixer uses the latest mass flow technology that is used widely in the gas industry but which has not until now been exploited for the food packaging sector. This allows the mixer to be housed in a very small cabinet and yet to

PACKAGING

exhibit versatility and a high flow rate. The large amount

Blow moulding machine

of different gas mixtures typically used in MAP can be

The Contiform 3 is the latest generation of Krones’ stretch blow-

achieved with only two different MAP Mix Provectus models.

moulding machine series. The blow-moulding module has been

The gas mixer can deliver flow of up to 1500 L/min and

entirely revamped. The field-proven linear oven of the Contiform

if greater capacity is needed it is simply a case of coupling

S/H series has been design enhanced and principally optimised

together more units. There is very low pressure drop over

in regard to its energy consumption.

the mixer, making it suitable for working with nitrogen or

During the development work for the Contiform 3, particular at-

oxygen generators.

tention was paid to the following objectives: increasing production

There are ten different programs allowing the operator

output per blow-moulding station; reducing total air consumption;

to set parameters such as gas mix and outlet pressure,

reducing total energy consumption; improving hygienic design;

and so forth. An intuitive touch-screen display makes the

shortening product changeover times, increasing flexibility; further

mixer simple to operate and it contains all the necessary

enhancing user-friendliness; and maximally dependable availability.

connectivity for data logging control.

The Contiform of Generation 3 has been developed in sizes

The gas analyser has a 5″ colour touch screen for easy

ranging from 8 to 36 blow-moulding stations, thus enabling record

use, and good connectivity for data logging and control

outputs to be achieved of up to 81,000 containers an hour. The

through USB, ethernet and Modbus TCP and is delivered

machine can also, of course, be directly monobloc-synchronised

with PC software. MAP Check 3 allows the operator to

with a filler, or in the ErgoBloc L with both a labeller and a filler. As

combine monitoring of gas content on a vertical or horizontal

from mid-2012, heatset and small-cavity versions will additionally

flow packaging machine with real-time control of package

be available, as will the integration of ProShape for producing oval

flushing via an advanced GasSave function. For most

containers, or Contipure for preform decontamination.

manufacturers, this could translate into a 20-50% decrease

Krones (Thailand) Co Ltd

in gas consumption.

Contact info and more items like this at wf.net.au/M136

MAP Check 3 is designed to operate seamlessly in tandem with the MAP Mix Provectus. The analyser constantly monitors the gas mixture entering the packaging machine. If it detects a change in the oxygen level it can send a signal

Load cell for weighbridges

back to the mixer to make the appropriate adjustments of

Mettler Toledo has announced the Powercell PDX load cell for

the gas flow automatically. This feedback control ensures

weighbridges, an addition to their Powercell range. The load cell

that the correct amount of gas enters the package at all

is designed to prevent such problems as weighing errors and

times for efficiency, consistency and quality assurance

unplanned downtime due to environmental

and, therefore, reduced waste and increased cost savings.

factors and includes predictive diagnostics

Pryde Measurement Pty Ltd

to keep users informed of their scale’s

Contact info and more items like this at wf.net.au/M162

performance. The load cell may eliminate failure-prone junction boxes, protect against damage from water ingress, provide lightning

Filling technology

protection and deliver weighing accuracy.

The TFC clean-fill thermoforming machine is an addition to the

For users with weighbridges in good

Bosch portfolio of forming and filling technologies. Its existing

condition, a load cell upgrade may lower

aseptic thermoforming portfolio allows manufacturers to achieve

operating costs and improve productivity.

high hygienic standards, eg, for dairy creamers, desserts and

Mettler Toledo can also provide options

baby food. The TFC thermoforming technology extends this

for traffic flow control, data management

range to provide a solution for the filling of fresh products, foods

and information system integration, as well as evaluating cost

requiring extended shelf life such as yoghurts and desserts,

comparisons for new weighbridges, repairs and upgrades.

and single-serve portions of butter, margarine, condiments and coffee. It is also suitable for cold filling, hot filling and retortable

Mettler Toledo Contact info and more items like this at wf.net.au/M314

products like ready meals and pet food. Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/M758

March/April 2012

www.foodprocessing.com.au

Printer labeller The Markem-Imaje 2200 Series printer labeller is an optimised solution for printing and labelling boxes and pallets. The 2200 series is capable of printing and applying labels at rates well in excess of 125 boxes/min. Label application is consistent - Âą0.25 mm - due to an optimised label path, automatic label tension and an integrated label pad sensor. Equipped with dual RISC processors, supported by a dedicated ultrafast coprocessor, the series delivers good performance. Markem-Imaje ribbons and labels ensure maximised print quality and long printhead life.

PACKAGING

The robust and strong industrial design of the 2200 series is built around a central solid 38 mm thick backbone. The label pad and contact parts are non-stick for ease of cleaning. In addition, all the vital components are all protected by covers. The media path has been simplified to allow operators to reload label and ribbon rolls in less than 40 s. Production line stoppages are reduced by 25% due to synchronised label and ribbon roll changes with lengths of 560 m compared to a market standard of 450 m. Finally, the printhead and rollers can be exchanged without tools in less than 60 s. The unit can be fitted with different label applicators: tamp (long or short), wipe or blow for top, side and front applications. There is also a corner wrap applicator for two adjacent side applications. The applicator is interchangeable in the event of new requirements. The print resolution and width can also be modified if necessary, simply by replacing the printhead. The 2200 series supports high-speed, real-time data generation, including barcodes, 2D codes, logos and serialisation. Printed codes are ANSI standard grade A and B compliant even at the highest application speeds. Markem-Imaje proposes an optional barcode scanner to make sure that 100% of boxes leave the factory with a readable code. CoLOS software solutions ensure data integrity, central data management and easy connection to the companyâ&#x20AC;&#x2122;s database. Markem-Imaje Contact info and more items like this at wf.net.au/M135

WITH DFC SHRINK SLEEVES ANY THING IS POSSIBLE - Shrink Sleeves to fit all difficult shapes - Shrink Sleeves offering total UV blockout - Offering great shelf presence through 360 deg. decoration - shrink sleeves in different materials including. OPS, PET, & PVC -Contract application available

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

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

www.foodprocessing.com.au

March/April 2012

PACKAGING

Pre-dosing equipment for mixed drinks with fruit chunks Krones AG has developed FlexiFruit pre-dosing equipment, a twin-flow concept for juices and milk-based mixed drinks to ensure separation between juice or milk-based mixed drinks and fruit chunks. The system ensures stringent separation between the juice or milk-based mixed drink and the fruit chunks in the process technology,

High-pressure wine barrel cleaner

Krones claims.

The PA Italia M28E high-pressure cleaner offers effective cleaning of wine barrels

The juice or milk-based mixed drink is treated in

with the added benefit of automatic siphoning and a specially designed holder to

its own process while the fruit chunks, measuring

secure the unit in place. The cleaner can be used to remove tartrates that have

up to 10 x 10 x 10 mm, are pasteurised elsewhere

crystallised over time on barrels used in wine production. The M28E improves upon

in a shell-and-tube heat exchanger with interior

its predecessor, the M25E, with the introduction of a flexible terminal as part of the

cross-corrugated tubes.

siphon pipe, to ensure complete fluid extraction in barrels of varying shapes and sizes.

The fruit chunks are inserted into the bottles

By being able to remove all the cleaning solution or rinse water, the barrel is cleaned

and then the juice or milk-based mixer is added.

faster and with greater effectiveness. The unit simultaneously extracts the fluid in the barrel as it cleans, ensuring maximum surface impingement. Also, by automati-

JL Lennard Pty Ltd

cally removing any cleaning fluids or rinse water through its integrated siphoning

Contact info and more items like this at wf.net.au/M588

feature, the cleaner eliminates the need to invert the barrel to drain residual fluids. The M28Eâ&#x20AC;&#x2122;s orbital spray delivers a high-impact 360Â° clean, ensuring all surfaces are reached. Its specially designed holder secures the cleaner in place, making operation of the unit much simpler and more stable. Because its body is made entirely from stainless seal, it is suitable for use in all types of wine or food manufacturing processes. Tecpro Australia Contact info and more items like this at wf.net.au/M065

WHO IS LOOKING AFTER YOUR PACKAGING DESIGN, IMPLEMENTATION AND SUPPLY CHAIN EFFICIENCY? DO THEY NEED FORMAL PACKAGING QUALIFICATIONS TO IMPROVE YOUR BOTTOM LINE?

ASK THE AIP HOW WE CAN HELP YOUR STAFF WITH THEIR PACKAGING EDUCATION PH: 07 3278 4490 info@aipack.com.au www.aipack.com.au 34

March/April 2012

www.foodprocessing.com.au

BEVERAGES

Megatrends in the beverage industry In January 2012, France introduced a ‘cola tax’ for all drinks containing added sugar or sweetener. Hungary has had its own ‘chips tax’ - targeting excessively sweet drinks among other things - since September 2011. In ©iStockphoto.com/Tom Young

Australia, too, a levy of this kind is under discussion. These and other new developments are forcing the drinks industry into rethinking the ingredients and manufacturing processes used in products.

our worldwide megatrends are currently dominating consumer beverage purchase behaviour. Drinks consumers are becoming more concerned about ‘naturalness’, preferring products made from natural ingredients. They are also on the lookout for products that confer health benefits - functional beverages are regarded at present as a main driver of innovation. But naturalness and functional value alone are not enough to keep the consumer happy. Drinking is supposed to be an enjoyable experience, and that means first-rate taste, aroma and mouthfeel. And finally, in the highly mobile society of today, sheer convenience remains a big factor. These trends are affecting all drinks - water, traditional soft drinks, juices and nectars, energy drinks, sports drinks and even instant coffees and teas.

whole fruit pieces. Careful handling of the fruit bits to prevent disintegration involves keeping them separate from the juice throughout processing - for instance, the fruit bits are pasteurised in their own separate tube heat exchangers. Consumer preferences governing vegetable juice production are much the same as for fruit juices. The key requirement is that the juice-extraction process must not impair the product’s natural properties. Speed, continuity and minimal oxidation are the watchwords here: all three are essential to the production of high-grade juices with high yield.

Don’t let your bits disintegrate

In the narrower soft drinks field, too, the trend to higher fruit content and use of natural ingredients means there have to be fresh approaches in process technology. These new products are frequently more susceptible to microbiological contamination so it is even more imperative that process components can be efficiently and sustainably cleaned.

Juice products are a growth market worldwide, with notable demand for new lines. This in turn means process technology must rise to new challenges. Where in the past producers’ main concern has been to maximise output, today’s priority in terms of performance is optimal product quality. It is now more vital than ever that products are not only processed rapidly but also without impairing quality, and under oxygen-free conditions. When it comes to expensive, premium-segment juices, the prime requirements are high quality and constant consistency. Processing methods highly protective of fruit quality have now been introduced for the production of juices containing

For individual syrup bases, life begins in the syrup room. Raw materials go through dissolving, blending, heating and filtration stages on their way to becoming the individual syrup variants, and then move on to the mixing process. New equipment entering the market can assist users to achieve the requisite high levels of precision, reliability, economy and flexibility. A further important element in the process chain is a modern water preparation plant. The homogeneity of the premix is of key importance when it comes to the blending in of the further ingredients. High product quality and elimination of product wastage are also key factors. www.foodprocessing.com.au

March/April 2012

BEVERAGES

Supplement your water In the water sector, too, constant innovation keeps paring costs and delivering improvements in microbiological quality. Still table water, carbonated, flavoured - whatever the water type, production involves ever more sophisticated process technology, for requirements ranging from degasification to precision carbonation to hygienic filtration. Instant and ready-to-drink products made with cereals, blossoms or plant roots may come in future to be used for gently beneficial effects on human health, with the potential for a considerably increased future role as diet supplements. With this end in view, the production process will involve the delicate operation of extracting the valuable active ingredients from plant cells for subsequent blending into the drink. In the view of Euromonitor International, the strongest future growth rates can be expected in ready-to-drink tea and specialty drinks from Asia, because of the associated health benefits. The producers’ ideal is process technology that will ensure meticulous - and hence benefit-conserving - treatment of the tea extract while also maximising product yield. Riding high in the instant coffee markets at present, meanwhile, are the aromatised specialty lines, flavoured for example with vanilla or chocolate. Research and development have moved into some entirely new areas, such as the DCD process (dynamic cellular disruption), which may in time supersede at least some of the processes currently used in the beverage industry. Improvement of the keeping qualities of smoothies by application of pulsed electric fields is a further exceptionally interesting research field.

Minimising your environmental footprint Recent decades have seen all branches of beverage technology achieve major advances in reducing consumption of resources. In the brewing industry, for instance, primary energy consumption levels in the mash-house - the industry’s heaviest user - have been cut by well over half. A similar reduction has been achieved in brewery water consumption, now down from what was often two-digit figures to about five litres or less per litre of beer produced. But there is still more to come: nearly all brewing groups with global reach have issued environmental policy statements that go much further. Consumption of fresh water has a target reduction to three litres per litre of beer by 2015 if possible; or failing that, by 2020 at latest. More ambitious still are the major international manufacturers of soft drinks with their declared target of the ‘closed loop’, meaning a water-in to beverage-out ratio of 1:1.

Alternative and renewable power sources In most places the sun can provide at least 50% of the thermal energy required by a brewery. The other 50% of the energy can came from combined heat and power (CHP), or cogeneration, fuelled by biogas from anaerobic waste water digestion. This heat reservoir can also be used, with the help of adsorption refrigeration systems, to supply a brewery’s refrigeration requirements. Although ‘cold from heat’ sounds quite innovative, it is in fact established technology. A bonus feature is that the biogas produced can be burnt off to provide back-up heat in the boiler-house. Depending on location, renewable energy forms such as wind and water can be fed into the power mix at any time. 38

March/April 2012

An attractive solution for SMEs can be the use of solar. Also of interest, though not yet quite ready for the market, is the use of wind turbines to produce compressed air which is easily stored for conversion into electrical power on a demand basis by means of a generator. Breweries and other beverage production plants can also be envisaged as well suited to the direct - and hence maximally efficient - physical use of the stored compressed air.

Renewables-based beverage manufacture By rethinking processes and technologies, beverage manufacturers are finding new ways to ‘close the circle’. For example: biogas consists of about 60% methane and 40% CO2. Separating off this CO2 by means of a new membrane technique produces biomethane; and biomethane, with its high and standardised calorific value, can be fed into the natural gas distribution grid. Businesses not in a position to use the biogas-derived thermal energy directly are enabled in this way to convert it into additional profit instead. The captured CO2, moreover, is a recyclable substance in its own right. In one vision of the future, renewable energy will be used to produce hydrogen and combine it with CO2 to synthesise an analogue to natural gas. This end product can then be stored in gas tanks pending return into the system or disposal on the market.

‘Green’ CO2 from fermentation processes

Across the world’s major growth regions, beverage manufacturers often have no direct access to CO2 in a usable form. This means costs are high and CO2 footprints are very significant, because of the distances over which the gas has to be transported and the consequent expense. One alternative used hitherto takes the form of so-called production facilities burning mineral oil or natural gas at deliberately low efficiency in order to retrieve CO2 from the flue gas. But that cannot be called a genuine solution. A true source of high-purity ‘green’ CO2 is to be found rather in fermentation processes such as beer brewing. Modelling to date has indicated that brewery and soft drinks groups will, in future, make a practice of setting up production premises on a combined site, enabling them to harvest, process and use the green CO2 to best advantage. But for a production method to be sustainable it takes more than the grand vision alone. The process itself still has to be optimised in every detail. Thus, reliable inline measurement, for example, is no less crucial as a link in the optimised production chain than are the right valves, heat exchangers or sterilisation strategies. drinktec www.drinktec.com

www.foodprocessing.com.au

The latest changes and innovations in beverage processing technology will be on view at drinktec 2013, which will take place at Messe München in Munich, Germany, from 16 to 20 September 2013. At this event, around 1500 manufacturers will present the latest technology for production, filling and packaging of all kinds of beverages and liquid food to approximately 60,000 visitors from more than 170 countries. Also encompassing raw materials and logistics solutions, the themes of beverages marketing and packaging design will round off the portfolio.

Tank washer upgrade Digital sodium chloride refractometer

updated and the Fury 602 introduces new benefits. The Breconcherry Fury 600 tank washer been used extensively

The Hanna Instruments HI 96821 digital sodium chloride refractometer

in the brewing, distilling, dairy, food and beverage industries

has been designed to meet the requirements of the food industry. This

over many years. With its compact design and low-speed piston

optical instrument employs the measurement of the refractive index to

mechanism, it produces high-impact, long-range jet cleaning

determine sodium chloride concentration in aqueous solutions used

for highly effective cleaning impingement.

in food preparation and is suitable for the analysis of: salad dress-

The Fury 602 combines all of these features with an improved

ings, cheeses, condiments, pickles, canned foods, jarred foods, milk,

nozzle tube and nozzle design. It offers a wide cleaning radius,

juices, energy drinks, soups, brines and whey. It is not intended for

delivering powerful jet cleaning in large and very large tanks.

seawater salinity measurements.

The Fury 602 is claimed to produce the highest impact force of

The measurement of refractive index is simple and quick and pro-

any jet washer. Its efficient piston-operated mechanism is driven

vides the user with an accepted method for NaCl analysis. Samples

by only 5% of the wash water, allowing 95% to pass directly to

are measured after a simple user calibration with deionised or distilled

the nozzles. This maximises jet impingement and wash rate and

water. Within seconds the instrument measures the refractive index of

also reduces the tank’s downtime and minimises effluent costs.

the sample. The meter features automatic temperature compensation

The Fury 602 offers 360° or 180° up, or 180° down wash

for accurate measurements, and the dual-level LCD displays measure-

patterns. The two nozzles oscillate through 90° while the

ment and temperature readings simultaneously.

mechanism continually indexes around a central axis. Lightweight

The digital refractometer eliminates the uncertainty associated with mechanical refractometers and is portable, for measurements where users need them.

and compact, it can be used on a mobile basis or installed permanently in the tank. The Fury 602 is entirely self-cleaning and, because it does not

The instrument uses internationally recognised references for unit

have high-speed turbines or complex gear systems, it suffers

conversion and temperature compensation. It can display the measure-

very little wear and requires minimal maintenance or servicing.

ment of NaCl concentration four different ways: g/100 g, g/100 mL, specific gravity and °Baumé.

The Fury 602 has a 1.5″ BSP connection and requires a minimum manhole/flange opening of 200 mm for unit insertion.

Temperature (in °C or °F) is displayed simultaneously with the

At a pressure of 10 bar, it has a cleaning radius of 13 m and

measurement (on three of the ranges) on the large dual-level display

wetting radius of 17 m, and is suitable for working temperatures

along with icons for low power and other helpful message codes.

up to 120°C.

Hanna Instruments Pty Ltd

Tecpro Australia

Contact info and more items like this at wf.net.au/M212

Contact info and more items like this at wf.net.au/M238

BEVERAGE & PACKAGING EQUIPMENT SPECIALISTS • PET Bottle Production • Beverage Filling & Processing • Packaging • Labelling • Handling Machinery www.foodprocessing.com.au

Ph: +61 2 8814 3100 www.hbm.com.au March/April 2012

BEVERAGES

The Breconcherry Fury 600 tank cleaning nozzle has been

Palletiser/depalletiser for lightweight plastic containers Autefa Automation has released a palletiser/depalletiser featuring Vacugrip technology that has been designed specifically for handling lightweight containers. For palletising, the technology enables the creation and placing of layers of empty containers/bottles onto pallets. As containers come off the blow moulder, they are positioned in a layer forming station and the VacuGrip gently lifts the bottles including the bottom layer pad from the forming station for placement onto the pallet. A top frame is placed on the top of the completed pallet top sheet and the pallets can then be either stretch wrapped and/or strapped before being transported. The system is suitable for palletising output from multiple low-speed blow moulders onto separate pallet stations of different container types due to the design of the universal Vacugrip head technology. This universal tool for palletising and depalletising layers has a layer capacity of up to 40 kg and

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can handle bottle sizes from 200 mL to 3.75 L. It can palletise and/or depalletise several product lines with various products consecutively as there is no need for format parts and the system does not require changeover time. Conversely, the VacuGrip system operates in a reverse sequence when used as a depalletiser where palletised containers are gently removed for feeding to a filler. HBM Packaging Technologies Contact info and more items like this at wf.net.au/M226

SEW-Eurodrive conveyors keep things moving at Swire An upgraded conveyor system has helped Australia’s largest cold-chain logistics service provider stay on top of its game - at low cost. Handling more than 30,000 boxes each day, Swire Cold Storage’s Cannon Hill site relies heavily on its conveyor system. As production levels rose over the years, however, it became apparent that Swire’s ageing conveyor system wasn’t handling the increased volume. “Because of the high volume of boxes coming down the main conveyor line, the chain drive pushers just couldn’t cope at peak times, with the boxes getting caught up and forcing us to stop the whole conveyor line,” explains Colin Carter, Swire’s Queensland Engineering Manager. Any downtime in the operation directly impacts Swire’s customers, something Swire was keen to minimise. After trying a number of approaches to address the problem, Swire approached SEW-Eurodrive. “In the end, using SEW-Eurodrive’s smart products and the company’s in-depth knowledge of conveyor systems, we managed to fix the problem for far less money than we initially thought,” said Carter. “In fact, it was a very lowcost project for such a big improvement to our production efficiency.” SEW-Eurodrive Applications Engineer Shahry Zand considered solutions for Swire’s pusher problem. He thought a servo drive with a high-resolution encoder would be ideal for the application, but it wasn’t going to be cheap: over $100,000 for the total solution. But Zand found a solution for Swire that was efficient and affordable. The original motor

March/April 2012

was replaced with an SEW-Eurodrive high-efficiency motor, and an MQD DeviceNet module with internal positioning and sequence control (IPOS) capabilities replaced the original module. To achieve a pushing cycle of less than 0.5 s, a speed profile was programmed in IPOS based on the pusher position. The aim of the set-up was to prevent the boxes being damaged by being hit at high speed while being able to stop the pusher at the home prox within the required accuracy. “Thanks to the new built-in encoder, the pusher hasn’t missed the Home Prox even once and it’s pushing the boxes quicker and smoother than ever before,” said Zand. With this solution, SEW-Eurodrive was able to fix the problem for less than $2200. Even better, the conveyor took just one day to install and was completed over a weekend, which meant no disruption to Swire’s production at all. Carter is very impressed with the improvements and SEWEurodrive. “Their engineering skills and professionalism are first class. Since putting in the new drive our downtime has decreased considerably. In fact, I’ve just ordered three more drives from SEW-Eurodrive. “We have over 150 of their drives on site and over 200 SEW-Eurodrive motors and gearboxes,” said Carter. “Basically you get what you pay for. There are probably cheaper drives on the market but they don’t go the distance. SEW-Eurodrive products are very flexible and reliable.” SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/M669

www.foodprocessing.com.au

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Nestlé’s robotic layer picker is a winner all round Choosing a Dematic robotic layer picker has helped Nestlé Australia improve safety, quality and productivity - and won Nestlé industry recognition for its system. Nestlé’s national distribution centre (DC) at Arndell Park in western Sydney stores and distributes several hundred of the company’s stock keeping units (SKUs). About 80% of the DC’s orders are distributed as full pallets. The remaining 20% of orders require manual handling of around five million cases each year, presenting a significant OHS challenge for the company. To deal with this challenge, Nestlé installed a Dematic integrated robotic layer picking solution. The layer picker has not only improved efficiency and quality at the Arndell Park DC, but has also eliminated the manual handling of four million cases each year. To initiate picking, orders from Nestlé’s SAP warehouse management system are downloaded into Dematic’s PickDirector warehouse control system. PickDirector interfaces with Dematic’s FreePick Maximiser software, ordering the stock required for layer picking in the required sequence for the next wave of orders. The stock is retrieved by forklift from the adjacent reserve storage bays and loaded onto the induction conveyor spur. The pallets are scanned as they move through the layer picker and the operator is directed by the control system to remove the required amount of stretchwrapping from the pallet. The pallet is then conveyed into the layer picker and into buffer storage or a pick-and-put location. These buffer storage locations enable pallets that are out of sequence to be temporarily stored online

March/April 2012

within the layer picker until they are required. The layer picker selects required layers as new pallets are fed through the system, transferring them to one of four customer order pallets. Stock that remains on the pallet is incorporated into the next order or is held in the storage bays until it is required. To build sandwich pallets to order, the layer picking system has four order picking positions, enabling up to four orders to be picked concurrently. The 4-axis picker uses a dual bellows and vacuum-gripping head that can handle most of Nestlé’s range, from cartons to bags and bottles. To pick up a layer, the bellows inflate and close around the product to create a seal. The vacuum head exerts just enough pressure to gently pick up the layer while minimising product damage. This system allows the picker to handle a variety of pallet configurations. Completed orders are checkweighed, stretchwrapped and labelled on their way through the system. Dematic’s system creates higher quality pallet build, ensuring less handling damage and fewer returns while improving transport utilisation. Another feature that has improved safety in Nestlé’s DC is Dematic’s VocoCollect voice picking system. Forklift operators wear a small headset attached to a lightweight voice computer and simply listen and respond to clear verbal instructions of where to go and what to pick. Voice-directed computing frees up operators’ hands and eyes so they can safely handle and pick cartons without distractions. Nestlé’s innovative system was recognised at the 2011 Australian Supply Chain and Logistics Awards, taking home awards for Manufacturing Logistics, Storage and Handling of Materials, as well as Supply Chain Management. Nestlé expects to see return on investment in less than four years. Read more about Nestlé's awards here. Dematic Pty Ltd Contact info and more items like this at wf.net.au/M676

www.foodprocessing.com.au

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Decentralised Technology \ Drive Automation \ Services

Servo Drive Systems from SEW-EURODRIVE Precise automation solutions Microcalligraphy on rice grains is an ancient eastern tradition which requires immense concentration, neatness of hand and keen eyesight. In the modern day precise tasks such as this are accomplished with technology. SEW-EURODRIVE offers a modular servo and automation system for just this reason. We supply complete automation solutions based around our range of synchronous rotary and linear servomotors, precise gear units, linear electric cylinders, frequency inverters, PLCs and motion controllers. Combined, we can engineer these components to provide exact position control for single or multiple axis applications in order to meet even the most demanding automation challenges.

1300 SEW AUS Melbourne (HQ) I Sydney I Adelaide I Perth I Brisbane I Townsville

www.sew-eurodrive.com.au

Dual bulk bag filling system with pallet dispenser Flexicon has integrated two Swing-Down Bulk Bag Fillers with a pallet dispenser and powered roller conveyors to create a dual bulk bag filling system which allows safe, high-capacity filling of bulk bags of all popular sizes. Programmable controls allow the fillers to operate separately or simultaneously, filling bags of the same size or two different sizes. When a filling cycle is initiated by push-button or contact closure, pallet dispenser forks lower the stack of pallets onto the roller conveyor, withdraw from the bottom pallet and raise the remaining pallets, allowing the roller conveyor equipped with photoelectric eyes to move the

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dispensed pallet into position below the filling station. The bag connection frame of the Swing-Down fill heads lowers and then pivots to a vertical position, allowing an operator at floor level to safely and quickly attach bag straps to automated latches, slide the bag spout over an inflatable spout seal and press a spout seal inflation button. The system then automatically pivots the bag connection frame back to horizontal, raises the entire fill head, inflates the bag to remove creases, fills the bag at a high rate, finishes filling accurately at trickle-feed rate, deflates the spout seal, releases the bag loops, raises the fill head to disengage the spout, rolls the bag out of the filling area and rolls a new pallet into place to begin another cycle. An annular gap inside of the fill head spout directs displaced air and dust during the filling operation to a single point connection. All system components are available constructed to industrial, food, dairy and pharmaceutical standards. The system is offered with the company’s own mechanical or pneumatic material delivery system integrated with the user’s upstream process equipment or other material source. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/M223

The little feeder that could A pneumatic feeder built by Vibration Systems & Solutions (VSS) in July 1999 is about to celebrate its 13th birthday. Luckily, VSS isn’t at all superstitious - and with good reason. The feeder continues to give great performance, delivering fruit and nuts to a multi-head packing machine, just as it has done since it was installed in 1999. The feeder had a new silencer fitted last month, but up until then required no maintenance down-time. Despite having changed hands three times and had three locations since 1999, the machine itself hasn’t needed any tuning or adjustments to keep it running well. Using a supply of clean, dry lubricated air, the feeder is pneumatically driven by a linear piston vibrator. This particular model is non-impacting, in which a piston oscillates in a cylinder, automatically generating an air cushion at each end of the stroke that eliminates metal-to-metal hammering and resulting noise.

The regulator on the air service unit adjusts the operating frequency while the feeder’s stroke is adjusted by a throttle on the vibrator’s exhaust. These features mean the feeder can be instantly controlled while in operation, giving the optimum feed rate required for the product being moved. This particular feeder is manually controlled, but all VSS feeders can be linked to an electronic scale to give feedback to an electro-pneumatic controller. This allows rapid fill and slow top-up when filling containers to reach a particular weight. VSS’s pneumatic vibrators are also available with lubrication-free operation, as well as with ATEX rating for use in hazardous atmospheres. Vibration Systems & Solutions (Australia) Pty Ltd Contact info and more items like this at wf.net.au/M521

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

For direct connection to your closest branch

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

www.locker.com.au www.lockernz.co.nz Leading manufacturer and supplier of metal belting 44

March/April 2012

www.foodprocessing.com.au

180x67mm

he Melbourne Exhibition Centre will host two trade shows in one this April. From 17-19 April, the Safety in Action and Melbourne Materials handling trade shows will combine to showcase solutions for managers in the food technology industry such as plant, lab, storage and logistics managers. Visitors can network and learn from industry experts through a variety of free industry knowledge centres. The show will feature a range of exhibitors. A major feature will be safety wear, with Wujiang Hangseng Knitting showcasing its range of safety wear products and the Safety Mate stand displaying Terra Safety Footwear that features metal-free toecaps, odour-free footwear and supportive insoles. Merv Hughes will be at the Diadora Utility Safety Boots stand to promote the boots and chat to visitors about safety footwear.

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ÂŠiStockphoto.com/ Marti Salmela

Safety in Action and Melbourne Materials Handling trade shows The Tennyson group will show its Take 5 Safety books and other printed safety items, while Kockums Bulk Systems Group will be displaying its range of vacuum lifters for bags, cartons and drums. ViSafe will demonstrate its wireless sensor technology, designed to measure movements and muscle activity in workers to give data on how workers move in order to eliminate, reduce or better manage physical effort and injury risks. Visitors can have their health assessed by WorkHealth, that will be offering free, quick and confidential health checks for risk factors associated with type 2 diabetes and cardiovascular disease. For more information, go to safetyinaction.net.au or materialshandling.net.au. Safety in Action 2012 www.thesafetyshow.com.au/safety-in-action-melbourne

www.foodprocessing.com.au

March/April 2012

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Cut-to-length plastic strap dispenser

Supply chain traceability tool The Lawson M3 Graphical Lot Tracker is a preconfigured supply chain traceability solution. Designed for rapid implementation and

The Sweed CL200 cut-to-length plastic

ease of use, the solution can help food and beverage companies

strap dispenser is available from Aus-

gain greater control over food supply chain safety and quality, and

tralian Warehouse Solutions (AWS).

help them address compliance and traceability.

By automating the strap cutting

The M3 Graphical Lot Tracker is an enhanced version of the

process, workers receive accurately

previous Lawson M3 Trace Engine. It helps improve supply chain

cut pieces of strap, and material cost

visibility and helps food and beverage producers track production

may be reduced by eliminating waste.

processes from raw materials, through production and to the point

While manual cutting operations

of sale. It can also help companies manage potential product

increase the risk of lacerations and

recalls, which can ultimately help protect their brands during a

repetitive strain injuries, this dispenser

crisis. Designed primarily for the food and beverages industry, the

requires users only to input cut length

Lawson M3 Graphical Lot Tracker can also be used in manufactur-

and strap quantity figures to operate.

ing and fashion environments where companies need to track and

The dispenser fits standard plastic

trace the links between different lots in their various supply chains.

strapping coils but can be adjusted

The software includes powerful search capabilities to help

to fit most coil sizes. It is low main-

companies quickly trace backwards to identify potentially tainted

tenance but designed for heavy

raw material lots - or forward to determine the potential scope

industrial use.

of product or safety issues. Customer recall lists can be generated to identify affected end products. In addition, ‘lots in stock’

Australian Warehouse Solutions Pty Ltd

reports identify products remaining inside an organisation’s supply

Contact info and more items like this at wf.net.au/M673

chain with the option to stop the product lots from further delivery. A grouped search function makes it possible to search multiple and combined product lots at the same time, which can be helpful when processing a large number of lots or conducting root cause analysis. To assist with crisis planning, the Tracker allows companies to

Process weighing terminal range

create ‘what-if’ scenarios, so they can simulate, test and audit

The Mettler Toledo IND331 range of process weighing terminals

likely scenarios before they happen. This dry run capability can

is claimed to be compact, easy to install and simple to use.

help companies identify inefficiencies and gaps in their processes

The terminals give precise measurement data that can

and helps prepare them for real-life situations before it’s too late.

be backed-up and restored using SD memory cards and

In addition to supporting reactive recalls, Lawson M3 Graphical

their organic LED weight display makes them readable in a

Lot Tracker can help companies streamline audits by providing

range of conditions.

proof of safety procedures, product quality and sourcing strate-

A choice of AC or 24 VDC power supply is available and

gies. An intuitive web-based user interface helps simplify use for

all terminals have a fast A/D conversion rate and TraxDSP

internal and external parties. Regulators and key customers can

digital filtering. An optional PLC interface allows bidirectional

have online access to traceability data, which can help build trust

information exchange with the terminal.

and confidence in a company’s products and brand.

Mettler Toledo

Lawson Software Australia Pty Ltd

Contact info and more items like this at wf.net.au/M889

Contact info and more items like this at wf.net.au/K605

Do you need flooring for your

Food Facility?

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March/April 2012

Hotels, Clubs, Nursing Homes, Deli’s, Hospitals, Sports Facilities, Restaurants, Bars, Conference Centres, Correctional Facilities, Retail Outlets, Butchery, Bakery, Seafood and all Safety Surfaces.

www.foodprocessing.com.au

1800 ROXSET 1800 769 738 Phone: (02) 9988 4822 Fax: (02) 9988 4833

©iStockphoto.com/Lauri Patterson

Changing refrigeration lighting could save millions

yle Steele, a master’s student at Kansas State University, has found that using LED lights instead of fluorescent in refrigeration can delay discolouration and rancidity in packaged meat products - and save money on operating costs. According to Steele’s research, meat products stored under LED lighting have colder internal temperatures, extending the products’ shelf life. Based on his findings, Steele said, “Beef loin steaks and inside round steaks that were stored under LED lights can have up to one day longer shelf life.” Colour shelf life was also improved by using LEDs. Fresh meat naturally changes colour due to exposure to oxygen, but consumers can be put off by discoloured meat, even if it is

still fresh. Discoloured meat products are often discounted or discarded, costing the meat industry up to a billion dollars a year, according to Steele. In addition, Steele found that LED lights have fewer cycles per running hour, making them more efficient to run than fluorescent lights. Steele is optimistic about the study, stating that his findings could save meat retailers millions of dollars a year by lowering operating costs and extending the shelf life of certain fresh meat products. Kansas State University www.k-state.edu

www.foodprocessing.com.au

March/April 2012

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Extending the shelf life of some meat products may be as simple as replacing fluorescent globes with LED lighting.

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Optyx sorter is the pick of the crop for Stemilt Growers In response to rising costs and labour shortages, many cherry packers are turning to automated inspection to increase throughput and reduce costs. To this end, cherry packer Stemilt Growers has recently installed an Optyx sorter in its plant in Wenatchee, Washington. The Optyx sorter uses colour cameras and lasers to inspect the size, shape, colour and structural properties of each cherry, automatically removing foreign matter and fruit with defects. By removing soft fruit, the Optyx ensures hand sorters do not need to touch and roll the fruit - a procedure that can slow inspection and damage good fruit. Removing the soft fruit improves shelf life, which can reduce shrink for packers and retailers and ensure high-quality product for consumers. Stemilt Growers’ Vice President of Operations, Jay Fulbright, said, “We’ve been operating Optyx 20 hours a day, seven days a week for most of the season, and we’ve been very encouraged with the sorter and with Key Technology as the supplier.” Key’s specially designed infeed for cherries, which includes a water spreader and dewatering belt, ensures the gentlest handling possible. Proprietary image processing technology allows the sorter to quickly analyse images of each cherry according to previously determined standards. The ejector system, which comprises a series of air jets spanning the width of the system, activates to expel foreign material and substandard cherries, while the quality cherries are discharged into a water flume. By automatically removing a large proportion of the cull, the Optyx reduces the number of manual sorters required, maximises the volume of product on the line and consistently maintains

March/April 2012

high product quality. “Optyx gives us the opportunity to process fruit better. We’re using it to sort out major grade defects before hand sorting. It’s allowed us to increase our throughput without increasing labour,” said Fulbright. Optyx’s bulk flow operation puts it ahead of other cherry sorting systems that use complex material handling equipment to rotate each cherry, and allows it to achieve high volumes. The Optyx 3000 features a 610 mm scan width and sorts between 2.7 and 3.6 t/h. The Optyx 6000, suited to higher volume operations, features a 1220 mm wide scan area and achieves 5.4 to 7.3 t/h throughput. Optyx’s KeyWare application software is specifically designed for cherry packers and uses terms common to the cherry industry to categorise defects on the user interface. User friendly and easy to master, the icon-based graphical user interface (GUI) reduces operator training and simplifies optimum operation. The GUI can reside locally on the sorter and accessed remotely, making remote factory troubleshooting and application assistance easy. Stainless steel construction, watertight double-gaskets on doors, a sealed control panel and easy access to areas needing periodic cleaning mean the Optyx operates in harsh environments and withstands high-pressure washdowns. Featuring a modular design and proven, high-performance connectivity standards such as Camera Link, FireWire and ethernet, Key’s Optyx offers flexibility that ensures forward compatibility to maximise the cherry packer’s long-term return on investment. Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/M408

www.foodprocessing.com.au

Programmable linear actuator The Haydon Kerk Idea Size 23 non-captive linear actuator is RoHS com-

LED beacon tower light Micromax Sensors and Automation has available an addition

pliant and combines high-output force, rotary to linear motion, stepper drive and programmable control in one integrated package. Linear travel per step ranges from 0.0031 to 0.127 mm and output force up to 890 N. The programmable linear actuator is fully programmable through

EZ-Light TL50 beacon tower light - a hybrid of the company’s

a user-friendly graphic interface and the actuator is available up to

TL50 tower and K50 beacon lights. As with Banner’s beacon

50.8 cm stroke length with various screw pitches allowing very fine resolu-

and tower lights, the light is segmented and may be ordered

tion. It is suitable for most applications requiring precision linear motion.

with up to four different coloured LED lights - red, yellow, green

Programming is much easier than complicated command sets or

or blue - which allows several messages to be conveyed at

proprietary programming languages. The software allows easy trouble-

once. In addition to solid light, these segments flash or rotate

shooting through line-by-line or multiple-line program execution using

their bright signals.

the interactive debug feature, and inputs and outputs can be simulated

Not only is the light suitable for indoor and outdoor use, but

in software before connecting actual I/O hardware.

the availability of audible and sealed audible models allows

The Idea programmable linear actuator runs on a single supply volt-

it to be used in a range of environments and applications.

age of 12 to 75 VDC, 3.85 A rms max rated current per phase with a

Banner Engineering claims that the TL50 is the most versatile

30% boost current capability for ramping, and eight general-purpose

indicator light it has developed.

I/O. Inputs are rated for 5 to 24 VDC, 4 mA max per input, and the

The bright output of the LED beacons provides easy-to-see indication from all directions when multiple lights may need to be on simultaneously - allowing operators to effectively monitor equipment from a distance. TL50 audible models with adjustable

outputs are open collector, 5 to 24 VDC, 200 mA maximum per output. Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/M228

sound intensity are available, in addition to multiple bracketing options, thus enhancing the light’s functionality and placement options. In addition, the TL50 beacon tower has a wide 12-30 VDC operating range, enabling battery-powered mobile use. All of Banner’s tower lights come completely preassembled and preconfigured, which may save time and money on installation. Energy-efficient LED technology helps reduce power consumption. Both the general-purpose and audible models of the TL50 beacon tower use Euro integral quick disconnect connectors, while the robust design of the indicator allows for direct machine mounting. Micromax Pty Ltd Contact info and more items like this at wf.net.au/M272

Custom gripper systems

Romheld Australia, in conjunction with its gripping system suppliers such as SAS Automatic, Schunk, Tunkers and Unigripper, can offer custom-made gripper systems to suit any application. The company has available grippers for robotic and other automated systems as well as manual grippers and end-ofhook solutions for lifting and overhead handling applications. Gripper systems can be provided for all industries. Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/M600 www.foodprocessing.com.au

March/April 2012

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to Banner Engineering’s line of lighting and indicators, the

What do space ships and soft drinks have in common? No, it’s not a corny joke. Both use cleanroom technology - a technology that started life as an aid to space flight and is now used in a number of other industries.

urrent consumer demand is for fresh food products but also, paradoxically, for foods that keep for longer. In response to this, cleanroom technology is changing to ensure hygienic preparation and processing of food products to allow foods to be stored for longer without spoiling. By preparing and packaging foods in germ-free conditions, products can keep for up to 50% longer.

The evolving room Industrial cleanrooms were first developed in the 1960s to create extremely clean conditions for manufacturing microelectronic circuitry for spacecraft. Today, all microchips are manufactured in environments with low particle counts. Cleanrooms are now used in electronics, pharmaceutical, medical, manufacturing and food processing industries. Although cleanrooms differ widely, they are always constructed on the same principle. The cleanroom is accessed by passing through a ‘grey area’ and then air locks, while the cleanroom itself is controlled by airflow systems and air filters that trap small particles and microorganisms. Using special high-efficiency particulate air (HEPA) filters, the systems filter out particles larger than 0.5 µm in diameter, which means that bacterium (with an average diameter of 2 µm) are excluded from the room. Requirements for particle counts differ between applications, with requirements defined by ISO classes. A Class 5 room, for instance, would permit no more than 3520 particles/m3, with each particle measuring no more than 0.5 µm in diameter equivalent to 3.5 particles/L. In contrast, air in a typical urban environment contains 35 million particles/m3, with particles 0.5 µm and larger. A Class 9 cleanroom has a comparable particle count to an urban environment. Dust particles don’t represent too great a threat to food production - as long as they aren’t attached to germs - so the food industry generally only requires cleanrooms of ISO classes 5, 6, 7 or 8.

Small is beautiful Large cleanrooms can be expensive to set up and maintain, so there has been a trend towards smaller cleanrooms in the 50

March/April 2012

food industry where practical. The risk of contamination is proportional to the size of the cleanroom, so smaller can often be better. More food processors are installing ‘mini environments’ or ‘flow boxes’ - small, enclosed cleanroom units - for processing plants. Some are even transportable. Some beverage-bottling manufacturers have embraced the small cleanroom concept with a technique called aseptic cold bottling, which involves cold bottling in a sterile environment, as a way to ensure sensitive, non-carbonated beverages have longer fridge life without the need for added preservatives or thermal stress. In aseptic cold bottling, only the path the sanitised bottles follow through the insulator and the filling and sealing machines are ISO 5 cleanroom spaces, significantly reducing the cleanroom space required in a beverage plant. In fact, many modern bottling plants require only 10% of the cleanroom space of older plants. Many aseptic bottling plants feature a Class 6 room installed within the Class 5 section to ensure recontamination does not occur. These room-in-room designs are not only cheaper to install, they may also guarantee a higher hygiene level than large cleanroom constructions.

Cleanrooms for less perishable food products Using cleanrooms in food processing has a number of benefits. Removing germs from the production and packaging processes ensures not only greater food safety but also improves the product’s longevity. Contamination by germs can cause a drop in the quality of a food product, or even premature spoilage, but refrigerated goods produced and packaged in cleanrooms keep longer than those that are not. Food that is processed in cleanrooms can also be transported and stored for longer, potentially opening up new markets for producers. As consumers continue to seek out fresh produce that keeps for longer, it seems that cleanroom technology will increasingly become a desirable way for food processors to keep ahead of the pack.

www.foodprocessing.com.au

©iStockphoto.com/ 4X-image

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Cleanroom technology ensures longer-lasting produce

Robot energy chains traction system), using the Triflex R 3D energy chain. The energy chain is used for power, data and media supply. The energy chain construction kit, designed for robot users, has approximately 250 components to guide cables and hoses securely around difficult geometries. These robot chains are available in several designs: the closed design is for cable protection in harsh applications, such as those involving spatter welding machines, chips and dirt;

Slice, dice, cut, cube, shred, strip or puree

the easy version is designed so the cables can be quickly pushed into the chain by hand at any time; and the light version is easily

Urschel® Laboratories offer high performance continuous cutting equipment for all manner of fruit and vegetable size reduction

managed and rapidly assembled. The chain ensures a predetermined minimum bend radius and torsional stop for careful cable guiding. The tensile strengths are absorbed by the energy chain to increase the life of the cables and minimise downtime. With the RSP, force is generated by a pneumatic cylinder. Retraction force is adjusted by changing the pressure in the cylinder. Force progression remains constant which, according to igus, ensures secure retraction of the energy chain in complicated

DiversaCut 2110® Small footprint versatile dicer

fillings, with cables and hoses in any position. The RSP can be attached easily to various robot models with compact mounting brackets. The systems, which have various extension lengths from 500 to 1000 mm, are compact and lightweight. An optional monitoring system is provided for robots whose

TranSlicer®2510 High capacity slice, shred & julienne

program sequences are frequently changing, alternating or not 100% predictable. This may be useful for robots that are steered by cameras or image acquisition systems. This monitoring, via a connection to the robot controller or PLC, provides an early warning signal when a predetermined tolerance value is about to be exceeded, which can give confidence in a

Comitrol® Puree, granulate, paste, desicate

system that is frequently reprogrammed. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/M334

Compact stock-picking unit Warequip has extended its Powered 2 Go range with the Bravi Spin-Go stock-picking unit. The lightweight, push-around unit has a working height of 4.2 m and includes traction-assist controls. At 1.155 long, 730 wide and 1500 mm high, the unit is suitable for stock picking in retail, offices and schools or anywhere with narrow aisle spaces. The unit’s operator capacity is 130 kg with a further 90 kg on the height-adjustable material shelf and 110 kg on

Exclusive distributor / AUS NZ +61 7 3877 6333 info@heatandcontrol.com.au heatandcontrol.com

the chassis storage area below. A low 360 mm step in, coupled with simple push-button up and down controls make the unit easy for a range of users to control.

Use our test facilities to determine your best cutting solution

Warequip Contact info and more items like this at wf.net.au/M721 www.foodprocessing.com.au Sept11_WhatsNewinFood_Urschel.indd 1

March/April 2012

18 Aug 2011 51 11:21:46

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Cutting fruit & vegetables down to size

Treotham Automation has available the igus RSP (pneumatic re-

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Conveyors boost beef productivity Established beef export company EC Throsby (ECT) has increased its productivity with a new conveyor system manufactured and installed by Adept Conveyor Technologies. Founded by Charles Throsby in 1950, the company is now headed by Edward Throsby. Continuing the family tradition, Edward oversees the Australian Beef Processing Plant near Singleton, NSW. ECT invested AU$4 million to upgrade the plant, from which it exports beef to 40 countries. The busy plant produces 20,000 cartons of frozen beef, processing 500 cattle per day. Of dealing with Adept, operations consultant Peter Sullivan said, “Adept Conveyor Technologies’ engineers provided a first class service by analysing our ideas and problem issues. They carried out some fine tuning of the concept, enabling us to become fully operational within five weeks of signing the order.” Sullivan says the Adept conveyor system has enabled the plant to eliminate double handing, increase efficiencies and improve safety standards and working conditions for employees. Since installing the conveyor, ECT has seen a 20% boost in production and expects a return on capital investment within five years. The biggest challenge Adept faced was installation time constraints. “As it was not possible to interrupt daily production, we only had a short window of opportunity to install the conveyor during the 2010 Christmas shutdown of the abattoir, which we achieved as planned,” said Ross Simpson, Adept’s director of engineering. After packing and barcoding, 60 carton types of beef cuts, each weighing up to 27kg, are conveyed from the boning room to the automated plate freezer. After freezing, the cartons are automatically conveyed to spur lines for palletisation, storage and shipment. During production, the system orientates cartons with

March/April 2012

the barcode on the appropriate edge so operators can ensure correct palletisation. The system accommodates the sorting of 140 product lines to seven destinations, where cartons are loaded at 42 different pallet positions. Adept’s system features barcode scanners that allow for variances in bar code quality due to frost build-up and mechanical damage - a vital component of the system’s capability. The system adapts to high volume throughput surges. High volume lines are allocated specific lanes. Operators then handsort low volume lines once full pallets arrive in the cold stores. The conveyor layout means the cartons must be rotated 90° while moving. To achieve this, Adept designed a carton rotator that accounts for the variation in carton weights. The rotator operates with a peak rate throughput potential of 12 to 15 cartons per minute. The entire operation is overseen at a touch screen control panel displaying important statistical data such as carton throughput per shift, product line breakdown, numbers of misreads and number of products processed per lane. Product lane sort destinations can also be altered. “The conveyor system has given us more control over the carton hand-palletising operation,” said Sullivan. “This in turn eased the effort and time required to load shipping containers with forklifts and resulted in better quality product presentations brought about by improving carton shape and reducing damage. The new system has most importantly resulted in a significant improvement in customer product satisfaction.” “In the final analysis the biggest winner is the customer.” Adept Conveyor Technologies www.adeptconveyor.com.au

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ÂŠiStockphoto.com/Alena Schweitzer

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The 19 best new products and technologies for food processors A total of 19 innovative projects will be receiving either Gold or Silver International FoodTec Awards at Aunga Foodtec this year. Gold Award winners Produce washing for germ reduction and prolonged shelf life The Vortex line by Kronen has been developed for the final treatment of vegetables (including leaf salads and root products) and fruit such as apples and grapes. The line features a tubular system with infeed and discharge openings. The precleaned products (fruit or vegetables) are transported into a hopper. Rotating nozzles located at the side gently and reliably flush the products into the system. The product is conveyed with water through the entire length of the tube and finally discharged. The products are moved on to a transport or vibration belt via a water slide. For germ reduction purposes and for enhancing the quality and shelf life of the products, chlorine dioxide or antioxidants can be added to the flushing water. The required contact time can be adjusted and controlled via the flow rate. Kronen is represented in Australia and New Zealand by Reactive Engineering (www.reactive-eng.com.au). Kronen, www.kronen.eu Ultrahygienic belt drive with synchronous drum motor SN062D is a new belt drive developed by Interroll Trommelmotoren GmbH that operates with a permanent magnet driven synchronous drum motor. This drive is ultrahygienic, environmentally friendly and an energy-saving solution aimed at the food and pharmaceutical industries. The stainless steel drive is completely housed-in and has been developed following the stringent EHEDG recommendations. Cleaning and disinfection times are reduced by up to 30%. In addition, it is only materials certified according to USDA/FAD requirements and Regulation (EC) No 1935/2004 that have been used to ensure proper compliance with the strictest requirements. Interroll Australia, www.interroll.com HDHF hygienic gripper The robot gripper system developed at the DIL is universally applicable, easy to clean and suitable for use in many food processing environments. The vacuum grippers ensure flexibility in the handling of food with irregular sizes. An underpressure applied between the gripper and the food surface holds the product securely. Contrary to other vacuum grippers, this one was designed

and constructed following strict hygienic design requirements. A vacuum is generated in the gripper, eliminating the need for tubes or pipelines which can easily soil. All gripper parts are made of food-grade stainless steel or food contact plastics materials. The gripping concept is based on the universally applicable HDHF vacuum generator with product-specific gripper geometry. German Institute of Food Technologies, www.dil-ev.de Instant maize BĂźhler AG has developed a process for the production of instant maize for the markets in southern Africa where corn meal mush is the most important staple food. The traditional preparation of mush is both time- and energy-consuming. With this innovative process, dried instant maize is produced that needs to be cooked only for two minutes. It comes very close to the traditional product in terms of taste, texture and mouthfeel. Due to the cost-efficient production process, the costs for the final products are only slightly above those of the traditional product. Consumers benefit from time and energy savings without any compromise of quality. Buhler AG Australia NZ, www.buhlergroup.com Manufacturer-independent process data acquisition Increasingly, the transparency of internal processes is becoming a decisive factor for the compatibility of companies. One key element is the digital connection of production and management levels using manufacturing execution systems (MES). A successful MES builds on a systematic and standardised set of data and ensures proper data processing. There have been problems with the systems commonly found in the food industry because of the many different controls implemented by the various machine manufacturers. The Technical University Munich Weihenstephan Standards are an innovative concept for the process-spanning data acquisition in the food and beverage industry that is independent of the manufacturer of the controls. This solution will contribute significantly to enhanced quality assurance and increased efficiency. Technical University Munich, www.tum.de Hop yield enhancement In traditional brewing, the extraction of bitter substances from hops is somewhat unsatisfactory. Losses can occur during wort preparation, fermentation, storage, filtration and filling. With www.foodprocessing.com.au

March/April 2012

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the new unit for hop yield enhancement, significantly more of the bitter and aroma substances can be obtained. Basically, the unit consists of different components. Apart from merely bitter substances, hop products often also introduce aroma compounds from the hops into the beer. Therefore, a hop aroma distilling unit can expand the unit for hop yield enhancement. With the hop yield enhancer, breweries can increase their compatibility as well as improve the ageing stability and with that the quality of their beers. Hertel GmbH, www.hertel.de Continuous production system for sausages ConProLink by Handtmann is the first globally available continuous production system for sausages, which makes visually appealing sausages with completely closed ends. The products are produced in one endless chain. Next, they are divided by twisting into individual sausages which can then be separated. The sausage meat is filled into the alginate casings in a coextruding process. The ConProLink system consists of two filling units and one twisting unit. One filling unit delivers the sausage meat and the other delivers the material for the casing for the subsequent coextrusion process. This system is an innovative solution aimed at automated production with high streamlining potential. Handtmann is represented in Australia and New Zealand by Multivac (www.multivac.com.au). Albert Handtmann Maschinenfabrik, www.handtmann.de/ Pasteurisation system with reduced thermal stress The application of heat in food processing may result in detrimental effects on the colour, taste, appearance and nutritional value of the food product. In order to reduce these quality deteriorations, the MicroPast system has been developed to reduce thermal stress to a minimum and to shorten pasteurisation time to between eight and 12 minutes. This is made possible by applying microwave energy and using pressure and heat stable packaging. Combining both features eliminates the disadvantages of microwave technology through a targeted generation of steam pressure inside the packaging. Steam is injected immediately prior to closing the packaging to prevent the packaging from collapsing during cooling. The most demanding challenge during development was to ensure uniform heating of the entire product mass, which is needed for proper pasteurisation. Creative New Food GmbH, www.cnf.li Integration of high-pressure equipment into processing lines High-pressure processing (HPP) can be used to improve the shelf life and safety of food without heat or preservatives within a few minutes. With this treatment, nutritional properties and taste are almost completely maintained. Multivac has succeeded in integrating HPP equipment into an automated packaging line on which modified atmosphere packaging can also be produced. In order to achieve this, the process parameters had to be adjusted to an optimum combination of product, packaging material and packaging concept. The amount of pressure can be freely adjusted during the high-pressure application, although it is important to allow for a short resting period during which the polymer from the modified atmosphere packaging can regenerate for stress reduction purposes. Multivac Sepp HagenmĂźller GmbH, www.multivac.com.au 56

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Silver Award winners Treatment of smoke gas in an air washer Process air loaded with smoke fumes must not be discharged into the environment without prior thermal or electrostatic treatment. Both methods consume rather a lot of energy. Westfleisch Erckenschwick GmbH has developed a process in which the smoke fumes are passed through an air washer where the contaminants are washed out and clean air can be discharged. The process water accumulating in this process is passed through a biological filter in which selected and adapted microorganisms metabolise the fume components. In this way, the exhaust air from cold smoke equipment can be ecologically and economically optimised. The advantage of this sturdy process is that significantly lower amounts of primary energy are needed, which results in excellent cost-effectiveness. Westfleisch Erkenschwick GmbH, www.westfleisch.de Wort stripper In order to control the evaporation of undesired aroma compounds from hot wort during brewing, Krones AG has developed the wort stripper Boreas which saves considerable amounts of energy and improves the quality of beer. The controlled stripping of undesired aroma compounds allows constant upstream brewing processes because the boiling process does not need to be adjusted for deviating raw material quality and the possible increase in dimethyl sulfide (DMS) levels. In addition, the boiling process can be optimised in terms of energy and time because the DMS formed during the process can later be reduced. Energy savings can be achieved due mainly to the low total evaporation rate. Lower rates of evaporation also go hand in hand with less warm water being needed for the previous stages in the brew house. The high stripping efficiency can be controlled precisely via the stripping gas flow. Due to the small footprint and the stand-alone construction, the system is easy to integrate and an interesting solution for medium-sized breweries as well as for industrial breweries. Krones, www.krones.com Raw sausage ripening system The raw sausage ripening system Ferma Quick developed by Van Hees GmbH offers many advantages for industrial companies producing raw sausages such as salami and other processed meat products. The process is based on predrying achieved with the use of freeze-dried meat, highly functional premium additives and spices. In this way, the capabilities that hurdle technology offers for the production of high-quality and safe raw sausages can be utilised. The ripening time for raw sausages can be reduced from 14 days to just 48 hours without any weight loss occurring as a result of the drying process. Van Hees is represented in Australia by CBS Foodtech (www.cbsfoodtech.com.au). Van Hees, www.van-hees.com Pectinase for cold-temperature wine production Processing grape mash and grape juice at temperatures below +10Â°C has several advantages in terms of quality and cost-effectiveness. However, the pectinases commonly used in winemaking for the degradation of the water-binding pectin in grapes are no longer active at these temperatures. Based on current enological findings from the area of mash and juice treatment, ErbslĂśh Geisenheim AG

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Cleaning system for modular plastic belts Habasit AG has developed the EHEDG certified cleaning system HyCLEAN CIP (clean-in-place) for the cleaning and hygienic treatment of modular plastic belts. This system provides for the automated and easy, effective and cost-efficient cleaning of conveyor belts. HyCLEAN CIP is an ‘all-round’ cleaning system, which means that it cleans all of the surfaces and edges including the side that the product is transported on. The cleaning process includes washing, foaming, flushing and disinfection of the belts in an automated operation. The belts are thoroughly cleaned and disinfected after a maximum of seven turns. The system operates at low water pressure of 5 bars. Compared to competitors’ products, the water consumption is clearly reduced, as are the operating and cleaning times when compared to manual cleaning. At the same time, user faults are minimised and water consumption is significantly reduced. The resulting advantages are higher standards of hygiene and better cost-efficiency. Habasit, www.habasit.com.au Pasta drier In conventional pasta driers, large volumes of air must be heated and conveyed in order to reduce the moisture content of spaghetti from approximately 30 to 12%. Depending on the temperature and moisture content, the starch-protein structures such as the ones found in spaghetti will have differing physical properties. When using these intelligently, it becomes possible to achieve the same pasta quality with a drying process that is slow at the beginning but needs a shorter processing time. This is due to the fact that less time is needed at the end of the drying process because there is less internal tension to be reduced which would otherwise promote the pasta to break. With the new technology concept of the pasta drier developed by Bühler AG, the process air is guided in such a way as to allow economical heat recovery through the condensation of the discharged air. Compared to traditional processes, this equipment can save 130 kWh thermal energy per ton of spaghetti. Buhler AG Australia NZ, www.buhlergroup.com Sorting potatoes by chemical composition The Sherlock separator by Insort GmbH is the first industrial sorting plant that can classify potatoes based on their chemical composition and allows them to be sorted into three different quality streams. The core of the plant is a highly sensitive camera system based on near infrared spectroscopy. The system delivers 3 x 3 mm spectral images on pixel-by-pixel basis in real time which are then converted into colour images following mathematical models. These images allow conclusions on the chemical composition of the object whose image has been taken. With this technology, all main defects and any type of foreign matter can be found and rejected with unrivalled precision. It also allows

for the identification of potatoes with sugar ends because these would cause undesired and intense browning reactions during the production of French fries. Insort GmbH, www.insort.at Cleaning robot The high levels of hygiene standards called for in the food industry require safe hygiene monitoring and ever more efficient cleaning processes. The cleaning robot Cleenius by Jürgen Löhrke GmbH can be used in high-risk areas in the food industry to ensure safe and reliable hygiene results. The robot can conduct complex cleaning operations even in confined spaces. It is supplied with energy and materials via a docking station. Due to its higher pressure stages, it can apply cleaning agents onto difficult surfaces. It is equipped with a lifting device that allows for the cleaning of high equipment, and it has a parking system for the off times with integrated self-cleaning and a gripper which allows materials to be moved and picked up in the processing plant. Jürgen Löhrke GmbH, www.loehrke.com Hygiene-compliant cutting technology The modular designed universal plant U-300 by food technology Lummer is suitable for the cutting, decoration and packaging of baked goods and pastry products. It features a new cleaning concept for companies of all sizes. Traditional and newly developed machine components are combined into a properly interlacing production line, which complies with the hygiene standards of the European Hygienic Engineering and Design Group (EHEDG) and food safety requirements. Rounded surfaces, as well as clearly defined dripping edges in combination with an open construction, are the features of this hygiene-compliant machine concept; the fully automatic cutting technology operates on ultrasonic principles. food technology Lummer, www.foodtechconsult.de In-pipeline contamination detection The Food Radar Systems Look 100 sensor has been optimised, in particular, for emulsions and foods that are pumped through pipelines. The difference between this sensor and other detection systems for foreign matter is that it operates with microwaves. In this way, it can detect low-density foreign matter including hard and soft plastic pieces, wood and rubber particles as well as pits or stones from drupes. The system is equally suited to detecting glass, metal and stones with the detectable particle size being dependent on the homogeneity and composition of the respective food product. Food Radar Systems AB, www.foodradar.com

The presentation of the International FoodTec Awards is a triennial event. Here, companies from the international food industry and its suppliers are honoured for their commendable innovation projects. The International FoodTec Award will be presented by the DLG in cooperation with the following partners: EFFoST (European Federation of Food Science and Technology), Koelnmesse, and the publishers Deutscher Fachverlag (trade journal Fleischwirtschaft), Th. Mann (trade journals EDM – European Dairy Magazine and DMW – Die Milchwirtschaft), Bücker-Fachverlag (trade journal FOOD Lab – Qualitätsmanagement, Analytik und Nachhaltigkeit) as well as LT Food Medien Verlag (Lebensmitteltechnik).

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March/April 2012

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has developed the enzyme preparation Trenolin Frio DF that is characterised by a high cold-temperature tolerance. It is an innovative pectinase product that can be used for the production of white and red wines. The most important benefits are the maintenance of the grapes’ quality, the higher quality of the final product and the cost savings due to energy savings. Erbslöh is represented by IMCD Australia Ltd (www.imcd. com.au) and in New Zealand by SCIOS Ltd (www.scios.co.nz). Erbslöh Geisenheim AG, www.erbsloeh.com

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Watson-Marlow ensures accurate dosage for Belgian brewery Winning a large ongoing order pushed the Carlier family to reconsider the way it doses sugar at its Brasserie de Blaugies microbrewery. Fortunately, an old family friend led the family Carlier to the Watson-Marlow Pumps Group and a 520 series peristaltic pump that ensures accurate, contaminationfree dosing for the brewery’s increased production. Too much or too little sugar can spell disaster for the brewing process, so the precise dosing of sugar is vital. When a large order meant the family needed to fill 20 and 30 L plastic fermentation barrels with their premium beer, accurate dosing became even more crucial. For a 20 L vessel, precisely 123 mL of sugar is required; for a 30 L vessel, the measure increases to 135 mL. Any variation to the proportion of sugar in the beer will impact the alcohol and flavour levels. The challenge to maintaining their unique premium beer, then, was to dose the precise amount of liquid sugar in each vessel. Family friend Andres Urban offered a solution to the Carliers’ need for increased efficiency and precision. Urban works for peristaltic pump manufacturer Watson-Marlow Pumps Group and recommended the 520 series pump, which features MemoDose for accurate single-shot dispensing. Brasserie de Blaugies produces only 5600 L of premium beer per month, exporting a significant percentage of its production. The 520 pump is typically used every second week, but is rated for 24/7 duties. Although the brewing process has been handed down from generation to generation, the Carlier family hasn’t looked back since installing the Watson-Marlow pump. The 520 series pump accurately doses the required amount of sugar into the fermentation vessels after all the other ingredients have been added. After a period of fermentation, the beer is decanted into smaller bottles for sale.

The Watson-Marlow pump has solved a dosing accuracy problem for Belgian microbrewery Brasserie de Blaugies.

Wa t s o n - M a r l o w ’s p u m p e l i m i n a t e s t h e r i s k o f contamination, with only the tube touching the fluid. This ensures the pump does not contaminate the fluid, and vice versa. The tube is squeezed between a roller and the track, which ensures complete closure of the tube. This gives the pump its positive displacement action, preventing backflow and eliminating the need to check valves when the pump is not running. The pump is used in combination with Marprene tubing, Watson-Marlow’s thermoplastic elastomer, which is a long-life tubing with a wide chemical compatibility. The Brasserie de Blaugies has seen many changes in the way the brewery operates over the years. Initially, the bottling process was mostly manual, as was the washing, corking, wiring and labelling of bottles. In 1992 the microbrewery invested in an industrial bottling line and in 2009 installed the Watson-Marlow pump. The Carlier family has been so impressed with the series 520 pump that they intend to use Watson-Marlow pump technology in a second bottling line being installed next year. Watson-Marlow (Pty) Ltd Contact info and more items like this at wf.net.au/M560

Robotic tool changer The ATI Robotic Tool Changer provides the flexibility to automatically change end-effectors or other peripheral tooling, with models available to cover a wide range of applications, from very small payloads to heavy payload applications requiring significantly large moment capacity. The double-taper locking piston in combination with the two locating pins provides good repeatability. Million-cycle testing, at rated load, is said to indicate that the typical repeatability is better than the guaranteed values. The Quick-Change tool changer has a large moment capacity due to the locking piston’s high coupling strength and large diameter. The coupled tool changer does not rock during high-inertia moves, preventing locking failure or repeatability problems. The double-taper locking mechanism wears in instead of out. The pneumatic ports use long-life rubber bushings which prevent any loss of air pressure. Spring probe electrical pins on the master plate ensure contact with fixed pins on the tool plate. The locking mechanism locks the master plate to the tool plate and remains locked even if pressure is accidentally removed. Featuring a lightweight and compact design, a wide range of electrical, pneumatic and fluid modules are available and Quick-Change Tool Changers can be configured to fit most applications. Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/M218 58

March/April 2012

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Servicing the Food Industry for over 30 years Food grade hoses for all applications - FDA approved Standard grade and Premium grade food hose options available Stainless steel end connectors in BSM, RJT and Tri Clover All food hoses hygienically assembled All food hoses pressure tested, tagged and capped Wash down hoses and guns, pressure wash hoses and accessories Protect lanolin lubricant that is 100% natural and food grade approved 92 convenient locations Nationally, all IS09001:2008 accredited

Resetting mouse trap Swift Metal Services has designed and launched a resetting mouse trap, the SwifTrap. The trap is suitable for food and beverage producers and other users requiring vermin control. The trap needs only a bucket and a screwdriver to set up and requires no batteries or

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electricity as it uses the weight of the mouse and gravity to trap mice. The SwifTrap’s tipping mechanism resets itself so resetting is not required. The company says the trap may eliminate the need for poisons, baits and spring-loaded trap mechanisms.

Anti-microbial, in-can preservative Dow Microbial Control has released Bioban 551S, an in-can preservative based on its antimicrobial active ingredient MBIT (2-methyl-1,2-benzisothiazol-3(2H)-one). Bioban 551S is a combination of MBIT and MIT that is effective at low dosages across a broad pH range. Prior to the release of this product, the most recently developed active ingredient for in-can preservation was released last century. The company claims that its active ingredient is effective against a broad spectrum of organisms including difficult

SWIFT Metal Services Pty Ltd Contact info and more items like this at wf.net.au/M393

to control strains that can thrive in recently developed in-can products. Formulations based on MBIT can provide proven, reliable performance while complying with current environmental,

Food and beverage certified hose assemblies Pirtek’s IRPF is a premium food-quality suction and delivery hardwall hose designed for conveyance of wine and alcohols.

health and safety requirements, according to Dow Microbial Control. The company says Bioban 551S outperforms commercial MIT-BIT combinations against yeast, mould and bacteria.

The tube specification meets FDA title 21, item 177.2600 for aqueous foods, BgVV

Bioban is a water-based and solvent-free

XXI cat.2 for aqueous and fatty foods, DM 21/03/73 for aqueous foods, IANESCO France

solution with good chemical and thermal

8 IV 87 for milk, DM 28/10/94 and 26/04/93 for alcohol and foods.

stability. Dow claims it does not release

The wide temperature range of -40 to 120°C makes this hose suitable for use in breweries and distilleries. It is odourless and taste free.

formaldehydes and its active ingredients do not contain added organohalogens or heavy

A key feature of Pirtek food grade assemblies are the hygienic crimp. This swaging

metals. It may be useful for paint and latex

technique ensures that no food particle or substance build-up eventuates behind the tail

manufacturers requiring an in-can preserva-

of the fitting and that the hose is always kept clean, with full flow also being achieved

tive for low-VOC and VOC-free water-based

during operation.

systems in line with the requirements of

The IRPF hose assembly is designed for standard CIP (clean in place) methods to

eco-labelling schemes without the need

increase hose longevity and for general cleanliness. Each hose assembly comes with a

for additional performance boosters. The

test certificate and is individually numbered.

company says its water solubility makes

While an RJT type termination is common, BSM Flat Face, Tri Clover and Stub ends

aqueous coatings.

are also available if required. The Premium Food Hose Assembly (IRPF) is part of Pirtek’s extensive range of food and beverage flexible hoses designed to handle milk, alcohol or food. Pirtek Fluid Systems Contact info and more items like this at wf.net.au/N213

March/April 2012

it suitable as a component for VOC-free

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Dow Chemicals Australia Ltd Contact info and more items like this at wf.net.au/M291

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Cook, quench and chill systems

Mozzarella cooker stretcher GoldPegâ&#x20AC;&#x2122;s GPiCS mozzarella cooker stretcher is a low pressure, low shear, direct steam injection, continuous cooking stretching system. The cooker stretcher is designed for the industrial production of natural mozzarella, string cheese and pasta filata varieties. The automated, hygienic enclosed system is claimed to have low shutdown wastes. The cooker stretcher produces sensitive natural mozzarella and pasta filata cheese varieties continuously with no bath cook water. The company claims the machine produces cheese with composition, sensory and functionality similar to a traditional wet cooker product. WineryEng_Ad.pdf

Gold Peg International Pty Ltd

4/04/2012

10:28:08 AM

DFC Foods Systems is distributing the range of Vortex cook, quench and chill systems. The systems come in two formats: the Vortex Mono, in which the cook, quench and chill tanks all sit on one compact sub-frame; and the Vortex 2, a dual frame format that allows for separation between high and low care areas. The cook and quench sides sit on separate sub-frames and can pass through a segregation wall. A range of products can be cooked in the units, including rice, vegetables, seafood and short, long and filled pasta. As it cooks, the water rotary flow system reduces product clumping, sticking and basket retention. The product exits the unit completely cooked and below 3Â°C, ready for immediate packaging. Production volumes range from 800 to 2400 kg of product per hour, dependent on the model and product. DFC Packaging Group Contact info and more items like this at wf.net.au/M892

Contact info and more items like this at wf.net.au/M698

MARLBOROUGH - SEPTEMBER 6-7, 2012

March/April 2012

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Corona producer installs CoMac complete keg line

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Grupo Modelo has recently installed a complete keg line from CoMac, an established global supplier of kegging and bottling equipment, in its Piedra Negras brewery in Mexico. Brewing and distributing Corona Extra, the number one selling Mexican beer in the world, Grupo Modelo is one of the largest Mexican beer manufacturers. It produces 65 million hL of beer annually, released under 13 brands. Under a strategic alliance with Nestlé Waters, it also produces and distributes bottled water. Grupo Modelo had CoMac install an HS6T medium-speed washing and filling machine, featuring an automatic palletiserdepalletiser machine. A six-head automatic keg washer and filler, the HS6T washes and cleans the kegs internally prior to filling. It processes different keg types without the need for manual changeover. Its keg loading system increases operation times and machine reliability by reducing the maintenance operations required. Both machines have highly efficient, energy-saving motors. The line operates at speeds up to 180 km/h.

CoMac manufactures a full range of kegging equipment for a variety of operations. For microbreweries, it offers semiautomatic single- or twin-head washing and filling units with integrated CIP tanks. Inline five- or six-head machines are suitable for medium outputs. CoMac also has a fully automatic combination keg de- and re-palletiser up to 1200 km/h, a flash pasteuriser with inverter controls, a keg tilting machine, weighing units, keg leakage control units, an inkjet coding station, keg labelling systems and an automatic spear tightening system. HBM Packaging Technologies Contact info and more items like this at wf.net.au/M427

NHP FOOD AND BEVERAGE SOLUTIONS Our partnership with leading global suppliers such as Rockwell Automation and an extensive network of technical support staff enables us to provide electrical and automation solutions for the food and beverage industry. Batch tracking and trace software, conveyer and motion control products, High IP rated controls and enclosures for wash down areas as well as intelligent motor controls and drives are a few examples of solutions we have available. Products and services we can provide include:

What you want, when, where and how you want it.

NHP Electrical Engineering Products Pty Ltd

• • • • • •

Logix controllers FactoryTalk® software PowerFlex® drives Intelligent motor control Process solutions OEM Partnering Programs

Sales 1300 NHP NHP Sales 0800 NHP NHP

• • •

Safety solutions including signalling and sensors Extended Warranty, System and Services support Sustainable Production Solutions

nhp.com.au nhp-nz.com

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March/April 2012

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CompAir’s Quantima cuts carbon and servicing costs for MGC CompAir’s Quantima compressor system has helped Australia’s largest milk processor, Murray Goulburn (MGC), reduce costs and carbon emissions. MGC has in place a continuous development program to reduce its carbon footprint. This program, in conjunction with the availability of Sstate funding towards the purchase of energy-efficient technologies, prompted MGC’s Group Maintenance Manager, Mark Gurney, to consider replacement options for the existing compressed air system at the company’s Leongatha plant in Victoria. The company required a complete new system to supply all of the factory’s compressed air requirements for both plant and packaging processes, including new compressor units, air supply pipes and dryers. CompAir Australasia put forward a proposal for the new system that involved replacing the four existing compressor units with just one 300 kW Quantima compressor and leaving two units for standby air. The new system was commissioned successfully in November 2007. A detailed audit was taken before and after the installation, proving without a doubt that the new installation has enabled MGC to meet its power reduction target with an overall energy saving of more than 35%. “By combining the innovative Quantima compressor with all downstream equipment, including desiccant dryers and new air distribution pipes, we have been able to reduce pressure drops and air leaks dramatically,” said Gurney. “Prior to the installation, our compressed air system was using 9.1 kW to generate each cubic metre of air per minute. Now, with Quantima, this specific power

March/April 2012

consumption has reduced significantly to just 6.12 kW/Nm3/min. In simple terms, we are now producing compressed air at best practice levels and with much better efficiency - to the effect it is now taking 33% less power for us to generate a higher air output.” MGC has already realised CO2 savings of 1908 tonnes - equivalent to planting over 2805 trees or taking 440 cars off the road. The Quantima saves energy through its Q-drive, a centrifugal compression assembly that consumes significantly less power than conventional technologies. Q-drive’s rotor shaft is its only moving part, reducing friction contact that can result in energy losses and performance degradation over time. A variable speed drive allocates airflow according to plant demand to further save energy. The Quantima has not only saved MGC energy; its predictive maintenance solution, Q-life, also saves on servicing costs. CompAir engineers monitor the machine’s performance remotely, moderating it where necessary to prevent a fault occurring or arranging a local engineer for remedial repairs. MGC and CompAir are working together to design water-cooling towers to reduce the plant’s energy consumption further. The towers are projected to save another 71 kW of installed power, meaning a further 677 tonnes of CO2 savings each year. Gurney is happy with the new system: “Instead of simply replacing one or two of our existing compressors, we chose to install a complete new system that would deliver a low cost of ownership, with the maximum energy savings possible. We are very pleased with the results. “After only five months, the Quantima compressor has already delivered the energy-saving and carbon footprint reductions that we expected. Overall the project will pay back, pre tax, in 22 months.” CompAir (Australasia) Limited Contact info and more items like this at wf.net.au/M577

www.foodprocessing.com.au

PROCESSING

FoodBowl installs Xenos aseptic bottle filling machine and pasteuriser Xenos Aseptic Beverage Systems has recently installed an X500PP aseptic bottle filling machine and a tubular UHT pasteuriser at the new Manukau Food Innovation Centre in Auckland. Commonly known as the ‘FoodBowl’, the NZ$18 million centre supports smaller food manufacturers in the development and testing of their products for commercialisation, particularly in the FMCG sector. While it is designed to assist smaller companies that lack the resources to commercialise their products, it will also provide a welcome boost to the New Zealand food market economy. Handling up to 500 plastic and glass bottles an hour in a range of bottle sizes, the Xenos X500PP is a pilot plant filler that is used for a variety of products, from the aseptic filling of milks and juices to pasteurised milks and hotfill juices. The system uses a sterilisation process that first steams and dilutes the bottles in hydrogen peroxide, then exposes them to UV light, achieving an extremely effective sterilisation in a short time. The Xenos aseptic bottling system is popular worldwide among beverage producers as the process eliminates the need for preservatives, caters for a range of bottle containers and provides a hygienic, long-life product. The ‘FoodBowl’ pasteuriser is connected to the filler and runs 150 L per hour and can process a wide range of beverage types as it has a broad temperature capacity from 72°C for milk to 142°C for other beverage products. Manukau Institute Technology Contact info and more items like this at wf.net.au/M321

www.foodprocessing.com.au

March/April 2012

Stainless steel pressure sensors The PI27 series pressure sensors have a high-grade 100% stainless steel housing that resists liquid ingress and is suitable for hygienic applications. The housing is resistant to cleaning agents used in the food and pharmaceutical industries whose effectiveness is constantly increasing. The completely

the programming menu.

Patties produces well-known brands such as Four’N Twenty Pies, Herbert Adams, Chef’s Pride, Creative Gourmet, Nanna’s and, of course, Patties from its Bairnsdale bakery in Victoria. Patties has been using the Bizcaps BRM Recipe Manager system for over six years, with each new concept, package or product starting off in the Recipe Manager system. The National Review of Food Labelling, or Blewett Review, prompted changes to rules regarding the Nutrition Information Panel, strictly specifying the way manufacturers must now include information on ingredients such as fibre and salt. Jake Lowing, new product development manager for Patties, says that Recipe Manager is integral to Patties’ compliance with the new regulations. “Recipe Manager delivers data integrity,” he said. “Bizcaps is the hub of the concept component of our product development and lets us easily track different formulations from concept to sign off. With Bizcaps, we have traceable version control. It also allows us to produce an initial Nutrition Information Panel and assess the cost along the way.” Bizcaps’ range of business solutions is designed to help manufacturers and other suppliers publish their product and supply chain information to their trading partners, including the major retailers. An Australian software company, Bizcaps also has extensive supply chain experience.

ifm efector pty ltd

bizcaps

welded housing prevents ingress from aggressive cleaning agents and withstands harsh washdown conditions. The transmitters vent design incorporates a Gore-Tex diaphragm that resists oils ingress.

PROCESSING

Bizcaps BRM Recipe Manager helps Patties cook up a storm

Benefits include: high protection IP69K; hygienic design; high-temperature resistance; high-purity ceramic measuring cell; quality materials (wetted parts); intuitive operation. For application versatility, multiple process fittings can be used. The company’s Tri-clamp adapters feature PEEK and Viton sealing for food and beverage applications. PEEK and Viton offer long-term sealing and are resistant to swelling and harsh chemicals. The pressure transmitter provides a high overall accuracy of ±0.2%. Outputs include switching and analog or dual switching that are selectable through

Contact info and more items like this at wf.net.au/L905

March/April 2012

Contact info and more items like this at wf.net.au/M433

www.foodprocessing.com.au

PROCESSING

Processed food gets real with advanced thermal heating technologies It seems consumers don’t know what they really want. Although many consumers opt for ready-to-eat meals, deli products and frozen and fast food, the current consumer trend is for processed foods that don’t look or taste like processed foods. Consumers are seeking foods that appear natural, homecooked or of restaurant quality, even if they are anything but.

“R

egarding quality RTE (ready-to-eat) products, consumers are placing a higher demand on our industry to develop products that appear to be naturally processed,” said Adam Cowherd, Unitherm Food Systems’ Vice President of International Sales. Fortunately, advanced thermal heating technologies can help food processors meet consumers’ paradoxical preferences. Food processors have a choice of four main methods of thermal heat: impinged air, flame, sear and radiant infrared heat. Combined with natural browning agents, these thermal heat methods can achieve colours and surface effects that look like the real thing quickly, efficiently and consistently. Unitherm’s Adam Cowherd explains some of the technologies available to food processors and which Unitherm products are best suited to which applications.

Impinged air With this thermal technique, high velocity air is directed at the product’s surface. When dealing with products that have less uniform surfaces, impinged air technology can be used to develop uniform colour on the top, bottom and sides of the product. Super-heated vapour is created by combining high-temperature air with steam. The browning process can be sped up by using super-heated vapour with impinged air. This method works well for meat, poultry and pasta dishes and baked foods like pastries and pizza bases. “The effect we see from products that are processed with

impinged air is more uniform colour without the shadowing that you see with radiant heat such as infrared,” Cowherd explained. Unitherm’s RapidFlow oven is one of a number of new impinging oven designs that allow users to alter multiple parameters, such as temperature, humidity and the velocity of the impinged air, to create the desired effect.

Flame Flame grilling is one of the original methods used for colouring food products. The term 'flame grilled' is widely used to market a range of products, from chicken wings to roasted tomato pasta sauce. “In the case of a grill-marked chicken breast, customers are beginning to ‘read between the lines’ of the traditional bar marks and want to see the same naturally occurring flamed highlights and colours they see on chicken prepared on their barbecue grills at home.” For this reason, flame grill systems need to be flexible to create authentic flame grill effects on food products. Unitherm’s flame grill system has multiple independently controlled ribbon burners, adjustable bar-markers and relative temperature controls to allow users to customise the grill effects to each product. “Everything characteristic of the flame can be adjusted from the angle to the length,” Cowherd said. According to Cowherd, when combined with surface marking, flame grill effects create an authentic appearance and taste. A bonus of this method is that the flame www.foodprocessing.com.au

March/April 2012

PROCESSING

grill can seal in moisture, which results in higher yield. This is particularly beneficial for products that need to be re-heated as it improves the quality.

Searing Searing technologies include high-temperature equipment belts and hot branding irons. Custom-made branding irons that sear patterns such as diamonds and crosses into the surface of the product are also available. Good quality searing technologies can not only make marks on the surface but also develop colour and texture between the marks to make the product appear as if it is chef prepared or homecooked on a grill.

must be uniform in size, shape and weight for it to flip on a transfer conveyor mechanism. Electric infrared is another form of radiant heat. The common household toaster is an example of electric infrared heat. Advances in electric infrared systems have resulted in high-temperature black-bar emitters that allow rapid browning on all of the productsâ&#x20AC;&#x2122; surfaces. Infrared technology has other benefits besides adding colour to products. An infrared system can be used to pasteurise a product and can even be used in conjunction with liquid smoke to pasteurise, smoke and add colour in the one process. A fully-cooked deli product, for instance, can be post-process pasteurised and smoked in 60 seconds with less than 2% yield loss. Cooking with this method can also obtain over a 3.0 log reduction in Listeria monocytogenes, according to a study run by Dr Peter Muriana at Oklahoma State University. Cowherd adds that the majority of smoked deli meat manufacturers in the US are using electric infrared technology. By smoking and browning with Unithermâ&#x20AC;&#x2122;s Infrared Pasteurizer, food processors can control colour and also make a safer product for consumers. Reactive Engineering Pty Ltd Contact info and more items like this at wf.net.au/M908

Infrared Usually gas or electric heated, infrared is one of the hottest thermal heat technologies in the industry. Gas infrared units tend to have a flat surface burner head, allowing colours with highlights to develop - this is where the higher points of the food surface brown more quickly because of their proximity to the infrared head. This fixed-head technology provides continuous in-line cooking and produces the golden-brown colour and unmatched yields required by major fast food chains in the foods such as breakfast sausage patties. However, it only colours the top of the product, so if both sides need to be coloured, the product

March/April 2012

www.foodprocessing.com.au

Adam Cowherd is the Vice President of International Sales at Unitherm Food Systems, in Bristow, Oklahoma. Established in 1985 in the UK, Unitherm began as a stainless steel fabrication shop, custom building equipment for food processors. The company is now known throughout the food processing industry for its innovative approach to the design and creation of machines and systems to maximise yields and reduce processing times while enhancing safety and profitability.

Ovivo system overcomes stringent trade waste limits Three of the 500+ panels we built in 2011

PROCESSING

When the local council changed the criteria for discharge to local sewage treatment works, a New South Wales juice producer turned to Ovivo Australia to supply, construct and commission a new waste water treatment plant (WWTP) at its factory. Specialising in shelf-stable juices, the prominent juice producer processes a variety of fruits and vegetables in its factory, removing the pulp to be sold as a by-product. The company found itself subject to stricter trade waste criteria when its waste - both wastewater and general waste - was found to have high loadings when discharged to the council sewage system. Ovivo’s solution was a biological treatment plant designed specifically to reduce BOD5 and TSS levels to below council limits, maintain the discharge pH range and keep the discharge flow below a set value. With the factory’s wastewater pH rising as high as 12 during cleans and instantaneous discharge up to four times the average flowrate, Ovivo had its work cut out for it. The treatment plant required a robust process design to overcome the feedwater variation. Ovivo’s design consists of a twin sequential batch reactor (SBR) system, with flow buffering/storage upstream and downstream of the tanks, and a sludge dewatering system for excess waste activated sludge dewatering. Neutralised effluent is transferred to the equalisation tank in the new WWTP. The tank provided temporary storage prior to the effluent entering either SBR. The equalisation tank is kept aerated to suppress odour, maintain mixing and remove a small amount of BOD5. Effluent is then transferred into one of the two SBR tanks, which are run out of sync so effluent is fed into one of the two tanks every three hours during a six-hour batch process. Sludge removed from the SBR during the batch process is sent to the sludge tank for intermediate storage and thickening. The sludge is then dewatered in a Huber inclined sludge press (ISP) and deposited into a bin for off-site disposal. The Huber ISP is a unique system that Ovivo has now employed at several sites across Australia that offers low washwater requirements, low rotational speed and high performance. The plant performs very well, with a 96% removal of BOD5 and a 90% removal of TSS. The range of the incoming pH to the equalisation tank is between 5 and 12, while the discharge pH has been maintained between 7.5 and 7.9, well within the allowable range of 7-10 pH set by the local council. Commissioning of the plant was rapid, with discharge limits being met within several weeks of plant seeding. Ovivo AeroStrip fine bubble diffusers were used due to their simple self-flushing design and high oxygen rates, typically 4-5 kg O2 per kWh. This aeration strategy enables the most efficient use of the positive displacement blowers, reducing power demand while ensuring sufficient dissolved oxygen levels are maintained within the reactor. The plant is controlled via a PLC and SCADA package, providing operators a modern and comprehensive control system to operate, maintain and optimise the treatment plant. Since commissioning, the plant has operated with stability and consistent discharge quality.

Our Sydney Systemhaus is ISO 9001 certified for the ‘development, assembly and distribution of customised system solutions,’ making Bürkert the ideal partner for large and small scope projects. In addition to standard panels, we engineer custom panels with pneumatics, I/O, transmitters and programming to meet your wider control system needs. Call on Bürkert to build your 2012 panels.

We make ideas flow

Ovivo Contact info and more items like this at wf.net.au/M887

www.burkert.com.au | 1300 888 868

www.foodprocessing.com.au

March/April 2012

Coating applicators Heat and Controlâ&#x20AC;&#x2122;s FPS tumble breaders, compact breaders and batter applicators have been designed to apply flour, cracker meal, any style of crumb (including Panko), sugar, spices, coconut and even potato sticks to various products. Built to Wisconsin Dairy Association and USDA sanitary standards, the applicators use no augers or transfer mechanisms that can contribute to downtime for repairs and cleaning. Instead, a Transverse Lift Conveyor (TLC) circulates coatings to reduce degradation, jamming and changeover delays common to applicators that use augers. All models use variable-speed

PROCESSING

AC drives to reduce maintenance. Coatings can be discharged quickly for fast changeovers and sanitation. The applicators are compact and portable, enabling different equipment layouts and offline cleaning. Hinged panels provide complete internal access and the belt can be removed without tools. The tumble breader uses a vibratory conveyor to tumble, coat and convey product at high transfer rates. The vibratory conveying eliminates wire belt conveyors, which are one major cause of unscheduled line shutdowns. The conveyor amplitude, frequency and coating delivery are adjustable for uniform coverage on many products, and the finished product can be spread, aligned or laned to suit downstream inspection and cooking and freezing equipment. The compact breader uniformly applies a variety of coatings from pre-dust to final pass. It is portable and requires less line length than traditional applicators. Sprockets are welded to shafts, eliminating keyway and set screw maintenance. The batter applicator uniformly applies batters and marinades to surfaces of formed and natural products. Electric drives, fully welded construction and pivot-up submerger can reduce maintenance and cleaning costs. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/M345

March/April 2012

www.foodprocessing.com.au

Compressor control system The Air Relief TurboLogix compressor control system monitors, protects and controls centrifugal air compressors.

compressor stages, turbine or motor drives and any pressure range.

Direct steam injection continuous cooking system

Additionally, it has been developed using a non-proprietary system,

The RotaTherm direct steam

which means parts will not become obsolete.

injection continuous cooking system is available from Gold Peg

The system is compatible with a range of centrifugal compressor makes and models and can be retrofitted without disturbing devices in existing control panels. The company claims it can handle a number of

International. It is suitable for cooking and processing food prod-

is accessible to the user. Its algorithms and electronics enable the

ucts such as processed cheese varieties (including high and low

centrifugal compressor controlled by the TurboLogix to compensate

moisture), baby food, chunky sauces, purees, dips, pie fillers, taco

for changing conditions. Multiple compressors can be connected

meat, desserts and pet food.

together for load sharing and load balancing. The TurboLogix selects

The flexible processing set-up allows users to set heating

the best compressor combination to run to optimise pressure and flow

and processing parameters as required. These include cooking

control, claims the company. By controlling pressure and temperature,

temperature, direct steam-injection heating profile, shear, pres-

the risk of surges is reduced, making the compressors more efficient.

sure and mixing.

The system has a built-in history that stores up to 12 months of

It is available in pasteurisation, UHT and aseptic configurations

data, which can be interrogated by a number of parameters, allowing

and can be operated continuously for up to 144 hours.

for full data trending. As an ethernet-based system, data can addition-

The cooker is suitable to process most products that are

ally be downloaded and accessed via modem or PC.

‘pumpable’ through closed pipework, cook in a single pass and

The system has a high-resolution colour 10.5” touch screen, ethernet

have water in the formulation or can accept moisture addition in

control interface for remote access, 16 4-20 ma analog output chan-

the cooking phase.

nels and 16 120 VAC digital input and output channels. CompAir (Australasia) Limited

Gold Peg International Pty Ltd

Contact info and more items like this at wf.net.au/M877

Contact info and more items like this at wf.net.au/M689

Customise

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www.foodprocessing.com.au

March/April 2012

PROCESSING

Developed with Allen Bradley components and software, the system

Rising cocoa and sugar costs in 2010/11 did not spoil the party for the confectionery industry as it continued

PROCESSING

to lead the food and drinks sector in terms of global launch activity in the first half of 2011.

any markets saw static or falling volumes, with value rises mainly reflecting these price rises; and manufacturers, in many instances, had to rely on ongoing product and promotional activity to maintain competitiveness. In the face of this, new product activity levels continued to gain momentum, building on the record global launch numbers recorded for confectionery in 2010. The first half of 2011 had a further rise in comparison with the same period for 2010. Chocolate continues to dominate in confectionery, both in terms of market value and of launch activity, with chocolate accounting for over two-thirds of the confectionery launches tracked by Innova Market Insights in the first half of 2011. Sugar confectionery was next with just under 30%; then chewing gum with 5%. The chewing gum sector has had some difficult years after a buoyant period in the mid-2000s. There are now signs that it is starting to recover, with rising launch numbers and some success in terms of product activity over the past year or so. Most notably, this has been with lifestyle products, particularly sugar-free and mouth-freshening gums, in convenient formats designed to appeal through groundbreaking flavours, packaging and graphics. Launches of particular interest over the past few months include Australia’s first approved fortified sugar-free gum in the form of Wrigley’s Extra Professional Calcium; a three-layer chewing gum under the Mentos 3 name in France including a mint and liquorice variant; and Kraft/Cadbury’s Trident Vitality range of enriched gums in Awaken, Vigorate and Rejuve variants in the USA. Meanwhile, in the chocolate confectionery market, brand extensions continue to dominate activity, with Nestlé’s Kit Kat

particularly active globally. It has seen launches ranging from a candied sweet potato Kit Kat variant in Japan, a boxed Kit Kat Singles variant in Germany and a range of Kit Kat Chunky 3 variants in Australia. Bite-size chocolates are also featuring strongly, particularly in the UK, with launches such as Cadbury Dairy Milk Chocos and Galaxy Bites. The sharing bags concept is also being heavily exploited in a number of countries, as exemplified by 2011 introductions such as Kit Kat Pop Chocs in the UK, Milka Crispy Snax, Daim Snax and Lila Stars Snax in pouches in Germany and Hershey’s Milk Chocolate Drops and Cookies’n’Creme Drops in the USA, featuring two of Hershey’s most popular brands but without the usual candy shell, packaged in resealable pouches. The award for the most unusual confectionery launch over the period should perhaps go not to the more usual destination of Japan, but this time to the USA, where Coco Preggers, a range of chocolate truffles with added folic acid and DHA omega-3 fatty acids, has been launched by Xan Confections, aimed specifically at pregnant women. Lu Ann Williams, Research Manager at Innova Market Insights, concludes: “The strong product and promotional activity seen in the confectionery sector in the first half of 2011 looks set to continue. The demand for small and relatively inexpensive snacks and ‘treats’ seems unlikely to be radically inhibited by consumer concerns over their finances, or indeed over health and obesity issues, and the confectionery industry remains well placed to deal with ongoing competition from other snack products.” Innova Market Insights (Australasia) Pty Ltd Contact info and more items like this at wf.net.au/M239

Germ-free packaging & conveyors with Fast & Effective UV disinfection. Less waste, improved quality, reduced risk of re-contamination.

www.heraeus-noblelight.com/au

Clean Cover UV tunnel - Steribelt - Bluelight UV module

March/April 2012

www.foodprocessing.com.au

Phone: 03 9874 7455 Email: sales.HALA@heraeus.com

Confectionery leads product launch activity

Only a BEST will do for Stahmann Farms Having seen BEST’s Helius free-fall laser sorter in action, the Stahmann team knew it was the right system for them. Using up to 12 laser signals, the sorter analyses each kernel’s structure, size and shape in a single pass and uses its precise air guns to remove defective kernels while still permitting quality product to continue its fall. Having the ejection system located at the rear of the sorter means that air valves can be extremely close to the product. This allows for highly targeted defect ejection but minimises instances of adjacent quality product being removed. The Helius system’s user-friendly interface also saves Stahmann time and money. “The design engineer that creates software in an R&D lab is not the operator that works with it every day,” said Burling. “A big advantage of the technology is its software is designed on a PC platform so an operator can intuitively perform very complex manipulations. If you can compose email at home, surf the web or use word processing, you can effectively operate this system.” BEST’s technology may have improved productivity in Stahmann’s Toowoomba plant but its customer service continues to keep Burling happy. “The company’s PAX remote diagnostic system is available 24 hours daily,” he comments. “I can logon and talk to BEST’s European technical staff any time. Having instant access to technical support is great peace of mind and sets BEST apart from other companies that eagerly support the sales but not the post-sales support.” The BEST Helius laser sorting system is available in Australia from Heat and Control. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/M541

Comprehensive Buhler short goods and long goods Pasta processing lines are offered for sale as complete lines as follows: ■ ■ ■ ■

Short Goods Line 1 Short Goods Line 3 Short Goods Line 2 Long Goods Line

Electrical installation cables/wiring included and available where required. All equipment supplied with detailed installation arrangement planning in drawings and comprehensive service manuals including electrical installation drawings/ manuals All equipment has been well maintained and is fully operational. The above pasta processing lines are offered for sale at New Zealand site in as is condition at attractive prices. For further information contact: Chris Norman ❘ Grain Tech Engineering Ltd Phone: 0064 9 2636926 ❘ Mobile: 0064 21 2290 390 Email: grain@ihug.co.nz

TH ER M A L

HEAT TRANSFER SYSTEMS

TH ER M A L INDUSTRIES

www.foodprocessing.com.au

March/April 2012

PROCESSING

A Helius free-fall laser sorter from BEST has helped Stahmann Farms towards its goal of being Australia’s leading tree nut company. The company sources pecans, macadamias and walnuts from around Australia, supplying to gourmet markets around the world. Having installed the BEST system at its Toowoomba sorting plant, Stahmann expects to see return on investment within two years. The laser sorting system has boosted pecan and macadamia output by 30% while lowering false rejects to less than 0.25%. Stahmann’s commitment to quality and its Sales and Processing Alliance (SPA), a contract with each grower that sets the overall value of the kernel, requires highly sophisticated sorting equipment that can be easily configured to accurately process each run based on parameters set by lab analysis. The Stahmann team have years of experience collecting very accurate data on acceptable product and needed a system into which they could input this data to impose rigid sorting specifications. “We’ve found the BEST Helius with its RES system the most reliable and easily adaptable technology to reduce our false reject numbers - less than 0.25% of acceptable product in the reject material,” claims Ross Burling, General Manager of Processing at Stahmann’s Toowoomba plant. “Our plant’s output of high-quality product has increased by 30% to 900 kg per hour average with grade slippage at >1%.” Difficulties with an older automatic sorting system helped Burling identify what was desirable in a new sorting system. “It created big production delays because the sorter took so much time to correctly program,” he said. “Despite these efforts, the result typically was the accidental and unacceptable rejection of too much good product with the bad.”

TESTING

Ocean Spray and Complete Phytochemical Solutions collaborate for improved of PAC testing Recognising a need for improving the current methods available for measuring and quantifying proanthocyanidin (PAC) levels in cranberries, Ocean Spray Cranberries and Complete Phytochemical Solutions have joined forces on a project to develop a cranberry-specific PAC standard. Cranberries apparently contain A-type PACs that are effective in reducing E. coli bacteria adhesion to the walls of the urinary tract, with 36 mg being the minimum effective dose recommended. According to a press statement released by Ocean Spray, the two colorimetric methods currently used to measure PACs can give quite different results. The DMAC method bases its quantification on the use of the Procyanidin A2 standard dimer (a polymer with a chain length of 2). However, this method can underestimate the PAC content in products that are enriched in PACs of different sizes and lengths, with degrees of polymerisation from 2 to 8 up to >10. Using the current analysis methods, varying processing techniques can lead to variations in PAC composition. The industry is calling for an improved method to provide product-specific quantification for compounds in natural products like cranberries. Tom Jones, senior manager of business development with Ocean Spray said: “We are committed to supporting scientific research on the health and wellness benefits of cranberries and have made this investment to support the industry’s quest for a solution to the longstanding debate on PAC measurement. An improved, standardised method will add further scientific validation to our high quality, innovative ingredient portfolio as well as establish an industry-wide standardised testing methodology.” In order to establish correct dosage guidelines for consumers, a method that delivers accurate analysis of PAC content in cranberry products is vital. Ocean Spray also believes it is essential for monitoring the efficacy and shelf life of dietary supplements and standardising test materials for research. Ocean Spray and Complete Phytochemical Solutions are confident that their research will benefit many players in the cranberry industry. “Since DMAC is now considered to be the industry standard method, we are committed to improving its accuracy for all cranberry products by developing a more robust, commercially available cranberry PAC standard,” said Amy Howell, an associate research scientist at Rutgers University and project team member. “We anticipate this new methodology will provide more confidence for suppliers, consumers and regulatory agencies in the assessment of PAC content which will have a significant impact on the cranberry industry” Ocean Spray ITG Contact info and more items like this at wf.net.au/M464

March/April 2012

www.foodprocessing.com.au

Analytical technique for carbendazim

New Look

Waters Corporation has announced its analytical technique to rapidly determine residue levels of the fungicide carbendazim in orange juice with no sample preparation, at regulated levels using the Waters Xevo-TQ-S mass spectrometer and Acquity UPLC I-Class system. The company claims the system allows users to employ which may increase analysis throughput and reduce

for 2012

method development time. Carbendazim is used legally in Brazil and other counHI93501NS digital thermometer

tries for plant disease control, post-harvest food storage

$188

or transportation and seed pre-plant treatment. It is not approved for use on citrus fruit in Australia and orange juice products in Australia will not be permitted to contain

plus gst

any carbendazim after the first quarter of 2012. Intensive sample preparation can be required in order to remove possible interferences and to enrich the analytes when testing for fungicides. The company claims its technique enables testing to be carried out without the need for sample preparation, which may be of benefit to users who need to rapidly meet analytical requests. Waters Australia Pty Ltd Contact info and more items like this at wf.net.au/M702 HI2211 bench pH meter

$658

plus gst

HI96821 refractometer for NaCl

$255

Detection method for foodborne pathogens 3M Food Safety has released is Molecular Detection System, a method of detecting foodborne pathogens such as Salmonella, E. coli O157 and Listeria.

plus gst

HI96801 refractometer for Brix

$255

plus gst

The system is based on a combination of technologies involving isothermal DNA amplification and

RESELLER ENQUIRES WELCOME

bioluminescence detection. The company claims it designed the product to suit customer testing needs, resulting in a compact, simple, robust system that offers easy implementation and low maintenance but is still accurate and reliable. Independent laboratory studies are underway to explore global method recognitions. 3M Food Safety Contact info and more items like this at wf.net.au/M430

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

March/April 2012

TESTING

a â&#x20AC;&#x2DC;dilute-and-shootâ&#x20AC;&#x2122; approach to orange juice analysis,

TESTING

GC-MS method package for residual pesticides in foods

Hygiene swabs for surface testing

Shimadzu has released its GC-MS Method Package Ver. 2 to address

SpotCheck surface hygiene swabs detect glucose and lactose, present in 85% of food products on a supermarket shelf. SpotCheck requires no instrumentation. The self-contained reagent turns from clear to green when food residue is present in a surface sample - indicating inadequate cleaning. With SpotCheck users detect, almost instantly, if a surface is not clean, allowing immediate corrective action. Protein detection swabs such as Hygiena’s Pro-Clean Swabs are commonly used for cleaning verification but their usefulness is limited to production areas that process protein rich foods such as meat, poultry and seafood. SpotCheck Plus has a wider spectrum and may be a better option for companies manufacturing a wide range of food types, especially fresh produce, bakery and dairy industries. SpotCheck Plus detects lactose and glucose residue in 60 s or less. Presence of either substance is indicated by a green colour change of the self-contained reagent. SpotCheck Plus allows users to detect residue from products containing lactose or glucose almost instantly, without instrumentation, allowing immediate corrective action.

the increasing demand for reliable testing of residual pesticides in foods, feed additives and veterinary drugs. Shimadzu claims that, when analysing up to 800 different residual pesticides, the package may improve the speed and efficiency of GC-MS technology as it provides simple inspection methods and batch analysis of multiple component samples. The package covers all the pesticides that can be analysed by GC-MS in accordance with the Positive List System. The package has been designed for use with Shimadzu’s GCMSQP2010 series of instruments and supports GCMS Solution Ver. 2.60. It includes a CD-ROM containing method files preregistered with optimised analytical conditions, compound information (including retention indices), report format files and tuning files. Also included are an instruction manual and five glass inserts. To help overcome the influence of contamination of matrices in actual sample analysis or erroneous identification caused by retention time shift, a GC-MS identification support tool is also included. The tool, which runs linked with GCMS Solution, enables identification results to be displayed in order from components having the highest potential to exist, allowing these results to be studied while viewing the chromatogram. Because the retention indices of all compounds are preregistered, GCMS Solution’s AART (Automatic Adjustment of Retention Time) function allows retention times to be corrected for easier analysis.

Key Diagnostics Pty Ltd

Shimadzu claims the easily installed method files are registered with

Contact info and more items like this at wf.net.au/M429

all of the pesticide standard reagents that are commercially available, including those in the company’s current pesticide libraries. Shimadzu Scientific Instruments (Oceania) Pty Ltd Contact info and more items like this at wf.net.au/M286

Wine test kits and reagents Megazyme International wine test kits and reagents are available through VWR International. The kits allow numerous analyses to be performed in order to determine the quality, stability and authenticity of wine after fermentation is complete and include enzymatic assays for acetaldehyde, acetic acid, L-ascorbic acid, ethanol, ethanol/glycerol ratio, D-fructose, D-glucose, D-fructose/D-glucose ratio, glycerol, D-gluconic acid, D-gluconic acid/ethanol ratio, D-gluconic acid/glycerol ratio, L- and D-lactic acid, L- and D-malic acid, D-sorbitol, succinic acid and urea. VWR International Pty Ltd Contact info and more items like this at wf.net.au/M929 76

March/April 2012

www.foodprocessing.com.au

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

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

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

SwabSURE ListeriaP

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

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

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

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

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

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

TESTING

Pill to prevent listeriosis may be on the horizon

A.B.N. 22 152 305 336 www.westwick-farrow.com.au Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 Ph: +61 2 9487 2700 Fax: +61 2 9489 1265 Chief Editor: Janette Woodhouse wnift@westwick-farrrow.com.au Publisher: Geoff Hird Art Director/Production Manager: Julie Wright Art/Production: Tanya Scarselletti, Colleen Sam

Modified probiotics, the beneficial bacteria touted for their role in digestive health, could one day decrease the risk of Listeria infection in people with susceptible immune systems, according to Purdue University research.

run Bhunia, a professor of food science; Mary Anne Amalaradjou, a Purdue postdoctoral researcher; and Ok Kyung Koo, a former Purdue doctoral student, found that the same Listeria protein that allows the bacteria to pass through intestinal cells and into bloodstreams can help block those same paths when added to a probiotic. “Based on the research, it looks very promising that we would get a significant reduction in Listeria infections,” said Bhunia, whose findings were published in the journal PLoS One in January. Bhunia’s earlier work showed that Listeria triggers intestinal cells to express heat shock protein 60 on their surfaces. That allows Listeria to bind to the intestinal cells using an adhesion protein and pass into them, acting as a sort of gateway to the bloodstream. Once in the bloodstream, even small doses of Listeria can cause fever, muscle aches, nausea and diarrhoea, as well as headaches, stiff neck, confusion, loss of balance and convulsions if it spreads to the nervous system. It can also cause abortion and stillbirth in pregnant women. According to the US Centers for Disease Control and Prevention, it sickens about 1500 and kills 255 people each year in the United States and primarily affects pregnant women, newborns, older adults and those with weakened immune systems. “We’re seeing fewer Listeria infections, but the severity of those infections is still high,” Amalaradjou said. The researchers found that probiotics alone were ineffective in combatting Listeria, so they stole a trick from the bacteria’s own playbook. By adding the Listeria adhesion protein to the probiotic Lactobacillus paracasei, they were able to decrease the number of Listeria cells that passed through intestinal cells by 46%, a significant decrease in the amount of the bacteria that could infect a susceptible person. With the adhesion protein, Lactobacillus paracasei interacts with heat shock protein on the surface of intestinal cells just as Listeria would. The probiotic then attached to the intestinal cells, crowding out Listeria. “It’s creating a competition,” Bhunia said. “If Listeria comes in, it doesn’t find a place to attach or invade.” Bhunia said he could one day foresee the development of a pill or probiotic drink that could be given to at-risk patients to minimise the risk of Listeria infection. Purdue University www.purdue.edu 78

March/April 2012

www.foodprocessing.com.au

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September 2011 total CAB audited circulation (Aust + NZ): 7127 readers (85% personally requested) Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP247345/00010 ISSN No. 1039-8414 NOTICE: All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.

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