What’s New in Food Technology May/June2013 by Westwick-Farrow Media

Served up on a plate

AirLINE Quick: High quality, cost effective, fast delivery Meet AirLINE Quick. AirLINE Quick has internalised all pneumatic air channels, and integrated primary and secondary components to deliver one single complete pneumatic (or electro-pneumatic) valve bank on a stainless steel adapter plate. Unlimited modularity in valves, functions, feedbacks, I/O, and accessories, is offered, with local assembly from Bürkert’s ISO 9001 Sydney Systemhaus. The stainless steel plate mounts directly into a cabinet, effectively minimising labour for cost effectiveness and fast delivery. Same day turn-around (on lower-quantity orders) is common. Last year Bürkert shipped around 600 panels, and this year with AirLINE Quick it could easily be thousands. Call us, and get your valve banks served up on a plate, or mounted in a cabinet, ready to go. Ideal for end-users, OEMs, and switchboard consultants. Designed for arduous environments, for physical and chemical resistance.

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We make ideas flow

food for thought

Bulk

10 Why you can’t stop at just one potato chip 18 Tailored energy procurement

May/June 2013

contents

meat, poultry, seafood 21 Risky meat 24 Electron-beam pasteurisation 29 Death by 1000 sausages

©iStockphoto.com/ PaulaConnelly

30 Horsemeat scandal side effect

32 37 48 testing

Packaging

processing

32 Testing for horse DNA in beef food samples

39 3 steps to successful lightweighting of PET bottle production

48 Upgrading food quality and processing efficiency

34 Greater proof for functional food claims

46 In-package plasma process quickly, effectively kills bacteria

58 Fungi in your drink 63 Anti-fouling coatings 71 Why E. coli like it rough 78 Stem cells for taste identified

www.foodprocessing.com.au

May/June 2013

Shhhh - don’t tell the government

©iStockphoto.com/ Marcello Bortolino

As usual the food industry, the largest manufacturing sector in Australia, was largely overlooked in the 2013 Federal Budget. The only bright spot was that the Clean Technology Program was not ravaged as had been speculated and dollar-for-dollar grant funding means that qualified applicants can receive grant funding of up to half of their eligible project expenditure. The Clean Technology Food and Foundries Investment Program is a $200 million competitive, merit-based grants program to support Australian food and foundry manufacturers to maintain competitiveness in a carbon-constrained economy. This program provides grants for investments in energy-efficient capital equipment and low-emission technologies, processes and products. Lots of companies have already taken advantage of the funding available. So why not join the likes of Coca-Cola, Primo Smallgoods, Mars, Kagome Foods … and have the government pay for half of the costs of making your plant more energy efficient? It really is a win-win-win scenario because not only will you pay less for the improvements, you will also save energy costs once the job is completed and the environment will also benefit. The government has now introduced a new dollar-for-dollar (1:1) funding category for manufacturing facilities with covered emissions of 25,000 tonnes CO2e or greater, but less than 100,000 tonnes CO2e. These facilities do not need to meet any turnover or maximum grant amount threshold to be eligible for the new grant funding ratio. Companies can use this funding for the development of products and adoption and deployment of technologies to reduce energy use and/or carbon emissions at their manufacturing sites; to build new and replace existing facilities; for process reengineering resulting in energy savings; conversion of facilities from coal to natural gas; and cogeneration infrastructure. Other energy-efficiency improvements that are covered by the assistance include improved design in production systems; behavioural changes such as reducing unnecessary usage; intelligent control system implementations; waste heat recovery, including cogeneration, insulation, heat exchange recovery on heating, ventilation and air conditioning (HVAC) systems, condenser heat recovery in industrial refrigeration; intelligent lighting, including improved lighting design, efficient lighting technology and control systems; improved efficiency for refrigeration and HVAC systems; and improved electrical motor efficiency. While everyone is busily talking down the Australian manufacturing industry, I got a very different message at AUSPACK Plus earlier this month. All the exhibitors with whom I spoke enjoyed the four-day event and reported lots of high-quality leads and sales prospects which seem to indicate a quiet resurgence is bubbling along. Quite a few companies made sales of equipment from their stands, which is also a good indicator that things are not as rough as reported. However, while I have been complaining that the food processing industry has been ignored by the government, I have to admit this is probably a safe place to be. We can mosey along doing our own thing without undue intervention.

Regards Janette Woodhouse Chief Editor What’s New in Food Technology & Manufacturing www.foodprocessing.com.au 4

May/June 2013

www.foodprocessing.com.au

Wine in supermarkets:

an opportunity or threat for Australian winemakers?

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thought

image©iStockphoto.com

A petition supporting the sale of wine in supermarkets has been presented to the South Australian State Government. 22,000 Foodland and IGA shoppers signed the petition over a one-week period in February, coinciding with the close of submissions to the government on the issue. Colin Shearing, Chief Executive of the Independent Supermarket Retailers Guild of South Australia, said Foodland and IGA plan to only stock South Australian wine in line with the companies’ policy to support local winemakers. The Australian Hotels Association (AHA) SA Branch and the Australian Liquor Stores Association SA have launched a campaign opposing the sale of wine in supermarkets. The Let’s Draw the Line campaign argues that the proposal will cripple independent bottle shops and hotels. “This proposal will open the floodgates for Woolworths, Coles, Aldi and the big grocery groups to put alcohol in their aisles, as well as in all the bottle shops they already own,” the campaign website says. “And history says they’re not going to be looking after the small, independent local wineries. They will simply fill the shelves with brands they own.” However, Shearing said a number of other Australian states already permit the sale of wine in supermarkets, and the practice is common overseas. “The state government should have no doubt that there is a huge groundswell of support for our position and we call on the government to act as soon as possible to enable the measure to be introduced,” Shearing said.

May/June 2013

Broccoli with higher glucoraphanin levels Field trials and genetic studies have shown that a new variety of broccoli reliably yields higher levels of a health-promoting compound. Broccoli contains a compound called glucoraphanin, which has been shown to promote health by maintaining cardiovascular health and a reduction in the risk of cancer. A long-term breeding program to increase glucoraphanin levels has resulted in the commercial release in the UK of Beneforté broccoli. Beneforté was developed by crossing standard broccoli with a wild relative derived from Sicily. Publicly funded research to develop Beneforté broccoli was led by two of the UK’s world-leading biological research institutes: the Institute of Food Research and the John Innes Centre, on the Norwich Research Park. They both receive strategic funding from the Biotechnology and Biological Sciences Research Council. Three years of field trials at over 50 different sites in Europe and the United States have shown that Beneforté broccoli consistently produces 2-3 times the amount of glucoraphanin than other leading varieties of broccoli, without affecting yield, quality or the levels of other nutrients. Glucoraphanin contains sulfur, which broccoli derives from the soil. New research, published in the journal New Phytologist, shows that Beneforté increases the amount of sulfur it takes up from the soil, and also channels more of it into glucoraphanin. Genetic analysis identified a single gene derived from the original wild relative that is responsible for both of these changes. In standard broccoli varieties, different soils can cause variation in glucoraphanin levels. These findings explain how Beneforté consistently delivers more glucoraphanin than ordinary broccoli. Professor Richard Mithen of the Institute of Food Research is now leading ongoing studies to understand how glucoraphanin in Beneforté exerts its effects on human health, with particular focus on the cardiovascular system and prostate cancer.

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How Salmonella survive dry conditions and contaminate dry foods In moist conditions, Salmonella thrive and reproduce abundantly. If thrust into a dry environment, they cease to reproduce, but turn on genes which produce a biofilm, protecting them from the detrimental environment. Researchers tested the resilience of the Salmonella biofilm by drying it and storing it in dry milk powder for up to 30 days. At various points it was tested in a simulated gastrointestinal system. Salmonella survived this long-term storage in large numbers but the biofilm Salmonella were more resilient than the freefloating cells treated to the same conditions. The bacteria’s stress response to the dry conditions also made it more likely to cause disease. Biofilms allowed the Salmonella to survive the harsh, acidic environment of the stomach, increasing its chances of reaching the intestines, where infection results in the symptoms associated with food poisoning. This research may help shape Food and Drug Administration’s regulations by highlighting the need for better sanitation and new strategies to reduce biofilm formation on equipment, thus hopefully decreasing the likelihood of another outbreak. © www.sxc.hu/ Ega he n

Virginia Tech scientists have provided new evidence that biofilms - bacteria that adhere to surfaces and build protective coatings are at work in the survival of the human pathogen Salmonella. Researchers affiliated with the Fralin Life Science Institute discovered that in addition to protecting Salmonella from heat-processing and sanitisers such as bleach, biofilms preserve the bacteria in extremely dry conditions, and again when the bacteria are subjected to normal digestive processes. The study is now online in the International Journal of Food Microbiology and appears in the April issue. “Biofilms are an increasing problem in food processing plants serving as a potential source of contamination,” said Monica Ponder, an assistant professor of Food Science and Technology in the College of Agriculture and Life Sciences. “We have discovered that Salmonella in biofilms survive on dried foods much better than previously thought, and because of this are more likely to cause disease,” said Ponder. Outbreaks of Salmonella associated with dried foods such as nuts, cereals, spices, powdered milk and pet foods have been associated with over 900 illnesses in the US in the last five years. These foods were previously thought to be safe because the dry nature of the product stops microbial growth. “Most people expect to find Salmonella on raw meats but don’t consider that it can survive on fruits, vegetables or dry products, which are not always cooked,” said Ponder.

Australian Made Campaign welcomes CoOL recommendations

Mixed reactions to Greens’ CoOL Bill The Greens’ new Bill on country-of-origin labelling (CoOL) has drawn mixed reactions from the food industry. AUSVEG has voiced its support for the Bill, while the Australian Made Campaign has reservations about the proposed changes. The Competition and Consumer Amendment (Australian Country of Origin Food Labelling) Bill extends country of origin labelling to all food for retail sale and simplifies labelling to just three allowable claims: • Product of or Grown in Australia • Manufactured in Australia • Packaged in Australia AUSVEG, the national horticultural body representing Australian vegetable and potato growers, is backing the Bill, saying it will support Australian farmers and empower consumers who want to be able to identify Australian food easily. “The present food labelling laws are a farce and Australian vegetable and potato growers would welcome any improvements aimed at making it easier for Australian consumers to confidently choose locally grown food, something which is currently very difficult to do,” said AUSVEG spokesperson Hugh Gurney. But the Australian Made Campaign says it cannot support the Bill in its current form. The campaign said a wider range of alternative claims should be allowable for products such as, for example, pickles processed in Australia from imported ingredients. “On the positive side, Australian Made supports the proposal that food may be labelled in a way that highlights significant ingredients, eg, ‘Manufactured in Australia from Australian milk’ for chocolate, as long as all the requirements for a ‘Made in Australia’ claim are met,” said Ian Harrison, Australian Made Chief Executive. Senator Milne expressed her thanks to CHOICE for its input into developing the Bill.

www.foodprocessing.com.au

May/June 2013

Bottled water to overtake carbonates in two years

image©iStockphoto.com

this region, particularly in underdeveloped markets like Pakistan, the Philippines and Vietnam. The Chinese market, despite its size, remains fragmented, with the four main players representing less than a third of category sales. While China represents the cornerstone of Asian packaged-water consumption, India is showing more dynamic advances, at more than 20% each year. Despite the North American market suffering in recent years, the rate of annual growth is now re-accelerating. This is due in part to rapidly rising prices of other beverages and packaged water’s healthy image. However, conditions still remain challenging, Canadean says. Water filters and Italian initiatives to promote tap water are creating challenging conditions in West Europe, in addition to the economic crisis. However, market positivity is slowly returning, and Canadean says it sees a positive future for packaged water across all regions.

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While some carbonated beverages are struggling in the current economic climate, one bottled beverage continues to thrive: bottled water. According to market research organisation Canadean, demand for packaged water has rocketed exponentially, with volumes doubling in the past decade despite the global downturn. This may be surprising in itself, but Canadean’s report reveals something even more unexpected: packaged water will overtake carbonates as the leading soft drinks category in 2015. Canadean says bottled water’s profile has been boosted by its healthy image, plus actual necessity in those areas of the world lacking safe water supplies. Canadean predicts volumes will rise in Asia by 16% in 2013 alone - more than twice the global rate of increase. The region already absorbs one in every three litres of packaged water consumed around the world, but the per-capita intake remains well below the international average. This underlines the huge market potential still to be released in

thought

Consumers don’t trust the Big 10 brands

May/June 2013

about where products come from and how they’re made. These companies need a major shake-up because across the board, they all fall short, with none emerging with an overall good score.” Almost half of all respondents said they would stop buying their favourite brands if a company’s policies and practices weren’t up to scratch. 60% believe their shopping habits can make a difference to the lives of farmers and workers in poorer countries. “This tells us that shoppers are recognising major brands have a vital role in tackling hunger and poverty by supporting the poor people with which they do business,” Dr Szoke said. Of the companies surveyed, Nestlé was the highest performing, followed by Unilever, Coca-Cola, Pepsico, Mars, Danone, Mondelez (formerly Kraft) and General Mills. While Kellogg’s was perceived as the most ethical company, it was scored secondlast in the rankings and was one of the worstperforming companies in terms of ethical policies, land rights and support for farmers and workers. Associated British Foods was the worst-performing company.

More than 50% of Australians don’t trust the 10 biggest food and drink companies, according to a survey conducted by Oxfam. The Behind the Brands report assessed the ten largest food and beverage companies - the ‘Big 10’ - on their sourcing of agricultural commodities from developing countries. The report revealed that 84% of Australian consumers want more information included on packaging about how their food and drink is made and where it comes from. Oxfam Australia’s Chief Executive Dr Helen Szoke said the report findings demonstrate that major brands are failing the millions of workers who produce our food and drink. “Our report connects what we eat and drink every day with the experiences of the farmers and workers in poorer countries who produce our food, with the bitter irony being the majority of the world’s hungriest people are those directly involved in making our food and drink,” Dr Szoke said. “The findings revealed the world’s 10 most powerful food and drink companies that produce our most iconic brands like Kellogg’s and Vegemite are overly secretive

www.foodprocessing.com.au

Domino A-320i Ink Jet Coder No maintenance, no fuss.

The intelligent i-Tech ink system monitors how you are using ink and works out when consumables are due for replacement. The revolutionary Qube fluid delivery system contains working ink & ink filters and is a system that anyone can change in less than 10 minutes eliminating the need for a service call out. With the ability to code up to 4 lines of text at a speed of up to 325m per minute, the A-320i is the most reliable class-leading filtration and modulation ink jet coder system.

Phone: 1300 467 446

Email: sales@insignia.com.au

Web: www.insignia.com.au

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Why you can’t stop at just one potato chip Researchers have discovered the secret of potato chips - why it is that once you pop, you can’t stop - and have even come up with a complicated-sounding name for the phenomenon: hedonic hyperphagia.

“T

hat’s the scientific term for ‘eating to excess for pleasure, rather than hunger’,” said Tobias Hoch, who conducted a study into the condition. “It’s recreational overeating that may occur in almost everyone at some time in life. And the chronic form is a key factor in the epidemic of overweight and obesity that here in the United States threatens health problems for two out of every three people.” Hoch presented his findings at the 245th National Meeting & Exposition of the American Chemical Society, the world’s largest scientific society. Hoch’s team at FAU Erlangen-Nuremberg, in Erlangen, Germany, explored the condition in a study in which one group of laboratory rats was fed potato chips. Another group was fed, as Hoch puts it, “bland old rat chow”. The researchers then used MRI devices to analyse the rats’ brains, comparing differences in activity between the ‘ratson-chips’ and ‘rats-on-chow’. The rat chow contained the same ratio of fat and carbohydrates as the potato chips, but the rats’ brains reacted much more positively to the chips. “The effect of potato chips on brain activity, as well as feeding behaviour, can only partially be explained by its fat and carbohydrate content,” explained Hoch. “There must be something else in the chips that makes them so desirable.” 10

May/June 2013

When offered one of three test foods - powdered rat chow, a mixture of fat and carbs, or potato chips - the rats more actively pursued the potato chips. What’s more, the rats were most active after eating the chips. Hoch puts this down to the chips’ high energy content. Mapping the rats’ brains with manganese-enhanced magnetic resonance imaging (MEMRI), the researchers found that the reward and addiction centres in the brain recorded the most activity. But the food intake, sleep, activity and motion areas also were stimulated significantly differently by eating the potato chips. “By contrast, significant differences in the brain activity comparing the standard chow and the fat carbohydrate group only appeared to a minor degree and matched only partly with the significant differences in the brain activities of the standard chow and potato chips group,” Hoch said. If scientists can pinpoint the molecular triggers in snacks that stimulate the reward centre in the brain, Hoch says it may be possible to develop drugs or nutrients that can be added to foods to block this attraction to snacks and sweets. The next project for Hoch’s team is to identify these triggers. Unfortunately, Hoch says these findings are unlikely to work the other way. He says there’s no evidence that ingredients could be added to healthy, but unpopular, foods like Brussels sprouts to affect the rewards centre of the brain so we crave healthy foods.

www.foodprocessing.com.au

Compact servo right-angle gear unit With the W series servo Spiroplan right-angle gear unit, SEW-Eurodrive is shifting its focus to simpler applications with a torque range of up to 180 Nm. The company says it is the smallest, most compact and least expensive servo right-angle gear unit series it has ever manufactured. The single-stage Spiroplan is available in models W10, W20, W30, W37 and

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W47. It can be used as a stand-alone gear unit for direct motor mounting or for mounting on the motor using the low backlash adapter. The series is also available in different output versions, either with a shaft and key or with a hollow shaft and a keyway. Both versions are available with a flange-mounted design. When combined with the CMP series of synchronous servomotors, the gear unit acts as a gearmotor. This compact version offers precision, dynamics and high torque. The servo Spiroplan right-angle gear unit is a cost-optimised drive solution with consistently low rotational clearance and a continuous positive shaft-hub connection. The variety of drive versions provides the user with maximum flexibility and an economic option for their application, the company says. SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/T624

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May/June 2013

Customised work stations for abattoirs and food processing plants

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Mr Mushroom commissions second forklift

Optimum Handling Solutions’ custom workstation for abattoirs and food processing plants will assist operators when

Perth’s first specialist mushroom wholesaler has added a second Toyota forklift to his fleet on the strength of Toyota’s dual-fuel capability and service support. Mr Mushroom managing director Glenn Mews was introduced to the Toyota Material Handling family in 2010 when he won a BT hand pallet truck in a raffle at the annual Perth Markets Ball. Following his success at the ball, Mews purchased his first Toyota forklift, a 32-8FG15 in 2012, and has recently commissioned a second 32-8FG15 forklift. Both forklifts have three-stage full free lift 4300 mm masts and are fitted with windscreens, an integral side shift attachment, solid tyres, mud flaps and markets-spec lighting. Mews said Toyota service was his number one reason for purchasing another Toyota product, followed by the reliability and flexibility of the forklifts.

constantly sorting or packing products onto pallets that are more than 1.5 m high. Optimum’s palletising workstation usually consists of an elevated work platform, electric scissor lift tables and a belt top conveyor system that provide a solution for carton/product removal from stillages/ conveyors that are to be packed onto pallets in the load-out areas.

Scissor lift tables can be primarily implemented within the raised workstation allowing the operators to pick product from the crate/stillage/conveyor quickly and efficiently without the constant hazard of bending and stretching that is related to product handling. The common load-out conveyor system continually feeds the finished products to the packing operator which picks

“The Toyota service centre has a spare forklift, which is an enormous help for a small business if one of our forklifts is being serviced,” Mews said. “In terms of reliability, the Toyota forklifts are virtually bulletproof. “We’ve found the dual-fuel option to be really valuable. We’ve had two occasions where there has been a shortage of LPG, but we’ve continued to operate our forklifts thanks to the dual-fuel option. “The latest Toyota forklift models have indicators for payload weight and vehicle speed, putting the cream on top of an already good cake.” Toyota Material Handling Australia Pty Ltd Contact info and more items like this at wf.net.au/T842

May/June 2013

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and loads products onto pallets which are raised up on Optimum’s Palevator spring lift unit. The company says large abattoirs and fruit processing plants that implement its solution will measure benefits in faster productivity and workplace safety. Optimum Handling Solutions Contact info and more items like this at wf.net.au/T625

Frequency inverters SK 200E series frequency inverters from Nord Drivesystems provide adaptable functions for applications within a distributed automation concept where drives with a performance between 0.25 and 22 kW are required. The inverters are available for installation near the motor or as motor-integrated models. Inverters from the SK 2x0E line are equipped with a process and PI controller, and qualify for use with fans and pumps through their internal 24 V power supply and two analog inputs.

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The SK 2X5E line is suitable for use with conveyors. These inverters are equipped with a brake controller and two integrated potentiometers which allow easy adaptation to drive task requirements. Standard features such as speed feedback (servo mode) and a positioning function (Posicon) allow these inverters to independently and precisely control positioning and lifting tasks. The units are performance graded and can be fitted with add-on functions, allowing users to choose suitable compact devices with the exact feature range for a task. All models include sensorless current vector control, a brake chopper, incremental encoder evaluation, Posicon and energy-saving functions. A plug-in memory module (EEPROM) enables users to quickly exchange parameter sets with other units of the same type. In addition to standard fieldbus options, the inverters are also available with an integrated AS interface as well as the STO ‘Safe Torque Off’ and SS1 ‘Safe Stop 1’ safety functions certified by TÜV. The inverters are primarily designed for direct installation on the terminal box of geared motors. The robust drive units are available in sizes 1 to 4 with a maximum output of 22 kW. NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R378

Tel NZ: 021 160 9990 Tel AUS: 0417 690 370 email: jacko@globalms.com.au

See the VIDEO @

www.backsaver.com.au www.foodprocessing.com.au

May/June 2013

Hygienic bulk bag filler The Hygienic Bulk Bag Filler by Tetra Pak was designed for accurate sanitary filling with a typical rate of up to eight bulk bags per hour. The USDA-compliant filler is designed and fabricated in New Zealand. It is suitable for â&#x20AC;&#x2DC;red lineâ&#x20AC;&#x2122; filling and eliminates pallets from the packing area. The filler offers a number of features: accurate bulk bag weighing, metal detection with an inline magnet trap, powder sampling, dust-tight powder filling, base compaction, MAP post-gassing and heat sealing of the barrier liner, transportation of the closed bulk bag to warehouse area, loading bulk bags on the pallets and conveying out to the forklift pick-up point.

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The increased accuracy of filling is achieved by synchronising weighing with the powder flow. The bulk bag stability for future transportation and storage is provided by compacting the bulk bag base during filling. The high throughput rate is determined by the fillerâ&#x20AC;&#x2122;s threestation design: interruptions to the ultimate filling process are minimal due to relocation of bulk bag closing and unloading to the separate stations. The filler can be run by one operator in the packing room and one forklift operator in the warehouse. With safety paramount, a number of ergonomic features ensure minimal manual input. Increased efficiency and safe operation throughout all steps of packing are enabled by handy location of operator panels, user-friendly HMI and touch screens. Tetra Pak New Zealand Ltd Contact info and more items like this at wf.net.au/R618

Handbook on weigh module integration Mettler Toledo has issued a handbook providing advice on the design and application of load cells and weigh modules for tanks, silos, vessels, hoppers and conveyors. The document covers the fundamentals of designing, building and installing customised solutions, which may help in making informed decisions regarding the integration of weigh modules. Using the right weighing technology is the base for achieving the required accuracy over the entire life cycle of a tank, silo, vessel, hopper or conveyor weighing system. However, the design of the support structure is equally important because it deflects downward as load is applied to it. An undesirable vertical force results any time that piping or wiring is connected. Both effects can cause severe weighing errors by supporting some of the weight that should be applied to the weigh modules. The handbook offers practical guidelines for engineers, designers and service people to avoid common errors when planning and installing weighing systems. It covers design calculations, thermal effects, piping connections, designing of support structures and calibration. With a greater understanding of these concepts, businesses can ensure they are choosing the best equipment for the job and in turn improve efficiency and enhance profits. The handbook can be downloaded for free from www.mt.com/ind-system-handbook. Mettler Toledo Contact info and more items like this at wf.net.au/T078

May/June 2013

www.foodprocessing.com.au

New ERP provider for ice-cream icon

©iStockphoto.com/ Jesus Jauregui

Peters’ network of freezers extends to all corners of the country. With such a vast footprint, it is essential that information on stock levels and deliveries is up to date and available in real time. Infor’s Sales Route Management system - provided by solution partner NCS - will meet Peters’ requirement for real-time customer information as well as provide on-the-ground access using mobility solutions. “This is a great opportunity for Infor to prove it is built for speed. Anyone can tell you that implementing a complete ERP system in seven and a half months is challenging - but we expect to successfully do just that,” said Ian Desbrow, Managing Director Australia and New Zealand, Infor. “Our advantage lies in the Infor M3 QuickStep solution, which includes a high number of preconfigured business processes for specific industries we specialise in, such as food and beverage, allowing a favourable mix of configuration and fast implementation.” Infor Global Solutions (ANZ) Pty Ltd Contact info and more items like this at wf.net.au/T770

www.foodprocessing.com.au

May/June 2013

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Infor, a leading provider of business application software serving more than 70,000 customers, has announced a deal with iconic Australian company Peters Ice Cream to implement a complete ERP system in just seven and a half months. Peters, makers of ice-creams with household names including Drumstick, Maxibon, Connoisseur, Heaven and Frosty Fruit, urgently needed to change its generic ERP system after the company was acquired by Pacific Equity Partners in August 2012. This ended 17 years of ownership by food giant Nestlé. Following the change of ownership, Peters has been operating on Nestlé’s ERP system while they establish a stand-alone IT system. The company looked towards a more functionally rich software solution, targeted to the specific needs of an icecream company. Peters chose to implement Infor’s M3 QuickStep for Food and Beverage solution. “During a competitive pitch, Infor was able to demonstrate its ability to quickly implement and roll out an allencompassing ERP solution that will provide clear visibility into the business,” said Jonathan Hutchings, Transition Manager, Peters. The key to partnering with Infor was the need to fast-track the rollout of the software from a typical time frame of 12 to 18 months to just over seven. Infor says it expects to meet this requirement due to the specialised Infor M3 Quickstep for Food and Beverage industry solution, which includes up to 70% of the necessary business processes preconfigured, ensuring a hassle-free implementation.

Enmin strikes gold in West Africa

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A gold mine in West Africa was the last place Enmin Engineers expected to discover one of their Electromagnetic Vibratory Feeders. Receiving an email request for spare parts for the feeder, Enmin staff were surprised to find attached a photo of a Series 1 model still operational in the mine. The company says the journey from a food plant in Australia to a West African gold mine shows that there is no end to the range of applications where Enmin Vibratory Feeders can be employed. The company began production of electromagnetic feeders in 1985 in response to requests from major food processing equipment suppliers. From the initial Series 1 models through to the current Series 5 version of the E Feeder, Enmin has delivered hundreds of vibratory feeders for all manner of applications. Used predominantly in the food and allied industries, the E Feeder has

found a home throughout Australia and New Zealand in confectionery, snack food, bakery and general food processing facilities. Further afield, this equipment is being used in North and South America, China, Malaysia, the Philippines, South Africa, India, Thailand and the Middle East. Enmin says its strength lies in reliability. In servicing offshore and domestic markets, major equipment suppliers put reliability foremost in their selection process. Price is always a consideration, but never the primary one, when a companyâ&#x20AC;&#x2122;s reputation or production continuity is paramount. Enmin says reliability is a key feature of its vibratory equipment, which is why many companies - both domestic and international - have confidence in its products. Enmin Pty Ltd Contact info and more items like this at wf.net.au/T918

Roller energy chain igus has introduced a roller energy chain and a modular plastic guiding profile designed for long travel lengths. The 3500R energy chain, which can be opened from the external radius, is variable due to its modular interior separation. Easy to install, it is suitable for horizontal applications and the modular design of the roller chain link allows the use of all widths of the standard series 3500 energy chain. The roller system not only safely drives energy, it is also energy efficient compared to other sliding solutions. The company says travels up to 150 m at speeds of up to 4 m/s can be achieved more economically. All energy chains of the series 3500R are part of a comprehensive modular system, meaning they are ready to install. The chain series 3500R can be safely guided in the guidelite system, a modular plastic guiding profile. While the lower run of the energy chain is guided in two L-shaped and glass-fibre-reinforced guiding troughs, the upper run partially passes through guide brackets that are mounted in distances of 1 m. This system is useful in harsh conditions with its weather resistance, insensitivity against dirt and high-impact strength at low temperature. Because the upper run of the energy chain is only partly guided, it is designed for slow applications with low cycle numbers. Due to its open design it is insensitive to dirt so, for example, can be used in greenhouses to guide water hoses. The corrosion-resistant, lightweight guidelite can be used as a cost-effective supporting trough for free-supporting applications and is suitable for different e-chains of the series E2/000 and E4.1. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/T505

May/June 2013

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Sanitary box tipper The Tip-Tite Sanitary Box Tipper from Flexicon forms a dust-tight seal between the container and the equipment, tips the container and discharges bulk material at controlled rates. The unit is intended for tipping of bulk foods, pharmaceuticals and contaminationsensitive chemicals from boxes weighing up to 1134 kg and measuring 915 to 1220 mm on a side and 990 to 1117 mm in height. The container platform is raised by dual hydraulic cylinders, creating a dust-tight seal between the top edge of a box and the underside of a discharge hood. Twin hydraulic cylinders then pivot the platform-hood assembly, with dust-tight seal intact, to 45, 60 or 90° beyond horizontal, including a motion-dampening feature at the termination of container rotation.

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A pneumatically actuated slide gate at the discharge end of the cone controls the flow of material into storage vessels or process equipment. An optional, gasketted discharge gate actuated by twin pneumatic cylinders provides a large opening with chute for the passage of larger objects or non-free-flowing bulk solids that may otherwise bridge across smaller openings, and allows control of the material discharge. The tipper is constructed of stainless steel with continuous welds ground and polished to sanitary standards. All horizontal frame members are fabricated of round stainless steel tubing to promote water run-off in washdown environments. Other sanitary features include capped threads, sloped-top control enclosures, guarding standoff brackets and food-grade epoxy paint on hydraulic cylinders. It is also available constructed of carbon steel with durable industrial coatings for tipping of dry solids, sludges and slurries from boxes, drums and other containers in less stringent environments, and is available configured with Flexicon mechanical or pneumatic conveyors to transport discharged material to any plant location. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/T313

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May/June 2013

BULK

ÂŠiStockphoto.com/ Derek Thomas

Tailored energy procurement can unlock potential operating savings for the food industry

Kathy Trayling

Energy in the form of electricity and gas is as essential to a food company as its staff, machinery and ingredients, which is why securing supply of both commodities at the lowest possible costs is paramount.

very business has watched the price of electricity and gas rise in recent times and felt unable to combat the rise of both eating into their bottom line. But through careful and tailored procurement of electricity and gas contracts, businesses can be confident that they are managing the risk associated with energy costs. It may surprise businesses that despite the media coverage of the carbon tax and â&#x20AC;&#x2DC;gold-platingâ&#x20AC;&#x2122; of networks, the cost to generate electricity has actually decreased in recent times. This has been caused by many factors including the decrease of the Australian manufacturing sector and the increase of low-cost renewable generation in the form of hydro, wind and solar. The reduction of peak demand has also been a factor in reducing the wholesale price of electricity because electricity at peak times is generated by expensive quick-tostart gas- and diesel-fired generators. The price of gas on the other hand is showing opposite price signs to electricity, and this is tipped to double in the coming years. This is driven by the sharp increase in investment to export liquefied natural gas (LNG) to Asian markets where a much higher price is paid for LNG. This will cause the domestic price of gas to creep upwards towards parity with these prices. Another determinant for higher prices is the scarcity of supply caused by the earmarking of LNG for export. This has led to many asking for a domestic reserve to be established, although with gas companies able to secure much higher prices internationally, little hope remains for the 18

May/June 2013

promotion of domestic sale incentives. All these factors may see the price per gigajoule increase from between $4 and $5 currently to $10 per gigajoule by 2020. However, there is some hope for large gas users as retailers are now offering longer-term contracts, which provides price security for companies. In order to minimise the risk of rising gas prices and secure opportunities surrounding lower electricity prices, companies should engage specialists to manage the procurement of electricity and gas contracts. There are several reasons for this. Firstly, energy markets are complex and are changing constantly. Understanding who to talk to about procuring contracts, how to get in touch with them and what questions to ask can be difficult. Secondly, the price of electricity and gas changes every hour. Watching the price of commodities and deciding when to buy takes your focus away from managing your business. Thirdly, energy prices are composed of a number of components including commodity costs, network charges, environmentals, and government and market charges. Being able to compare quotes accurately from energy companies in a like-for-like fashion can be difficult, and understanding what areas can be negotiated is also important in securing best pricing for energy contracts. T&O Consulting www.tnoconsulting.com.au

www.foodprocessing.com.au

simple weighing solution for sticky meat, poultry and fish Fresh, frozen or marinated meat, poultry, fish and various convenience food components can be difficult to handle as they often stick to equipment during feeding. Multipond have developed a new solution that allows for the fully-automated weighing of difficult products, is gentle on the product, with an easyto-clean profile. Multipondâ&#x20AC;&#x2122;s new stepped profile minimises the contact surface between the product, the central distribution cone and feed tray surfaces, which leads to lower product adhesion. this means the product moves positively with simple vibration without the addition of screw feeders or other mechanical influences. the new surface technology has been tried and proven in Europe. Multipond weighers are made in Germany and now available in Australia through Jl lennard.

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Minced beef and chicken are by far the riskiest meat and poultry products in the American food supply and pose the greatest likelihood of hospitalisation, according to a new report by the Center for Science in the Public Interest. Furthermore, according to the non-profit group’s analysis of more than 33,000 cases of foodborne illness connected to products regulated by the US Department of Agriculture, chicken nuggets, ham and sausage pose the lowest risk of foodborne illness.

he report, Risky Meat: A Field Guide to Meat & Poultry Safety, ranks 12 categories of meat and poultry based on outbreak reports and the likelihood of hospitalisations associated with the pathogens most commonly reported in those foods. Minced beef and chicken are not only responsible for the largest numbers of outbreaks and cases of illnesses, but those illnesses tend to be more severe. The deadly bacterium E. coli O157:H7, for instance, was responsible for 100 outbreaks associated with minced beef in the 12-year study period. Because that pathogen is estimated to result in hospitalisation in nearly half of those infected, minced beef had the highest severity index of the 12 meat and poultry categories. Minced

beef is also connected to illnesses caused by Clostridium perfringens and Salmonella. “Outbreaks from minced beef and chicken are reported frequently, and all too often cause debilitating illnesses illnesses that lead to hospitalisation,” said CSPI food safety director Caroline Smith DeWaal. “For example, approximately a quarter of those who are sickened by Salmonella will go to the hospital. The hospitalisation rate for E. coli infections is nearly 50% and for Listeria infections it is more than 90%.” Hospitalisations caused by Salmonella put chicken in the ‘highest risk’ category alongside minced beef. Clostridium perfringens and Norovirus also cause outbreaks associated

www.foodprocessing.com.au

May/June 2013

MEAT, POULTRY & SEAFOOD

©iStockphoto.com/Juan Carlos de la Calle Velez

Risky meat

Highest

MEAT, POULTRY & SEAFOOD

High

Medium

Low

Outbreaks

Cases of illness

Severity index*

Chicken

452

6,896

657

Minced beef

336

3,801

869

Beef (other)

2,414

398

Steak

1,935

509

Turkey

130

4,349

453

Barbecue

2,484

312

Deli meat

1,515

258

Pork

129

2,262

248

Roast beef

2,470

178

Chicken nuggets

203

Ham

1,094

Sausage

823

*Calculating the Severity index Not all cases of illness are equal, and that is reflected in CSPI’s rankings. Most cases probably involved stomach cramps, nausea, vomiting and diarrhoea; other cases may have resulted in hospitalisation, kidney failure and even death. While each case is included in the analysis, the rankings go one step further. CSPI’s rankings are based on an analysis of severity, a metric derived by determining the number of illnesses caused by each pathogen for each food group, and then applying the hospitalisation rate due to that pathogen. For example, using the severity metric, each case of Listeria monocytogenes, with a 94% hospitalisation rate, was counted as 0.94, and not simply as 1.0; a case of Clostridium perfringens, with a hospitalisation rate of 0.6%, was counted as 0.006.

with chicken. Campylobacter bacteria are also believed to two hours of serving the meal and using shallow storage cause a large number of individual illnesses associated with dishes to ensure rapid chilling are all good strategies consumers can use to reduce their risk of getting sick from chicken but rarely cause outbreaks. “Meat and poultry producers must bear primary re- this common bacterium.” CSPI’s ‘medium risk’ category includes barbecue, deli sponsibility for keeping pathogens out of their products, but when it comes to beef, chicken and other raw meats, meat, pork (excluding ham and sausage) and roast beef. restaurateurs and home cooks must treat them like hazard- Listeria monocytogenes, though not a common cause of outous materials and take steps to minimise risk,” said CSPI breaks, is a critical concern with deli meats. That bacterium senior food safety attorney Sarah Klein. “Care should be hospitalises almost everyone (94%) who becomes infected, taken to avoid spreading germs from the meat around the with the elderly, ill and immune-compromised consumers kitchen, and meat thermometers should be used to ensure being at greatest risk. CSPI’s barbecue category includes beef and pork barbecue, but not that minced beef, chicken and chicken barbecue, and its pork other meats are fully cooked.” Meat and poultry producers must bear primary category includes chops and CSPI’s second tier, or ‘high roasts, but not ham. With both risk’ category of meats includes responsibility for keeping pathogens out of their of those categories, Salmonella, steak and other forms of beef, products, but when it comes to beef, chicken and other Clostridium perfringens and but excludes roast beef, which raw meats, restaurateurs and home cooks must treat Staphylococcus aureus are the is of medium risk. Steak is them like hazardous materials. primary pathogens of concern. typically seared on both sides, Chicken nuggets, ham and which helps to kill surface bacteria, but E. coli O157:H7 is still a problem. (The sausage make up the ‘low risk’ category, reflecting their practice of mechanically tenderising steak with blades or lower frequency and severity of illnesses. Norovirus is a comneedles may drive surface bacteria into the steak’s interior, mon cause of infections from foods in this category, which thereby increasing risk.) With steak and other forms of suggests that improper food handling, such as insufficient beef, Clostridium perfringens was the pathogen responsible handwashing by restaurant workers, may be responsible for for the greatest number of illnesses. Rounding out CSPI’s more illnesses than the foods themselves. CSPI says that its assessment of food safety risk is tohigh-risk category is turkey. November and December are big months for turkey-associated Clostridium illnesses - in- tally separate from the risk of chronic diet-related disease dicating that holiday turkey left out on the table too long presented by the saturated fat or sodium in meat and poultry products. In other words, this analysis shouldn’t is partly to blame. “Clostridium doesn’t get the same kind of headlines that be interpreted as a licence to eat a lot more sausage, the its far deadlier cousins E. coli and Salmonella get, but it’s group says. responsible for an enormous amount of foodborne illness linked to leftovers or food left out too long on the buffet,” Center for Science in the Public Interest Klein said. “Keeping hot foods hot, refrigerating it within www.cspinet.org

May/June 2013

www.foodprocessing.com.au

Seafood facility fit-out keeps the sushi rolling

system, Colorbond Permagard, which incorporates Microban antibacterial technology making the surface immune to attack from mould, fungi, mildew and vermin. The panels are also FM-certified fire-safe. Traditionally surface-mounted services were concealed to assist with the washdown process to prevent any possible bacteria buildup. The new facility features a production area with airlock, holding cool room, stainless steel drainage system, grease intercepter trap and a highly durable food grade flooring and cove system of the highest standard. Stainless steel fixings and hardware have been used throughout the facility, helping to prevent corrosion due to constant washdown. Brady IPS also introduced Hygiene Select - a package of ancillary items incorporating hot wash hose reel and colour-coded cleaning utensils. “The quality of the end product is over and above anything we could have hoped for,” said Jackson. Brady Insulated Panel Systems Pty Ltd Contact info and more items like this at wf.net.au/T950

www.foodprocessing.com.au

May/June 2013

MEAT, POULTRY & SEAFOOD

Brady IPS, specialist food facility builders, recently completed a new seafood facility fit-out for YNJ Japanese Catering, a family-run business producing traditional handmade sushi and sashimi for catering companies and venues throughout Melbourne. In 2012, with a need to upgrade facilities and expand the business, Gregor Jackson of YNJ purchased an existing factory in Moorabbin, which had previously been used as a mechanics workshop. Brady IPS was commissioned to assist with the design and carry out fit-out works to meet HACCP and building code requirements, transforming the factory into a state-of-the-art hygienic food environment. Brady IPS arranged all necessary permits through to occupancy. The fit-out was completed in March 2013. “The combination of knowledgeable tradesmen, wonderful attention to detail and swift communication has made this entire process a breeze,” Jackson said. Featuring FM-approved insulated panel walls and a suspended ceiling specifically developed for the food and cold store industry, the modular composite panel comprises a traditional zinc-coated steel sheet coated with a custom-formulated paint

MEAT, POULTRY & SEAFOOD

Electron-beam pasteurisation to reduce viral contamination of raw oysters Researchers have found that electron-beam pasteurisation may reduce the possibility of food poisoning caused by viral infection of raw oysters. This would reduce the $200 million that virus infection risks are estimated to be costing the US each year.

o address the issue of health risk from eating raw oysters, Texas A&M University graduate student Chandni Praveen, along with Texas A&M AgriLife Research scientist Dr Suresh Pillai and a team of researchers from the US Department of Agriculture, the US Food and Drug Administration and University of Texas School of Public Health-El Paso regional campus, studied how electron-beam pasteurisation of raw oysters may reduce the possibility of food poisoning through virus. “The study was performed using a human norovirus surrogate called murine norovirus (NoV) and a hepatitis A (HAV) virus along with advanced quantitative microbial risk assessment tools,” explained Pillai, professor of microbiology and director of the National Center for Electron Beam Research at Texas A&M University. “A salient feature of e-beam pasteurisation technology is that it uses commercial electricity to generate the ionising radiation that inactivates 24

May/June 2013

the viruses. It is a green technology because no chemicals are involved.” Pillai said the FDA already has approved the use of electron beam technology as a pathogen intervention strategy to control the naturally occurring Vibrio vulnificus bacterial pathogen in shellfish. According to the FDA, raw oysters contaminated with Vibrio vulnificus can be life threatening or even fatal when eaten by someone with liver disease, diabetes or a weakened immune system. “We’re all for any means of technology that enhances the safety of our product,” said Sal Sunseri, co-owner of P&J Oysters and a representative of the Louisiana Oyster Dealers and Growers Association. “While we provide a safe product, we know there are at-risk groups, and that processing methods like freezing, high-pressure treatment and electron-beam irradiation reduce or eliminate the risk for

www.foodprocessing.com.au

May/June 2013

MEAT, POULTRY & SEAFOOD

those groups and enhance the overall safety of our product.” “This is the first study that has attempted to quantify At this time, however, electron-beam technology is not the reduction in infection risks of raw oysters contaminated being used for commercial oysters sold in the US. with different levels of virus when pasteurised at FDA“For the study, we chose the norovirus and hepatitis A approved doses,” he said. virus, as these are pathogenic Pillai said that the study threats to those consuming showed if a serving size of 12 shellfish, and chose oysters raw oysters was contaminated A salient feature of e-beam pasteurisation as they are a type of mollusc with approximately 100 hepatitis technology is that it uses commercial electricity that’s more commonly eaten A and human noroviruses, an eto generate the ionising radiation that inactivates raw,” said Praveen, a doctoral beam dose of 5 kGy (kilograys) the viruses. candidate in the toxicology would achieve a 91% reduction program of the Food Safety of hepatitis A infection risks and and Environmental Microbiology Laboratory at Texas A&M. a 26% reduction of norovirus infection risks. A kilogray is Praveen said she and the other researchers also chose the a unit of absorbed energy from ionising radiation. viral pathogens as opposed to bacterial as they were more Pillai said the study showed that if electron-beam difficult to treat and also require a host species. pasteurisation technology was included as part of a com“Bivalves such as oysters are also filter feeders that obtain prehensive food safety plan to reduce illnesses from raw their food by pumping water through their system and filter- oysters, significant public health benefits and, by extension, ing small organisms,” she said. “This can lead to the possible significant savings in medical and related expenses due to accumulation of NoV and HAV viral pathogens, as well as foodborne illness, can occur. bacterial pathogens.” The study can be found in the June issue of Applied Pillai said non-thermal food processing technologies are and Environmental Microbiology or online at the American needed to reduce these infection risks. Society of Microbiology website.

NEWS

Meat

The European Food Safety Authority (EFSA) has released a scientific opinion on public health risks and detection methods for mechanically separated meat. EFSA’s Panel on Biological Hazards (BIOHAZ) has also developed a model to help identify mechanically separated meat and differentiate it from other types of meat. Once the main cuts have been removed from an animal carcase, the remaining meat can be mechanically removed from the carcase and used in other foods. There are two types of mechanically separated meat: ‘high-pressure’ mechanically separated meat, which is paste-like and can be used in products such as hot dogs (also known, infamously, as ‘pink slime’); and ‘lowpressure’ mechanically separated meat, which is similar in appearance to minced meat. W h i l e t h e E F S A’s o p i n i o n c o n c l u d e s t h a t microbiological risks are similar for mechanically and non-mechanically separated meat, it does suggest that high-pressure production processes can increase the risk of microbial growth. Mechanical separation results in greater muscle fibre degradation and an associated release of nutrients that “provide a favourable substrate for bacterial growth”, the EFSA says. BIOHAZ considered different parameters to distinguish mechanically and non-mechanically separated meat. The panel found that calcium, released from bones during processing, is the most appropriate chemical parameter. EFSA’s experts developed a model that uses calcium levels to support the identification of mechanically separated meat products. The EFSA says this model will assist policy makers, as well as food operators and inspectors, to differentiate mechanically separated meat from non-mechanically separated meat. The full scientific opinion is available on the EFSA website: www.efsa.europa.eu.

In Wuxi, in east China’s Jiangsu Province, suspects made fake mutton from fox, mink and rat by adding chemicals. The products were sold to markets and the suspects made more than 10 million yuan (US$1.62 million) from the illegal activities. In south-west China’s Guizhou Province, police in March busted two meat processing and selling dens and arrested six suspects. According to an initial investigation, the suspects had been using hydrogen peroxide solution to process chicken claws since July 2011. With an output of 300 kg per day, suspects made more than 4 million yuan in profits. The police are now claimed to be focusing on crimes involving dairy products as there are apparently some deep-seated food safety problems which have not yet been solved.

w.s x

c.h

May/June 2013

u/w

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EFSA finds detection method for pink slime

A three-month Chinese Ministry of Public Security (MPS) campaign has resulted in the arrest of 904 people who are alleged to have been involved in meat-related crimes such as producing fake beef and mutton made from rat and fox. The ministry said since 25 January, police had uncovered 382 cases involving meat-related offences, and seized more than 20,000 tonnes of illegal products. Crimes also included the production of water-injected meat, the use of chemicals while processing products, as well as the selling of diseased and fake meat. The ministry published five typical cases uncovered during the campaign.

MEAT, POULTRY & SEAFOOD

Fox and rat passed off as lamb in China

Plantic and Profish commit to sustainable fish packaging

MEAT, POULTRY & SEAFOOD

Plantic Technologies has announced a new commercial supply agreement with Dutch company Profish Food, a sourcing agent, processor and distributor of fresh fish. The partnership will bring Plantic eco Plastic trays to the European retail fish pack market. Plantic says the ultrahigh barrier performance of its trays will keep products fresher and at peak quality for longer. Managing Director of Profish Frank Schreur says the partnership enhances the company’s sustainable credentials. “For many years we have sourced and packed sustainable fish and now we are doubling up by using sustainable trays,” he said. Profish is the first European fish company to adopt Plantic’s eco Plastic technology. “Our life cycle assessment shows that over the course of 12 months, the impact of adopting Plantic eco Plastic trays begins to add up - each 100 MT of eco Plastic used in place of oil-based polymers will reduce carbon emissions equivalent to planting 42,100 trees or taking 130 cars off the road. It would also save enough electricity to power over 70 homes for a whole year,” said Brendan Morris, CEO of Plantic Technologies.

17/7 Salisbury Rd, Castle Hill, NSW 2154 PO Box 8078, Baulkham Hills BC NSW 2153 p. 02 9659 4545 f. 02 8415 7134

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Lab45 stems from a dedicated

team of metal fabricators with over 3 decades project experience across the engineering sector. We pride ourselves on applying old style craftsmanship to modern world applications. Specialising in turnkey projects and deadlines that are usually perceived as impossible, we approach via lateral thought and bring new perspective.

OUR PRIMARY MARKETS INCLUDE:

FOOD PROCESSING The provision of high level, turnkey services to the food processing industry to meet all of your production requirements. These include consultation on factory layouts, customised design and installation of food processing lines, metal fabricators, conveyor design and production, plant relocations, ongoing processing line maintenance including shutdowns and emergency services. We provide assistance with new plant purchases, installation of new plant, troubleshooting, plant and processing line technical plan writing and failure analysis.

SPECIALIST METAL FABRICATORS The provision of specialist metal fabricators services to the domestic and commercial sector, including applications such as stainless steel hand rails, balustrades, all forms of mild steel fabrication, CNC machining and material handling.

SERVICES ● Consultancy & Design ● Food Processing Systems (inc conveyors) ● Drainage, Pressure and Vacuum Systems ● Large Scale Factory & Plant Relocations ● Factory / Plant Maintenance ● Aluminium, Stainless & Sheet Metal Work ● Structural Steel Work ● Pipe & Tube Work (ferrous and non ferrous) ● Laser Cutting ● Water and Wire Cutting ● CNC Automation (all forms of Machining) ● General Fabrication ● Project Management

www.foodprocessing.com.au

May/June 2013

Vacuum chamber machine Multivac has introduced its C 800 vacuum chamber © www.sxc.hu/arinas74

machine, which is equipped with a 1.4 m wide chamber. This makes it suitable for long food products such as cylindrical sausages and whole fish. The C 800 is the largest single-chamber machine in the company’s portfolio.

MEAT, POULTRY & SEAFOOD

Salmon-trimming robot

With a sealing bar length of 780 mm and an effec-

Marel’s ITM2 Trimming Robot is suitable for high-value salmon trimming. The

tive chamber volume of 1400 x 780 x 170 mm, the C

company claims the robot can work more quickly, reliably and consistently than

800 is wider than the Multivac C 500. The sealing bars

a master trimmer working at peak performance, and can do so continuously.

are located on the right and left sides of the cover in

Using advanced vision technology, the ITM2 calculates the most profitable cut configuration based on weight, shape and colour grade parameters before

the C 800, as compared to the C 500, where sealing occurs in the front and back. The machine is reliable and precise and offers

trimming loins, belly sides and fillet surfaces as high speed. The robot can improve yield by delivering uniform trimming tailored to users’

consistent implementation of the Multivac Hygiene

specifications, with high reliability and throughput. The ITM2 is designed for

Design with stainless steel construction and a high

seamless integration into pre- or post-rigor fillet processing lines.

production speed. The intuitively operated electronic

Implementing Marel Innova yield monitoring software can further increase

control ensures a simple and reliable packing process.

productivity. By integrating predefined weighing points along the processing line,

In addition to the vacuum ‘quick-stop’ function, the

the Innova software enables processors to monitor the raw material utilisation at

C 800 also offers automatic progressive ventilation.

each processing step. Furthermore, with an instantaneous overview of productivity

This ensures that sharp or pointed products do not

and system uptime, the processor can react quickly and keep the line running

destroy the film pouch during ventilation.

at maximum efficiency, while also improving traceability.

Multivac Australia Pty Ltd

Marel New Zealand Ltd

Contact info and more items like this at wf.net.au/T910

Contact info and more items like this at wf.net.au/S711

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May/June 2013

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

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New research is claiming that 3% of all premature deaths can be attributed to the high consumption of processed meats such as sausage products, salami or ham.

n a huge study of half a million men and women, research in Biomed Central’s open access journal BMC Medicine has demonstrated an association between processed meat and cardiovascular disease and cancer. The problem is that carcinogenic substances such as nitrosamines form through salting, pickling or smoking, and these might be the cause of the increase in cancer mortality. However, processed meats are also rich in cholesterol and saturated fats, which are linked to an increased risk of cardiovascular disease. One of the difficulties in measuring the effect of eating meat on health is the confounding effect of lifestyle on health. Often vegetarians have healthier lifestyles than the general population, they are less likely to smoke, are less fat and are more likely to be physically active. Only within a very large study can the consequences of eating meat and processed meat be isolated from other lifestyle choices. This EPIC (European Prospective Investigation into Cancer and Nutrition) study involved 10 countries and 23 centres in Europe and 450,000 participants.

In general, a diet high in processed meat was linked to other unhealthy choices. Men and women who ate the most processed meat ate the least fruit and vegetables and were more likely to smoke. Men who ate a lot of meat also tended to have a high alcohol consumption. A person’s risk of premature death (increased risk of ‘all cause’ mortality) increased with the amount of processed meat eaten. This is also true after correcting for confounding variables, although residual confounding cannot be excluded. However, a small amount of red meat appeared to be beneficial, which the researchers suggest is because meat is an important source of nutrients and vitamins. Prof Sabine Rohrmann, from the University of Zurich, who led this analysis, explained, “Risks of dying earlier from cancer and cardiovascular disease also increased with the amount of processed meat eaten. Overall, we estimate that 3% of premature deaths each year could be prevented if people ate less than 20 g processed meat per day.”

www.foodprocessing.com.au

May/June 2013

MEAT, POULTRY & SEAFOOD

Death by 1000 sausages

MEAT, POULTRY & SEAFOOD

Horsemeat scandal side effect The horsemeat scandal, which broke in January 2013, has already made its mark on British consumers who are raising concerns over the way in which meat from overseas has entered the UK food chain. They are voting with their feet and showing increased preference for British products.

n an exclusive Mintel report looking at provenance in food and drink, British consumer attitudes were compared prehorsemeat scandal (Dec 2012) and post revelations (Mar 2013). The research found British origin continues to rise in importance among the nation’s shoppers. Indeed, in December 2012, four in 10 (40%) Brits agreed that British food was better quality than imported food; in just three months, this figure has risen to one in two (49%). In addition, Mintel asked consumers about factors which would influence their buying choice in food and non-alcoholic drinks. British origin (34%) was the most important issue to shoppers - a figure which had risen from three in 10 (30%) at the end of 2012. Being of local origin has also risen in importance, from 17% in 2012 to more than one in five (21%) in March 2013. Regional, likewise, saw a rise up from 10% in December 2012 to 14% in March 2013. Amy Price, Senior Food and Drink Analyst, said: “The importance of food being British has leapt in popularity in the wake of the horsemeat scandal. The food industry is likely to feel the effects for some time, with consumers taking a greater interest in British and local origin and a more proactive stance on questioning the provenance of their food. The horsemeat scandal has reaffirmed consumers’ faith in the quality of British-produced food.” While “traceability” is only of concern to 14% of British shoppers, this latest research shows it is an issue which has shown the greatest increase in importance amongst today’s more savvy consumer - a figure which has risen from just 6% in three months. “Even in the aftermath of the horsemeat scare, traceability as a key choice factor is far behind, for example, British origin. This 30

May/June 2013

indicates that British origin is seen by consumers to provide the most effective shortcut to reassurance, when considering various food issues. “Focusing on promoting transparency to consumers, either through proving British sourcing through logos such as the Red Tractor or through placing greater emphasis on traceability as well as communicating steps that are being taken to shorten or tighten the supply chain would likely resonate with consumers in the current climate, helping to build credibility and restore trust among consumers,” Price continues. Not only is British origin growing in importance, but consumers are also becoming more passionate about supporting British farmers and growers. Three quarters (74%) of all consumers feel it is the duty of the retailers to support British farmers and growers - up from (68%) in December 2012. But while the nation grows more interested in British food - the consumer has become ever more suspicious about the food on their plate - almost seven in 10 (68%) Brits admitted it is hard to know when food is really British, up from 59% in December 2012. Despite this questioning, today, a third (33%) of the nation say that they are willing to pay more for food and drink with a “made in Britain” label - a figure which has risen from a quarter (24%) back in December 2012. “The fact that consumers are willing to pay more for British produce in these difficult financial times is extremely encouraging for British food producers. British growers and producers should emphasise these tangible benefits in their marketing messages in order to remind consumers of the positive attributes of buying British,” concludes Price.

www.foodprocessing.com.au

Protein determination system The BUCHI KjelMaster system, K-375/K-377, together with the Digest Automat K-438, offers greater productivity for protein determination according to the official Kjeldahl method. It allows up to 80 samples to be processed in an 8 h shift.

MEAT, POULTRY & SEAFOOD

The Digest Automat K-438 with automatic lift for raising and lowering batches of digested samples offers users full walk-away convenience during digestion. The rack, holding a batch of 20 samples, can be placed in the KjelSampler K-377 for automated distillation and titration. The K-377 features two independent rack trays so that a second batch of 20 samples can be loaded while the first batch is being processed. This semi-continuous workflow reportedly allows the highest possible sample throughput using just one integrated digestion/distillation/titration system. A smart distillation mode facilitates routine measurements and increases the result accuracy. Data traceability for GLP compliance is guaranteed by multiple access levels of authorisation and thorough documentation in conjunction with the KjelLink PC software. KjelLink facilitates not only data integrity and exchange with LIMS but also displays the status of operation on an external PC, allowing a minimum level of on-site supervision. In Vitro Technologies Pty Ltd Contact info and more items like this at wf.net.au/T849

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May/June 2013

©iStockphoto.com/ Paula Connelly

TESTING

Testing for horse DNA in beef food samples Is the beef in your ready meals really beef? The current scandal in Europe is resulting in a scramble from food processors to check that their beef isn’t actually horse.

uropean Union ministers have called in Europe’s law enforcement agency to help tackle the spreading crisis over mislabelled frozen meals containing horsemeat and promised rapid DNA food testing in an effort to restore consumer confidence. The European Health Commissioner Tonio Borg said the EU was calling on all 27 member states to carry out DNA tests on beef products to see if they contained horse meat.

Testing There are two methods used to detect different species of meat within a food sample (for example testing for horsemeat in a beef lasagne). The first is ELISA (looking for animal protein) and the second is PCR (detecting animal DNA).

ELISA ELISA has a lower detection limit and requires different test kits depending on the species and whether the meat is cooked or raw. In the current food crisis this information is not readily available because the exact source of contamination is unknown. Therefore, DNA testing with a superior detection limit and almost 100% specificity and sensitivity is the most suitable method.

PCR Polymerase chain reaction utilises short sections of DNA called primers specific to beef and horse. In the experiment, these primers bind to the animal DNA in the sample and allow the animal DNA to be copied millions of times until there is sufficient material to be visualised and compared to known standards. 32

May/June 2013

Test procedure 1. Prepare the sample. Mix the food sample (eg, beef lasagne) thoroughly in a blender/stomacher to evenly distribute any DNA contamination. 2. Extract the DNA. Careful preparation of the sample is performed by experts in a laboratory by diluting, washing and centrifugation of the DNA. 3. PCR analysis. DNA from the prepared sample is amplified in a thermal cycler using nuclease-free water, the enzyme Taq DNA polymerase, dNTPs, MgCL2, reaction buffers and animal-specific primers. The thermal cycler treats the mixture to 35 cycles of: a. 94°C for 30 s b. 60°C for 30 s c. 72°C for 1 min 4. Separation of DNA - the amplified DNA is stained and separated by size into distinct bands using a widely used technique, agarose gel electrophoresis. 5. Results analysis - the resulting gel is placed into a gel documentation system which takes an image. The operator can then compare the sample DNA against known standards. This indicates with a high level of certainty whether the sample contains horse or beef DNA.

DKSH Australia Pty Ltd Contact info and more items like this at wf.net.au/T217

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Water test system The Colitag iMPNplate 1600 is a definitive system for measuring microbial contaminants in water with what is claimed to be the widest testing time window in the industry: 16 to 48 h. The system offers greater selectivity for total coliforms and E. coli with the help of selective growth inhibitor of Aeromonas and Pseudomonas strains. The selective dehydrated media formula automatically resuscitates and detects chlorine-injured bacteria, resulting in a complete, highly sensitive tool for regulated site testing. The Colitag is an easy-to-use device for enumerating microtraditional method of serially diluting the sample on a statistical model to produce the most probable number (MPN) index. The time-consuming and labour-intensive process of serial tube dilutions is done by the patented plate system of five duplicate wells in 10, 1 and 0.1 mL well volumes, with a 16th well for collecting the remaining sample. Results readings are direct for coliforms and definitive for E. coli with the use of a UV light source. Tests using the iMPNplate-1600 offer a high degree of sensitivity, with a detection limit ranging from 0-1600 MPN per 100 mL sample within the standard reading window. The device is stand-alone in set-up and requires only an incubator and UV light source to perform the test.

A test for detecting foodborne Salmonella with the DuPont BAX system has been certified as Performance Tested Method #081201 by the AOAC Research Institute. This assay uses powerful polymerase chain reaction (PCR) technology with real-time detection to deliver fast, accurate results. This Salmonella assay may help food companies that require certified testing methods release products faster, saving inventory costs and extending shelf life. The AOAC Research Institute - a non-profit, international, scientific organisation that administers the Performance Tested Methods program - provides an independent, third-party assessment of proprietary analytical methods to ensure that products perform as claimed. Validation of this assay found it to be an effective method for detecting Salmonella in raw ground beef, chicken rinses, cream cheese, bagged lettuce, dry pet food and on stainless steel surfaces.

The Colitag is US EPA approved for use in MPN format.

DuPont (Aust) Limited

Pacific Laboratory Products

Contact info and more items like this at wf.net.au/T221

Contact info and more items like this at wf.net.au/T826

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

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

Tel: 03 9769 0666

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

www.hannainst.com.au

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May/June 2013

TESTING

organisms in a liquid sample. It is a modern approach to the

Assay for Salmonella detection

TESTING

ÂŠiStockphoto.com/ Jana BlaĹĄkovĂĄ

Greater proof for functional food claims on the horizon with noninvasive gut health testing

Harro Timmerman

NIZO food research and Medimetrics have joined forces by developing a technology to sample from the small intestine in a non-invasive way. The small intestine plays a crucial role in digestion and immunity. Building proof of the effects of nutritional and probiotic interventions based on small intestinal content is now within reach.

ealth and functional claims made for foods such as probiotics still need to prove their effectiveness - an important part of the answer rests in our small intestines and their role in digestion, and immunity. NIZO food research and biotech pioneer Medimetrics are bringing this a step nearer, using the latest microelectronics. They have joined forces to create a means of sampling and mapping content from the small intestine to identify its microbiological composition, in a non-invasive way. The mapping process would provide novel insights into how certain 34

May/June 2013

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foods and ingredients might react in our gut and so affect our health. Using the IntelliCap system, an intelligent capsule developed by Medimetrics (a company pioneered by Philips), it will be possible to take samples in vivo, at targeted locations, in a non-invasive way and, importantly, away from a clinical setting. IntelliCap is already being successfully used by the pharmaceutical industry for the targeted and controlled delivery of drugs in the human gastrointestinal tract. The small intestine is critical to health. It is where the absorption of 95% of nutrients takes place and generates signals to control our me-

explained: “By assessing the way food and probiotics affect microbiota composition inside the small intestine of healthy individuals, we can better decipher the mechanisms which influence gut health, host metabolism and immunity. We may even access new markers which enable us to substantiate claims regarding the health properties of certain foods.” Medimetrics’ scientist Christoph Wanke, the company’s clinical program leader, added: “Food scientists wanting to develop functional foods immediately see the potential of the IntelliCap technology in enabling them to apply it as a novel tool to characterise the gut microbiome. In addition, considering its established functionality as a targeted, oral delivery device, we can see further extensions of the technology in relation to health and disease. This offers the potential to explore novel therapeutic approaches which would enable clinicians to control the microbiological composition of the gut in the treatment of diseases like obesity and diabetes.” During 2013, NIZO and Medimetrics plan to carry out extensive studies to explore and validate the technology before making it available to the food industry. There are strict guidelines drawn up by the European Food Safety Authority (EFSA) regarding the substantiation of a health claim in the area of gut health and immunity.

Get results early! Rapidcult™ E.Coli Enrichment Broth reduces your time to result for EHEC testing significantly. Fast:

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May/June 2013

TESTING

tabolism. It also contains most of our immune cells. Mounting scientific evidence shows that an imbalance in the ‘microbiota’ in our gut is linked to diseases such as obesity and diabetes. The tiny (11 x 26 mm), pill-shaped IntelliCap capsule is swallowed, passing through the digestive tract as a result of natural gut movement (peristalsis). The scientific collaboration with NIZO has enabled the capsule to be adapted to ‘freeze’ each sample as it is taken, avoiding deterioration. This guarantees sample stability through its journey in the intestines right up to the point of analysis. The remotely controlled capsule also measures its transit time, pH levels and temperature. Once the capsule has left the volunteer’s body, molecular analysis of its contents will be carried out by the specialist platform pioneered by NIZO generating this ‘quantitative and representative’ map of each sample’s microbiological composition. It is increasingly important to be able to verify functional claims of certain foods by testing the effects of nutrients, proteins, vitamins and microorganisms (probiotics). However, this has previously been an expensive and difficult process, with the invasiveness of existing methods particularly unpleasant for the volunteer. Harro Timmerman, principal scientist at NIZO, expressed his enthusiasm for what he calls a ‘revolutionary tool’. As he

Portable pH and temperature meter for meat processing The Hanna Instruments HI 99163 is a portable pH and temperature meter for meat processing applications. The meter utilises a specialised pH electrode designed specifically for meat applications. The FC232D pre-amplified pH electrode and removable stainless steel blade enables users to perform measurements quickly and easily. The free diffusion junction helps to avoid a clogged reference and the external body material is non-toxic and food compatible. The meter has automatic one- or two-point calibration, automatic temperature

TESTING

compensation and BEPS (battery error prevention system), which alerts the user in the event that low battery power could adversely affect readings. Battery power percentage is also shown at start-up. With a multilevel LCD and on-screen tutorial messages for calibration and setup, this compact unit is waterproof and easy to clean. Hanna Instruments Pty Ltd Contact info and more items like this at wf.net.au/T801

X-ray detection platform The Thermo Scientific NextGuard X-ray detection platform has been designed to enable food processors to meet the global demand for more thorough inspection for product contamination. According to the company, the platform combines three key at-

Liquid nitrogen vapour storage system

tributes - performance, simplicity of use and price point - to make X-ray product detection more affordable for food, pharmaceutical and other applications.

VWR International has available the Custom

Based on Thermo Fisher testing, the NextGuard offers up to 50%

BioGenic Systems Isothermal Carousel Liq-

better detection sensitivity than the company’s previous X-ray system,

uid Nitrogen Vapor Storage System, which

the EZx. The system is designed to be reliable, easy to install and

combines the -190°C isothermal design

compact (it is 1 m long). It comes equipped with intuitive software.

with a small opening and an interior

The system includes: multiple contaminant detection algorithms

rotating carousel.

to increase detection probability; QA check mode, automating operator audits and record keeping; built-in internet remote support hardware and software; an easily removable conveyor that facilitates quick cleaning and service; and on-machine reject image storage for up to 90 days. Detector diagnostics warn when preventative maintenance is needed, while the system’s wraparound detector is intended to reduce ‘blind spots’. The system allows users to modify, test and change detection parameters on the fly. The series’ first model, the NextGuard C330, is designed for packaged product contaminant detection and complements the Thermo Scientific Xpert and POWERx X-ray inspection systems.

low temperature in the freezer. The interior carousel rotates by a unique ratcheting handle on top of the freezer that will position samples to the front of the freezer, even with the lid on. Each system includes the 2301 auto monitoring controller to provide security and ease of operation. Four models are available, as are a selection of inventory racks to store any size tube, vial, box, microplate, etc to complete the system. Custom configurations can also be designed to meet user requirements. VWR International Pty Ltd

Thermo Fisher Scientific Contact info and more items like this at wf.net.au/T852

The small opening provides low liquid nitrogen consumption, a lightweight, user-friendly lid and a consistently

May/June 2013

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PACKAGING

3 steps to successful lightweighting of PET bottle production George Wolfe, Agr International’s Chief Technical Officer, delivered a presentation on successful lightweighting of PET bottle production at the Packaging Conference in Atlanta, Georgia, in February.

olfe’s formula for lightweighting success is: 1. 100% measurement of production bottles for material distribution. 2. Hourly performance checks of key performance parameters such as top load, burst pressure and volume. 3. Automated, real-time control of the blow-moulding process. The theory behind this approach, Wolfe said, is based on the continual management of material distribution during bottle production. Since material distribution is the one attribute that most affects bottle performance, it is critical to manage this aggressively, especially when producing lightweight bottles. Measuring distribution on every bottle produced gives a good view of the process, especially when and where deviations occur. “If you know when and where the process is changing, you have the ability to react swiftly to make adjustments and manage your process proactively,” Wolfe said.

In addition, hourly performance checks on a sampling of bottles provide confirmation of the efficiency of the process control system. These checks should include topload and fill-volume testing, and for pressurised products, pressure testing. “Proactive blow-moulder management is the part that makes it all come together,” Wolfe said. “Even the best blow moulders, with the latest innovations, are subject to production variations.” Whether due to plant environmental changes, material variations or preform quality - and so forth - events occur that affect material distribution and bottle quality. According to Wolfe, the best way to accomplish this is by performing thickness distribution measurement on every bottle and incorporating automated blow-moulder adjustment to maintain desired material distribution parameters. Wolfe cited a number of manufacturers using Agr’s Process Pilot automated blow-moulder management system to

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May/June 2013

PACKAGING

proactively manage the blowing of very light containers. ject of their own, Agr International offers several programs In these examples, he showed how process variation was in this area. One such program is designed to help bottle dramatically reduced and bottle performance was improved manufacturers determine their ‘lightweight readiness’. This with much less waste. program includes an analysis Most blow-moulding operaof the blow-moulding op tions today function within a eration and methodologies to If you know when and where the process is changing, three to four sigma range based determine process efficiency you have the ability to react swiftly to make adjustments on typical sampling testing pracand identify areas that might tices, Wolfe said. compromise lightweighting and manage your process proactively. “This may have been adequate capabilities. in the past. However, in today’s The Agr team can also marketplace, with the ever-inprovide a number of other creasing demand to reduce the material content while services that can assist bottle manufacturers improve their maintaining bottle performance, the three to four sigma process and profitability by examining blow-moulder operaapproach leaves a lot to chance.” tion/performance, feeder process stability, quality sampling When lightweighting bottle production, a higher standmethodology, overall process efficiencies and six sigma ard is necessary to ensure success. To be able to produce statistical instruction. George Wolfe is the Chief Technical Officer for Agr Inconsistent, high-quality bottles with minimal waste, manuternational Inc. He also heads Agr’s professional services facturers must work towards achieving a five to six sigma segment that provides a variety of consultative and evaluproduction process. ation services geared towards production efficiency in the Achieving a five to six sigma operation is not as difficult PET bottle industry . as you might think. By incorporating automated process control equipment, this can be achieved quite simply. For Agr International www.agrintl.com those who require assistance to embark on a six sigma pro-

Label inspection system for cylindrical plastic packages

High-speed rotary blow-moulding machine MAER’s NTN850 high-speed rotary blowmoulding machine offers productivity IntraVis Vision Systems of Germany, a global supplier of video inspection machinery, has released the IntraWatcher PVLC system, designed for the quality control of labels on cylindrical unoriented containers. It inspects pressure-sensitive, injection-moulded and heat-transferred labels. IntraVis recognised the challenges that manufacturers face with inspecting the presence, position and identity of labels and decorations on cylindrical unoriented containers. The parts cannot be compared to a reference sample, as proper alignment is not guaranteed. The system simplifies the inspection process as the optical inspection module takes images from all sides of the container using four cameras and creates a full 360º image. The images are then orientated, stitched together and the perspective is straightened by the image processing software. These images are then compared to the reference sample. The system can inspect 10 parts/s and has special non-shadow lighting that provides consistent conditions during the inspection process. The IntraWatcher PVLC inspects: presence and identity; measurement of label offset; measurement of angular position; print errors; and folds and bubbles. HBM Packaging Technologies Contact info and more items like this at wf.net.au/S986

May/June 2013

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and versatility in neck to neck (NTN) technology at 80,000 bottles per hour. The NTN series produces double bottle bodies joined at the neck by a dome and made from the same mould. Bottle changeover takes less than 5 min. It has been designed for bottlers of liquid yoghurt and dairy drinks in small PDE-HDPE single-serve bottles and linear or rotary blow-moulding machine manufacturers. The machine has been designed to complement the blow-moulding machine with NTN double-cavity moulds, as well as the end-client’s in-house bottle blow-moulding operations. MAER www.maer.es

Ketone-free ink Linx Printing Technologies is introducing a ketone-free ink to meet increasing demands for an ink that does not contain MEK and acetone, suitable for a variety of coding applications across industries such as food and drink, cosmetics, confectionery and tobacco. Linx Black Ink 3401 offers a drying time of 1-3 s on both porous and non-porous materials, as well as light fastness and good adhesion and contrast on a wide range of materials including paper, card, plastic and flow-wrap. The ink has good general chemical resistance across many substances, which makes it resilient to chemical splash from alkalis, acids, water, alcohol, petrol and cutting fluid, and is capable of heat resistance of up to 30 min at 300°C with no adhesion or colour change. Linx Black Ink 3401 joins the company’s existing range of MEK-free ethanol-based inks. It can be used with Linx’s 4900 and 7900 CIJ printers to provide a range of coding solutions for all types of production and packing line requirements, delivering consistently reliable and high-quality codes. Matthews Intelligent Ltdmm, CC-en46-AZ033 04/13 Zukunft, What‘s New in Food Identification Technology, 150Pty x 195 Contact info and more items like this at wf.net.au/T844

Full-wrap label applicator The Herma 752CFW full-wrap label applicator is capable of accurately applying full-wrap labels around products such as meat trays, clamshell-based packaging and multipack formats. The machine applies a label that is narrow-edge leading, which is claimed to deliver the best possible yield in label printing and enable users to purchase labels in the most efficient form possible. Application is simple via the servo-driven controller. A tight pack is ensured, as control of tension is delivered through the servo system itself and the machine is not completely reliant on traditional wipe-down brushes and rollers. Additionally, secondary thermal printers can be easily incorporated into the applicator for printing of variable information such as weights, nutritional panels, ingredients lists and barcode as well as date and traceability information. The machine’s servo-driven controller ensures accuracy, even at high speeds. The machine has a speed of up to 40 m/min or 80 products/min. Changing label reels is easy and fast, based on the holding systems used. The machine’s configuration is based on a German design, but with modularity for fast delivery.

Securing value for a strong future

www.krones.com

Result Packaging Pty Ltd Contact info and more items like this at wf.net.au/T503

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May/June 2013

Measuring OEE at greenfield plastics moulding site PACKAGING

Zubi is a web-based system that calculates all the compliance information for a food label and provides it in one PDF document. It is fast and can avoid costly mistakes that lead to recalls or label reprints. The system eliminates the need to enter ingredient, formulation and product information into multiple systems and then combine all these into one report. © www.sxc.hu/Nbauer

Operations Feedback Systems (OFS) has gone live at the Food Plastics Co’s greenfield moulding facility in Campbellfield, Victoria. Food Plastics Co is a Melbourne-based plastics blow-moulding and injectionmoulding company supplying high density polyethylene (HDPE), low density polyethylene (LDPE), polyethylene terephthalate (PET) and polypropylene (PP) blow-moulded plastic bottles, tubs, buckets and containers. The company also manufactures HDPE and LDPE lids and closures for the dairy, food, chemical and beverage industries. OFS software is configured on stateof-the-art blow-mould bottle lines and injection-mould cap lines at the Campbellfield facility measuring OEE, live production and waste. The OFS Analytics suite is providing valuable live information to both the management and operational teams and has been a factor in successfully commissioning the new plant. “I had already seen OFS running in another production facility and thought it was outstanding. I knew it would be beneficial for our business straight away,” said Hugh Donelly Managing Director, Food Plastics Co. “We’ve gone from sign off to having production lines up and running in no time and with a minimum of fuss. I can now monitor the performance of these lines anywhere, anytime. The information really is insightful.” “When I first saw the plant it was totally empty and then, a few short weeks later, it was great to see production in full swing, with OEE hitting the high 90s,” said Shoni Even-Chaim, owner and founder of OFS.

Web-based food compliance information system

Zubi automatically creates the ingredients list, including adding characterising ingredients when requested. When formulations are adjusted, the system will recalculate the list. The product can calculate nutrition information such as whether a vitamin should be removed because it is less than 10% RDI. It lets users add any extra nutrients and will calculate the % DI. The system can track all allergens from ingredients and processes and can create an automated allergen statement. It provides peace of mind and eliminates time spent double-checking for allergens. The web-based system can be accessed from anywhere where there is an internet connection. Staff can look at the same formulations from different places. Zubi is structured around a database so any changes a user makes to an ingredient or formulation will instantly flow through to all products they are used in. The system allows users to convert a product back into an ingredient so it can be added to a formulation and then used in another product, which is useful for pre-mixes made on-site. The ingredient database in Zubi includes more than 700 items from the NZ Food Composition tables. As well as providing nutrition information, these items have ingredient and allergen declara-

OFS - Operations Feedback Systems

tions already loaded.

Contact info and more items like this at wf.net.au/T270

Zubi www.zubi.co.nz

May/June 2013

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>>> Transport and distribution

PACKAGING

On 26 April 1956, 58 truck bodies were hoisted onto an old tanker moored at Newark, New Jersey. The container revolution had arrived and five days later the tanker, Ideal-X, docked in Houston with its cargo, this time packed into the quasi containers. On land, rail rather than road had been preferred for shifting large volumes of goods. With the termini of rail networks located in cities and ports, manual handling was necessary as products were loaded into box cars. Meanwhile, on the roads, large vehicles were developed but they still involved manual handling. Historically, as early as 1885, rail in the USA had offered the opportunity to transport produce wagons to ferry landings opposite New York City. In the 1950s, flat-top rail wagons were used to ‘piggy back’ trailers as a means of transportation for long distances. However, all of these systems involved multiple handling and there was no standardisation to facilitate the various systems. Unit load concepts had been around for centuries with unitising items on a base and using a windlass to raise them, but in WW2 the pallet (and forklift truck) came to the fore. However, it was another war which saw this principle taken to the next step. The Vietnam War saw the introduction of a logistical approach with the setting up of the First Logistical Command and the introduction of ‘unitised packaging’. Previously the movement of materials and supplies had created bottlenecks and the port facilities were inadequate for the volume of traffic. Pallets were dumped at random on the docks, creating chaos. Containerisation was one answer; however, the military bureaucracy was divided over the concept. Finally, in 1966, following a visit by the Secretary of Defence Robert McNamara, the nexus was broken and in 1967, the shipping company Sea Land provided seven ships and the project got underway. This then was the genesis of containerisation and air transport absorbed the concept, thus unifying the distribution system. The container and the associated handling systems have not only revolutionised distribution, they have impacted on design, packaging material and reduced inventories. They have facilitated the rapid distribution of products from the producer to the retail shelf with minimal handling and savings in materials.

May/June 2013

Exair’s 54″ Super Ion Air Knife neutralises static electricity while blowing away dust and particulates from printed surfaces, paper, plastics and three-dimensional

shapes. The 54″ (1372 mm) wide laminar airstream, full of static eliminating ions, is effective at high speeds and provides cleaning up to 6.1 m away. Poor print quality, dust attraction, tearing, jamming and related equipment downtime may be reduced by using the air knife. Available from Compressed Air Australia, the air knife is efficient, using only 16.7 SCFM of compressed air at 5 PSIG to entrain high volumes of surrounding room air. An electrically powered static control bar fills the uniform sheet of air with a high concentration of positive and negative ions. The laminar airstream increases the surface exposure to the ions, making it effective for high-speed processes and over long distances. Force can be adjusted from a ‘blast’ to a ‘breeze’. The shockless design is UL Component Recognized to US and Canadian safety standards, and power supplies are CE and RoHS compliant. There are no moving parts to wear out. Applications include surface cleaning, neutralising plastics, bag opening, prepaint dust removal, printing machinery, packaging operations and elimination of

Emeritus Professor Harry Lovell OAM, FAIP info@aipack.com.au www.aipack.com.au

Air knife with staticeliminating ions

static electricity shocks. Many lengths, up to 96″ (2438 mm), are available Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/S849

www.foodprocessing.com.au

High-speed liquid filling machines Romaco has extended its Macofar LF 200 product family with two models for filling liquids into glass and plastic bottles at high speeds. The Macofar LF 200 FD and LF 200 FS series were developed for bottling pharmaceutical liquids. The LF 200 family comprises five different models for filling a variety of applications of almost any viscosity gently and efficiently. The LF 200 FD is used for high-speed filling of pharmaceutical sprays, nose and ear drops as well as ophthalmics and syrups. It has a maximum output of 12,000 bottles per hour with a filling volume of up to 100 mL. Equipped with two closing stations, it is capable of handling a

PACKAGING

range of closure types including pipettes, dosing cups, spray pumps, plungers and screw caps. The dual closure system is flexible and facilitates many different combinations. The bottles are filled continuously, speeding up the filling process. The movement of the swivelling dosing systems is synchronised with the bottle transport through the machine. The LF 200 FD is suitable for glass and plastic containers 16 to 80 mm in diameter and 35 to 200 mm in height with a filling volume of 0.5 to 500 mL. The transport system that transfers the packaging can be adjusted to different container dimensions quickly and easily. The company’s FS machines are designed for applications with a single closure system such as pump, pilfer-proof, child-proof, screw or press-on caps. The LF 200 FS likewise fills the containers in a continuous process at a maximum rate of 12,000 bottles an hour. It is suitable for processing pharmaceutical liquids that are orally administered or applied to mucous membranes. Servo-controlled processes assure safe and reliable handling throughout the filling and closing operations. Romaco www.romaco.com

Beverage & Packaging Equipment Specialists Benchtop tensile and COF tester VT100 is a robust and portable benchtop tensile and COF tester that is designed to carry out quick and accurate quality assurance testing in an industrial production environment. The VT100 is suitable for packaging manufacturers and companies that are packing and sealing their own plastic packaging, paper packaging and food packaging. VT100 carries out seal testing, slip testing and tensile testing and can be easily operated on the factory floor with minimal training. Its rugged design makes it suitable for use inside a factory. The tester can also be integrated into software called Tool Suite. This will provide the operator with automated testing capabilities via an easily operated touch screen. Tool Suite will save the test results in a database for future analysis and reference. VT100 can be customised and is designed to meet ASTM D882-2009, ASTME4-10 and ASTME83-10a. Remote support is provided. Convex Plastics Ltd

• PET Bottle Production • Beverage Filling & Processing • Packaging & Labelling • Bottle & Preform Handling

Contact info and more items like this at wf.net.au/T827

Ph: +61 2 8814 3100 Packaging Technologies

www.foodprocessing.com.au

www.hbm.com.au

May/June 2013

quickly, effectively kills bacteria

Brian Wallheimer

PACKAGING

In-package plasma process

Exposing packaged liquids, fruits and vegetables to an electrical field for just minutes might eliminate all traces of foodborne pathogens on those foods, according to a Purdue University study.

evin Keener, a professor of food science, is looking for new ways to kill bacteria, such as E. coli and Salmonella, that contaminate foods and cause serious illnesses and deaths. His method uses electricity to generate a plasma, or ionised gas, from atmospheric gases inside the food package. This process creates a wide variety of bacteria-killing molecules including ozone, nitrogen oxides, hydrogen peroxide and others. These molecules only exist for a few hours and then revert back to the original atmospheric gas, leaving a bacteria-free product. In findings published in the Journal of Applied Microbiology, Keener and researchers at the Dublin Institute of Technology demonstrated that sealed-package atmospheric plasma works well to kill bacteria in growth media. Their experiments showed that bacteria on these surfaces were eliminated with 20 seconds of treatment and 24 hours of exposure to the gases it creates. Keener said the cost of the process should be comparable to current chemical and heat treatments used to sanitise foods. “Even in the most resistant bacteria-growing media, 45 seconds of treatment gave us complete elimination of the E. coli,” Keener said. “Under a microscope, we saw holes forming in the cell walls of the bacteria.” Adapting the technology for liquids could allow development of portable devices to clean drinking water in areas with contamination or that lack other purification methods. It could also allow food processors to bottle juices without 46

May/June 2013

first heating them, a process widely used to kill bacteria that can alter products. “This could be developed to allow you to achieve something similar to pasteurisation without the heat and quality changes that occur with that process,” Keener said. In Europe, especially, new methods are being sought as alternatives to washing foods in chlorine baths. “Chlorine water works well on hard surfaces. But there can be issues if bacteria get inside organic matter on the produce, making chlorine ineffective,” Keener said. Keener is working with researchers at Dublin Institute of Technology, National Centre for Plasma Science and Technology at Dublin City University in Ireland, and Innovació i Recerca Industrial i Sostenible (IRIS) in Spain to develop a precommercial system for larger-scale decontamination testing. After that, he would like to build a commercial system that could be used in food-processing plants. Future research will also consider how the process affects food quality. “Results from recent testing of E. coli bacteria in liquid suspensions demonstrated significant bacterial reductions with no heating or visual colour change,” Keener said. “This suggests that atmospheric cold plasma treatment may achieve a cold pasteurisation process for liquid foods to extend shelf life and improve safety.” The European Community’s Seventh Framework program funded the research. These results are part of a larger EU project entitled SAFE-BAG.

www.foodprocessing.com.au

PROCESSING

ÂŠiStockphoto.com/ LukaTDB

Upgrading food quality and processing efficiency The use of advanced inline cooking systems is improving product quality and cooking efficiencies among food processors in Australia - and saving on costs.

May/June 2013

www.foodprocessing.com.au

“Before getting this equipment we used combination

noticeable trend in this market,” said Barry

ovens and other small cooking devices,” said Ben Watt,

Hansell, sales manager at Reactive Engineer-

general manager. “When we first looked at the spiral oven,

ing in Sydney. “Ready-to-eat (RTE) meals

it seemed like a great piece of equipment that could have a

are a good example. Ten years ago you’d be hard pressed

lot of potential uses - which is exactly what it is. We can

to find good quality in frozen meals. But now processors

steam, roast, bake and super roast (roast and steam). The

are focusing more on fresh-prepared meals, which allows

system is really versatile, so it’s in use almost all the time.” Primo Moraitis Fresh’s principle products are wet salads

for higher quality and much greater variety. “Yield improvement remains important, but with newer cooking system designs, food processors no longer have to

for gourmet dinners, such as creamy pastas, potato salads and coleslaw.

sacrifice quality simply to get a bit of extra yield,” Hansell

“We use a lot of bacon, pancetta and meats like that,”

said. “The opportunity exists for them to gain or maintain

Watt said. “We roast those items through the spiral oven.

yield while improving quality and cooking efficiencies.”

The continuous process gives us great volume with an even

Hansell says his customers are increasingly switching

cook and great consistency.”

from labour-intensive batch cooking to high-efficiency

The spiral oven is also used for steaming potatoes, as it

inline processing that improves quality, consistency, yield

does a better job than boiling the potatoes in water. The com-

improvement and throughput,

pany produces approximately

while extending shelf life and

400 kilos of steamed potatoes

improving taste and appearance. Spiral ovens and flame grillers are often important components of these inline cooking systems.

Yield improvement remains important, but with newer

per hour using this system. Jewel of India is another Aus-

cooking system designs, food processors no longer

tralian-based processor using a

have to sacrifice quality simply to get a bit of extra yield.

spiral oven with a spiral chiller

Sydney-based Prontier pro-

to meet quality standards and

duces ready-to-eat protein sand-

improve yields and efficiencies.

wich fillings and meats for pizza

Jewel of India is an RTE

and salad toppings, and covers all aspects of manufacturing,

chilled meal manufacturer cooking authentic Indian foods.

distribution and retail operations.

The company supplies clubs, hospitals, airlines and stadi-

Prontier recently acquired a Unitherm Food Systems flame grill and spiral oven, which gives added flavour and a more

ums, as well as butchers, delis, supermarkets and caterers that service the military and mining industry.

authentic product appearance, plus improved efficiencies.

“The spiral oven is installed in our new high-risk pro-

The flame-grill individually quick-flames products, max-

duction facility, which will provide food safety similar to

imising the effects of flame searing while minimising yield

the newest European and pharmaceutical standards,” said

losses. Multiple independently controlled burners and touch-

Jim Keating, Jewel of India general manager. “We primarily

screen recipe selection make this unit flexible and efficient.

cook chicken on this system, but it will cook other items

“We use this equipment to wrap the outside of items

that we adopt in the future. We have trialled meatballs,

in flames and seal the meat,” said Saxon Joye, Prontier

moulded lamb balls, chicken balls and fish through the

founder. “It also browns meat products such as chicken

spiral system, and it has proved very flexible. The system

with a char-grilled stripe. The natural-looking flamed colour

will allow us to adapt quickly to market changes so we

and authentic grilled flavour are dramatic improvements

don’t run the risk of being left behind.” Although the spiral oven is newly installed, Keating ex-

in the quality.” Prontier’s meats are fully cooked in a spiral oven - a

pects overall yield improvements of 15 to 20%. The system

flexible, small-footprint cooking system developed for pro-

will also improve throughput, optimise product consistency

cessors wanting the benefits of continuous cooking with

and reduce labour. “Today, it’s really about output; it’s no longer all about

reliable consistency and lower energy usage. “Now, instead of batch processing we have a ‘production

input - the price of beef or lamb, or power, etc,” Keating

river’ which provides huge labour-saving advantages and

said. “If you can improve quality and efficiency, that is

gives us real control over the way we finish every piece of

where the competitive advantage and profits lie.”

food, making it a beautiful product,” said Joye. The spiral oven is also used by Primo Moraitis Fresh, which manufactures, processes and packages RTE salads,

Reactive Engineering Pty Ltd

soups and fresh-cut processed vegetables.

Contact info and more items like this at wf.net.au/U077 www.foodprocessing.com.au

May/June 2013

PROCESSING

“E

mphasis on the quality of the foods is one

Food-grade dry PTFE spray The Bel-Ray No-Tox Food Grade Dry PTFE Spray is a multipurpose, dry-film lubricant in a convenient aerosol form that has been NSF-H1 approved for use in ‘clean industry’ applications. The spray is fortified with polytetrafluoroethylene, a synthetic fluoropolymer of tetrafluoroethylene, which offers one of the lowest coefficients of friction against a solid surface. It is designed for ‘incidental contact’ lubrication

PROCESSING

applications in the following industries: food processing, food preparation, pharmaceutical processing, personal

Energy efficiency and sustainability program

care and other industries requiring ‘clean’ applications. The user-friendly formula does not affect plastic or

For organisations whose machinery is costing thousands of

painted surfaces, while also being non-toxic, non-corrosive

dollars in electricity to run and for those wanting to consider

and non-irritating. It offers superior dry film lubrication that

energy efficient upgrades but who are unsure where to start,

remains water resistant after application. Uses include lu-

or what financial assistance may be available, Energy Action

brication of bearings, slide ways, conveyors, cams, hinges

offers a unique energy efficiency and sustainability partnership

and other locations where a clean, durable, long-lasting

program, Activ8+.

film is required.

The Activ8+ team works with businesses to identify energy

Safe for industries where molybdenum and graphite are

efficiency opportunities and manage projects through to com-

not allowed, the spray meets NSF-H1 and FDA requirements

pletion. Where available, the team can even assist with grant

for incidental food contact. It is recognised as compliant

applications to secure funding. Most importantly, their team of

under the volatile organic compound (VOC) criteria estab-

engineers can aid with the complex measurement and verification

lished in California’s Consumer Products Regulation by the

process (now required to be outlined in many applications) to

California Air Resources Board (CARB) and the proposed

quantify the investments and the expected return. Partnering with

VOC limits by the Ozone Transport Commission (OTC) for

Activ8+ allows an organisation to work smarter, not harder - aim-

lubricants classified as ‘dry lubricant’.

ing to minimise disruption internally to bring projects to fruition.

Bel-Ray Company Inc

These services will allow an organisation to achieve genuine

Contact info and more items like this at wf.net.au/T604

cost savings through a reduction in the energy component of its energy bill. This cost saving will be achieved while also reducing the carbon footprint of the organisation. Energy Action Contact info and more items like this at wf.net.au/T779

Customised motor delivered in four weeks maxon motor recently delivered a customised low-voltage brushless DC motor to a customer requiring a robust motor for a drilling tool operation. The brushless motor is a heavily modified version of the 45 m 250 W 24 V catalogue brushless motor. The entire rear section of the motor was modified to meet the exact dimensional requirements of the application. The catalogue version of this motor has a radial cable exit and a radial extension of the cable glands. This radial cable exit can interfere in applications where the motor needs to be fitted inside a pipe or other round tube space. maxon was able to produce drawings of the modified design within two days and, after customer approval, the motors were manufactured and delivered in four weeks. The rear cable housing, gland and sealing were not the only parts of the motor that were modified. The drilling application sees the motor sprayed with high-pressure jets of water. To protect against this, the front motor bearing was fitted with rubber seals. To keep the electronic components and motor speed control unit well away from the harsh environment, the cables also needed to be manufactured with a specific length, connection and shielding. maxon motor Australia Pty Ltd Contact info and more items like this at wf.net.au/T921

May/June 2013

www.foodprocessing.com.au

PROCESSING

Cape Cod Potato Chips produces one of the top-selling brands of batch-cooked potato chips in the US. Hosting more than 250,000 visitors each year, Cape Cod’s plant and store are one of the top tourist destinations on the Cape. An almost cult-like following for the company’s style of distinctively crunchy batch-cooked chips has developed. When the company decided it needed to significantly boost production capacity to keep up with demand, plant manager Jeff Newell was faced with a conundrum. How do you squeeze higher output from the same floor space used since 1980, without changing product quality or ruining the charm of a popular tourist destination? “We were space-constrained and simply didn’t have the ability to make the plant bigger with brick and mortar,” Newell said. “The project was based on the premise that the kettles we work with are the original fryers the brand was started with. So our challenge was to replace those fryers without expanding the plant and still make the Cape Cod Potato Chips our customers love.”

Since the original fryers were Heat and Control Mastermatic models, Newell contacted the company to replace six of the 18 batch fryers and then replace the remaining fryers if the project succeeded. Additionally, Newell wanted fryers providing a higher oil turnover rate and a broader, more controllable frying temperature profile. “The goal was to make the same product whether we have low-gravity potatoes or high-gravities, and do it with much higher throughput,” reasoned Newell. Heat and Control developed a new fryer based on its proven 800B platform, which closely matched the footprint of the company’s existing fryers. Heat transfer tubes were positioned lateral to product flow with BTUs provided by a new combustion system. To preserve floor space, combustion components were mounted above the fryer, instead of beneath it. PLC-controlled Chip-Stirr systems automatically agitate slices for safe, uniform cooking and discharge of the finished chips. This design met every one of Newell’s requirements but introduced yet another challenge: how to cost-effectively remove the significantly greater volume of steam and oil vapours generated by the increased chip capacity.

May/June 2013

The company had exhaust hoods mounted two metres above each of the old fryers, which pulled a large amount of draft air from the cook room. The new fryers would pull up to 30% more air and add nearly a million dollars to the project for additional air make-up equipment if a similar approach was used. To eliminate this deal-breaker and save energy, Heat and Control equipped each fryer with a hood enclosure, like those commonly used on continuous fryers. In addition to reducing draft air volume to below 1700 acfm, the hoods blanket the oil with steam, purging oxygen to improve oil quality by reducing oxidation. Oil Mist Eliminators built into each hood remove oil from exhaust emissions to improve air quality and prevent potentially combustible deposits of oil from coating the roof. Newell says the eliminators and the hoods are a big environmental improvement, both inside and outside of the building. “This technology exceeded the expectations of the regulatory agency and they were impressed with the lower particulate numbers given our increase in throughput,” he said. “Heat and Control made sure that the equipment was sized properly, that the combustion system was capable, that the right amount of BTUs were transferred to mimic our profile and that modulation between high and low fire was programmed into the PLC to do anything we wanted to do.” It also helped that PLC codes for the new equipment were written on the same basic platform as the old systems. This helped start-up run smoothly. “We started up the first two new fryers on a Monday, the second two on a Tuesday, and the third set on a Wednesday and it was almost flawless. We started at the target batch size and never turned back. On the first two fryers we were making the right product within five batches. After that, product was as it should be after one or two batches on the remaining fryers,” concluded Newell. On the old fryers, the temperature profile was sluggish and occurred over a longer period of time. The new fryers are far more responsive, says Newell. “We can now go to whatever bottom temperature we want, so we can get more flexibility to make a little bit harder bite if we want to. “There is an improvement in product appearance. And because the BTU conversion is so powerful in the new fryers, I get a searing effect early on in the batch cycle which holds the chips to the right number of fold-overs and a good cup shape. “Texture change is neutral,” he added, “which is a good thing. The fact that I’m making significantly more product in the same size of equipment and not sacrificing any texture is a huge positive.” “Innovation and collaboration between our two companies yielded a unique solution in terms of square footage and capacity,” said Newell. “What we ended up with was pretty close to the same footprint. “We got a huge boost in capacity, no changes in brick and mortar, all kinds of finished product profile control, significant quality improvements and a big positive environmental impact.” Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/T627

www.foodprocessing.com.au

Keeping the crunch while raising productivity

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NEWS

Processing

No tariffs for imported tinned fruit, PM says

PROCESSING 54

May/June 2013

The government will not consider imposing tariffs on imported tinned fruit, the Prime Minister has told ABC Rural, despite calls from SPC Ardmona to put temporary tariff protection in place. The Goulburn-based processor requested the government temporarily impose tariffs on imported tinned fruit after it was forced to cancel contracts with 60 stone-fruit growers. But the Prime Minister says that specific tariffs risk retaliatory taxes on other agricultural exports. “We say, ‘Okay, we will protect a particular producer or a particular industry with a tariff’, only to find that other countries around the world who import things from Australia, including agricultural products, then retaliate with their own tariffs,” Julia Gillard said during a visit to northern Tasmania. SPC called for the protection after its forecasts for the coming season led to a reduction of up to 50% in intake tonnages for some fruit tonnages for the 2014 season. The company says market share of imported private label canned fruit has grown to 58%, while its canned fruit share has declined to 33%. SPC’s export market volumes have declined by 90% in the past five years. Emergency Safeguard actions are permitted under the World Trade Organisation rules. These actions would permit the imposition of an emergency tax on cheap imported foods where domestic industries are suffering injury. According to AUSVEG Public Affairs Manager William Churchill, “A flood of imported produce is wrecking regional businesses, employers and families.”

Olam International has opened a $60 million almond hulling and processing plant in Carwarp, Victoria. The 12,000 m2 facility is reportedly the largest of its kind in the Southern Hemisphere. The plant is expected to de-hull and shell 14 tonnes of almonds per hour and employ approximately 19 permanent and 54 casual staff once in full production. It will feature state-of-the-art laser sorter technology to shell and hull the almonds, generating significant efficiencies and ensuring consistent product quality, traceability and food safety. The company is minimising its environmental footprint by using modern technology. The warehouse can operate in complete darkness, reducing electricity use for lighting, while a cogeneration plant fuelled by almond hulls is also being explored. “The plant’s total capacity will reach 40,000 MT of almond kernels each year, meeting all of our upstream orchard volumes and positioning us well to meet the rapid growth in demand for almonds in India, China, South-East Asian and Middle Eastern countries,” said Bob Dall’Alba, Olam Australia Executive Director and Country Head.

$52m Mars upgrade supported by government The Australian Industry Group (Ai Group) has welcomed the Victorian Government’s announcement of support for the $52 million expansion of the Mars confectionery plant in Ballarat. Tim Piper, Victorian Director of Ai Group, said the expansion and support shows Mars’ and the government’s commitment to manufacturing. “Mars has been very important in the Australian confectionery landscape and is a major employer in Ballarat,” Piper said. “Its expansionary plans will be a fillip for the area.” “The state government’s support for the new plant is positive recognition for Mars manufacturing in the state and for employment in Ballarat, and is helping to deliver on the government’s promise to support manufacturing.” The Ballarat production line upgrades are expected to benefit export opportunities and boost productivity at Mars.

www.foodprocessing.com.au

New ISO standards for product safety and recall

Murray Goulburn Co-operative (MG) has announced a $19.1 million upgrade to its Leongatha plant, increasing the site’s UHT manufacturing output by 70 million litres each year. The Leongatha upgrade is part of MG’s planned $200 million investment in leading-edge dairy food manufacturing facilities for UHT milk, butter/spreads and cheese. MG Managing Director Gary Helou says the company is making the significant investment in

its Leongatha plant to meet increased demand for UHT milk. “The demand for Australian dairy products is growing rapidly,” Helou said. “To meet the demand for UHT milk, we realised we had to make the upgrade at Leongatha now.” According to Helou, the expansion and upgrade of the company’s UHT manufacturing footprint has been prioritised as the business is currently operating at capacity. “The Leongatha upgrade will help MG meet immediate demand for UHT milk from world markets, particularly Asia, while the long-term strategy is confirmed. It will also help us to lift our supplier/shareholder returns.” Work on the Leongatha upgrade will begin in late April and is expected to be completed by December 2013.

www.foodprocessing.com.au

May/June 2013

PROCESSING

MG invests $19.1 million in Leongatha UHT

New ISO standards have been released for Consumer Product Safety (ISO 10377) and Consumer Product Recall (ISO 10393). These two new ISO Standards provide practical guidance to suppliers of consumer products in assessing and managing the safety of their products, from the design of the product to the final product end user as well as consumer product recalls and other corrective actions after the product has left the manufacturing facility. ISO 10377 and ISO 10393 aim to foster improved consumer safety and seamlessly interoperate with GS1 standards in many areas, including the requirements for globally unique product identification, supply chain traceability and multijurisdictional product recall. “The new standard places a strong emphasis on understanding risk, good communication and being able to monitor the effectiveness of the recall through a variety of measures,” said Steve Hather, Managing Director of RQA Product Risk Institute and leading member of the International Working Group that developed the ISO 10393 standard. “The difference between an effective product recall and a crisis that can cost millions of dollars and threaten the survival of a consumer goods company comes down to four key elements investigation, assessment, strategy and communication. Get these elements right and the chances of a recall escalating into a crisis are very much reduced. The new standard places a heavy emphasis on these areas and is why we have created training courses that focus on these key elements,” The standards were developed in parallel and with the contribution of GS1 Australia and RQA Product Risk Institute. The two organisations will host a series of web-based presentations about how the new standards will benefit businesses by improving consumer product safety and the management of product recall events.

High-temperature chain lubricant Stella HT 300 Food Grade High Temperature Chain Lubricant is designed for the lubrication of conveyor chains and bearings running continuously at high temperatures up to 280°C, and short periods up to 300°C in the food manufacturing industry. Stella Chain Oil HT 300 is used on chain-driven bakery ovens, drying machines and other high-temperature food processing equipment.

PROCESSING

Utilising biodegradable base oil, the HT 300’s highly polar molecules strongly adhere to the surface and withstand high temperatures, while at the same time separating the moving parts due to its highly viscous lubricating film to provide maximum protection. HT 300 is available in 5, 20 and 205 L packages. Food Grade Oils Contact info and more items like this at wf.net.au/T821

Touchless X-ray inspection system The Thermo Scientific EZx Touchless contaminant detection system is an entry-level X-ray system designed to pass open or lightweight products through the system without the need for radiation shielding curtains. The touchless version of the compact EZx X-ray system eliminates sanitary and health concerns raised when lead or non-lead curtains touch food products being inspected. It is suitable for inspecting raw meat, poultry and fish in open trays prior to wrapping, and for lightweight products that may be hindered by heavy lead curtains. According to the company, the EZx system is designed to offer the lowest cost of ownership of any X-ray system. Its source and detector design eliminates blind spots found on most other X-ray systems. It is certified for harsh environments with an IP65 rating. The intuitive HMI with on-screen inspection results and quick-learn wizard enable easy operation and quick set-up. JL Lennard Pty Ltd Contact info and more items like this at wf.net.au/T850

Food-grade approved PVC piping For decades, PVC has been successfully used worldwide for drinking water supplies as well as industrial piping. Now, a high-purity PVC from Georg Fischer Piping Systems is food-grade approved. This piping system is claimed to provide cost advantages compared to stainless steel or other polymers for this application. In regards to corrosion resistance and durability, high-purity PVC offers the range of benefits of a PVC-U piping system. In addition, a straightforward installation technique by adhesive jointing is included with the piping. The high-purity PVC has been tested according to European Standards. Based on the results of these tests, any deterioration of the food - such as beer, wine, milk, juices and vinegar - that is transported in high-purity PVC pipes can be excluded. Georg Fischer Pty Ltd Contact info and more items like this at wf.net.au/T896

May/June 2013

www.foodprocessing.com.au

Fungi in your drink A research project at Indiana State University into Kraft’s Capri Sun, a popular packaged drink in the US,

PROCESSING

has found five types of fungus.

athleen Dannelly, associate professor of microbiology we have sent it to a leading, accredited lab for testing. They at Indiana State University, said one previous study independently confirmed it was mould. Because this product published online found only one fungus in Capri contains no preservatives, the beverage can spoil and mould Sun. However, the research in Dannelly’s lab found can grow.” five different fungi. “The significance of this is that for the majority of people, “As far as I can tell, the fact that they don’t put preservaother than being grossed out when you open a package and it tives in this is really allowing lots of fungi to survive the drink has a large fungal mat, which is a really nasty looking thing, process,” she said. it will probably not hurt you,” Dannelly said. “However, in Dannelly became interested in researching the drink after a patients who are immune-compromised and some other untelevision reporter contacted her regarding an object found in derlying diseases, this could create a health concern for them.” a package of Capri Sun by a Terre Haute family. For the next stage of testing, Dannelly and Horn plan to test “A father had brought it to him and was very upset about what the theory that the fungal mats grow in compromised packages. was this large ugly thing in his child’s drink,” Dannelly said. “We’re just going to puncture these Capri Sun packages “So we took it from there and determined it was a fungal mat.” and see if there are spores already in there, which we think A further investigation found other online reports of other is already the case, and see if we can get those mats to grow,” fungal mats found in Capri Sun. Horn said. “I got really interested after Dannelly said their theory is seeing it to take this further and that a gas put into the packages As far as I can tell, the fact that they don’t put see how prevalent it was in the removes oxygen, which the fungi preservatives in this is really allowing lots of fungi to drink,” Dannelly said. need to grow. survive the drink process. Dannelly recruited senior biol“Maybe what happens is that ogy major Leah Horn from St Louis the package just gets breached to conduct the research. Horn has enough, not a big hole, a tiny spent the past year filtering Capri pinhole that’s enough to let air Sun through a vacuum and seeing if any fungal microbes reand oxygen in so that gives fungi room to grow, what they mained behind and grew on filter paper. She found five - three need to grow, then you get fungal mats,” Dannelly said. “Maybe from the tropical punch flavour, one from the Roaring Waters that’s why it’s only occasionally there’s the large growth of an flavour and one from the fruit punch flavour. organism.” “They are all five different species. We’re not 100% sure Such a project proved perfect for undergraduates to research, which ones they are,” Horn said. “We’re still testing.” according to Dannelly. “When you start with these projects that are more about Kraft operates a website answering questions concerning mould microbes, especially microbes in food or in water, they’re easy found due to breaches in packaging and a lack of preservatives to understand and very exciting because this is so close to in the drink. The company has assured worried consumers that home,” she said. the fungi are not harmful to humans. In the Frequently Asked Horn said the research has given her a better understanding Questions page about Capri Sun and the mould, the company of what happens in a lab. stated, “While unpleasant, it is more of a quality rather than a “I can take things people have said and apply them for safety issue. However, we take consumer concerns very seriously. When we had the opportunity to look at a sample in the past, myself,” she said. “It’s a really rewarding experience.” 58

May/June 2013

www.foodprocessing.com.au

Seafood, gut health and lasers: 46th annual AIFST Convention

PROCESSING

From sessions on seafood science and gut health to a laser fence that shoots down mosquitoes, the 46th annual Australian Institute of Food Science and Technology (AIFST) Convention will be full of cutting-edge and compelling topics. To be held in Brisbane from 14 to 16 July this year, session highlights include: • Seafood makes a splash: Microbiologist Graham Fletcher will provide insight into the seafood industry and share exciting innovations from around the world. Fletcher is an expert in seafood safety, packaging, optimisation of chilled fish, ultrahigh-pressure processing of seafood and horticultural products. • Gut health: The global probiotics products market was estimated at $24.23 billion in 2011, with more than 500 food and beverage products introduced in the last decade. Three international presenters will speak about the wonders of pre and probiotics and the latest advances in digestive health. • Neuroscience of leadership: Award-winning communications expert Amanda Gore uses the latest research in neuroscience, positive psychology, epigenetics and emotional intelligence to help business leaders achieve results and create flourishing workplaces. The conference will feature a host of domestic and international speakers who will deliver on topics such as: • Food science, history and culture • Digestive health - pre and probiotics • Technology matters - innovative technology • Meeting modern expectations of shelf life • Salt/sodium - mini workshops The conference will have something for everyone working in farming or food processing, food safety or quality control, training, retail or mining. Professionals and students, members and non-members, marketers and scientists will all find the conference a must-attend event. Several hands-on workshops will also run. Topics range from understanding the new Health Claims Standards to shelf-life validations and verification, and tips on how to influence your boss. For more information on the convention and to register to attend, visit www.aifst.asn.au/ convention.htm.

Safety padlocks, hasps and lockout cables for small-diameter lockout points Master Lock has launched a range of safety padlocks, hasps and lockout cables designed to fit smaller diameter lockout points. Designed for lockout/tagout, the S31 safety padlock has a durable non-conductive Zenex lock body and a 4.76 mm marinegrade 316 stainless steel shackle. Available in nine colours, the lightweight safety padlock is easy to carry and comes with a weather tough cover designed to keep out dust, dirt and grime. It also performs well in extreme conditions with a temperature rating range of -46 to +177°C and the ability to withstand harsh chemicals and corrosion. When work is being undertaken by more than one employee, it is vital that a lockout hasp is used. In response to industry needs, Master Lock has developed the S430 and S431 hasps to fit smaller lockout points. The S430 is a compact, lightweight lockout hasp that has a 4 mm diameter steel shackle to fit these applications. The S430 has a plastic body that closes like a book and accepts two lockout hasps. The S431 is suitable for highly corrosive environments as it is constructed from marine-grade 316 stainless steel. The S806 is a multipoint lockout solution from that measures 4 x 1.8 mm. To use, simply feed the cable through the points to be locked out, then back through the lockout body, cinch it tight and apply a safety padlock. Mayo Hardware Australia Contact info and more items like this at wf.net.au/T335

AIFST

Electromagnetic flow sensor Dwyer Instruments’ Series IEFS Insertion Electromagnetic Flow Sensor comes in brass or stainless steel, allowing it to handle a wide range of pressures and temperatures as well as a variety of available saddle fittings to fit pipe sizes from 3 to 24″. The IEFS-3X and IEFS-4X have isolation valves which allow hot-tap installation and optional stainless steel construction. Additional options for this flow meter include adapter fittings and a reverse flow output. The series IEFS is suitable for ‘dirty’ water applications or any application where moving parts may be an issue. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/T274

May/June 2013

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Vibration sensor monitor ifm efectorâ&#x20AC;&#x2122;s easy-to-use VNB001 vibration sensor monitors, displays and records vibration values. A display with colour change in traffic light colours shows machine conditions at a glance. The unit is the first member of a series of vibration sensors. The compact sensor monitors online the overall vibration condition of machines

PROCESSING

and plants according to ISO 10816 and has an onboard time-stamped history function as well as data logging and trending - all directly on the machine. The sensing principle is based on the efector octavis technology, which can also be used reliably in mobile applications. The sensor measures the effective vibration velocity in mm/s or in/s. Measured value and switching status are indicated on the LED display. Critical machine conditions can be signalled using two switching outputs or one switching output and one analog input. As an alternative, the sensor can be powered via USB interface and used as a handheld device. The product also offers rapid and easy handling and set-up as the parameters can be adjusted directly on the device. No additional configuration software is required.

Low-pressure homogenisation device Tetra Pak has developed a homogenising device for dairy products that reduces the required pressure during milk production. Using the device reduces energy consumption, which lowers operational costs and environmental impact. Known as the HD EnergyIQ, it is designed for high-capacity (15,000 to 52,300 L/h) Tetra Alex homogenisers, models 30, 350 and 400. The pressure reduction means less load on the homogeniser, so maintenance and the replacement intervals of worn parts is up to 40% longer, the company said, meaning production time is increased. The HD EnergyIQ can easily be retrofitted to older machines by using upgrading kits. Tetra Pak Marketing Pty Ltd Contact info and more items like this at wf.net.au/T914

ifm efector pty ltd Contact info and more items like this at wf.net.au/S511

Weâ&#x20AC;&#x2122;re getting social! We are providing more opportunities for you to stay up to date with all the latest industry information from the social networks of your choice. Follow us and join the conversation with thought leaders from your industry.

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May/June 2013

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Anti-fouling coatings make equipment easier to keep clean

PROCESSING

Contaminated industrial plants cost billions every year. Special coatings can prevent the build-up of contaminants. Researchers are now able to adapt ultrathin coatings for an extremely wide range of applications - even inside pipes in food processing equipment.

ll of us are faced with the same daily battle against dirt. Keeping industrial plants and equipment clean is a constant challenge where the devil is often in the detail. For example, in milk pasteurisation processes dissolved milk proteins tend to build up in pipes, boilers or heat exchangers of the equipment being used. After one working shift they are already soiled to such a degree that the entire plant has to be shut down for cleaning. This translates into huge costs for manufacturers. Such deposits, that are referred to by experts as ‘fouling’, can disrupt production processes. Studies suggest that this results in costs of between 5 and 7 billion euros per year in Germany alone. The Fraunhofer Institute for Surface Engineering and Thin Films IST has developed a range of technologies that prevent fouling within plants in the first place. Special coatings prevent proteins, salt crystals and calcium carbonate deposits from sticking to the surfaces of plants or system components. The difficulty in achieving this is that the types of deposits vary depending on the materials used to manufacture the plant and the liquids used. Scientists have now found a way to adapt the coatings for a wide variety of different industrial applications and loads. They achieved this by ‘custom tuning’ the structures and surface energy of the coating surfaces. One important variable in this formula is the surface energy of the coating. It determines to what extent deposits are able to cake on. “The range of properties relating to these layers range from high wear protection through to an extreme antifouling effect. With the help of special process technology, we are now able to create practically any desired property,” explains Dr Martin Keunecke, Head of Department for New Tribological Coatings at IST.

The coatings are made up of carbon and other elements and are just a few micrometres thick. That corresponds to approximately 50 times thinner than a human hair. Both extremely hard and durable, carbon layers are characterised by excellent anti-corrosion and anti-wear properties. Their surface energy, and thereby cohesive properties, can be further reduced by integrating nonmetallic elements such as fluorine and silicone. This leads to an additional antifouling effect. “Depending on the type and quantity of the elements used, we are able to control the properties of the coatings in a targeted way,” explains Dr Peter-Jochen Brand, Head of Department for the Tribology Transfer Center at IST. “This is necessary because industrial plants are subjected to a wide range of differing stresses resulting from liquid substances. Just consider milk processing or fruit juice manufacturing in the foods industry, paint production in the chemical sector, production of medications in the pharmaceuticals industry or the transportation of crude oil.” Industry currently uses carbon-based coatings primarily in order to reduce friction and wear. Although already in great demand, anti-fouling applications are still in their infancy. For this reason, Keunecke and Brand are anticipating fresh momentum from the market as a result of their innovation. “Now that we understand how to individually configure the layers, the next stage involves tackling the question of how to most efficiently produce the coated equipment. Anti-fouling already works extremely well for external surfaces; however, internal coating, for example for pipes, is anything but straightforward. For this reason, we are now collaborating with industry and research partners to create new manufacturing processes,” concludes Keunecke.

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May/June 2013

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Korean brewery sees the light As part of its environmentally conscious approach to brewing, Korea’s Hite Brewery Company recently installed 25 Hanovia UV water disinfection systems at its Massan and Gangwan plants. The UV systems ensure water used in the production processes remains free from microbial contamination, ensuring a highquality final product. Seven units are installed at Massan and 18 at Gangwan. In Massan, the UV is used to treat clean-in-place (CIP) water, cooling water injected after the CIP and activated carbon-filtered water. At the Gangwan plant, three UV units are used to treat water after deaeration and the remaining 15 units treat activated carbonfiltered water. CIP is used for cleaning the interior surfaces of pipework, vessels, filters and other process equipment. CIP water must be completely free from microbial contamination, otherwise it could infect the whole system. As CIP uses very hot water, pipework and vessels need to be cooled down afterwards and before beer production can recommence. Cooling water also helps flushes out the remaining CIP water, which contains acid and caustic soda. The purity of the cooling water is therefore extremely important to prevent any residual contamination. Activated carbon is commonly used in water treatment for decolouring and deodorisation, due to its strong adsorption properties. This adsorption can also remove residual chlorine from the water, leaving the post-filter water vulnerable to microbial contamination. UV therefore plays a vital role in ensuring the postfilter water is adequately disinfected. Deaeration removes dissolved oxygen from water prior to the addition of yeast, a key part of the brewing process. Any contamination of the deaeration water could kill the yeast, meaning the whole batch would have to be destroyed. UV is ideal for this step as it is quick acting and effective without producing any unwanted disinfection by-products which could affect the yeast.

May/June 2013

“When Hite was considering UV for the first time it looked at a number of UV system suppliers,” said Ying Xu, Hanovia’s Asia-Pacific Sales Manager. “Hanovia was selected as our UV systems not only produced the highest microbial reduction rates, but we also offer a comprehensive and cost-effective spare parts and maintenance service. Hite now uses over 45 Hanovia UV systems in its breweries across Korea, including the latest project at Massan and Gangwan.” “According to the company it also needs to do CIP less frequently, it uses less preservative in the finished product, and the final water has no unwanted residuals, so the taste and colour is not altered in any way. This all adds up to a cleaner, greener process and product,” she added. For manufacturers seeking to improve the quality of the end product, Hanovia says UV is an economic, realistic option. It is an established method of disinfecting drinking water throughout the world, and is also widely used for highpurity applications such as pharmaceutical processing and microchip manufacturing, where water of the highest quality is essential. There are no microorganisms known to be resistant to UV - this includes pathogenic bacteria such as Listeria, Legionella and Cryptosporidium (and its spores, which are resistant to chlorination). UV disinfection systems are also easy to install, Hanovia says, with minimum disruption to the plant. They need very little maintenance, the only requirement being replacement of the UV lamps every 9-12 months, depending on use. This is a simple operation that takes only a few minutes and can be carried out by general maintenance staff. Hanovia www.hanovia.com

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Package water and wastewater treatment solutions Package water and sewage treatment solutions for potable water treatment and water recycling applications. Cost effective, reliable and energy efficient treatment solutions covering the full water management cycle from transport of water to treatment and distribution. Your access to global water solutions expertise backed up with excellent local support from an extensive national branch network. Service and rental options are available.

Australia Tel: 13 19 14 www.xylemwatersolutions.com/au

New Zealand Tel: 0800 33 19 14 www.xylemwatersolutions.com/nz

Adelaide • Auckland • Brisbane • Christchurch • Darwin • Devonport • Kalgoorlie • Karratha • Mackay • Melbourne • Mt Isa • Newcastle • Orange • Perth • Sydney • Townsville May/June 2013 65 www.foodprocessing.com.au

Air nozzle range EXAIRâ&#x20AC;&#x2122;s Super Air Nozzles offer a highly efficient way to blowoff, cool, dry and clean. Many designs are available to suit a range of applications. In most cases, Super Air Nozzles pay for themselves in just a few weeks. Air savings compared to typical blowoffs can be as high as 80%. The

PROCESSING

noise level is a fraction that of ordinary air nozzles (typical noise reduction is 10 dBA). Applications include: part cleaning, chip removal, part drying after wash, liquid blowoff, part cooling, material conveying, part ejection, fibre conveying, air assist, bag opening/filling operations and scrap removal.

Economical & Scalable... Many Super Air Nozzle designs are available in zinc aluminium alloy construction, suitable for general-purpose Pilz has a wide variety of cost effective & flexible safety solutions for your packaging machinery. Looking for a reliable Partner for the automation of your packaging line? We offer you a comprehensive portfolio of solutions ranging from the

applications. EXAIR Super Air Nozzles are also available in Type 303 or Type 316 Stainless Steel construction, which is suitable for food and pharmaceutical applications where resistance to high temperatures and corrosion is required.

small with only a handful of sensors using our new PDP technology all

High-force models are available for applications where

the way though to the most complex of systems utilising our PSS4000

additional reach and extreme force are needed. Swivel

safe automation platform.

Fittings and Stay Set Hoses to aim the nozzles and an electronic control to minimise air usage are also available.

Talk to us today about your packaging safety requirements!

Super Air Nozzles help reduce compressed air cost and allow users to meet OSHA noise level and dead-end pressure requirements. They are CE compliant and provide an average noise reduction of 10 dBA. The compact nozzles can improve production, conserve compressed air, improve blowoff performance and improve safety.

safety@pilz.com.au

www.pilz.com.au

May/June 2013

03 9544 6300

Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/T851

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Workflow application software ArchestrA Workflow Software is an advanced workflow application that allows companies to digitise manual and automated processes that include people, equipment and/or systems. Based on a sophisticated business process management (BPM) foundation, ArchestrA Workflow enables companies to model, execute, analyse and improve processes inside and outside of their organisation to drive higher levels of collaboration, productivity and innovation. With ArchestrA Workflow, companies can institutionalise work

PROCESSING

processes that manage normal, unscheduled or disruptive events within their operations environment. The industrial-strength workflow application benefits operations, maintenance, engineering, quality, environmental and safety departments within an organisation by increasing productivity, providing ownership-driven innovation and enabling good management. For the food and beverage industry, the application helps standardise processes for the operators: clean-in-place or other regularly scheduled activities can be initiated, enforced and validated, with e-signature, escalations and audit trail capture. It helps optimise processes and provide better analytics: baseline processes can be measured and net improvements tracked by activity, line or shift. The application enables continuous process improvement practices by establishing workflows for corrective action, process improvements and centrelining. Using ArchestrA, recalls and quarantines can be effectively executed, with multiple-level signatory releases. Invensys Operations Management Contact info and more items like this at wf.net.au/T797

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May/June 2013

Networkable motor protection, control and energy monitoring system NHP has announced the release of AmpCom, a networkable motor protection, control and energy monitoring system. With a compact and modular design suited to constant combines motor-related parameters and metering (current,

Medical-grade brushless DC micromotor and gearhead

voltage and power) functions together with available I/O

maxon medical has added a 4 mm brushless DC micro-

to monitor, control and protect processes from safe and

motor and gearhead to its medical range.

PROCESSING

speed AC motor applications up to 2000 A, AmpCom

Generally, the power output of microdrives is too low for

convenient locations. The system is suitable for a range of industries and

the application, due to the physical dimensions. maxon

applications, including mining, mineral processing, oil and

medical was able to increase the performance of this

gas, energy/utilities and food and beverage.

tiny motor using up-to-date winding technology, powerful

The system helps users achieve plant optimisation

magnets and optimum use of the air gap. According to

and prevent breakdown situations, as well as accomplish

the company, the integration of Hall sensors is unique

sustainable production and maintain higher efficiency, ap-

for motors of this size. The 4 mm brushless DC motor is suitable for applica-

plicability and expandability. Installation flexibility to meet any MCC requirement also increases usability. The AmpCom range can be combined with Cubic MCC Multi-Draw solutions and other NHP switchgear such as

tions in the fields of micropumps, analytic and diagnostic devices, ophthalmic surgical devices, laboratory robots, endoscopes and anywhere size is an issue.

Terasaki circuit breakers and Sprecher + Schuh contac-

maxon motors are designed to satisfy medical industry

tors to achieve an MCC solution while maintaining safety.

demands. The maxon medical motor production is certi-

NHP Electrical Engineering Products Pty Ltd Contact info and more items like this at wf.net.au/T041

fied to ISO13485. maxon motor Australia Pty Ltd Contact info and more items like this at wf.net.au/T623

May/June 2013

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PROCESSING

Pre-rinse spray nozzles for commercial kitchens Spray Nozzle Engineering has available the Strahman Kwik Clean 3 and Vari-Spray Pre-Rinse Spray Nozzles for commercial kitchens. These two industrial-strength washdown spray nozzles form part of a line of pre-rinse products for commercial food service kitchens, restaurants, hotels, cafeterias and institutional markets. The Kwik Clean 3 tri-spray nozzle offers good performance with 15.6 s cleanability. In addition to its robust stainless steel body, each of its three tips uses less than 3.79 L/min and can save up to 640,000 L of water, according to the company. Each Kwik Clean 3 is US EPAct 2005 compliant and is claimed to provide 35% savings in hot water, sewer and energy. The Vari-Spray is a low-flow, pre-rinse spray nozzle with good flexibility and good cleaning performance. Vari-Spray is an industrial-strength nozzle previously with a pre-rinse handle that has been converted into a pre-rinse nozzle. It offers a wide choice of spray patterns - from a hollow cone to a powerful solid jet stream - instantly available at the squeeze of the trigger. Not only does it eliminate the need for a separate handle, the nozzles stands at a low-flow rate of 4.73 L/min at 413 kPa; this consumes 12% less water, sewage and energy than the industry standard. Both Vari-Spray and Kwik Clean 3 are constructed of all stainless steel operating parts. Spray Nozzle Engineering Contact info and more items like this at wf.net.au/T822

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May/June 2013

PROCESSING

14-month turnaround for dairy processing facility

Tasmanian Dairy Products (TDP) recently opened a new $80 million milk production facility in north-west Tasmania. The Smithton Dairy Product Processing Facility will process raw milk purchased from local farmers to produce high-quality dried milk products primarily for export to overseas markets in Asia and the Middle East. Engineering consultancy pitt&sherry met a rigorous design and development project timeline to accommodate the opening of the Smithton facility. The project’s timing was key to its success, as TDP had signed contracts for milk delivery 18 months from project inception.

“The tight deadline we were provided with to have the facility up and running is what sets the achievement apart,” said Andrew Buckley, Senior Project Engineer Food and Beverages at pitt&sherry. “A facility such as this can often take two to three years to complete, but from the moment the project was confirmed, it took just 14 months to have the facility operating and producing powder.” pitt&sherry was initially engaged by TDP to undertake concept design, engineering works, site selection and initial planning works on the project. The company’s involvement was broadened to installation project management, building and infrastructure design, site services and securing environmental and planning approvals. Completing the planning and environmental approvals process in a staged manner as construction took place proved a key challenge for pitt&sherry to meet the project’s tight deadline. Buckley said the project team determined a series of strategies to undertake the building schedule in order to effectively manage this. “We developed a number of innovative methods to start building while still maintaining the necessary environmental and planning approvals, and in the process keeping Circular Head Council up to date with our progress,” Buckley explained. “The achievement is an excellent example of pitt&sherry’s capabilities to carry out facilities such as this and on the strength of this work we are well positioned to pursue further opportunities in this area.” Pitt & Sherry Contact info and more items like this at wf.net.au/T443

MORE CHOiCEs. MORE sOlutiOns. SPX offers one of the widest selections of food and beverage equipment and systems in the market. Combined with over 100 years of design and application expertise, our innovative and flexible solutions are designed to maximize process efficiencies and food safety while minimizing waste and energy consumption. Now including Seital separators, we offer you even more choices and solutions. Contact us at (03) 9589 9222 or email ft.aus.cs@spx.com to find out how SPX can help improve your process today. EVAPORATORS • DRYERS • HOMOGENIZERS HEAT EXCHANGERS • MIXERS • VALVES • PROCESS SYSTEMS • PUMPS

SPX Flow Technology, Level 1, 300 Wellington Road, Mulgrave VIC 3170

May/June 2013

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PROCESSING

Why E. coli like it rough New research from Harvard University helps to explain how waterborne bacteria can colonise rough surfaces - even those that have been designed to resist water.

team of materials scientists and microbiologists studied the gut bacterium Escherichia coli, which has many flagella that stick out in all directions. The researchers found that these tails can act as biological grappling hooks, reaching far into nanoscale crevices and latching the bacteria in place. The scourge of the health care industry, bacteria like E. coli are adept at clinging to the materials used in medical implants like pacemakers, prosthetics, stents and catheters, spreading slimy biofilm and causing dangerous infections. The findings, published in the Proceedings of the National Academy of Sciences (PNAS), suggest that antibacterial materials should incorporate both structural and chemical deterrents to bacterial attachment. E. coli are equipped with two types of appendages: pili, which are short, sticky hairs, and the whip-like flagella, which are often twice as long as the bacterium itself. Pili had previously been recognised as playing a critical role in the formation of biofilms. These short hairs, up to only a micron in length in E. coli, can stick to surfaces temporarily, while the bacteria secrete a thick slime that holds them permanently in place. Flagella, on the other hand, typically play a propulsive role, helping bacteria to swim and steer in liquid environ-

ments. As it turns out, though, when it’s time to settle in one place, flagella also contribute to adhesion on rough surfaces, where the pili would have access to fewer attachment points. Nanoscale crevices, such as those deliberately built into superhydrophobic materials, often trap air bubbles at the surface, which initially prevent E. coli from attaching at all. The new research shows that the bacteria can gradually force these bubbles to disperse by, essentially, flailing their arms. Once the cracks and crevices are wet, although the cell bodies can’t fit into the gaps, the flagella can reach deep into these areas and attach to a vast amount of new surface area. “The diversity of strategies and methods by which bacteria can adhere reflects their need to survive in a huge variety of environments,” says lead author Ronn S Friedlander, a doctoral student in the Harvard-MIT Division of Health Sciences and Technology. “Of course, if we could prevent biofilms from forming where we didn’t want them to, there would be immense benefits in medicine.” Friedlander studies in the lab of Harvard professor Joanna Aizenberg, who holds a joint appointment as Amy Smith Berylson Professor of Materials Science at the Harvard School of Engineering and Applied Sciences and as Professor of

www.foodprocessing.com.au

May/June 2013

PROCESSING

Chemistry and Chemical Biology (CCB). Aizenberg’s labora- area that was immediately accessible to bacteria via their tory group has been working to develop extremely slippery pili, but also engineered in terms of its surface chemistry surfaces that repel water, dirt, oil and bacteria. to reduce the ability of the flagella to make bonds within The surface chemistry of antibacterial materials appears those crevices,” says Aizenberg. “Surface structuring alone to be just as important as the topography. E. coli flagella will not achieve this goal.” have previously been known to In 2012, Aizenberg’s group adhere to certain proteins on the demonstrated a material they surface of cells in the gut wall, call SLIPS (for slippery, liquidRather than having to find a perfect molecular match, indicating that the bacteria are infused porous surfaces). It the flagella of E. coli appear to cling to surfaces using capable of bonding with specific was patterned with nanoscale molecular matches. But in the pores, which were filled with a combination of many weak bonds. 1970s, biologists observing E. a fluorinated lubricant that was coli on microscope slides had shown to prevent biofilms from also seen something curious: attaching. bacteria wheeling about under the coverslip, as if tethered The findings from this line of research are relevant beyond to the glass by a single flagellum. This ability to stick to the field of medicine, as biofilms also pose problems for the any surface at all - termed nonspecific adhesion - is part food industry, water treatment, ship maintenance and other of what makes it easy for bacteria to survive on the surface industries where slime can clog pipes and filters, corrode of medical implants. metal or cause contamination. But this latest work also Rather than having to find a perfect molecular match, helps to explain, on a basic level, how bacteria succeed at the flagella of E. coli appear to cling to surfaces using a colonising such a wide variety of environments, including combination of many weak bonds. the human gut. Having many flagella, the authors note in “The ideal antibacterial material would be topographically their paper, “may be particularly important in an intestinal patterned with tiny crevices to limit the amount of surface environment coated with microvilli”.

Digital temperature indicator series

Grant assistance pays off for Mars

Noshok has added the 820/821 Series Digital Temperature Indicators to its tempera-

mounting configurations are possible.

Mars Food Australia has won a $190,866 grant with help from Energy Action’s Activ8+ team. The company was seeking funding to assist with an energy-efficient lighting upgrade costing more than $570,000. The Activ8+ team assisted Mars with its application for funding under the Clean Technology Food and Foundries Investment Program. In February, Minister for Industry and Innovation Greg Combet announced approval of the application. The grant will cover a third of the project cost. Mars will install energy-efficient light fittings and controls to its facilities using the grant money. The project is expected to reduce the carbon emissions intensity of Mars’ lighting system and result in savings of $77,000 in energy costs per year. The Clean Technology Food and Foundries Investment Program provides support to food manufacturers looking to invest in energyefficient capital equipment and low-emission technologies, processes and products.

AMS Instrumentation & Calibration Pty Ltd

Energy Action

Contact info and more items like this at wf.net.au/T267

Contact info and more items like this at wf.net.au/T915

ture measurement solutions offering. The temperature indicators are a suitable replacement for bimetal, liquid bulb and glass thermometers in applications such as pharmaceutical, food preparation, utilities and municipal, refineries, chemical and petrochemical plants, paper mills and hydraulics. The indicators have a large 4-digit LED display and a 4-20 mA programmable linearised output signal. They are field re-programmable and are available with an optional PC interface module and software. A security feature that prevents accidental reprogramming is included in the software. An optional fully programmable switch output, relay or transistor is available. A self-calibration feature gives accurate and stable performance, and a PT100 Ω RTD Class A element is used for temperature sensing. The indicators have an M12 x 1 (5-pin) plug or a 36″ integral cable electrical connection. The 316 stainless steel-constructed indicators offer IP65/NEMA 4-rated environmental protection. The instruments are easy to install and various

May/June 2013

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Stainless steel screw jacks Pfaff-silberblau has released its stainless steel SSP and SHE screw jacks for extreme environment corrosive applications, including the papermaking process industry, food-grade production and offshore applications. Lifting capacities for the SSP with integrally cast swivel brackets range from 15 to 25 T. All components that can come into contact with corrosive materials have been made from corrosion-resistant materials. The jacks are designed for easy cleaning, from the shape of the stainless steel housing, through each component that comes into contact with harsh corrosives. The lift screw, bearing housing caps and clevis are also made in stainless steel; the worm wheel and guide rings are made from special bronze, with all fasteners in corrosion-resistant materials.

PROCESSING

SSP jacks have the mounting face built into the casting with externally threaded mounting screws. There are no bearing covers, and the design dispenses with tapered roller input bearings and replaces these with angular contact ball bearings. SSP stainless jacks are self locking, with their whirled screw shafts available in any length required. The clevis or head can be standard or made to customer requirements, again in stainless steel. Two ratios are available (N and L), and the jack can be configured as a travelling screw or a travelling special nut to customer dimensions. For applications not requiring a pivoting mount, the company offers the traditional SHE series in full stainless steel construction. Three different housings give a range of 3 to 15 T, with the N and L ratios complementing the range. The jacks are delivered standard with mineral-grease-based lubricants, but can also be delivered with food-grade grease or other lubricants without need for any modifications. Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/T109 E X M 0 0 6 1 _ 1 3 5 x 1 8 0 WN F T

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

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May/June 2013

Stainless steel pump series Tsurumi cast 316 stainless steel SFQ series pumps, supplied by Australian Pump Industries, are specifically designed for corrosive water applications. They are suitable for use in industrial and marine applications. The SFQ series is claimed to be unique in that even the stator housings are cast and machined 316 stainless steel. Casings, impellers and suction covers are also cast 316 stainless steel. The grade of stainless steel used has a higher content of carbon for strength. It also has a high proportion of nickel and molybdenum for improved corrosion resistance. No welds are required, which means no pitting and reduced oxidisation. This material is also capable of withstanding abrasive liquids.

PROCESSING

The range includes 2 and 3″ ports with heads to 44 m and flows to 2000 lpm. They feature a high-capacity, semi-open style impeller that will perform in tough conditions. According to the company, inclusions such as an anti-wicking cable gland enhance the life expectancy of the pump and cut maintenance costs. The cable gland prevents water from wicking down inside the cable. The motor is protected even if the cable is damaged or the end accidentally immersed. Tsurumi pumps have a double silicon carbide mechanical seal. Both seal surfaces are submerged in an oil chamber, well away from the pumped liquid. A patented oil lifter ensures the mechanical seal faces are always lubricated and cooled, even if the pump is installed horizontally. Australian Pump Industries Pty Ltd Contact info and more items like this at wf.net.au/T772

32-bit safety controller wmb-602 quarter page artwork_Layout 1 10/01/2013 13:20 Page 1

For safety-related applications in mobile machines, ifm efector offers the R360, a powerful 32-bit safety controller. The device is suitable for complex and demanding control functions. With a graded error handling feature, the unit has various response thresholds. The fast 32-bit safety controller has a safety switch off component to bring a plant into the safe state. Additionally, areas of a plant that are not hazardous can still be used.

Join the no-valve metering revolution • No valves, no ancillaries, no vapour lock

The function of the inputs and outputs can be adapted to the respective application easily and precisely using the CODESYS programming software. 2 CAN safety interfaces are possible.

• Accurate, linear and repeatable flows

According to the company, the R360 safety controller is a

• Up to 5000:1 flow control to 500ml/min at 7 bar • ReNu pumphead technology: fully sealed for safe, tool-free maintenance

new development in a tried-and-tested housing. Even under extreme operating conditions it gives guaranteed monitoring and protection function. This unit has been developed according

qdospumps.com.au Tel: 1300 WMBPUMPS

May/June 2013

to current standards and certified by TÜV. ifm efector pty ltd Contact info and more items like this at wf.net.au/T920

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Internal compressor controller The Sigma Control 2 (SC2) from Kaeser is a PC integrated into a compressor. All current Kaeser rotary screw compressors and mobile air compressors are equipped with the product. The controller is equipped with its own web server, which allows direct communication with the compressor via intranet/internet. Within the scope of the company’s teleservice facility, for example, password-protected compressor settings and operational data can be called up and adjusted on any PC with an internet browser without the need for additional software. Compressor operation and maintenance are therefore made even easier, as is regular monitoring of cost and energy efficiency.

PROCESSING

The operating panel is dominated by an LED backlit, 256 x 128 pixel LCD screen on which plain text messages can be easily read. Nine LED indicators signal additional operational parameters and conditions, and 13 membrane keys labelled with easy-tounderstand icons ensure unmistakable input of the various commands. The operating panel communicates directly with the product’s main control system. It comes with four interfaces for active and passive communication: with compressor (IO-Bus for up to six I/O modules); with Sigma Frequency Control speed controllers; with the internet and/or computer networks; with the user’s various control systems via plug-in communication modules. Documentation of all operating conditions and parameters is essential to ensure optimum compressor performance. This task is facilitated by the product’s memory feature, data from which can be easily and quickly uploaded to a computer thanks to the addition of an SD card slot. The same slot makes it possible to transfer and install software updates onto the unit using a pre-loaded SD card. Updates can be carried out quickly and all operational settings are retained. The product provides high-level security with its integrated RFID functionality. Not only does the technology ensure secure log-in, it also safeguards the system against unauthorised changes or operation. Kaeser Compressors Australia Contact info and more items like this at wf.net.au/S632

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May/June 2013

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

List (B) Industry 1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery 12 Food Industry - Beverages 13 Food Industry - Confectionery 14 Food Industry - Dairy 15 Food Industry - Fruit & Vegetables 16 Food Industry - Meat 17 Government - Federal 18 Government - State 19 Government - Local 20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking 23 IT - Security 24 IT - Storage 25 IT - Wireless 26 Laboratory - Analytical 27 Laboratory - Clinical/Medical 28 Laboratory - Life Sciences 29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining 32 Oil/Gas/Coal 33 Packaging 34 Processing 35 Retail/Wholesale/Hire 36 Service/Maintenance 37 Telecommunication 38 Testing/Certification (eg NATA) 39 Utilities

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Respirator kit for food manufacturing workers 3M has released six respirator starter kits that are designed to provide respiratory protection to food manufacturing workers in a convenient and easy way.

PROCESSING

The Dust/Particle Kit 6225, P2 provides protection against multiple hazards and, in particular, protects against fine food powders found in many food manufacturing environments. This kit includes the economical, low-maintenance 3M Half Face 6000 Series Respirator that is simple and lightweight. One pair of 3M Particulate Filters 2125 that provide P2 protection are also part of the kit. In addition to respirator and filters, all kits include a pair of 3M Filters, 3M Earplugs, 3M Respirator Cleaning Wipes and a 3M Respiratory Protection Guide. To avoid moisture and contaminant exposure, the respirator and kit accessories are stored in a handy, sealable storage container. 3M Personal Safety Contact info and more items like this at wf.net.au/T839

Processing software Only Wonderware MES software provides dependable consistent quality without sacrificing flexibility. Find out why the leading food and beverage processors and CPG manufacturers choose Wonderware MES solutions. Invensys Operations Management Contact info and more items like this at wf.net.au/T528

www.foodprocessing.com.au

May/June 2013

Stem cells for taste identified Scientists at the Monell Center have identified the location and certain

PROCESSING

will facilitate techniques to grow and manipulate new functional taste cells for both clinical and research purposes.

genetic characteristics of taste stem cells on the tongue. The findings A.B.N. 22 152 305 336 www.westwick-farrow.com.au Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 Ph: +61 2 9487 2700 Fax: +61 2 9489 1265 Chief Editor: Janette Woodhouse wnift@westwick-farrrow.com.au Publisher: Geoff Hird Art Director/Production Manager: Julie Wright Art/Production: Tanya Scarselletti, Jeanette Teuma, Colleen Sam Packaging Section Editor: Alice Richard Assistant Editor: Alice Richard Circulation Manager: Sue Lavery circulation@westwick-farrow.com.au Copy Control: Mitchie Mullins copy@westwick-farrow.com.au

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aste cells are located in clusters called tastebuds, which in turn are found in papillae, the raised bumps visible on the tongue’s surface. Two types of taste cells contain chemical receptors that initiate perception of sweet, bitter, umami, salty and sour taste qualities. A third type appears to serve as a supporting cell. A remarkable characteristic of these sensory cells is that they regularly regenerate. All three taste cell types undergo frequent turnover, with an average life span of 10-16 days. As such, new taste cells must constantly be regenerated to replace cells that have died. For decades, taste scientists have attempted to identify the stem or progenitor cells that spawn the different taste receptor cells. The elusive challenge also sought to establish whether one or several progenitors are involved and where they are located, whether in or near the tastebud. Drawing on the strong physiological relationship between oral taste cells and endocrine (hormone-producing) cells in the intestine, the Monell team used a marker for intestinal stem cells to probe for stem cells in taste tissue on the tongue. Stains for the stem cell marker, known as Lgr5 (leucine-rich repeat-containing Gprotein-coupled receptor 5), showed two patterns of expression in taste tissue. The first was a strong signal underlying taste papillae at the back of the tongue and the second was a weaker signal immediately underneath tastebuds in those papillae. The Monell scientists hypothesise that the two levels of expression could indicate two different populations of cells. The cells that more strongly express Lgr5 could be true taste stem cells, whereas those with weaker expression could represent those stem cells that have begun the transformation into functional taste cells. Additional studies revealed that the Lgr5-expressing cells were capable of becoming any one of the three major taste cell types. The findings are published online in the journal Stem Cells. “This is just the tip of the iceberg,” said senior author Peihua Jiang, PhD, also a Monell molecular neurobiologist. “Identification of these cells opens up a whole new area for studying taste cell renewal and contributes to stem cell biology in general.” Future studies will focus on identifying the factors that program the Lgr5-expressing cells to differentiate into the different taste cell types and explore how to grow these cells in culture, thus providing a renewable source of taste receptor cells for research and perhaps even clinical use. 78

May/June 2013

www.foodprocessing.com.au

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March 2013 total CAB audited circulation (Aust + NZ): 6501 readers (81% personally requested) Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP100007395 ISSN No. 1039-8414 NOTICE: All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.

Compare these Blowoffs

Facts about Blowers

There are a variety of ways to blow the water from the bottles shown in the photo below, but which method is best? To decide, we ran a comparison test on the same application using four different blowoff methods: drilled pipe, flat air nozzles, Super Air Knife™ (each using compressed air as a power source), and a blower supplied air knife (using an electric motor as a power source). Each system consisted of two twelve inch long air knives. The following comparison proves that the EXAIR Super Air Knife is the best choice for your blowoff, cooling or drying application.

Energy conscious plants might think a blower to be a better choice due to its slightly lower electrical consumption compared to a compressor. In reality, a blower is an expensive capital expenditure that requires frequent downtime and costly maintenance of filters, belts and bearings.

The goal for each of the blowoff choices was to use the least amount of air possible to get the job done (lowest energy and noise level). The compressed air pressure required was 60 PSIG which provided adequate velocity to blow the water off. The blower used had a ten horsepower motor and was a centrifugal type blower at 18,000 RPM. The table at the bottom of the page summarizes the overall performance. Since your actual part may have an odd configuration, holes or sharp edges, we took sound level measurements in free air (no impinging surface).

Drilled Pipe

Blower Air Knife

This common blowoff is very inexpensive and easy to make. For this test, we used (2) drilled pipes, each with (25) 1/16" diameter holes on 1/2" centers. As shown in the test results below, the drilled pipe performed poorly. The initial cost of the drilled pipe is overshadowed by its high energy use. The holes are easily blocked and the noise level is excessive - both of which violate OSHA requirements. Velocity across the entire length was very inconsistent with spikes of air and numerous dead spots.

The blower proved to be an expensive, noisy option. As noted below, the purchase price is high. Operating cost was considerably lower than the drilled pipe and flat air nozzle, but was comparable to EXAIR’s Super Air Knife. The large blower with its two 3" (8cm) diameter hoses requires significant mounting space compared to the others. Noise level was high at 90 dBA. There was no option for cycling it on and off to conserve energy like the other blowoffs. Costly bearing and filter maintenance along with downtime were also negative factors.

Flat Air Nozzles

EXAIR Super Air Knife

As shown below, this inexpensive air nozzle was the worst performer. It is available in plastic, aluminum and stainless steel from several manufacturers. The flat air nozzle provides some entrainment, but suffers from many of the same problems as the drilled pipe. Operating cost and noise level are both high. Some manufacturers offer flat air nozzles where the holes can be blocked an OSHA violation. Velocity was inconsistent with spikes of air.

The Super Air Knife did an exceptional job of removing the moisture on one pass due to the uniformity of the laminar airflow. The sound level was extremely low. For this application, energy use was slightly higher than the blower but can be less than the blower if cycling on and off is possible. Safe operation is not an issue since the Super Air Knife can not be dead-ended. Maintenance costs are low since there are no moving parts to wear out.

Here are some important facts: Filters must be replaced every one to three months. Belts must be replaced every three to six months. Typical bearing replacement is at least once a year at a cost near $1000.

• Blower bearings wear out quickly due to the high speeds (17-20,000 RPM) required to generate effective airflows. • Poorly designed seals that allow dirt and moisture infiltration and environments above 125°F decrease the one year bearing life. • Many bearings can not be replaced in the field, resulting in downtime to send the assembly back to the manufacturer. Blowers take up a lot of space and often produce sound levels that exceed OSHA noise level exposure requirements. Air volume and velocity are often difficult to control since mechanical adjustments are required. To discuss an application, contact:

Compressed Air Australia Pty Ltd GPO Box 2792 Darwin NT 0801 Phone: 1300 787 688 Fax: 1300 787 637 email: info@caasafety.com.au www.caasafety.com.au

The Super Air Knife is the low cost way to blowoff, dry, clean and cool.

Blowoff Comparison

$952 *Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

$2,669

Now save time, money and space with BULK-OUT® multi-function dischargers Condition, de-lump, screen, feed, weigh batch, combine with liquids, and convey as you discharge, with a custom-integrated, performance-guaranteed discharger system from Flexicon Dual Bulk Bag Weigh Batch Eductor conditions, discharges by weight, and blends into a liquid stream

Bulk-Bag-To-Bin Weigh Batching System discharges, de-lumps and feeds material gravimetrically

Continuous Loss-of-Weight Bulk Bag Unloader allows continuous gravimetric discharging

Bulk Bag Unloader for Pneumatic Conveyors has surge hopper with rotary airlock feeder for metering

Sanitary Bulk Bag Discharger with patented USDA-accepted flow control valve cleans rapidly

Bulk Bag Unloader for Pneumatic Conveyors has surge hopper with non-flowthrough pick-up adapter

Bulk Bag ConditionerUnloader loosens solidified material, then discharges, de-lumps and conveys

Half Frame Unloaders with Conveyor or Airlock require forklift, eliminating cost of upper frame

Combination Bulk Bag Discharger and Manual Dumping Station has multipurpose hopper interface

Split-Frame allows loading of bag frame or rigid bins onto subframe within 100 mm of ceiling

Unlimited configurations: All Flexicon dischargers are available as fully enclosed, dust-free systems with durable industrial finishes or in stainless steel finished to food, dairy, pharmaceutical or industrial standards, and as weigh batching systems complete with automated controls and pneumatic or mechanical conveying systems.

Flexicon innovations: • SPOUT-LOCK™ clamp ring*: forms high-integrity seal between clean sides of bag and equipment • TELE-TUBE™ telescoping tube: maintains constant downward tension on spout as bag empties/elongates, promoting complete discharge • POWER-CINCHER™ flow control valve*: allows retying of partially empty bags dust-free by cinching spout concentrically.

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

AUSTRALIA sales@flexicon.com.au 1300 FLEXICON

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