What's New in Food Technology May/June 2012

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food for thought

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meat, poultry, seafood

processing 13 With a pinch of salt

47 Revamping Hazeldene’s chicken plant

20 A breath of clean, fresh air for industry 26 Winery Engineering Association’s national conference and exhibition 32 Communicating food safety crises

©iStockphoto.com/ Grant Shimmin

©iStockphoto.com/ José Luis Gutiérrez

36 Food fraud

55 73 86 bulk handling, storage & logistics 70 Green energy from wastewater

packaging

76 Accurate and efficient barcode inspection

testing and quality assurance 90 Gutter oil

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Not innocent until proven guilty As a food manufacturer, it is entirely reasonable that you can be sued for damages if your product causes food poisoning. In a recent case, damages of around eight million dollars were awarded against KFC after the court found in favour of a young girl affected by Salmonellosis-induced Encephalopathy. Now, there is absolutely no doubt that Monika Samaan, her parents and brother all suffered food poisoning caused by Salmonella Typhumurium 135a. Nor that, in Monika’s case, this developed into Salmonellosis-induced Encephalopathy, which has left her profoundly disabled, for life. But was KFC really the source of the bacterium? I have been reading the judgement in the case: Samaan bht Samaan v Kentucky Fried Chicken Pty Ltd (www.caselaw.nsw.gov.au/action/pjudg?jgmtid=158093). [KFC is appealing the judgement and I have not spoken to any of the parties involved.] When you read the KFC case, it is brought home to you that, in civil actions such as this one, there is no “innocent until proven guilty”. In civil proceedings “the court must find the case of a party proved if it is satisfied that the case has been proved on the balance of probabilities.” [Section140 of the Evidence Act 1995]. Damages were awarded against KFC because the plaintiff satisfied the court “that KFC was more probably than not” the source of the bacteria that affected Monika. I would like to see Monika receive every assistance possible, but I feel uncomfortable that a food company has to bear the cost in both monetary terms and damage to its reputation, based on a judge’s decision about “probable” cause. I remember once speaking with a man who was involved in a suspected food poisoning case. He said that he got his first intimation that there was problem after 5 pm on a Friday evening. His immediate response was to implement a recall as he was desperate to ensure that no one else was affected. He assumed that, in spite of all his care, HACCP program etc, that the information he was acting on was correct and that his product was to blame. In the longer term, the recall, publicity and lost sales nearly broke his company, yet it was never clearly established that his product was faulty. He was never actually charged with anything and he could not even find out what happened to the one person who had been affected. He went on to say that if this type of event ever happened to him again his first call would be to a lawyer. Even though this disappoints me, I can understand it. Read the judgement above and make sure all your insurance is up-to-date. Regards Janette Woodhouse Chief Editor What’s New in Food Technology & Manufacturing www.foodprocessing.com.au

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McCormick Flavour Forecast 2012 predicts future culinary trends

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image©iStockphoto.com

How does eggplant with harissa and honey sound for dinner? Or blueberry with cardamom and corn masa? Perhaps grapefruit with red pepper is more to your liking. McCormick’s Flavour Forecast 2012 has certainly predicted some interesting emerging culinary trends for the coming years. Although some of the flavour combinations might seem unusual,

thought

McCormick said that “flavours showcased in past reports have moved once-edgy ingredients into mainstream popularity”. Alan Wilson, Chairman, President and CEO of McCormick, said, “As an extension of our leadership in the flavour market, we are uniquely posed not only to forecast emerging flavours and trends, but to really impact the future of flavour with this report.” In previous years, multiple forecasts have been released, each specific to a particular region. In 2012, McCormick claims this forecast - its first global edition - “reveals a singular set of forces driving what we will eat across the globe in coming years”. The forecast is available in multiple languages. The forecast identified six key emerging trends: Honouring Roots, Quest for the

Ultimate, Veggies in Vogue, Simplicity Shines, Flavourful Swaps and No Boundaries. The report offers recipes for the forecasted flavour trends, such as cucumber-herb gazpacho with watermelon croutons, braised cod with gingered carrot-coconut sauce and spiced duck arepas with blueberry port sauce. “If there’s one thing the food lovers of the world have in common, it’s that we approach eating with greater curiosity than ever before and really celebrate the enjoyment of it,” said Simone Fergie, Culinary Development Chef at McCormick Foods Australia. “We have a very strong food culture in Australia and our culinary trends are certainly tracking in the same direction as other parts of the world.”

Tate & Lyle launches dedicated website for beverage manufacturers Tate & Lyle has launched a dedicated website for beverage manufacturers - www.yourdrinksolutions.com. The website is intended to be a “one-stop shop for innovation” for beverage manufacturers, the company said. It will feature case studies, consumer insights, examples of prototypes, ideas and ingredients. “Beverage manufacturers around the world can dip into a world of solutions, ideas and ingredients for their products all developed with consumer trends and manufacturing costs in mind,” the company said in a press release.

Shopping experience more important than price in fruit and vegetable intake A study by researchers at RTI International and George Washington University has shown that food shopping experience, rather than cost of produce, may impact how many serves of fruit and vegetables people eat. The study examined the connection between the food shopping experience and the consumption of fruit and vegetables in an inner-city, low-income population. The shopping experience was rated on three characteristics: quality, selection and convenience. Researchers found that participants in the study were more likely to eat three or more servings of fruit and vegetables each day if they shopped in stores, co-ops or farmers markets that they considered convenient and offering high levels of quality and selection. Surprisingly, the cost of produce was not found to be a factor in how many servings of fruit and vegetables the participants ate. Those who

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considered cost as a barrier to purchasing fruit and vegetables actually ate the same amount of produce as those who did not. “We found that low-income shoppers do not simply make dietary choices based on cost and availability,” said Dr Jonathan L Blitstein, lead author of the study. “Shoppers also consider less tangible aspects of the food shopping environment that relate to quality and satisfaction. “This study contributes to the growing literature on effective ways to work in neighbourhood settings to promote a more healthful diet among people with lower incomes,” Blitstein said. “Working with local retailers to improve shopping convenience and provide a good selection of quality food items may influence consumers’ overall fruit and vegetable intake, independent of price and availability.” The study was published in the February issue of Public Health Nutrition.

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GM maize has no adverse effects on human health, says EFSA The European Food Safety Authority (EFSA) has released a report stating that genetically modified maize has no adverse effects on human and animal health or the environment. In the Post-Market Environmental Monitoring (PMEM) report for the 2010 cultivation season of genetically modified maize MON810, the EFSA’s Panel on Genetically Modified Organisms (GMO Panel) concluded that the GM maize did not have a negative impact on health or the environment, and that the outcomes of the report corroborate the findings on MON810 cultivation for the 2009 season.

Wilmar acquires 10% share in Goodman Fielder Wilmar International has acquired a 10.1% share in Goodman Fielder at a cost of about $115 million. The acquisition makes Wilmar the largest shareholder in Goodman Fielder. Goodman Fielder shares rose to 69 cents, an increase of 34%, following the purchase, The Sydney Morning Herald reported. Wilmar said in a news release that it is currently assessing whether to further increase its shareholding in Goodman Fielder. The move comes only weeks after Goodman Fielder announced that it suffered a 77% profit drop in 2011. CEO Chris Delaney called the company’s profits “unacceptable”. Agribusiness group Wilmar owns a range of businesses including a consumer pack business that sells branded products throughout Asia and also Sucrogen’s branded sugar business in Australia.

Salt-tolerant durum wheat developed by CSIRO The CSIRO has developed a salt-tolerant variety of durum wheat that gives a 25% higher grain yield than other varieties on salty soils. Using non-GM breeding techniques, CSIRO scientists introduced a salt-tolerance gene from modern-day wheat’s ancestral cousin, Triticum monococcum, into a commercial durum wheat. Researchers from the University of Adelaide conducted research to understand how the gene delivers salinity tolerance to the plants. The results were published in the journal Nature Biotechnology. “The salt-tolerant gene (known as TmHKT1;5-A) works by excluding sodium from the leaves,” said Dr Matthew Gilliham, senior author of the paper. “It produces a protein that removes the sodium from the cells lining the xylem, which are the ‘pipes’ plants use to move water from their roots to their leaves.” “This work is significant as salinity already affects more than 20% of the world’s agricultural soils and is an increasing threat to food production due to climate change,” said Dr Rana Munns, CSIRO scientist and lead author of the paper. “Salinity is a particular issue in the prime wheatgrowing areas of Australia, the world’s second-largest

wheat exporter after the United States,” said Dr Gilliham. “With global population estimated to reach nine billion by 2050, and the demand for food expected to rise by 100% in this time, salt-tolerant crops will be an important tool to ensure future food security.” Importantly, the wheat performs as well as other durum wheat under standard conditions. “This is very important for farmers, because it means they would only need to plant one type of seed in a paddock that may have some salty sections,” said Dr Richard James, who led the field trials. “The salt-tolerant wheat will now be used by the Australian Durum Wheat Improvement Program (ADWIP) to assess its impact by incorporating this into recently developed varieties as a breeding line.” New varieties of the salt-tolerant wheat could be a commercial reality in the near future, said Dr Munns. www.foodprocessing.com.au

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©iStockphoto.com/Factoria Singular

Swiss engineers develop costeffective microsilver formula

thought

Swiss engineers have developed a new formula for microsilver that could benefit the healthcare and food industries. Antibiotics and chemicals are generally used to combat mites, fungi, viruses and bacteria, and especially E. coli in the food industry, but with the rise of antibioticresistant strains, demand for antibioticand chemical-free solutions has increased. Together with the Max Planck Institute and the Fraunhofer-Gesellschaft, Sterilos engineers have developed Sterilos PLC. The company claims the formula requires only one-hundredth of the quantity of

microsilver to obtain the same antibacterial effects that have previously been achieved with microsilver. According to Sterilos, the microsilver is in demand for coating oil and gas pipelines and tanks to destroy ironeating bacteria and stop microbial erosion. Sterilos said the coatings are effective in drinking water facilities, pipes and water treatment plants. Other applications include antimicrobial transportation of food, wall paints and varnish for the food industry, hospitals, schools and restaurants. QualityLabs in Germany has confirmed and certified the product.

Heat and Control adds Spray Dynamics to its portfolio Heat and Control has added Spray Dynamics to its portfolio. The Spray Dynamics range of coating and seasoning applicators applies oils, seasonings, vitamins, tack and release agents, chocolate, yoghurt and candy coatings, antioxidants, polishing wax and anticlumping agents. US-based Spray Dynamics was founded in 1952 and began making equipment for the snack food industry in 1970. It has partnered with Heat and Control on a number of projects over the years. Heat and Control now offers the Spray Dynamics range of coating and seasoning applicators to Australian and New Zealand food manufacturers. Food applications include snack flavouring; pet food flavouring and coating; breakfast cereal coating; coffee flavouring; meat, poultry and seafood flavouring and coating; and chocolate enrobing and coating.

$7m dairy research centre opens at Gatton A $7 million dairy research centre focusing on subtropical dairy production has opened at the University of Queensland’s Gatton campus. A collaboration between UQ and the Queensland Department of Employment, Economic Development and Innovation, the centre combines UQ’s Gatton Research Dairy with DEEDI’s dairy research facilities in an updated, more energy-efficient centre. The focus of the centre will be research, development, extension and education in subtropical dairy production, making it particularly relevant for farmers not only in the Gatton region - where around 60% of the state’s dairy farms are located - but also in northern New South Wales. “It is the only facility of its kind in Australia focused on a subtropical feed base and it will provide research, development and education for

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the national and international dairy industries,” UQ Pro-Vice-Chancellor Alan Rix said in a media release from UQ. “The Gatton Research Dairy will be able to provide expertise in the areas of nutrition, forage production, business management, reproductive management, animal health and welfare, animal physiology and biochemistry,” Professor Rix said. The Managing Director of Agri-Science Queensland, John Chapman, said, “We plan to undertake research and development into a number of areas, including enhanced and sustainable subtropical and tropical feeding systems, adaptation to climate change and dairy business development, and education and training programs. “The goal is to develop on-farm strategies designed to improve the productivity and profitability of the dairy industry in Queensland.”

www.foodprocessing.com.au



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©iStockphoto.com/ TheCrimsonMonkey

PROCESSING

With a pinch of salt Reducing salt in processed foods

Alice Richard

The unholy trinity of bad-for-you food ingredients has traditionally consisted of MSG, trans fats and sugar. Recently, however, a fourth nutrition sin has been added to the mix: salt. Health and consumer groups have been pressuring food processors to reduce the amount of salt in processed food products, but changing salt content could affect more than just consumers’ blood pressure.

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ur bodies need it to function, but many health groups say we’re getting far too much salt in our diets, leading to a host of health problems such as stroke, heart disease and even stomach cancer. AWASH - the Australian Division of World Action on Salt & Health - has said that, after smoking and physical inactivity, high blood pressure accounts for the third greatest burden of disease in Australia. Researchers at Deakin University have found that increased salt intake is directly linked to increased blood pressure - and high blood pressure is the single biggest modifiable risk factor for stroke. Given the huge burden that excess salt consumption places on our society, it’s no wonder that groups like AWASH are aiming to raise consumer awareness of the effects of a highsalt diet. If, as National Stroke Foundation CEO Dr Erin Lalor has said, reducing average salt intake by just one gram per day worldwide could prevent thousands of deaths from stroke each year, the solution seems clear: reduce salt intake and we reduce the health burden on our society. But is it really that simple? Although sodium occurs naturally in a range of foods, “It’s important to remember that it’s not just the salt people add at the table that matters,” said Professor Bruce Neal, Senior Director at the George Institute and Chairman of AWASH. “Most salt is hidden in processed and fast foods so that even

people who don’t add salt are still eating far more salt than is good for them.” Because of this, health and consumer groups are pressuring food manufacturers to reduce the amount of salt in their processed food products. The problem is that it’s not as simple as just adding less salt during processing and - hey presto everyone’s healthier and happier. Removing salt from many processed foods can have a major impact on shelf life, food safety and consumer acceptance. Dr John Lucey of the Center for Dairy Research at the University of Wisonsin-Madison has argued that, since salt acts as a preservative in cheese, modifying the salt content can provide a hospitable environment for bacteria to flourish, reducing shelf life and increasing the risk of food poisoning. This is true of many processed foods. Lucey also commented that the push for a sodium reduction in foods “may not be stemming from a push by consumers, but from a push by government and regulatory agencies”, citing a lack of consumer interest in low-sodium cheeses as a specific example. Other food producers have noted a similar reluctance from consumers to take up low-salt versions of their products: The Sydney Morning Herald reported that Heinz no-added-salt Baked Beanz account for only 1.3% of Heinz’s overall baked beans sales, with customers preferring the standard variety with a much higher salt content. www.foodprocessing.com.au

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PROCESSING

Recent research from Deakin University has shown that reduced salt labels affect consumers’ taste perception, making reduced salt products seem less tasty compared with the same products that aren’t labelled as low in salt. Researchers from the University’s Centre for Physical Activity and Nutrition (C-PAN) offered 50 participants the same type of soup with three different salt levels and different labels, and asked them to add salt if they felt it was needed. The results were surprising. Dr Gie Liem said, “We found that when a product was labelled as ‘reduced salt’, people believed the food was not as tasty as the unlabelled version” - even if they actually contained the same amount of salt. “The negative taste experience resulted in more people adding more salt to the soup than when such a label was not present.” But that’s not all. “Interestingly, the Heart Foundation Tick did not influence taste perception,” Dr Liem said. “This study highlights that promoting salt reduction as part of front-of-pack labelling can have a negative effect on how consumers perceive the taste of the product and on salt use.” What these results suggest is that we need to consider the best approach to reducing salt in processed foods - and communicating this to consumers. So, what’s happening in the industry in terms of salt? Here are some recent developments:

technologies or methods should not involve artificial additives or e-numbers or include currently available potassium salt blends. For the company to adopt a new method or technology, Unilever says it should “enable a reduction in sodium of at least 20%”.

LycoRed This Israeli-based company has developed a tomato concentrate product that it claims enhances taste and flavour and can be used in place of artificial flavours and flavour enhancers. LycoRed claims that using its product can actually be cheaper in the long run for food processors as it replaces expensive flavouring ingredients. Dr Sam Bernhardt, Director of New Food Ingredients at Lycored, said, “After five years of intense research and development, we were able to create LycoRed SANTE as a healthy, natural solution for the industry with umami and kokumi flavour characteristics. LycoRed SANTE can be applied to a wide variety of food systems, such as culinary products, soups, sauces, baked products, snacks and proteinbased formulations.” SANTE is available in liquid and powder form, is heat and pH stable and suitable for ambient, frozen, baked, cooked and fried products, the company says. It can be applied as a seasoning, dusted on or mixed into food or dough mixes.

Unilever Unilever has made a public call for ideas on reducing salt. The company’s Open Innovation website section details its “challenges and wants” and encourages innovation partners to submit ideas for collaboration. One of Unilever’s challenges and wants is to reduce the amount of sodium in food. It claims to have already reduced salt in its products by up to 25%, but is hoping to decrease sodium content by a further 15 to 20% while still delivering on flavour. Unilever said it is looking for alternatives to salt. “That might mean ingredients that provide taste without sodium - but it could also mean technology that helps us understand ways that consumers can experience satisfying taste while enjoying food with reduced salt levels,” its website said. “Solutions could be highly specific - a way to improve particular products or dishes - or could apply to the way people consume salt more generally.” Salt alternatives, taste perceptions, salt education and methods for professional kitchens are some of the concepts Unilever is exploring. It stipulates that any new salt-reduction 14

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Givaudan Rather than simply replacing salt, Givaudan says it assesses the role of salt in a product, then reassembles it by using its flavour- and texture-enhancing products “to maintain the desirable salt profile without recreating the associated negative health issues”. “It is now well understood in the food industry that salt is a very efficient and complex taste enhancer that goes beyond just making food taste salty. Salt has a range of taste effects over time which we have named ‘The Salt Curve’,” said Laith Wahbi, Global Product Manager, Savoury. Givaudan has developed Sense It Salt language - a way of describing the way the physical and taste effects of salt in food can be broken down into distinct temporal phases that influence the flavour profile of the food. “We saw that the taste profile changed across the salt curve and concluded that the term ‘salty’ was no longer sufficient to describe the taste effects of salt or what happens sensorially when it is added, removed or replaced,” said Sophie » continued page 16 Davodeau, Global Head of Sensory.

www.foodprocessing.com.au


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PROCESSING

“The development of Givaudan’s Sense It Salt language allows us to accurately assess the consequences of reducing salt and the performance of flavours or ingredients that are used to restore the taste of low-sodium products.”

Hampstead Farms A personal brush with high blood pressure led Hampstead Farms’ founder, Kevin Stone, to drastically alter his diet. Struggling to find low-sodium cooking sauces in the supermarket, Stone set out to make his own. Hampstead Farm now produces four cooking sauces that have no added salt, no preservatives and are gluten free. The range includes a ginger and lime stir-fry sauce, a madras curry base and a spicy arrabiata pasta sauce. According to the company’s website, when the products were tested on Brighton locals, 99% of those surveyed were happy with the salt levels of the sauces - despite none being added.

Sonneveld With the Dutch government reducing the maximum allowable levels of salt in bread from 1.8 to 1.5% by 2013, Sonneveld released a product called Proson Taste, a bread character influencer. Sonneveld claims that adding 1% of its product to bread can reduce the salt required by up to 50% without negatively affecting the dough characteristics and flavour of the final product. A bonus of Proson Taste is that 10% less yeast is required when using the product.

Wonder White Goodman Fielder has reduced the salt content in its largest-selling bread product, Wonder White, by up to 20%.

The company announced its intention to roll out the saltreduced bread on the eve of World Salt Awareness Week. Wonder White has received the Heart Foundation Tick for meeting the organisation’s strict standards on saturated fat, trans fat, sodium and fibre. “The beauty of this move is that customers don’t have to change their purchasing habits to eat healthier. The company is doing the hard work for them,” said Professor Bruce Neal. “This is exactly what our ‘Drop the Salt’ campaign calls for - removal of salt at the source.”

FoodSwitch This smartphone application is the result of a collaboration between Bupa Australia and the George Institute. Users simply scan barcodes on packaged food products and the app suggests healthier alternatives. Since being launched in January 2012, the app has been downloaded by 150,000 iPhone users, with an Android version released recently. “The app is being used by doctors to help patients manage their health risks, but also by parents to teach their children about healthier eating, using real-time, on-the-spot examples as they consider what goes into the shopping trolley,” said Dr Stan Goldstein from Bupa.

The assault on sodium levels Campaigns such as AWASH’s Drop the Salt and World Salt Awareness Week (26 March to 2 April 2012) aim to educate consumers about the dangers of a high-salt diet. But given consumer reluctance to embrace low-salt products, it seems the pressure may continue to fall on the food processing industry to reduce salt in processed food products. While salt reduction is a simple solution to a host of health problems, it’s clear that many factors - including safety, shelf life and consumer acceptance - must be considered before we launch into an all-out attack on salt in processed foods.

Hose pump range Apex model hose pumps from Bredel are designed for dosing, metering and transfer applications from 2.8 to 1200 L/h. The pumps have a cast aluminium housing to allow heat dissipation, robust direct-coupled technology and precision-machined hose elements. The company claims they provide decreased cost of ownership, reduced operating costs and low inventory stocking. A single Apex pump body is adjustable for three hose sizes (10, 15 and 20 mm). Continuous pumps speeds up to 100 rpm provide a wide capacity range. The longlasting hoses support repeatable accuracy when dosing additives, Bredel claims. Apex pumps are suitable for a range of applications from lime dosing and slurry transfer through to handling food and beverage products. They have no expensive wearing components such as seals, valves, membranes, stators, rotors of glands, claims Bredel, and as such are suitable for ‘difficult’ fluids, such as those that are abrasive, corrosive, viscous, shear-sensitive or crystallising. Watson-Marlow (Pty) Ltd Contact info and more items like this at wf.net.au/N565 16

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PROCESSING

Pinguin sorts out its efficiency with Manta 2000 series Investing in three Manta 2000 series sorters for processing spinach and green beans has helped Belgian company Pinguin reduce its yield loss to less than 2%, enabling the company to more efficiently handle the 6- to 8-week Belgian spinach harvest. A member of the PinguinLutosa Food Group that specialises in frozen vegetables, Pinguin chose the Manta sorters from Key Technology as part of its strategy to continuously invest in product quality and food safety. The sorters feature laser technology and top- and bottom-mounted cameras and are designed to improve detection and removal of foreign material (FM) and defects from green beans and wet spinach after washing. “Historically, the vast majority of frozen spinach has not been sorted, which poses serious product quality and food safety risks,” said Tim Lobdell, Managing Director of Key Technology BV. “A few processors have tried to sort prior to washing due to the challenges of handling wet spinach after washing. The problem with sorting prior to washing is that muddy leaves are rejected because the sorter ‘sees’ surface mud as a defect, which creates a yield loss of up to 7% that is unacceptable to most processors. “By solving the product handling challenges associated with wet spinach, Key now enables sorting after washing, which reduces the yield loss to less than 2%. This is acceptable to processors who benefit from dramatically reducing the risk of foreign material in their product and customer complaints.” The sorters’ two-metre-wide scan area allows it to sort up to 4500 kg of spinach each hour and up to 15,000 kg of green beans per hour. Top-mounted colour cameras and lasers, and bottom-mounted Vis/IR (visible infrared) cameras help maximise detection capabilities for both spinach and green beans. Two-sided viewing finds FM under spinach leaves to maximise product quality and food safety. To reduce the yield loss traditionally associated with bottommounted cameras, Manta sorters feature Valve Activity Tracking that detects product on viewing windows and automatically activates an integrated clean-in-place (CIP) system to clear the window without operator assistance, allowing the sorter to continue operating. Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/N764

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Sanitary, continuous mixing and dispersing system SPX has added the APV Cavitator to its family of mixing and dispersing equipment specially developed for sanitary applications. The modular process technology in the system offers benefits for heating liquids without scale build-up as well as provides solutions for many of the most difficult mixing and dispersing challenges for food and beverage processing. The APV Cavitator is named for the powerful effects of shockwaves produced from the collapse of ‘controlled cavitation’ bubbles and works by taking a fluid into the machine housing, where it is passed through a controlled cavitation field created by the reactor’s spinning rotor. The design uses the intense force of cavitation in a controlled manner, rather than typical impellers or blades to process materials, increasing the mass transfer rate and producing results claimed to be superior to those of many current mixing and heating technologies. Additionally, the cavitation effects are achieved without damage to metal surfaces. This advanced technology can be used for a multitude of sanitary applications ranging from pasteurisation to low-pressure homogenisation. Benefits include improved process efficiencies (time, operating costs, and/or capital costs); enhanced product quality, yield and/or raw material savings; extended process run times related to scale-free heating; and elimination or reduction of process downtime from maintenance requirements. The system has a smaller footprint than traditional technology and has been designed for easy disassembly. It is fully CIPable and manufactured to meet 3-A standards. SPX has licensed the ShockWave Power cavitation technology from the Italian company Hydro Dynamics. SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/N697


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PROCESSING

A breath of clean, fresh (compressed) air for industry Dino Alessio

The cleanliness and quality of compressed air used is vital to prevent contamination of the end product in food and pharmaceutical manufacturing, and to provide safe operation of specialised equipment in hazardous environments. Dino Alessio, compressor engineer and National Sales Manager at CAPS Australia, reviews the international standard for compressed air quality and the technology to provide Class 0 air.

C

ompressed air is an important and major part of most manufacturing and industrial processes. Knowing the proper air quality level required for effective and efficient operation of equipment or a manufacturing process is an important factor in containing compressed air energy and other operating costs. Higher-quality air is more expensive to produce and requires additional air treatment equipment, which increases capital costs as well as energy consumption and maintenance needs. The degree of dryness and filtration of compressed air required for a process, and the minimum acceptable contaminant level of any finished product, should determine the quality of air required. One of the main factors in determining air quality is whether oil-free air is required. If only a single process requires this type of air, it may be supplied by a dedicated oil-free compressor or by the necessary filtration equipment at the point of use. If the end uses in a plant require different levels of air quality, it may be advisable to divide the plant into different sections so that air treatment equipment that produces higher-quality air is dedicated to the end uses that require the higher level of compressed air purification.

Using clean and pure compressed air For the taste of it Food and beverage manufacturers use compressed air to push foodstuffs, such as powders and cereals, through 20

May/June 2012

pipes and they often has direct contact with the product during processing. It may also be used to cool down baked goods, clean bottles or spray produce. In some applications, compressed air supplies oxygen to bacteria for fermentation or is pumped into liquids to raise dissolved oxygen levels. The cleanliness and quality of compressed air used in food and beverage processing is therefore vital to prevent contamination of the end product and potential harm to the health of consumers. Food product recalls and food safety concerns are increasingly influencing consumer shopping behaviour. A recent study found that such concerns prompted 38% of consumers surveyed to stop purchasing certain foods. Compressed air is often identified as a potential source of contamination. While the majority of consumers acknowledge that they have some level of responsibility for ensuring the products they consume are safe, a growing number of consumers ultimately hold the manufacturers accountable. Improved product purity Compressed air is used in a variety of manufacturing processes in the pharmaceutical industry. It is frequently used to de-dust tablets or spray on pill coatings. Compressed air is used to maintain over-pressurisation in mixing and holding tanks to ensure product integrity. It may also have direct contact with the product or packaging during dosing and filling, or when the application demands aseptic air. Pharmaceutical industry regulations state that “each manu-

www.foodprocessing.com.au


facturer shall establish and maintain procedures to prevent contamination of equipment or product by substances that could reasonably be expected to have an adverse effect on product quality”. In order to prevent contamination of the end product and possible harm to patients, the cleanliness and quality of the compressed air supply is vital to eliminating the risk of rejections and/or health risks associated with oil contamination. Safe operation in hazardous areas Oil and gas production and handling can be dangerous processes in which health and safety are paramount. Compressed air is non-flammable so it can be used in hazardous environments and be used in a multitude of applications in these industries. Whether used for breathing air or operating manufacturing equipment used in many processes, compressed air is the first choice for safety. Compressed air is used in a vortex tube for cooling processes and to drive air-operated pumps as an alternative to electrically driven pumps which could spark and cause an explosion. Compressed air is also used in a variety of cleaning processes such as reverse air jet purging of filters or as the propellant for the cleaning ‘pig’ when clearing the inside of pipelines. Portable compressed air systems can be used for the internal de-scaling of mobile oil and gas tanks or as a stand-by backup for a site’s stationary compressors.

The three primary contaminants of a compressed air system are airborne particulates, water and oil. It is possible for a single drop of unwanted oil to cause an entire automated process to malfunction by causing seals to swell which may result in complete seizure of moving parts. Other contaminants that may impact production processes include solid particles such as dust and rust, condensed water droplets from ambient humidity, and liquid oil and oil vapours. Solid contaminants can wear out compressor machinery, cause motors to jam, and block valves and vent orifices. Airborne particulates will cause pneumatic equipment to malfunction, failure of instruments and control systems, and contamination of end products. These events increase the cost of running the compressors by increasing the maintenance required to clean and repair components. Water, both liquid and vapour, will oxidise pipework and pneumatic equipment, ruin paint finishes and can potentially make the products being manufactured unable to be sold. Oil-based vapour and liquid can have similar effects on machinery and end products. In addition to the cost of increased maintenance and loss of manufactured product, sudden equipment stoppages are expensive in terms of loss of product and time to repair and restart a production line.

Setting the standard The International Organization for Standardization (ISO) developed the compressed air quality standard - ISO 8573 - in 1992. The standard was designed to provide plant engineers and equipment suppliers with an internationally known and accepted unit of measure. The standard defines a series of ‘Quality Classes’ relating to the concentration of solid particulates, water vapour and oil in output of an air compressor. For example, ISO 8573-1:2010 Class 1.2.1 specifies a particular air quality. The last three digits in the designation - in this case 1.2.1 - relate to the purity classifications selected for solid particulates (1), water (2) and total oil

www.foodprocessing.com.au

May/June 2012

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©iStockphoto.com/Thomas Vogel

Sources of contamination


PROCESSING

contamination (1). The designation begins with the name of the standard document and its revision number. Class 1 for solids means that in each cubic metre of compressed air, not more than 20,000 particles in the 0.1 to 0.5 micron size range, 400 particles in the 0.5 to 1 micron size range and 10 particles in the 1 to 5 micron size range are permitted. The 2 classification for water indicates that there must be a pressure dewpoint (PDP) of -40°C or better and that no liquid water is allowed in the output air. The third digit, 1 in the example, indicates that the total level for liquid oil, oil aerosol and oil vapour must not exceed more than 0.01 mg of oil in each cubic metre of compressed air. Class 0 is the most stringent air quality classification, strictly limiting oil contamination in liquid, aerosol and vapour forms. This classification requires agreed and measurable contamination levels that are included as part of a written specification for a compressor. Air for critical applications such as breathing or medical and food production may still require additional purification equipment in both the compressor room and at the point of use depending on the nature of the air being drawn into the compressor.

Oil-free compression Rotary screw compressors use two meshed rotating helical screws to force the gas into a smaller volume and are usually used for continuous operation in commercial and industrial applications. This type of compressor can have engine sizes from 2.2 kW to more than 890 kW and from low pressure to moderately high pressure more than 8.3 MPa. The gas compression process of a rotary screw is a continuous sweeping motion, which minimises pulsation or surging of the discharge flow. In an oil-free version, the air is compressed entirely through the action of the rotary screws, without the assistance of an oil seal. These units often have lower maximum discharge pressure, but multistage oil-free compressors where the air is compressed by several sets of screws - can achieve greater pressures and output volumes of more than 50 m 3 per minute. Oil-free compressors are used in applications where oil contamination is not acceptable, such as medical research and semiconductor manufacturing. Some form of additional filtration is often required as contaminants can be drawn in from the ambient air and must be removed prior to where the compressed air is used. Oil-free rotary screw and reciprocating compressors usually have higher initial costs, lower efficiency and higher maintenance costs than their lubricated counterparts. However, the additional separation, filtration and drying equipment required by oil-injected compressors will generally cause some reduction in system efficiency, particularly if the system is not properly maintained. 22

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By providing pure air, free from additional contaminants, these compressors minimise downtime associated with cleaning filters and other air system components. Oil-free technology increases productivity and ensures higher overall product quality. All Ingersoll Rand compressors that are designated oil-free and supplied by CAPS Australia - the largest Australianowned independent compressed air company - have been certified as meeting the Class 0 air quality standards. This certification was achieved following rigorous testing by TĂœV Rheinland - a global leader in independent testing and assessment. Certified Class 0 compressors deliver consistently clean, sterile air to critical applications. Ingersoll Rand oil-free rotary screw and centrifugal air compressors also help manufacturers comply with environmental standards such as ISO 14001 and European Union regulations. Because the compressors are oil-free, manufacturers do not encounter disposal issues with waste oil and filtration components. Disposal of air compressor condensate can also be an issue in traditional, lubricated compressors. By creating a clean condensate that is easier to dispose of, oil-free compressors do not require special treatment for oil and water mixtures.

Summary Class 0 compressed air ensures higher product purity and process integrity, minimising the risk of oil contamination being transferred directly to a product being manufactured or interfering with the operation of equipment. By selecting certified oil-free compressors, food and beverage manufacturers, pharmaceutical companies and process operators can enjoy the peace of mind that comes with knowing their critical air supply is completely free of compressor-created contaminants.

CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/M022

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


©iStockphoto.com/ Diane Diederich

PROCESSING

Krones line is a sparkling success for Bodega Jaume Serra Cava, the Spanish equivalent of champagne, is fizzing with success. Cava producers are barely able to keep pace with demand: in 2009, cava exports exceeded those of champagne for the very first time. Capacities are consequently being upsized. The biggest investment, thus far, is €42 million for the first-stage expansion at Bodega Jaume Serra, a subsidiary of the major beverage producer J. García Carrión (JGC). The upgrade and expansion project for the winery included a Krones line for bottle filling prior to in-bottle fermentation. JGC’s system sees up to 900 bottles placed horizontally on a single pallet, offset and supported by plastic layer pads. Over an area of 28,000 m2, the pallets are placed in storage by a fully automated system. Also installed were driverless laser guided vehicles (LGVs) which convey pallets to high bay shelving. These keep labour costs down: the winery employs just 48 staff. Given the demand, there is an option for almost doubling the storage capacities by adding another 20,000 m2. Jaume Serra now has four bottling lines. The most efficient of these is the Krones line, rated at 24,000 bottles per hour (bph), replacing an existing line rated at 7000 bph. Jaume Serra also operates a 7000 bph line for bottling still wine and 12,000 bph and 5000 bph lines for disgorging and bottling the cava. The grape pressing and wine production systems handle 3 million kg of grapes, most of which is the base wine for cava. Fifteen storage tanks, each holding 100,000 L, plus 28 tanks of 50,000 L, are used. After cooling and filtering, the wine passes to a 200,000 L tank where sugar, yeast and finings are added, then passes via a 500 m long pipe to the filler for the tirage, dosed by Krones' new rinser filler monobloc, rated at 24,000 bph. Krones’ Isofill VV-CIP vacuum filling system bottles still wines. The wine enters the bottle through a filling tube under natural gravity. A vacuum correction feature with product return capability ensures accurate fill levels. When the liquid reaches the filling tube, the vacuum correction function comes into play, returning any superfluous beverage to the ring bowl with maximised accuracy. The ‘no bottle - no vacuum’ principle ensures only bottles actually pressing against the filling valve are subjected to vacuum. The reduced suction rate is gentler on the product. The CIP variant, where a closed CIP circuit ensures maximised hygiene during bottling, was also installed. The filler has a cleanroom enclosure featuring HEPA filters and an extractor unit. The Isofill VV-CIP is monobloc synchronised with a Variojet single-channel rinser. Two closer units for plastic plugs and crowns are linked to the monobloc. The fill level of the product in the wine bottles is monitored by a Checkmat FM-HF. A MultiDivider then distributes bottles among eight lanes, feeding to four robots, which then place the bottles on in-house developed pallet carriers where they are stored for in-bottle fermentation. The line runs year round, with two shifts scheduled in the first quarter and three for the rest of the year. In three-shift operation, the line offers annual production of over 100 million bottles. Krones (Thailand) Co Ltd Contact info and more items like this at wf.net.au/N152

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Pneumatic vibrator range VSS has available a range of ATEX-certified pneumatic vibrators. While pneumatic vibrators are often thought of as being safe for use in explosive atmospheres, many still have metal to metal contact internally. In models in which a ball or roller runs around the inner race of the unit, the issue lies not in the actual running in the race but the ‘bounce’ that occurs when the vibrator is turned off and is running down. Linear piston vibrators, even if non-impacting in design, can still have metal to metal contact when turned off. VSS claims its turbine vibrators do not have this problem as the turbine is held in bearings so this ‘bounce’ cannot occur. The vibrators are also supplied with special fittings that make them suitable for use in Zones 1, 2, 21 and 22 and category 2 (2G and 2D 85°C [T6]). Netter non-impacting NTS Series vibrators can be supplied with earthing straps, special inlets and exhausts to bring them into line with ATEX requirements for dust and explosive atmospheres. The Netter PKL and NTP Series are impacting models that can be fitted with elastomer inserts that VSS claims eliminate metal to metal impacts. Using these inserts makes the vibrators compliant with ATEX regulations. Vibration Systems & Solutions (Australia) Pty Ltd Contact info and more items like this at wf.net.au/N586



he Winery Engineering Association’s national conference and exhibition keeps key operational staff up to date with the latest global technological advancements - ensuring that the Australian wine industry retains its competitive edge wherever possible. This year’s conference and exhibition, WineEng 2012, will concentrate on many aspects of wine production and is aimed at production operations personnel including engineering and maintenance staff, winemakers, bottling and packaging management, general management and winery suppliers whose goal is to ensure that the Australian wine industry remains competitive both in the domestic and global markets. Registration for the conference and associated exhibition starts at 10.00 am on Wednesday 20 June. The conference will then commence at 11.15 am and,following a welcome from the WEA President Geoff Leighton, a keynote address will be given

Speaker Dr Vince O’Brien - Business Development Manager, AWRI Ms Abbie Arbon - Regional Manager - Northern SA, AusIndustry Dr Leigh Francis - Research Manager - Sensory, AWRI Dr Simon Nordestgaard - Senior Engineer, AWRI Mr Karl Forsyth - Senior Engineer, AWRI Mr Frederic Guillet - Head of Negociants & Bottlers Market, Bucher Vaslin Mr Ashley Wass - Asset Reliability Engineer, CBC Mr Brad Semmler - Director, Cold Logic

What: WineEng 2012

Mr Nick Sterenberg - Operations Manager, Coopers Brewery

When: June 20 and 21

Mr Paul Baggio - Managing Director, Della Toffola - Pacific Mr Don Allen - Gas & Systems Specialist, Gas with Panache

Where: Vine Inn, Barossa

Mr Scott Clydesdale - Senior Refrigeration Engineer, Gordon Brothers Refrigeration

More information/registration:

Mr Blair Hanel - Director, Hanel Consulting Mr Ivan Winter - Director, Ingenia

www.wea.org.au

Mr Andrew Raine - Director, Matrix Process Solutions TBA, Matthews Mr Michael Bellstedt – Director, Minus 40 Mr Michael Bellstedt - Director, Minus 40 Mr Eric Bosch - National Sales Manager: F&B Systems, Pall Australia Mr Harvey Gough - Managing Director, Novasys Group Mrs Jo Stagg - General Manager SA/NT, Programmed Property Services Mr Gordon Bartlett - Architecture & Software Business Manager, Rockwell Automation Mrs Maggie Thomas - Snr Inspector OH&S, SafeWork SA Mr Damian Jolly - MES Solution Manager, SAGE Automation Mr Chris Travers - Director, Travhotec Mr David Carey - Operations Training & Process Controller, Vinpac ©iStockphoto.com/ Matt Keal

PROCESSING

Winery Engineering Association’s national conference T and exhibition

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Mr Peter Critchley - Senior Sales Engineer, Visy Automation Mr David Zerbo - Manager, Ridgelea Mr Samuel Plumjeau - Regional Sales Manager - Australia & NZ, Bucher Vaslin Mr Glen Jacob - Food & Beverage Industry Manager, Rockwell Automation Mr Andrew Raine - Director, Matrix Process Solutions TBA, Matthews

www.foodprocessing.com.au


Dr Vince O’Brien, who holds the position of Business Development Manager with the Australian Wine Research Institute. At the conclusion of the keynote address, the presentation of technical papers will follow. The 2012 National Conference theme, titled ‘Building customer value’, will focus on new innovations and improvements in winery production techniques that have been developed in recent times and are either currently available or are about to be released. Some of the key areas that will be addressed will be as follows: • More efficient use of utilities and resources. • Improving the level of engineering services provided to production by understanding the appropriate maintenance strategy required. • Understanding and implementing overall equipment effectiveness (OEE) programs and tools. • Implementing quality systems including a number of case studies. • More effective use of refrigeration. • Developments in wine and lees filtration. • Government funding for Clean Technology Investment programs. • Developments in gas application technology. • Implications of the new model National Work, Health & Safety Act.

Winery Engineering Assoc Contact info and more items like this at wf.net.au/N765

Presentation Keynote presentation - Building Customer Value Clean Technology Investment Program What do consumers like? Opportunities to eliminate wasteful resource use Managing your environmental credentials to benefit your business Will diatomaceous earth disappear and will crossflow take advantage? Monitoring plus Efficiency and capacity improvements to existing refrigeration systems Continuous improvement at Coopers Brewery Flash Détente Bio Thermal Vinification Technology Adapting to Change - Adding quality and value with gas technology Refrigeration plant and condenser efficiency Wine filtration: past, present and future - our customers’ needs! The importance of utilising the correct maintenance strategy to improve OEE Fermentation optimisation, in tank mixing, sparging and cleaning system Implementing OEE (overall equipment effectiveness) measures in the packaging hall Typical energy efficiency opportunities on winery refrigeration systems - which ones work and how much you can save The practitioners perspective: key steps in the process towards obtaining CTIP funding for your energy-saving projects Bentonite dosing directly upstream of the crossflow to further reduce wine movements Solar cooling for winery applications Engaging diversity - influencing for positive outcomes Convergence: integrating operations and production in your winery Work health and safety - building capability Implementing a paperless quality system Energy sustainability with co and tri generation Computer-based quality assurance in the wine packaging process Building customer value through recycling Padovan ‘Dynamos’ rotary crossflow lees filter New destemmer and sorting technology Automation and information solutions for building customer value Reducing trade waste while increasing product recovery (pigging system uses) Industry tools for OEE

www.foodprocessing.com.au

May/June 2012

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Key speakers will address these issues over two days of presentations which will provide opportunities to share and improve knowledge for the entire winery team. An integral part of this annual event is the display of products and services available from Australian and international providers. With the conference and associated exhibition being one of the few that is run on an annual basis, it also provides an excellent opportunity for annual face-to-face networking amongst key operational staff from small boutique operations to those representing large multinational wine companies. The finale to the event will be the conference dinner to be held during the evening of the final day of the conference. The WEA conference dinner is always well accepted and enjoyed by all in attendance and once again gives the opportunity for important networking in a relatively informal environment and, of course, as always there will be a fundraising section to support the Royal Flying Doctor Service. For more information and to register to attend this event, please visit www.wea.org.au.


2-wire liquid transmitter series

A joint initiative of a German engineering firm and Australia’s largest industrial automation and control systems integration company is generating returns on investment for manufacturers in months, rather than years. Prozess - formed by SAGE and Project Engineering and launched in February 2012 aims to generate “bankable process improvements” for manufacturers across industry sectors. Joint Managing Director Garry Williams said the company meets a market need for a more forensic approach to manufacturing process optimisation. “Providing a solution to a client brief is just one part of the puzzle. To truly add value to a business, you must first identify the core problem. In many cases it’s the problem that the client is unaware of that is really restricting their growth or competitiveness.” Prozess has delivered return on investment for its clients with as little as seven months’ payback. The joint venture brings together a network of partners with experience and expertise across all areas of manufacturing. “We bring a global approach to the table, uniting German quality and precision with Australian entrepreneurial spirit and experience while our approach is based on the proven Japanese method of lean manufacturing,” Williams said. The Prozess approach for manufacturers involves four stages: 1. Identify: Uncover direct influences to production wastage by analysis of conveyance, motion, waiting, unnecessary actions, inventory and overproduction as well as indirect influences to the production process. 2. Scope: Identify and develop innovative and cost-saving solutions. 3. Do: Execute strategy. 4. Bed down: Follow-up analysis to ensure process is integrated and generating the expected results. Prior to its official launch, Prozess had already been involved with known companies across the mining, building materials, food and beverage, agriculture processing and automotive industries. Its clients have included Adelaide Brighton Cement, SMR, Drake Foodmarkets, Golden North, Balco and SPC. Ice-cream manufacturer Golden North was considering capital expenditure to increase production capabilities and efficiencies. By carrying out analysis of the entire value chain, Prozess identified ways for the company to better its available capacity by improving stock turnaround and reducing additional capital expenditure costs. Prozess worked with manufacturer SMR to assist in the concept and planning of a new cleanroom for automotive and medical products. Prozess carried out a detailed analysis covering output, machinery, staffing and hygiene requirements to enable optimal integration within the existing production process. Adelaide Brighton Cement’s dry-mix production process involves multiple raw materials, mixing and packaging. Prozess undertook a detailed analysis of the company’s dry-mix production, reviewing equipment, investigating major cost drivers and identifying a range of process and system improvements.

The Rosemount Analytical 1066 2-wire

SAGE Automation

include cable capacitance and series

Contact info and more items like this at wf.net.au/N087

resistance.

©iStockphoto.com/ Red Ice Cream

PROCESSING

Prozess: generating “bankable process improvements” for manufacturers

liquid transmitter series from Emerson Process Management is suitable for pharmaceutical and food and beverage applications and harsh environments like chemical plants, metals processing and effluent monitoring. The series is registered under the Interoperability Test Kit 6 (ITK6) from Foundation fieldbus. ITK6 compliance means the transmitters have field diagnostics and common software downloads. The transmitters can measure pH, ORP, resistivity/conductivity, per-cent concentration, total dissolved solids, total chlorine, free chlorine, monochloramine, dissolved oxygen and dissolved ozone. A second sensor input allows continuous pH correction for free chlorine measurement. The company claims the transmitters’ smart pH sensor capability eliminates the need for field calibration. The smart capabilities also enable the transmitter to accept pre-calibrated Rosemount Analytical smart pH sensors. The transmitters can use analog output function blocks to link to temperature and pressure measurements from the bus for temperature and pressure compensation, which may increase the accuracy and responsiveness of the measurement. They also have analog control and math function blocks for use by the 1066 or other devices on the bus to facilitate control in the field. The HART version of the 1066 is switchable between HART 5 and 7, allowing the transmitters to be used with HART 7 capable, as well as legacy, hosts. Housed in a 1/2 DIN enclosure, the transmitters have a large, user-friendly display. A diagnostic key allows for fast troubleshooting. The transmitters’ configuration is compatible with the smart wireless Thum adapter for commissioning to Emerson wireless networks. The transmitters use low-frequency noise reduction, and

Emerson Process Management Contact info and more items like this at wf.net.au/N262 28

May/June 2012

www.foodprocessing.com.au



PROCESSING

GWE creates renewable energy from wastewater in Bangkok In rapidly growing cities throughout Australasia and the Asia-Pacific, space is at a premium, clean water supply is precious and global warming is a major issue. In these cities, food and beverage companies face challenges to minimise their physical and environmental footprints and therefore must choose technology wisely. Ideally, the systems they use to upgrade wastewater quality should generate renewable energy while taking up less space than older systems. Global Water Engineering (GWE) has provided a solution to these challenges. Represented in Australasia by CST Wastewater Solutions, the company has used advanced anaerobic technology to comply with and exceed environmental objectives at a confectionery plant. To make the challenge even more complex, the plant is located in Bangkok, falling under one of the toughest municipal regulatory regimes in Asia. Bangkok’s population is currently in excess of eight million people - and is growing at a rapid rate. The Thai government has strong plans to combat global warming that this increasing population is generating. In line with Bangkok’s Action Plan on Global Warming Mitigation 2007-2012, an international confectionery company recently upgraded its Bangkok plant using advanced anaerobic technology from GWE that cuts the chemical oxygen demand (COD) from discharge water by more than 90% to 1600 mg/L. The new process water treatment plant occupies only 60 m2 and has not only lifted output standards beyond specification, but also produces 1800 m3 of biogas each day at nominal load. “It is exceeding the 90% COD removal specification in service and frequently achieving 95%,” said GWE CEO Jean Pierre Ombregt. By delivering biogas at 70% methane content to power boilers and heat processes, the plant saves on expensive and polluting bunker oil. The wastewater plant is using less energy than the previous system. “Previously, the plant engineer said they had two big aerators going all the time. Now they find they don’t need them, even though they are expanding production,” said Ombregt. “You can see the water is very clean and there is no smell.” The plant’s wastewater passes through several pretreatment steps before entering a GWE methane reactor. In the reactor, the wastewater’s organic content is digested by bacteria in a closed reactor. This degrades the compounds and converts them into valuable biogas and cleaned effluent. The biogas powers the plant’s boiler drying equipment, with surplus power being sold back to the grid. The company saves money on bunker oil, which is subject to wide fluctuations in price. “The confectionery plant installation shows how it is possible to attain top environmental standards of wastewater cleanliness while generating green power on compact sites. A high-efficiency anaerobic/aerobic system that is properly designed from the outset occupies less space than the system it replaces,” said Ombregt. GWE specialises in industrial wastewater solutions and renewable energy solutions. Its wide range of technologies encompasses solutions for water recycling; digestion of biomass, sludge and slurries; biogas production and re-use; bioenergy and carbon credits.

Fruit and vegetable washing and sanitising The Kronen Vortex sanitising waterflow system claims germ reduction on fresh-cut products. It has been developed for the final treatment stage of vegetables such as leaf salads, root products, etc and also fruits like apples and grapes, achieving germ reduction and prolongation of shelf life and, consequently, increase of product quality. The principle of the Vortex is simple: it operates by means of a tubular system (inside diameter 150 mm) with in-feed and out-feed openings. The washed produce (vegetable, fruit) will be poured into a funnel. The produce will be flushed gently and reliably into the sanitising water flow by lateral rotation nozzles. Thereafter, the produce flowing through the total tube length will be conveyed to the outlet. The produce then will be delivered to an out-feed belt or vibration belt by means of a water slide. Flexible contact and dwell time of the produce is adjustable from 1 to 3 min. The modular and space-saving tubular system can easily be integrated into existing salad processing lines. Installation layouts for specific operations can be provided.

CST Wastewater Solutions

Reactive Engineering Pty Ltd

Contact info and more items like this at wf.net.au/M723

Contact info and more items like this at wf.net.au/L279

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www.foodprocessing.com.au


Plate heat exchangers Teralba Industries has released a range of plate heat exchangers designed for pasteurising and general cooling and heating of beverages, food, dairy, brewery and viscous products. With a compact footprint, units can

Inductive sensors Benefits include: increased sensing ranges and correction factor 1 for steel and stainless

plications. The heat exchangers can be

steel; wide temperature range of 0-100 째C;

selected from models designed for flow

temperature shock resistant even in case of

rates as low as 200 L/h, increasing up to

frequent temperature fluctuations; high ingress

1.2 million L/h.

protection: IP67/68/69K; food-grade housing

Available with all stainless steel components, the plate heat exchangers are

materials; resistant to high-pressure cleaning and aggressive cleaning agents.

designed to provide hygienic and low-

The increased sensing ranges for non-flush

maintenance operation to food and beverage manufacturers. The stainless steel reduces

installation give users more safety in case of

the need for epoxy coatings or spray paints, used with traditional mild steel frames.

mechanical tolerances.

The company claims the stainless steel construction provides several other advan-

The sensors are suitable for applications

tages, including lower maintenance costs, aesthetics, elimination of painting and a

up to 100째C that undergo frequent cleaning

sanitary finish with high corrosive resistance. The units include plate materials, such

operations and temperature shocks, and

as grade 316 stainless steel and titanium, to resist corrosion.

feature high resistance to cleaning agents.

The product range includes: the FrontLine Series, constructed of premium stain-

A video of the sensors in operation in the

less steel; the BaseLine Series, constructed of standard stainless steel; the TS6-M,

food industry is available at http://www.ifm.

which includes tall and short models; and AlfaNova welded plate heat exchangers.

com/ifmaus/news/full-metal-sensors-for-the-

The exchangers are suitable for use in production of soups, sauces, jams, starch heating, wine, fruit juices and similar food products. Teralba Industries Contact info and more items like this at wf.net.au/M977

food-industry.htm. ifm efector pty ltd Contact info and more items like this at wf.net.au/P253

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May/June 2012

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PROCESSING

be sized and configured for specific ap-


PROCESSING

Communicating food safety crises Following a crisis such as an intentional food contamination, a food company is less likely to experience severe economic consequences if its public message communicates the actual damage, confirms containment of the contamination and is sensitive to varied cultural interpretations of blame, according to recent research.

F

ood is a natural target for intentional contamination or terrorism and such an act can disrupt a society and its economy. Past food contamination incidents have had major economic and reputational impacts on companies, and communication about the crisis are known to play a vital role in shaping the public’s response and the outcome of the crisis; people are willing to pay more for products they perceive as safe. However, different cultural groups may respond differently to how blame is assigned. The findings are in an analysis entitled ‘Predicting Psychological Ripple Effects: The Role of Cultural Identity, In-Group/Out-Group Identification, and Attributions of Blame in Crisis Communication’, co-authored by Deepa Anagondahalli of the University of Maryland and Monique Mitchell Turner of George Washington University. Their research findings are published in the February 2012 issue of the journal Risk Analysis, published by the Society for Risk Analysis. Risk perception of dramatic events typically occurs quickly, automatically and under the influence of emotions like anger and fear. The authors looked at how communication about the affiliation of the perpetrator and motives were received based on the cultural identity of the audience. Previous crosscultural psychology work has highlighted the cognitive differences in individuals, dependent on whether they were raised in what is sometimes called the ‘holistic’ East (eg, China, Korea, Japan, or India) or the ‘analytical’ West (eg, United States). To examine consumer responses, the authors recruited two groups - American (n=149) and immigrant Asian (n=146). 32

May/June 2012

In this study, participants reviewed a news release on food contamination. They were then asked to respond to questions aimed at measuring their attributions of blame for the contamination, trust and anxiety levels related to the food, and intentions for future purchases. The research found no statistical difference in the degree that Asian or American message receivers blamed the company. However, in conjunction with the attribution communicated in the message, Asian participants blamed the company more and trusted it less if its message included situational/ external attribution (eg, company fires the employee, which serves as crime motivation), whereas Americans expressed distrust when the message included personal/internal attribution (eg, company points to a ‘quick to anger’ individual with access to the food supply). For the American receiver, a correlation was evident between purchase intention and blame, trust and anxiety. For Asian message receivers, however, company blame correlated with trust and anxiety, but not with purchase intention. This points to a more complex relationship between blame and related emotions and cognitions for Asians. “Our findings suggest that any kind of attribution, external or internal, has to be carefully handled as different subgroups within the mass media audience will react differently,” according to Turner. Related to trust, the authors explored the importance of consumer trust in the company’s remediation process versus trust in the company’s image. They found that although purchase intention correlated with trust in the company’s image for Asians, purchase intentions for American consumers cor-

www.foodprocessing.com.au


©iStockphoto.com/Brooke Elizabeth Becker

PROCESSING

related significantly only with trust in the process and not in the image. In other words, American receivers desired reassurance that the company was doing everything it could to deal with the crisis, rather than to be reminded of the company’s virtues. This finding emphasises the organisational need to provide specific details on how it is rectifying the current crisis and to outline its plans for preventing future crises. “Post-crises, organisations are in a hurry to shift or explain the blame away but they should be aware that this effort may have the opposite rather than the desired effect on their audiences if cultural factors are not considered,” according to Anagondahalli. For some time, crisis communication experts have been advocating the use of culturally sensitive message practices, such as delivery by a prominent individual in the community, heeding the nuances of language and otherwise taking swift action to protect the consumer and repair the organisation’s reputation. The findings from this study provide additional insights into the underlying cognitive processes of two cultures. The authors note that following an intentional food contamination, “a one-size-fits-all message may not be an effective communication strategy”. Asian receivers will focus on situational cues to determine causality, whereas American receivers will focus on the personal characteristics of the perpetrator. Crisis messaging has become more critical as the diversity in the US population and the presence of Western corporations in Asia both increase. The authors suggest future research should explore other message characteristics potentially related to the message receiver’s cultural identity. www.foodprocessing.com.au

May/June 2012

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PROCESSING

Seasoning and flavouring system The tna intelli-flav 3c is a one piece system suitable for both wet and dry seasoning and flavouring that provides even coverage at throughput rates of up to 500 kg/h for a variety of applications. Configured for on-machine seasoning, the product’s spray capability allows application of liquids, liquid flavours and slurries and dry powders and can also be used as a standalone seasoning system for small snack lines. The system consists of two high-precision continuous spray guns, with a range of nozzles for tailored seasoning. Liquid is delivered by a closed loop spray system. tna claims the system makes each part of the seasoning process independent, so that seasoning can be easily repeated and customised for each product. The 17-flight drum gently turns the product without excessive lifting, minimising damage while exposing all surfaces to the liquid spray and the 400 mm powder curtain, for even coverage. Also available are a vibratory in-feed conveyor, to even out the product before it is weighed and moved into the tumble drum to be seasoned, and a spray lance that gives good access to the guns, for maintenance. TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/N538

Turn tap water into sanitising solution Key Diagnostics’ range of dissolved ozone systems converts tap water into a fast-acting sanitiser composed of dissolved ozone water. This is not a water treatment system but rather a replacement for traditional chemicals for the sanitation of equipment, floors and walls, and is also approved for direct application to food to reduce bacterial levels. The advantages of ozone include: 3000 times more effective than chlorine; kills 99.999% of bacteria in 5-15 s; degrades pesticides in 2 min; destroys odours; breaks down into oxygen and water. The PC-25 is a portable unit capable of producing 9000 L/h with the only costs being the tap water and 240 V power supply. The ozonated water can be applied using a spray nozzle or connected to a CIP system. Ozone sanitation can replace many high-cost processes such as hot water, steam and UV sanitation systems. Ozone works optimally at room temperature and has low power requirements compared to heat-based technologies. Ozone can also cut water wastage and labour costs by replacing post cleaning water rinsing with ozone water, which also acts as a sanitiser. Ozone can also replace many of the sanitisers used in the food industry. As ozone breaks down into water and oxygen, it can be used as a mid-process sanitiser to reduce bioload on critical control points without running the risk of tainting the product or shutting down the production line. Key Diagnostics Pty Ltd Contact info and more items like this at wf.net.au/L425 34

May/June 2012

www.foodprocessing.com.au


Soft confectionery depositor The Baker Perkins ServoForm soft confectionery depositor is designed to make centre-filled toffees, fondants and fudges. The depositor can one-shot deposit soft centres such as jam, cream, jelly, chocolate, praline and fruit paste, potentially adding value and variety to users’ product ranges. Two-component depositing capabilities can also be used to produce layered or striped soft confectionery, while solid inclusions such as nuts and fruit pieces can be added. for direct linking to inline chocolate enrobing. The nature of the depositing process creates flexibility and process control, the company claims. Dimensional, shape and weight accuracy are high, fillings are accurately positioned in the centre and scrap rates are low. According to the company, when compared with the traditional starch forming process, depositing can reduce space, labour and maintenance costs, improve hygiene and cut production cycles. The ServoForm confectionery depositor offers good levels of hygiene, easier operation and lower maintenance than previous versions. Fast automatic start-up and cleaning cycles have replaced manual operations. Priming the pumps at start-up and cleaning the pumps and hopper after every production run are essential; these operations are now controlled via a button. The depositor head is raised and lowered, with purging and washout trays placed and withdrawn automatically. The cycles are preprogrammed and require no operator intervention. SPX Flow Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/N107

TH ER MA L

HEAT TRANSFER SYSTEMS

TH E RMA L INDUSTRIES

www.foodprocessing.com.au

May/June 2012

35

PROCESSING

Where chocolate coating is required, the depositor can be configured to discharge in a regimented format, suitable


Food fraud The most fraud-prone food ingredients are olive oil, milk, honey, saffron, orange juice, coffee and apple juice, according to a review of records from scholarly journals. Potentially harmful issues identified included spices diluted with lead chromate and lead tetraoxide, substitution of Chinese star anise with toxic Japanese

high protein content foods.

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May/June 2012

www.foodprocessing.com.au

ŠiStockphoto.com/enviromantic

star anise and melamine adulteration of


F

which in the past has been substituted for glycerin with deadly consequences. Diethylene glycol has been fraudulently added to wines and also used as an adulterant of glycerin in pharmaceuticals. In addition to identifying specific food ingredients and food categories vulnerable to adulteration, the researchers also analysed the types of analytical detection methods used to discover the fraud, as well as the type of fraud using three categories: replacement, addition or removal. High-performance liquid chromatography and infrared spectroscopy were the most common analytical detection procedures and chemometrics data analysis was used in a large number of reports. The authors found 95% of records involved replacement - an authentic material replaced partially or completely by another, less expensive substitute. An example is the partial substitution of olive oil with hazelnut oil. Other examples include potentially harmful substitution of toxic Japanese star anise for Chinese star anise (a common spice used in foods) and the partial replacement of low-quality spices with lead tetraoxide or lead chromate to imitate the colour of higher-quality spices.

Utility of database The database provides information that can be useful in evaluating current and emerging risks for food fraud. In addition to providing a baseline understanding of the vulnerability of individual ingredients, the database offers information about potential adulterants that could reappear in the supply chain for particular ingredients. For example, records in the database regarding melamine as an adulterant for high-protein-content ingredients date back to 1979. Speaking to that example, the paper notes, “Perhaps if this information had been readily available to risk assessors before the 2007 and 2008 incidents of melamine adulteration and wheat gluten and milk powders, it could have helped risk assessors anticipate these adulteration possibilities.” This information also could have stimulated research aimed at developing new methods to measure protein content, which could signal adulteration with melamine and other unexpected constituents - an effort that has only recently gained substantial interest. Another practical application of the database involves analytical testing strategies to detect food fraud. A commonly used strategy at present is testing for the absence of specific adulterants - an approach that excels at detecting known adulterants at very low levels but has the critical limitation of not necessarily being able to detect unknown adulterants. An alternative strategy is compendial testing (via FCC and other sources) for the identity, authenticity and purity of a food ingredient (ie, what should be present and in what quantity instead of what should not be present). While this testing may not always be capable of detecting adulterants at trace levels, it is capable of detecting both known and unknown adulterants. “Well-designed compendial testing approaches can be a very powerful tool for guarding against food fraud,” said Dr Moore. “Their potential to detect both unknown and known adulterants is a significant benefit in an environment where no one knows and is worried about what harmful adulterant criminals will use to create the next generation of fake food ingredients.” The USP Food Fraud Database is publicly accessible at www.foodfraud.org. www.foodprocessing.com.au

May/June 2012

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PROCESSING

ood fraud is generally recognised as a collective term that encompasses the deliberate substitution, addition, tampering or misrepresentation of food, food ingredients or food packaging, or false or misleading statements made about a product for economic gain. A more specific type of fraud, intentional or economically motivated adulteration of food ingredients has been defined by US Pharmacopeial Convention’s (USP) Expert Panel on Food Ingredient Intentional Adulterants as the fraudulent addition of non-authentic substances or removal or replacement of authentic substances without the purchaser’s knowledge for economic gain of the seller. Currently, it is difficult to know the adulteration risks associated with different foods as a comprehensive compilation of information about known problematic ingredients and detection methods has not existed - until now. The USP has created a database that provides baseline information to assist users in assessing the risks of specific products. The database includes a total of 1305 records for food fraud based on a total of 660 scholarly, media and other publicly available reports. Records are divided by scholarly research (1054 records) and media reports (251 records) and will be published in the USP’s Food Chemicals Codex, 8th edition. Future expansion of this database will include additional publicly available articles published before 1980 and in other languages, as well as data outside the public domain. Researchers Drs Jeffrey C Moore (lead author) and Markus Lipp of USP, and Dr John Spink of Michigan State University analysed the information in this database and their paper, ‘Development and Application of a Database of Food Ingredient Fraud and Economically Motivated Adulteration from 1980 to 2010’, has been published in the April 2012 Journal of Food Science. While traditionally considered primarily an economic issue and less a consumer safety threat, the authors of the paper defined empirically that in some ways food fraud may be more risky than traditional threats to the food supply. The adulterants used in these activities are often unconventional and designed to avoid detection through routine analyses. Melamine, for example, was considered neither a potential contaminant nor an adulterant in the food supply before the episodes of adulteration of pet food in 2007 and infant formula and other milk products in 2008 (with tainted products still appearing sporadically today, principally in China). Although, as records from this database indicate, melamine was used as an adulterant to mimic protein as early as 1979; however, this remained virtually unknown until 2007. Hence, testing for melamine was not included in routine quality assurance or quality control analyses. Additionally, current food protection systems are not designed to look for the nearly infinite number of potential adulterants that may show up in the food supply. “Food ingredients and additives present a unique risk because they are used in so many food products and often do not have visual or functional properties that enable easy discrimination from other similar ingredients or adulterants throughout the supply chain,” the paper states. Glycerin, for example, is a sweet, clear, colourless liquid that is difficult to differentiate by sight or smell from other sweet, clear, colourless liquid syrups - including toxic diethylene glycol,


CE compliant safety air guns Exair has announced that its range of safety air guns has attained the CE mark through independent laboratory testing, meeting the EU’s rigorous safety, health and environmental standards. The air guns are suitable for blow-off, drying or cleaning and are available through Compressed Air Australia. Designed to maximise entrainment of room air while minimising compressed air consumption, the company’s products use engineered air nozzles for high

PROCESSING

performance. The range includes precision, soft-grip, heavy-duty and super-blast safety air guns. Precision safety air guns are lightweight and comfortable to operate during periods of extended use. The small diameter nozzles can fit into tight spaces while providing strong blowing force. Soft-grip safety air guns have a durable cast-aluminium body suited to rugged industrial use. The ergonomic design has a large trigger for easy operation and a hanger hook for storage. Extension pipes and stay set hoses for hard-to-reach areas are available. Heavy-duty safety air guns are powerful air guns with a durable cast-aluminium body that is suited for heavy use in rugged industrial environments. The ergonomic composite rubber grip and wide curved trigger are designed for comfort during extended use. Extension pipes for hard-to-reach areas are available. Super-blast safety air guns provide strong blowing force suitable for long distance, wide area blow-off and cooling and drying applications. The comfortable foam rubber handle provides a firm grip and the spring-loaded valve instantly shuts off the air supply if the air gun is dropped. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/M311

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May/June 2012

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Heat stress meter The Lutron WBGT-2010SD heat stress meter measures indoor and outdoor wet bulb globe temperature (WBGT) values, black globe temperature, humidity, air temperature, wet bulb temperature and dew point and is designed for objective assessment of working conditions in extreme weather. Objective criteria for determining appropriate levels of outdoor physical activity can be valuable for manual labour in industrial situations, as they provide clear

PROCESSING

parameters for appropriate action. The US military developed the WBGT basis for their training camps, and it has since become widespread for workplaces and sports activities. The WBGT Index is useful for providing guidelines for work breaks and restrictions on intense activity. Temperature and dew point values can be read on the device’s display and logged to SD card memory. An audible alarm attracts attention if conditions change. Data can be logged automatically in real time at intervals from 1 to 3600 s with unlimited records or manually, by button press, to 99 readings. This means any decisions made on activity can be backed up by factual evidence of environmental conditions at a given time. The SD card can be transferred to a PC and data analysed and saved using a standard spreadsheet program. ECEFast Contact info and more items like this at wf.net.au/M317

Cooking oil sensor Testo AG has introduced its testo 270 - a sensor for testing total polar materials (TPM) and temperature measurements in cooking oil. The device measures whether cooking oil is still within the optimum range or whether it needs changing. The Auto-Hold feature - an automatic final value recognition - provides an audible signal once the measurement has been calculated. The percentage value is clearly displayed on a backlit display, while an alarm bar based on the traffic light principle shows the status of the cooking oil: green means it falls within the optimum range, yellow means it is still acceptable and red means it needs to be changed. Users can adjust the limit values depending on individual quality requirements. In addition to the TPM measurement, the testo 270 also has a temperature warning system that is triggered when the oil temperature exceeds 190°C. To allow rapid testing, the sensor has been designed to be rapid, even when only a small quantity of oil is present, such as in flat fryers. It also has a metal cover and is laminated with a protective layer to protect the sensor from breaking and scratching. The sensor is watertight due to a TopSafe protection case, which can be easily removed and is dishwasher-safe. An optional handstrap is also available. Testo Pty Ltd Contact info and more items like this at wf.net.au/M921 www.foodprocessing.com.au

May/June 2012

39


UnitecH indUstries Nutritional Beverages Premixes

Solenoid valve range Rotork Australia’s Fluid System division has available the Bifold Group range of direct mount solenoid valves, manifold and accessories for general valve actuator applications. These valves are available in 3/2 or 5/2 5/3 port configurations.

Precision Powder & Liquid Blending

Compact in design, the solenoid valves feature a NAMUR mounting pattern, according to

Tablet Manufacture

VDI/VDE 3845, that is designed to mount to any NAMUR valve actuator. This may reduce

Sachet Packing

actuator response times, space requirements and also negate the need for a back plate.

Product Design Services

Rotork claims that installation costs are lower as the need for tubing fittings, brackets and

PROCESSING

assembly labour are reduced. All mounting screws and seals are included with the valve.

Unitech Industries specialise in the custom manufacture of nutritional beverages and premixes for the New Zealand and International food, dairy, beverage, bakery and pharmaceutical industries. Unitech can assist with the provision of a range of services surrounding the supply of your product including; formulation design, product validation trials, regulatory and or label claim compliance, sourcing materials, manufacture, quality assurance and delivery. Contact Unitech to determine the possibilities for improving and developing your quality products to create new market opportunities. •

innovation

Precision

trust

commitment

The solenoid valves have a mounting/spacer block which is free to rotate through 360°. This feature prevents the solenoid housing from coming into contact with the switch box and ensures the filter regulator remains upright. The range also includes the manifold option which incorporates the NAMUR interface kit, based on the AXIS system, allowing the direct mounting of, for example, filter regulators and check, flow control, pressure relief and manual valves. Rotork claims the system will accommodate all valve actuators in any orientation, resulting in no restrictions. The multifunction rotating system includes: inlet/exhaust flow control valve, high flow quick exhaust valve and optional fully rotational filter regulator. The robust design is manufactured from 316 L stainless steel with an operating temperature range of -60 to 180°C, complies with worldwide approvals Ex d, Ex ia, Ex emb and is explosion-proof. A wide range of override options is available including auto reset, spring return manual override, stayput manual override, manual reset, tamperproof manual latch and latch energised. The solenoid valve assemblies have SIL 3 third party certification to IEC 61508. Rotork Australia Contact info and more items like this at wf.net.au/M871

Recordkeeping program Key Technology’s FoodSafetyPRO is designed to help food processors improve their recordkeeping. The program is available for new and installed G6 optical sorters - Manta, Optyx and Tegra - as well as G6 ADR Automatic Defect Removal Systems.

sales@unitech.co.nz www.unitech.co.nz

FoodSafetyPRO is a multidimensional program that combines four elements: a comprehensive system audit, RemoteMD Premium real-time equipment monitoring, online equipment training for one year and online HACCP training for five HACCP operators and one HACCP manager. The system audit certifies the sorter or ADR meets OEM specifications or provides a list of issues to resolve. The certification provides documentation that the sorter or ADR meets OEM criteria. RemoteMD Premium remotely monitors the sorter or ADR, looking for issues or changes to settings that may require corrective action and alerting the user if problems are detected. A secure two-way remote session between the sorter and a Key service technician can be initiated, reducing in-plant service calls and improving resolution time. RemoteMD Premium tracks and records changes to the software including changes to the application settings from the user interface. It also reports the history of alarms and collects and reports data on product metrics. Key’s online training program offers up to 60 self-paced training modules that cover the hardware, software and user interface of the sorter or ADR as well as Iso-Flo conveyors. Online HACCP training covers many of the preventative food safety principles of the FSMA as well as SQF and GFSI certifications, exploring the concepts as well as the actions that may be needed to implement an effective HACCP plan. Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/N109

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Biological drain cleaning treatment Drainbo Drain Cleaner is a biological drain

Long-range inductive proximity sensor

treatment designed to improve the flow of drain lines without the hazards associ-

Turck has released a long-range inductive

ated with chemical drain cleaners. The

proximity sensor, the Q42, that uses FDA-rated

active ingredient is a bacterium which,

materials for wash down applications.

once activated by warm water, enters the pipeline to digest fat, oil, grease and

front-facing model - is an addition to the uprox+

organic proteins that can cause block-

range of factor one sensors that require no cor-

ages. Once in the drain, it continues to

rection factor to detect any metal type. It is designed for use in applications that require

work for weeks, digesting material that

frequent cleaning with chemicals found in food and beverage applications or where the

cause clogs.

sensor is exposed to wet environments, such as car washes or outdoor applications.

Unlike conventional chemical drain

Featuring a durable stainless steel connector, the device has a PA12 thermoplastic

cleaners, Drainbo does not dilute in the

housing that is resistant to chemicals and caustic cleaning agents, as well as shock

pipeline, so it can be effective along the

from impact. Additionally, the housing materials are food-safe and meet FDA Regulation

length of a drain. It is also non-toxic,

21CFR 177, 1500(9) for the US and FDA/EGVO 1935/2004 for the EU.

non-hazardous and readily biodegradable

The Q42 features integrated pre-damping, providing designers with the flexibility to

and does not contain bleach or ammonia.

partially recess the sensor into their design.

Drainbo is suitable for use in busy

The existing uprox+ washdown family is comprised of 12, 18 and 30 mm diameter

commercial kitchens and can work ef-

barrels with sensing ranges between 4 and 30 mm. The Q42 offers a sensing range of

fectively in conjunction with Drainbo

50 mm to all types of metals. This not only eliminates the need to change the position

Drain and Grease Trap Treatment to deal

of the sensors for different metal applications, but also reduces the number of sensor

with potential issues such as clogging,

types needed for plant operations. In addition to an extended sensing distance, the Q42

flooding and unpleasant odours.

delivers reliable operation in temperatures ranging from -40 to 100째C.

CIPL Pty Ltd

Turck Australia Pty Ltd

Contact info and more items like this at wf.net.au/M323

Contact info and more items like this at wf.net.au/M870

Delivering Starfrost Spiral & IQF Freezers Milmeq - exclusive Australasian agent for the Starfrost Range of Chilling & Freezing Systems. Suited to food processing operations requiring continuous quick freeze or chilling for products such as meat, pastry, ready meals, poultry, pizza, potato products, seafood, desserts, bakery products, rice, pasta, vegetables, herbs, ice cream and more. Starfrost systems are tailored for each application and deliver an efficient, robust solution with low maintenance;

Spiral Freezers

Impingement Freezers

IQF Fluidised Tunnels

Multibelt IQF Tunnels

Contact Freezers Available as compact packaged units or larger custom designed site-built systems to suit your operational needs. Contact us to discuss your Chilling & Freezing requirements Offices in New Zealand & Australia. Partners worldwide. Installations worldwide.

Brisbane, Australia Auckland, New Zealand

www.milmeq.com

info@milmeq.com

Dunedin, New Zealand

+61 7 3340 1100 +64 9 526 5943 +64 3 477 7485

www.foodprocessing.com.au

May/June 2012

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PROCESSING

The Q42 - available in a top-facing model and


TDR level transmitter The Optiflex 1100C from Krohne is a 2-wire TDR level transmitter for measuring distance, level, volume and mass of liquids and solids. Its simple, compact design allows users to quickly

Industrial tablet PC

assemble the probe and attach it to a threaded connection. The device has been designed with no brittle

Phoenix Contact has available a 13.3″ touch screen industrial tablet PC.

PROCESSING

The basic version allows integration into an existing network via the standardised WLAN according to IEEE 802.11 a/b/g or via Bluetooth Class 1 and Class 2. With an optional expansion, it can also connect to a UMTS network or receive GPRS signals. The tablet PC is equipped with a 1.6 GHZ Z530 Intel Atom processor or with a dual-core processor clocked at 1.2 GHz for applications demanding high computing power. Its rugged casing conforms to protection class IP65, making the tablet suitable for both indoor and outdoor use. The tablet is lightweight and can be carried using hand straps or a shoulder harness. The PC has watertight USB, audio and RJ45 interfaces. It can be retrofitted with a barcode scanner or RFID wireless identification system for managing inventories. It uses two lithium-ion rechargeable batteries, which Phoenix claims allows for flexible operation independent of a power supply. The tablet’s

parts and is always top-mounted or in a bypass cage. It is suitable for applications that do not require a high level of accuracy and is an alternative to traditional level controls such as RF capacitance, conductive and DP transmitters. As TDR is a time-of-flight measurement and measures distance, usual variations of the dielectric constant - such as those due to a change of process temperature - do not impact the accuracy of the level measurement. Its performance is not influenced by sludge in the bottom of a tank, nor by dust, foam, vapour, agitated or boiling surfaces, changes in pressure and temperature or changes in dielectric constant and density. The 1100C offers good repeatable signal for storage of general liquids and solids, buffer tanks, sludge and condensate collectors and more simple process

zero power management minimises battery discharge while in idle state.

applications.

Phoenix Contact Pty Ltd

Krohne Australia

Contact info and more items like this at wf.net.au/M556

Contact info and more items like this at wf.net.au/N214

Production Optimisation Solutions for Consumer Packaged Goods Industry Today’s successful manufacturers understand the value in integrating the factory from beginning to end, bridging islands of automation and carrying data throughout the plant to provide information for improving operations and reducing costs. An integrated information and control architecture offered by Rockwell Automation provides a foundation that enables flexible manufacturing, while simplifying the exchange of real-time data. www.RockwellAutomation.com.au www.RockwellAutomation.co.nz

FB_foodtech_April2012.indd 1

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Checkweigher range Checkweighers are usually positioned at the end of the packaging line to do a final check on individual product or package weight. But Thermo’s range of VersaWeigh checkweighers can also be used in the production process to control products that are volumetrically dosed, reducing the amount of giveaway. Suitable for packages up to 25 kg, the checkweighers can also be integrated with the Apex metal detector. They are available from JL Lennard. With large, easy-to-read colour touch-screen operation, the

PROCESSING

checkweighers use Windows XP and have configurable security access levels. Automatic set-up reduces the need for formal training, while contextual help-screens guide operation. A SmartZone display offers a snapshot of product information on the main screen, a bright ‘good/bad’ indicator, as well as a large, high-visibility weight display. Users can also access detailed views of production line performance, including product giveaway. The checkweighers have 100 standard product memories that are expandable and searchable by product or name. With few wearing parts, the checkweighers have full stainlesssteel frames, electronics enclosures, conveyor beds and hightorque, sealed, brushless DC motors. Rapid-release conveyor belts provide easy access for cleaning, while the trapezoid frame minimises bacteria traps. Rounded tube and cabinet surfaces help to avoid build-up of product. The range includes dynamic broad spectrum vibration analysis

SPX LAUNCHES THE NEW INNOVATIVE APV CAVITATOR

and compensation (DBSVAC) that minimises ambient environmental influences to improve performance, while a modular weigh-engine approach enables integration into larger packaging systems. JL Lennard Pty Ltd Contact info and more items like this at wf.net.au/M680

SPX has added an innovative new modular process technology to its family of mixing and dispersing equipment. The new APV brand Cavitator offers

Air knife kit Exair’s Deluxe Super Ion Air Knives are

breakthrough benefits for heating liquids without scale build-up as well as provides solutions for many of the most

available in kits from Compressed Air

difficult mixing and dispersing challenges for food and

Australia.

beverage processing. The APV brand Cavitator is another

The kits neutralise static electricity while blowing away dust and particulates from printed surfaces, paper, plastics and 3D shapes up to 2438 mm across.

example of how SPX continues to focus on innovation to better address the needs of its customers. SPX can leverage its extensive industry experience and process

An electronic flow control (EFC) turns the

expertise to support customers in applying the new APV

knife on only when it is needed.

brand Cavitator to their process. To learn more, visit us

Exair claims the knives are powerful static eliminators that prevent jamming, tearing, shocks and

at www.apv.com

dust up to 6.1 m away. The laminar sheet of air sweeps surfaces clean of static, particulates, dust and dirt. The knives require only 105 slpm of compressed air per 300 mm at 0.3 bar. Included in the kits are a Super Ion Air Knife, Model 7907 Power Supply, EFC, universal mounting system, shim set, filter separator and pressure regulator with coupler. Super Ion Air Knives are available in lengths from 76 up to 2438 mm. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/M603

Phone: +61 2 9763 4935 www.spx.com

www.foodprocessing.com.au

May/June 2012

43


Air and gas flow conditioner The Vortab VIP (Vortab Insertion Panel) is an air/gas flow conditioner that can maximise air and gas flow meter measurement accuracy and reduce flow meter straight run requirements. It is available from AMS Instrumentation & Calibration. The flow conditioner combines tab-type flow conditioning technology performance with the low-cost, simple installation of an insertion panel-type flow conditioner. In comparison with alternative technologies such as tube bundles, screens and perforated plates, tab-type flow technology can reduce line pressure drop, which may minimise plant energy consumption and costs.

PROCESSING

Many flow meter technologies, especially centre-point types, may require several diameters of straight pipe run for accurate and repeatable measurement. However, process industry plants often have elbows, valves and tees that can make it difficult to achieve the required pipe straight-run configuration for accurate flow measurement.

Fully sealed stainless steel waterproof monitor

requirements. Flow distur-

The ADP-1193T stainless steel fanless waterproof

bance can be reduced by in-

monitor is sealed to IP65 specifications on all

stalling the conditioner three

six sides.

pipe diameters downstream

The Vortab VIP conditioner addresses this problem by reducing pipe straight-run

The monitor combines a high brightness 19″

from the disturbance. Install-

300 cd/m TFT LCD and an analog resistive

ing the flow meter down-

touch screen in a thin stainless steel enclosure

stream from the conditioner

measuring 470 x 388 x 60 mm.

can result in a swirl-free

2

All external I/O, including the DC power input,

repeatable flow profile that

VGA and USB touch-screen port, use waterproof

enables accurate measure-

sealed connectors. The monitor is designed for

ment. The thin, lightweight

arm or pedestal mounting and is supplied with

panel design of the con-

VESA 100 standard mounting holes. Rear-mounted,

ditioner is easily installed

on-screen display controls allow the monitor to

between flanges or welded

be configured for different lighting conditions.

into place.

The ADP-1193T is designed to operate in tem-

The conditioner can be used with wide turndown or low flow sensitive flow meter

peratures ranging from 0 to 50°C. Its wide-range

technologies, such as thermal dispersion, which measure transitional flows. The

DC input (11 to 32 VDC) allows the monitor to

conditioner provides a repeatable flow profile during laminar, transitional and turbulent

be powered from almost any DC source, the

flow conditions. It has been tested in Vortab’s NIST traceable flow stands under

company claims.

actual installation conditions with elbows, valves, headers and other flow disturbers.

The monitor is suitable for industrial and process

The VIP flow conditioner comes in 316 L stainless steel in sizes from 50 to 999.9

control applications in food processing, medical

mm pipe diameters. Other construction materials and larger line sizes are available

and marine environments.

on request. The conditioner is available in both ANSI and DIN flange-mount or

Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/N178

weld-in-place configurations. The conditioner weighs less than 560 g per diameter, which means it is easily transported and installed on site without requiring special handling equipment. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/M319

Control & Power Switches Extensive Range of

Stainless Steel & Insulated Enclosures

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

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www.foodprocessing.com.au




©iStockphoto.com/Richard Clark

Chicken meat consumption in Australia is forecast to continue trending upwards according to the Australian Chicken Meat Federation and the Australian Bureau of Statistics. It is anticipated that consumption will increase from 43.9 kg per person in 2011 to 46.1 kg per person by 2015.

T

his is good news for Hazeldene’s Chickens as the company has recently upgraded and revitalised its plant on the outskirts of Bendigo, transforming it into one of the most advanced poultry processing facilities in the world. The family-owned company was established in 1957 by Dick and Mavis Hazeldene and the brand is now over half-a-century old. The Australian, fully integrated regional poultry processor is now owned and run by the second generation of the Hazeldene family. The comprehensive upgrade of the Hazeldene plant involved the construction of a new, cutting-edge processing facility on the family’s Lockwood site, approximately 15 kilometres from the centre of Bendigo. The processing plant is set on 1500 acres of land and is the only major business in the Lockwood area. Hazeldene’s is also one of the area’s largest employers. According to the revamp project driver, Adam Hazeldene, “The old plant had high maintenance and downtime costs, reduced productivity and downgrading of product quality as a result of being in use for more than twenty years.” He went on to explain that the new project “will improve animal handling and welfare for chickens, further enhancing ‘high’ standards of finished product quality and will significantly increase our overall productivity”.

lines and compressed air and sanitary lines for sanitising the plant post production, were all installed by Lab45. The company also refurbished the spin chiller from the old plant, supplied and installed the stainless steel drip trays and also supplied a bidirectional, cleated conveyor to divert product to trucks at the offal discharge area. The new plant was delivered on time over the March long weekend. Lab45 and Hazeldene’s maintenance staff worked hand in hand on the changeover weekend to remove the final pieces of equipment from the old plant which completed the mechanical installation of the new plant. The new plant’s layout was predominantly Marel Australia’s processing equipment and included a new receivals area, controlled atmosphere stunner, kill line, evisceration line and spin chillers that are used to bring product temperatures down after the birds are processed.

Improved animal welfare Hazeldene’s is focused on systems and procedures that increase animal welfare. The Marel processing GP Live Bird Handling System installed provides effective animal welfare. The modular system is easily installed and pro-

The new plant and equipment The Marel Australia poultry processing equipment, kilometres of stainless steel tube work including vacuum service lines for transporting product around the plant, steam www.foodprocessing.com.au

May/June 2012

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MEAT, POULTRY, SEAFOOD

Revamping Hazeldene’s chicken plant


MEAT, POULTRY, SEAFOOD vides for fully automatic washing, cleaning and disinfection programs. Also, live birds travel through a system of controlled atmosphere stunning. This offers several welfare advantages as the birds are numb and lack any feeling by the time they are hung on the shackles. Prior to atmospheric stunning, the traditional methods of hanging the birds on the processing line used to induce stress in the birds and the trauma resulted in lesser quality meat. The new system will surely increase consumer acceptability in terms of animal welfare.

Stainless steel for cleanliness and corrosion resistance Stainless steel tube and pipe is normally specified in food processing plants, as well as for pharmaceutical and chemical applications, due to its corrosion resistance and ease of cleaning. At Hazeldene’s, the vacuum, feather, steam and blood lines are all constructed of 25 to 300 mm diameter stainless steel tube. Various grades from 304 to 316 were specified in different applications, depending on the product being carried. Lab45 purge welders and tube fitters completed the welding requirements. The purge welding process is a technical and specialised process that significantly reduces bacteria counts in the tube. Without a purge, the weld and heat zone on the tube would be dark and crusty, easily corroded and impossible to maintain in any kind of sanitary condition. This process significantly reduces the accumulation of food particles and organic matter and thus minimises the opportunity for increases of microorganisms. The Lab45 crew is equipped with the latest orbital tube cutting machines which also assist in better sanitary outcomes. 48

May/June 2012

A Lab45 developed stainless steel bracketing system compensates for movement in the vacuum lines as product is fired throughout the plant. Sanitary washdown stations have been installed in 52 locations around the new processing facility. The stations provide easy access for cleaners to Maxifoam foaming sanitiser, Quatrasan disinfectant spray, hot and cold water lines and compressed air at each location. Hazeldene’s cleaners and maintenance staff simply hook on hoses at the desired station. Lab45 provided the design, fabrication and installation of the laser-cut wash stations. The stations are 304 stainless steel for sanitary purposes. Blucher stainless press fit systems were installed to feed each station via recirculation pumps.

Up and running The new plant was delivered on time and the plant’s production times were maintained throughout the installation process. Saleable cuts were made on the first day of the processing operation. Lab45 General Manager Miles Pepperall commented that “our company has been heavily focused on providing turnkey solutions to the Australian poultry market and is now looking to expand in building factories across the food processing industry. The new facility at Hazeldene’s is cutting edge.” He commended Hazeldene’s no-fuss approach saying, “the Hazeldene team has been great to work with. They assisted Lab45 in every way possible has been great to bring the installation together and I wish them every success in their new world-class facility.” Lab45 Contact info and more items like this at wf.net.au/N857

www.foodprocessing.com.au



Kemin has launched an antimicrobial for ready-to-eat (RTE) products. BactoCease is a propionic acid-based antimicrobial designed to protect RTE meat and poultry products from Listeria monocytogenes. The company says the product helps control Listeria, reduces microbial spoilage, extends shelf life and increases the safety of RTE meat and poultry products. “Until now, meat manufacturers have only had one primary option for Listeria control - lactates,” says William Schroeder, Director of research and development for the Food Technologies Division of Kemin. “BactoCease is a cost-effective lactate alternative on the market that has scientifically sound research demonstrating excellent, more consistent performance in controlling Listeria in RTE meat and poultry when compared to lactates.” According to Kemin, BactoCease has been shown to consistently inhibit Listeria in turkey, ham and roast beef for an average of 10-12 weeks. The product reportedly has no negative impact on the flavour of RTE meat and poultry products and apparently contributes to lower sodium levels in the finished product.

FSANZ announces decision on country-of-origin labelling for unpackaged meat

Meat

Unpackaged beef, sheep and chicken meat could soon be required to have country of origin labelling. Food Standards Australia New Zealand (FSANZ) has approved a proposal to extend country of origin labelling to some unpackaged meats. Food regulation ministers have been notified of the decision and have 60 days to seek a review. If no ministers seek a review, the decision will become law in Australian states and territories. There will be a six-month implementation period once the change is gazetted. The Australian Government asked FSANZ to address an inconsistency in country of origin labelling requirements for unpackaged meat after the rules for beef imports were changed in 2010, said FSANZ CEO Steve McCutcheon. FSANZ was also asked by food regulation ministers to continue this work following the recommendations of an independent review of food labelling headed by Dr Neal Blewett. “Research indicates country of origin information is important to consumers and is valued more in fresh food products such as fresh meat than other food categories,” McCutcheon said. “Mandating additional country of origin labelling requirements will ensure consumers are provided with access to this information consistently across the retail sector.” Many retailers already label products voluntarily, McCutcheon said, so the cost to industry as a result of the change is unlikely to be large. FSANZ said that beef imports have accounted for around 0.5% of beef consumption, while sheep imports accounted for 0.2% of consumption in recent years. Due to quarantine restrictions, Australia does not import any fresh chicken meat. 50

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Woolworths opens $31 million meat processing plant

NEWS

MEAT, POULTRY, SEAFOOD

Antimicrobial for RTE products launched

Woolworths has opened a $31 million extension to its meat centre in Bunbury, Western Australia. “The Bunbury Meat Centre is attached to a beef and lamb abattoir owned and operated by V&V Walsh. Having a meat processing facility together with a dual species abattoir makes the Bunbury Meat Centre a unique facility in Australia,” said Pat McEntee, General Manager of Fresh Food. “The extension has added over 4000 square metres to the current facility and includes new staff amenities and offices, a cold storage warehouse that can hold over 2000 pallets of chilled meat and a new meat production facility that consolidates Woolworths’ meat processing under one roof,” said McEntee. “In addition, Woolworths has invested over $3 million in equipment that will increase production and enable a greater variety of meat and value-added products to be manufactured. “The new facility embraces the latest technology in equipment and refrigeration that delivers world-class coldchain practices, guaranteeing the quality of our meat products delivered to our 84 supermarkets throughout the state.” Woolworths and V&V Walsh employ about 650 people at the site, with Woolworths employing a further 70 people for the expansion. McEntee said this makes the site one of the largest employers in the Bunbury and south-west region. The centre was opened by Terry Redman, Minister for Agriculture & Food, Forestry & Corrective Services on 21 March. Also in attendance were Mike Norton, President of the West Australian Farmers Federation and David Smith, Mayor of the City of Bunbury.


NEWS

Meat

Most foods contain acceptable sulfite levels, FSANZ study shows

This information is reproduced with the kind permission of FSANZ.

Webby Award for Beef Essentials iPhone app Reactive, Australia’s largest independent digital agency and Meat & Livestock Australia (MLA) have won the judges’ Webby Award in the category of ‘Mobile & Apps - Lifestyle’ for the Beef Essentials iPhone app. Beef Essentials is a simple and easy-touse guide for cooking the perfect steak. The app offers advice on selecting the right cuts of beef, the ability to choose from a range of cooking methods and even a cooking timer that tells you when to turn and how long to rest the meat before serving. “We are thrilled that Reactive has been recognised by such a prestigious global awards show for our work with MLA on the Beef Essentials iPhone app,” said Tim O’Neill, Co-Founder and Joint Managing Director, Reactive. “Reactive has experience in creating mobile apps for some of Australia and the world’s leading brands and we love providing our clients with userfriendly solutions that inspire and engage their customers.”

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MEAT, POULTRY, SEAFOOD

Most foods contain sulfites at acceptable levels, a recent Food Standards Australia New Zealand (FSANZ) survey has shown. The survey examined sausages, cordials and dried fruit and found that sulfite levels in almost all foods tested were well below those allowed in the Food Standards Code. “The results showed only three sausages, out of 156, had levels above the limits set in the Food Standards Code,” said FSANZ CEO Steve McCutcheon. “These exceedences have been reported to the relevant state or territory agency for follow up.” The survey was conducted as preliminary work on a proposal looking at the use of sulfites, McCutcheon said. Sulfites occur naturally in foods and in the human body, but are also used to preserve food. They also have antioxidant and antimicrobial properties. In people who are sensitive to sulfites, they can cause allergic symptoms and asthmatic reactions. The Code requires any added sulfites, above a certain level in a food, to be declared on the ingredients list. FSANZ says it “is considering the overall dietary exposure to sulfites across a wide range of food groups to ensure there are no food safety concerns for the whole population.”


Antimicrobial food additive for treating poultry Ecolab has launched a poultry export program featuring Inspexx 150, a peroxyacid-based antimicrobial food additive for treating poultry carcasses,

Range of food-grade lubricants Cassida, Fuchs’ range of food-grade lubricants, has been visually updated to minimise the risk of contamination

MEAT, POULTRY, SEAFOOD

due to human error. The updated product range will have a clean, white appearance to differentiate it from other non-food-grade products, and the range of grease cartridges and aerosols will be colour-coded according to application. The company claims the updated range will simplify processes, as users match colours for different applications instead of numbers and words. The labelling and colour-coding will allow manufacturers to integrate Cassida’s colour system into their HACCP policy program, claims Fuchs. Cassida products are registered by NSF International, a global standard that follows the guidelines of the US Food & Drug Administration. The products are also Kosher, Halal and ISO 21469 certified.

parts and trim. The additive is a direct-contact food tissue treatment that can reduce levels of Salmonella, Campylobacter, E. coli and total bacteria on poultry surfaces, and can help US poultry processors meet the unique microbiological and chemical requirements for exporting to Russia. Applied via spray rinsing and chill water, the additive is FDA cleared for direct contact with poultry carcasses, parts and trim. Inspexx 150 is a single chemical system that is compatible with processing equipment and complements the company’s range of food tissue treatments that help control

Fuchs Lubricants Contact info and more items like this at wf.net.au/N488

foodborne pathogens and spoilage microorganisms on food services. Ecolab Pty Ltd Contact info and more items like this at wf.net.au/M379

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Quick tests for EHEC in food Infection by the EHEC (enterohaemorrhagic ) E. coli pathogen is thought to be spread primarily through the consumption of contaminated food. A common key feature of these highly pathogenic serovars of

Radio frequency defrosting systems

and are divided into verotoxin 1 and verotoxin 2. Merck Millipore’s

Stalam Radio Frequency (RF) defrosting systems are tempering,

Duopath Verotoxin is a simple, quick, lateral flow test which can

softening and defrosting systems for food products including, meat,

be used to detect VT1 and/or VT2. The serogroup O157 (includ-

poultry, seafood and vegetables. The systems are available in Australia

ing H7) and other serovars, such as O26, O103, O111, O145

and New Zealand from Heat and Control.

and O14, can thus be detected indirectly by detecting verotoxins.

The RF systems ensure the product is defrosted to the correct

The product range also includes Singlepath E.coli O157,

temperature required for the next stage of processing. This is achieved

which detects the most common serogroup of pathogenic E.

in minutes rather than hours or days as can be the case with large

coli O157, which has been known about for a long time. Using

product blocks.

an immunological quick test, detection is faster than classic

The processing speed and uniformity minimises the risk of product

microbiological methods. It is easy to use and no additional

degradations such as drip losses, deterioration of sensorial, chemi-

instruments are required.

cal and physical characteristics and bacteria growth. This helps to

The Duopath Verotoxin and Singlepath E.coli O157 tests make

maintain product quality.

detection of EHEC bacteria easier than standard methods. They are

The systems enable products to be defrosted in large blocks and

simple, quick, lateral flow tests. The one-step design is conveni-

directly inside packaging such as carton boxes and polyethylene

ent, which reduces errors in application. Following an overnight

bags. RF equipment requires less floor space than traditional large

enrichment process, the kit delivers a positive or negative result

defrosting rooms and equipment.

20 minutes from inoculation of the test.

Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/N074

Merck Pty Limited Contact info and more items like this at wf.net.au/L190

introducing our latest

tray sealing machines...

Automatic in-line tray sealing system • 45+ packs per minute • Optional ‘free flow’ gas flush (MAP) available for extended shelf life

Automatic, large capacity, high speed in-line tray sealing system

Automatic, large capacity, high speed in-line tray sealing system

• 75+ packs per minute (GT1) • Optional ‘free flow’ gas flush (MAP) available for extended shelf life • New GT1V vacuum MAP in-line tray sealing system, designed to cut labour costs and produce up to 32 packs per minute

• 90+ packs per minute (GT2) • Optional ‘free flow’ gas flush (MAP) available for extended shelf life • New GT2V vacuum MAP in-line tray sealing system, designed to cut labour costs and produce up to 60 packs per minute

proven performance and reliability

contact us for more information Proseal Australia Pty Ltd Unit 4 16-18 Tennyson Street Williamstown Victoria 3016 telephone 03 9397 0955 fax 03 9397 1488 email info@prosealaustralia.com website www.proseal.com

www.foodprocessing.com.au

May/June 2012

53

MEAT, POULTRY, SEAFOOD

to detect this group. Verotoxins are also called Shiga-like toxins

the EHEC group is the build-up of toxins, which can be used


X-ray product inspection system Eagle Product Inspection has released the Eagle Pack 240 XE X-ray system. The system operates with Eagle’s SimulTask XE image analysis software, a traceability tool designed to aid compliance with HACCP principles. The company says the system will help food manufacturers comply with international food safety regulations and retailer guidelines and establish documented product inspections. The system can support a ‘supermarket package’, a software and hardware option offering control measures required by supermarket brands for product safety. This feature may reduce the

MEAT, POULTRY, SEAFOOD

possibility of human intervention to increase security levels in production lines. Eagle’s SimulTask image analysis software has a customised interface that simplifies product set-up to facilitate changeovers, reduce downtime and increase flexibility in the product inspection process, claims Eagle. It includes various operator log-in levels, allowing access rights only to designated users. Food Processing Equipment Pty Ltd Contact info and more items like this at wf.net.au/N584

Tray sealer for full vacuum trays Proseal has extended its range of tray sealers with the GT1V, a high-speed model offering a full vacuum system. While all existing Proseal models are capable of delivering gas flushing for MAP applications, the GT1V has been specifically developed for products such as meat and poultry where residual gas levels need to be less than 1%. At the same time, the machine retains the high-speed capabilities of the GT range, delivering a typical running speed of 8 cycles/min although this can be as high as 11 cycles/min for certain applications. Designed to accept randomly spaced trays from any conveyor and capable of being fully and easily integrated with other line equipment, the GT1V offers ease of operation, fast changeovers, easy access and reliability. User-friendly benefits include completely lead-less and hose-less connection of both gas and electrical supply, thanks to the GT1V’s auto connect tool docking facility, which means tool changes can be carried out in a matter of minutes. The machine also offers maximum flexibility with the option to run multiple depth trays on a single tool set. Further machine enhancements include tool diagnostics such as a leak test routine and cycle-time analysis, which can be accessed via the advanced touch screen. This provides full graphical operator interface and allows complete machine and tooling set-up to be fully ‘recipe’ controlled, with all settings easily stored for fast retrieval. The GT1V also offers an electronic gas mixer integration option where preset gas mixtures can be included as part of the recipe selection. Proseal vacuum machinery can also handle vacuum skin packaging applications which are growing in popularity for fish and meat. Proseal has also extended its vacuum range by introducing the GT2V. The GT2V model has all the same features as the GT1V and has increased capacity, sealing up to 60 packs/min with vacuum gas flush. Proseal Australia Contact info and more items like this at wf.net.au/N781 54

May/June 2012

www.foodprocessing.com.au



Kiel Industries Pty Ltd The Short Run Specialists Whilst most companies are suffering a downturn in the market place, Kiel Industries are expanding their world class facility in regional Victoria. Currently the Morwell facility provides an area of 4,800 sq. metre factory comprising the state of the art modern rotational moulding machines capable of producing products from bollard caps to 5000 litre rainwater tanks. The additional facility will provide another 2,500sq. metres to house another machine transferred from their Mirboo North site. Rotational moulding is best known for the manufacture of tanks, but it can be used to make complex medical products, toys, leisure products such as spas, and highly aesthetic point of sale products. Kiel Industries specialise in providing in house design with their own unique and affordable tooling facilities. Customers can take their ideas and have them transformed into workable products. With 20 years plus experience in design and manufacturing of quality materials handling equipment, Colin can design and guide customers through the process to finalisation. An innovative approach and sound engineering background has led to the development of a range of plastic bins. Made from robust UV stabilised materials, the Kiel range of bins have been designed for ease of use. The advantages of rotational moulding are: •

That hollow parts can be made in one piece with no weld lines or joints. The end product is essentially stress free.

Moulds are relatively inexpensive.

Lead time for the manufacture of a mould is relatively short.

Short production can be economically viable.

No material wastage in that the full charge of material is normally consumed in making the part.

It is possible to make multi layer products

Different types of products can be moulded together on the one machine.

The machinery at Kiel Industries is world class, having the only 3 of its kind in the world, Kiel Industries has the capabilities to manufacture from 1–10,000 parts for their customers depending on their requirements. For further information please contact: Kiel Industries on (03) 5135 3900


Returnable packaging and fit-for-purpose heat pads help Alba Edible Oils to grow

BULK

When West Australian manufacturer Alba Edible Oils set the task of moving its canola oil and tallow across the Nullabor, the challenge was not just cost-effectiveness, but finding a solution to a ‘sticky’ issue. Producing more than 60,000 L of canola oil a day at its 24/7 plant in Perth, Alba manufactures edible oils, fats and other ingredients for domestic and international food manufacturing and service industries. With a growth strategy aimed at increasing production by 60% over 12 months, Alba needed a business partner to accommodate this expanding capacity. Alba Edible Oils Chief Executive Officer and company director Ashley Palmer, whose family acquired WA-based Alba in the late 1990s, said CHEP’s returnable packaging system - featuring the HACCP certified Unicon Plus - was more cost-effective for Alba than a one-way packaging system. Alba also needs to quickly heat and decant tallow, which is solid at room temperature, into its customers’ on-site vessels. While CHEP’s existing heat pad suits medium-viscosity products that require a gentler heat (such as liquid sugar, honey and syrups), tallow requires heating at a higher temperature in a specific timeframe. To address this, CHEP worked in collaboration with Alba over several months to develop the Unicon Hi Temp Heat Pad. CHEP Australia’s Senior Business Relationships Manager, Peter Gaddes, said the project team ensured shipping efficiencies were maximised without risking the quality of the product. “The added benefit of using the Unicon Hi Temp Heat Pad for Alba is its flexibility, as it can be simply slipped into a standard IBC where and when the customer needs it and removed when they don’t,” Gaddes said. Ashley Palmer says the partnership with CHEP was built on a need to work with a supplier that could meet its growing demand for equipment and services. In addition to the heat pads, Alba uses specially designed co-extruded liners with the Unicon Plus units as well as CHEP pallets and CHEPStretch for load containment. Part of Alba’s growth is a new industrial non-food division which devises new uses for oils, particularly oils that can replace synthetic products with better environmental outcomes and better returns. “We’ve added a million litres a month to our capacity and we intend to grow this. CHEP has the capacity to grow with us and has demonstrated this in WA by being there for us at peak periods to keep up with production.” Chep Australia Contact info and more items like this at wf.net.au/N704

Motion controller Trio Motion Technology’s MC464 Motion Coordinator is based on the 64-bit MIPS processor and is claimed to help machines run faster. The MC464 provides interface options for traditional servo, stepper and piezo control together with many digital interfaces for current digital servo drives. Increase the flexibility of equipment with support for up to 64 axes of motion control. The MC464 supports programs written in TrioBASIC, allowing a smooth upgrade path from earlier series of Motion Coordinator. In addition, G-Code, HPGL and the standard IEC 61131 languages are supported, with full operation of the IEC 61131 language requiring a software licence. I/O expansion is provided via a built-in CAN Bus interface. Further fieldbus networks supporting common factory protocols are supported via the HMS Anybus adapter module. Every axis can be programmed to move using linear, circular or helical interpolation, electronic cams and gearboxes. Features include support for merging multiple moves that are typically generated by CAD/CAM software and support is provided for continuously rotating machinery. The axis expansion modules feature many options for drive network interfaces, analog servo, pulse/ direction, absolute or incremental feedback and accurate hardware registration. Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/M067 www.foodprocessing.com.au

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BULK

CHEP finds a sweet logistics solution for Haigh’s Chocolates Established in 1915, Haigh’s Chocolates is Australia’s oldest chocolate manufacturer. The fourth-generation, family-owned company has six stores across the country, including its original shop in the Beehive Building on Adelaide’s Rundle Mall. The company now makes and distributes more than 250 products - including the iconic Easter Bilby - at its factory just out of Adelaide city centre. The Haigh’s distribution centre manages up to 800 pallets with 100 to 120 transfers through the warehouse each week - and this doubles at Christmas and Easter. Not surprisingly, Haigh’s Distribution Centre Supervisor David Elliot said managing so many pallets was a challenge. “When we were getting the CHEP account in and we checked our pallets, we found we had more pallets than what we were being invoiced for,” said Elliot. “In warehousing terms, it’s just good governance to ensure the stock you hold matches your invoice. Haigh’s turned to CHEP to find a solution. “For us, our priority is to make sure we have our fine chocolates on the shelf, so when we came to a logistical obstacle with our pallets, we went straight to CHEP to draw on their asset management experience,” Elliot said. CHEP’s Asset Management Consultant, Rachel Silby, worked with Haigh’s to resolve the issue. “We sat down with Haigh’s, went through their problems and helped them implement simple processes to resolve their issues,” Silby said. “As a result, Haigh’s now has full transparency of their pallet management throughout the supply chain.” Rachel set up an asset management system to reduce the administration workload for Haigh’s. In addition, CHEP conducts a pallet count every month for Haigh’s. This helps identify any discrepancies and they can be dealt with immediately. “We went through our current processes and were given suggestions and ideas on how to improve and be more cost-effective,” said Elliot. “It’s taken a couple of hours off my weekly task. “To have CHEP’s knowledge of the system right behind Haigh’s has helped us in dealing with our suppliers. We’ve seen much quicker and more permanent responses to remedying discrepancies on our account. “Also, simple strategies such as tagging and tracking pallets have helped us locate our assets and make our logistics process more effective. We’ve also started using the Portfolio+ Plus system for ordering pallets, doing transfers, making corrections and keeping track of paperwork.” Having addressed their pallet logistics issue, Haigh’s can now make sure the Easter Bunny - and the Easter Bilby - always runs on time: “We now always know there are enough pallets in our manufacturing warehouses to cater for our demand of our outgoing goods,” Elliot concludes. Chep Australia Contact info and more items like this at wf.net.au/

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Modular gripper system The Tunkers modular gripper system, available from Romheld Automation, uses standard components that can be assembled to construct simple or complex robot grippers for applications where complex and difficult-to-handle parts are involved. Gripper elements such as finger-type grippers, vacuum cups, locating pins and proximity sensors can then be selected and mounted directly to the tubular frame via specific adaptors and clamps. Using the modular gripper system may reduce both design and build times, resulting in shorter lead times and lower costs. The company claims that, as the system is already well proven, there is minimum requirement for debugging, one of the major causes for projects running late. The Tunkers modular gripper system can be used in applications where flexibility and performance are required. It is suitable for both material handling operations and welding operations using pedestal welders. Grippers constructed from the Tunkers modular system can handle workpieces up to 4 x 2 m in size and 80 kg in weight. Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/M709



BULK

18-tonne lift truck The Crown CDV180S-7 18-tonne lift truck is claimed to offer more power than any other comparable IC vehicle. With a 1200 cm load centre, the CDV180S-7 delivers high levels of capability and capacity. The lift truck has a Tier 3 electronic control 254 HP 7.6l diesel engine that provides high torque at low revs, reduces fuel consumption and meets or exceeds current environmental requirements. This power and efficiency is matched by advanced synchronisation of the drive train with the vehicle’s hydraulics system. The driver cabin has a centrally positioned heated leather seat that gives a clear, uninterrupted view of the forks. Heating and cooling comprises separate air-conditioning and heating ducts for the dash and the roof, as well as an efficient defrosting nozzle for the front window. The dash is fitted with both digital and analog instrument panels, as well as a technically advanced sound system. Additional features of the CDV180S-7 include a rear-view camera, distancemeasuring infrared camera, wheel steering sensors, weight scales and an air compressor for general cleaning and maintenance of the driver’s seat and footwell. Operating the CDV180S-7 is easy, with all controls ergonomically located and with six roller bearings giving speed and precision to the lifting process. Ease of maintenance has also been designed and built into the CDV180S-7, with a tilting cabin and hood system, centralised fuse and relay box, centralised steering axle grease inlet and conveniently located control valve. Crown Equipment Pty Ltd

Material handling robot Adept Technology has introduced the Adept Viper s1700D, a 6-axis robot designed for material handling, machine tending, packaging, cutting and assembly. The s1700D robot features Adept ACE software, which deploys the robot through a user-friendly interface. The ethernet TCP/IP capability allows the robot to be controlled through a PC, PLC or controller. Selfdiagnostics enable proactive monitoring and quick troubleshooting. Offering a reach of 1.7 m and a payload capacity of 20 kg, the Viper is interchangeable with other Adept robots and controllers, which can ease deployment, support and maintenance, including parts availability. Adept Technology International Ltd Contact info and more items like this at wf.net.au/M262

Contact info and more items like this at wf.net.au/M222

Coordinated motion system The Allen-Bradley Kinetix 350 single-axis servo drive provides motion scalability. It connects and operates with the family of CompactLogix controllers, supporting integrated motion on EtherNet/IP. CIP Sync and CIP motion technologies provide real-time, closedloop motion control on standard ethernet. This topology-independent network provides a simplified integration of the entire control solution on one network, including programmable automation controllers (PACs), human-machine interface, I/O and motion. With its compact design, the Kinetix 350 requires less panel space and can be connected easily. In addition, users can reduce design, installation and commissioning time by re-using code across various Logix control platforms. Programmed with RSLogix 5000 software, the servo drive provides a scalable motion system to be used with ControlLogix and CompactLogix PACs. It is also equipped with embedded safe torque off. Its scalable platform is optimised for lower axis count systems. The Kinetix 350 supports 100 and 200 V single-phase and 200 and 400 V three-phase class voltage models. Power ranges from 400 W to 3 kW. Users can reduce commissioning time with the automatic drive identification of the MP-Series and TL-Series motors and actuators. Rockwell Automation Australia Contact info and more items like this at wf.net.au/N701 60

May/June 2012

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Slat lane dividers Cermex has expanded its range of packaging solutions with the 100% in-house manufacture of slat lane dividers, offering users the option of lane dividers as stand-alone machines or as part of complete end-of-line equipment. Lane dividers are designed to divert, distribute, sort, balance or collate primary or secondary packaging in preparation for the subsequent stage in the production line. Cermex’s slat lane dividers can be used for forming batches of primary and efficiency of a shrink-wrapper, case packer or palletiser may depend on the way products or batches are prepared. Cermex claims that by adding this range of slat dividers to its manufacturing it can now exert greater control on the synergy between its machines and upstream operations. Modules designed and manufactured in the same plant may benefit from the same management process for lead times and quality. In addition, the rationalising of components may help to optimise parts management throughout the machine’s life cycle. Cermex ran a program of 3D development, modular architecture, industrialisation and rationalisation prior to integration in the industrial process. In proposing the slat technology from design to manufacture, via the creation of a unit with a product manager and a dedicated team of technicians who are specifically trained in assembling these modules, Cermex claims to be capable of covering all its users’ requirements with slat lane dividers made by its own teams rather than purchased externally. Allied Industries Pty Ltd Contact info and more items like this at wf.net.au/M267

Food grade equipment supply! Now an australian made & owned company

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Brushware & Sundries: Anti Microbial, Metal Detectable, Huge Range including Scrapers and spatulas

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products prior to case packing or shrink-wrapping, or forming batches of packs or cases prior to palletising. The speed


Handheld computer Dematic has released the Psion Omnii XT15 handheld computer. Designed for rugged industrial operation, the

Modular wide belt conveyor FlexLink has released a modular wide belt conveyor.

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The company claims all components of the conveyor are standardised to make engineering, maintenance and operation easier. The conveyor’s modular design simplifies assembly and modifications. The system can be adapted to users’ different requirements. The flat, smooth belt surface may reduce the risk of scratches and the guide rails prevent items falling off. Available as components, modules or a complete system, FlexLink’s conveyor comes in three widths: 322, 424 and 626 mm. It is suitable for handling cartons, bundles, bags and other large individual items. It also allows large flows of smaller products. The vertical bends and a length of up to 15 m allow simple layouts in three dimensions without additional elevators in constant flow, the company claims. The conveyor operates at a maximum speed of 40 m/min.

XT15’s display can withstand a 1.25 joule impact breakage. The computer is fully modular, allowing users to change components when necessary rather than replacing the whole unit. Data capture options include a range of sensitive scanners with good/bad scan indicators, Imager Control Services (ICS) and cameras. An expanded wireless offering includes 3.8 G HSPA+ and 2G EDGE (WWAN-Broadband) and 802.11n (WLAN-WiFi). Six keypad styles are available, including QWERTY numeric. Each has an ergonomic design and ultrawhite backlight. The computer’s tri-sensor has an accelerometer, GPS and a digital compass to enable screen rotation, data geotagging, compass calibration detection and motion sense. The XT15 is IP67 rated and has a 500 mAH battery with a life of up to 20 h. Dematic Pty Ltd Contact info and more items like this at wf.net.au/N696

FlexLink Systems Contact info and more items like this at wf.net.au/N585

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Electric forklift range Toyota Material Handling Australia (TMHA) has launched its 8FBN range of four-wheel, counter-balance, battery electric forklifts. The 8FBN series consists of five models, ranging from 1.5 to 3 tonne rated capacity at 500 mm load centres, with a choice of masts, hydraulic controls and attachments.

Modular gripper systems Modular gripper systems from SAS Automation comprise extruded alloy profiles in seven sizes which are secured by a standard range of connectors and clamps to provide the basic gripper frame. To this frame a selection cups, sprue pliers and sensors etc. Users can order specific components to build up a gripper or alternatively select from a range of standard gripper kits which comprise everything needed to build a gripper. Both design and build times are reduced significantly and no special tools or equipment is necessary. A key benefit of the modular gripper system using standard parts is that the components can be re-used when new or redesigned workpieces are introduced. This means that grippers can be quickly rebuilt and costs are significantly reduced over the lifetime of the systems. The system also includes a low-cost, quick-change chuck which can be fitted to any robot for efficient tool changes.

charges and Toyota claims the range also offers improved safety and environmental performance, reduced operator fatigue and increased durability. The range includes an AC power system and improved equipment layout, as well as more efficient motors and controllers. The company claims these changes give around a 5% improvement in operating times over the 7FB models. 8FBN series forklifts include automatic turn-speed control which combines lift-height and load-weight-sensing along with turn-speed control to automatically limit the forklift’s speed when turning. Vehicle speed, acceleration and deceleration are limited at high lift heights, according to the load carried. Further options include a height selector, joystick controls, shock sensor, corrosion protection pack and a cold storage pack for operating at -45°C. Toyota also offers the choice of roll-in-roll-out or fork pockets at the bottom of the battery case for a side-out battery that can be used for multi-shift application. The active-mast function controller includes rear tilt levelling and an active steering synchroniser. Water resistance to IPX4 rating and zero emissions, including a design free of hexavalent chrome, mean the range is suitable for a variety of uses and may challenge some engine truck applications.

Romheld Automation Pty Ltd

Toyota Material Handling Australia Pty Ltd

Contact info and more items like this at wf.net.au/M601

Contact info and more items like this at wf.net.au/M625

The savings speak for themselves. The same efficient screening you have come to expect redesigned to be maintained by only one person in less time.

APEX ™ Dry Separation Screener

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www.ibulk.com.au

VIC / NSW: (03) 9768 3955 – SA / WA / NT: (08) 8339 7160 – QLD: (07) 3823 4405 – NZ: 04 387 7009

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of mountings is available to secure grippers, vacuum

Features such as pedal-stroke regenerative braking increase times between


Feeder controllers Enmin’s digital frequency controllers assist users to find the correct resonance frequency to ‘tune’ electromagnetic vibratory feeders. Electromagnetic vibratory feeders all suffer from the inherent problem of repetition of build since they all are a combination of a machined base and a fabricated tray or bowl. The latter being the problem since no two will ever be exactly the same. The result of this condition lies in tuning the electromagnetic feeder to achieve the best possible conveying rate. Tradition-

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ally, springs would be altered or weights added to the system to compensate. Enmin’s digital frequency controllers simplify the optimisation of the feeders. The FQIN model can be used to service vibratory feeders from 4 to 15 A power. Operating from a standard single-phase power supply, the simple push-button operation quickly searches for the resonance frequency; and combined with amplitude adjustment, the vibratory feeder is able to be tuned to its maximum potential. The problem of tuning any electromagnetic vibratory feeder is more apparent when the tray or bowl fabrication is of a more complicated design. For standard tray or bowl designs, the R series feeder controllers are acceptable. When multiple drives are employed either side by side or inline, the tuning function becomes much more difficult, so the FQIN overcomes this problem. Many other features are available as standard with the Enmin FQIN, such as password protection which denies access to unauthorised personnel, connections for operational feedback load sensors and delay start and stop functions. The digital readout display program provides a host of messages for the ease of operation, fault finding and operating conditions. The FQIN is built to IP55 standard and complies with European CE standards for electromagnetic compatibility. Enmin Pty Ltd Contact info and more items like this at wf.net.au/N759

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Layer picking robot Dematic’s 4-axis layer picking robot has a Qubiqa vacuum

Air compressor range Sullair Australia has introduced the Champion CSD compressor range and an additional larger model to its offers a combination of efficiency, output and quiet operation. Likewise, the CSE50 model extends the CSE range with a cost-effective 55 kW air compressor that is suitable for a broad spectrum of industrial ap-

It can accommodate most pallet stacking patterns, even those with a hole in the middle, and is capable of handling cartons, cases, bags, sacks, cans and bottles. Dematic claims the layer picker’s software enables the system to operate at efficiency rates of up to 150% and eliminate as much as 80% of manual handling. The robot has the company’s FreePick Maximiser software that cross-matches orders and pairs those with compatible order profiles. This can enable up to 50% of goods to be distributed without being handled, the company claims. The system also has reduced forklift operation and improved transport utilisation. According to the company, the system provides good pallet build quality, less product damage and fewer returns. Dematic Pty Ltd Contact info and more items like this at wf.net.au/N233

plications. The gear-driven CSD compressors are available in two sizes. The smaller 55 kW unit - the CSD55 - has an output pressure choice of 7.5 or 10 bar, and is rated for a maximum free air delivery of 163 L/s. The 75 kW CSD75 similarly has a choice of output pressures and can deliver a maximum of 210 L/s. The CSD range is suitable for mine-site operations and harsh operating conditions. Both lines are suitable for production or manufacturing environments. Rated at 55 kW, the CSE50 provides a belt-driven alternative and extends the CSE range from 15 to 55 kW. It has an output pressure of either 7.5 or 10 bar, and is rated for a maximum of 141 L/s free air delivery. All three compressors have IP55-rated motors, which are fully MEPS2 compliant and feature a totally enclosed fan-cooled design for low temperature rise. The compressors come with IP54-rated electrical cabinets, along with ‘deluxe control’ to provide multiple compressor sequencing, scheduled on/off switching and remote monitoring. The CSD55, CSD75 and the CSE50 can be upgraded to meet specific application requirements, with options including ‘dirty environment packs’, mine electrics and complete skid packaging. Sullair Contact info and more items like this at wf.net.au/M387 www.foodprocessing.com.au

May/June 2012

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existing CSE range. The CSD range

gripper head that provides versatility in product handling.


Bulk bag conditioner for loosening solidified material Flexicon has launched the Block-Buster bulk bag conditioner for loosening material that has solidi-

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fied during storage and shipment. The conditioner has two hydraulic rams and specially contoured end plates and operates by pressing opposing sides of bulk bags to loosen the solidified material, enabling bulk bag unloaders to discharge it through bag spouts. A cantilevered I-beam with motorised hoist and trolley allows loading and unloading of bulk bags without the use of a forklift. The bag can also be raised and lowered using the hoist and rotated manually for conditioning at any height on all sides. The system controller and hydraulic pump can be mounted on the exterior of the safety cage or remotely. The conditioner is fully enclosed on all four sides for operator safety and includes fullheight doors that are interlocked to halt operation of the system when the doors are open. The conditioner is recommended for bulk bags containing hygroscopic chemicals, certain spice blends, heat-sensitive products and other materials prone to solidifying. Some pneumatically actuated flow promotion ac-

Robotic palletising system ABB has launched the PalletPack 460, a preengineered package of proven robotic palletising components featuring the IRB 460 robot designed specifically for high-speed, end-of-processing-line palletising. The speedy, 4-axis IRB 460 features a 110 kg capacity plus a reach of 2.4 m. Its compact footprint makes it suitable for integration into existing packing lines, convenient for high-speed bag or compact end-of-processing-line case palletising. ABB’s PalletPack consists of an IRB 460 robot; a Flex-Gripper (either the claw or one-zone clamp gripper); a control PLC; a safety PLC; PalletWare support software; user documentation; and the FlexPendant featuring an easy-to-use graphical human machine interface. The PalletPack is claimed to be easy to work

cessories integral to bulk bag

with. There’s no need for any specialised robot

dischargers can be inefficient

programming know-how. Robot, grippers, safety

or ineffective for this use.

and cell control PLCs, graphical human machine

An optional hydraulically

interface and software come in the PalletPack all

actuated, variable-height

ready to plug in and perform.

turntable allows automated

A key feature of the PalletPack is the wizard-

in-frame bag rotation and

enabled set-up and programming, which makes

conditioning of bulk bags at

programming very similar to that used for a tradi-

varying heights. The number

tional PLC. This enables PLC programmers - without

and pressure of hydraulic

specific robotic experience - to program the system,

ram actuations, the height

eliminating the complications that can arise when

of the turntable, and the

a specific programming skill set is required. The

number of 90° rotations are

programming and operation are carried out via the

user programmable.

user-friendly FlexPendant, the standard ABB Robotics

The conditioner is offered

human machine interface. This features a graphical

as a stand-alone unit or

interface with four user-friendly screens: pallet and

integrated with the com-

pick set-up, pallet pattern set-up, path profile and

pany’s bulk bag discharging

movement edition.

systems. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/M455

It is claimed that programming time for the PalletPack 460 can be reduced by as much as 65% compared to traditional methods, shortening the return on investment and making robotic palletising more attractive to a wide range of end users. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/N694

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

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Robotic pallet layer picking solution Dematic has introduced an integrated robotic layer picking solution, combining an advanced robotic layer picker with software that enables the system to operate at efficiency rates of up to 150% and, in some cases, eliminate as much as 80% of manual handling. The layer picking system achieves high throughput rates via the FreePick Maximiser software. By cross-matching orders and pairing those with compatible order profiles, FreePick Maximiser enables up to 50% of goods to be distributed without them being handled at all. Dematic’s PickDirector warehouse control system initiates picking and orders the stock required for layer picking in the sequence required to fulfil the next

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wave of orders. Pallets of stock are automatically conveyed to the layer-picking robot where they go direct to one of several pick-and-put locations, which enable several orders to be picked concurrently.

Extended power range for AC drive Rockwell Automation has extended the power range of its PowerFlex 755 AC drives to 900 kW as well as adding 690 V ratings. The new drives, suited to a variety of heavy industrial applications, provide users with increased application flexibility, advanced diagnostics and a common DC bus option. Rockwell claims the extended range will help heavy industrial users reduce costs through improved flexibility, reduced downtime and low meantime to repair. The common DC bus option allows users to connect the drive to a common DC bus While the software requests pallets to arrive at the layer-picking robot in a

configuration, taking advantage of different

particular sequence to suit order assembly, the reality is that pallets occasionally

drive cycles to share energy. In this configu-

turn up out of sequence. Buffer storage locations enable such pallets to be

ration, a DC bus acts as a common energy

temporarily stored online until required. An empty pallet station accommodates

source that feeds energy from a generating

the production of multiple layer sandwich pallets.

load to a motoring load. Managing energy

As new pallets of stock are fed into the system, the layer picker selects the required layers and transfers the stock to customer order pallets. The 4-axis layer-picking robot is equipped with a Qubiqa vacuum head for better handling reliability.

from a shared source increases overall system performance and reduces losses, which can improve the application’s energy efficiency. The PowerFlex range includes an embedded

Completed orders are conveyed to despatch through check weighing, stretch

ethernet port and five option slots. Option

wrapping and labelling, meaning even greater savings in reduced handling.

modules include I/O, feedback, safety, addi-

Dematic Pty Ltd

tional communications and an auxiliary power

Contact info and more items like this at wf.net.au/N695

supply. A rollout design allows easy access to the drive for fast installation and maintenance. The drive’s converter and control pod remain in the unit while the inverter is rolled out, so control wiring can remain connected. In addition to the extended power range, a firmware upgrade for all PowerFlex 755 drives will contain interior permanent magnet motor control and a ‘stop dwell’ feature, which helps prevent a motor from coasting to a stop. This is suitable for converting applications, as it allows users to preconfigure the motor to perform a controlled stop to protect valuable motor investments. Rockwell Automation Australia Contact info and more items like this at wf.net.au/M335

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Despite surging energy prices and ever-spreading carbon taxes to counter global warming, many sections of the dairy industry are still pouring potential profit down the drain by overlooking the green energy potential of wastewater.

T

he industry has tended to treat its wastewater as a cost and place into which production process mistakes are flushed. “If there were spills or if a production product was out of specification, it would be flushed down the drain into the wastewater - that’s where the mistakes go,” said wastewater and green energy specialist Mike Bambridge, Managing Director of CST Wastewater Solutions. “Such outdated approaches have resulted in bigger and bigger lagoons that are both groundwater hazards and big consumers of expensive energy and fossil fuel because of the large energy-intensive aeration systems needed to treat their contents. They also create a lot of sludge and disposal problems.” In fact, wastewater represents a huge potential as a source of renewable energy, says Bambridge, whose company represents Global Water Engineering. GWE has built more than 250 plants producing biogas as part of the industrial effluent clean-up system, of which more than 75 were supplied with subsequent biogas utilisation systems for clients worldwide. Many of the latest installations use advanced technologies - including anaerobic pre-treatment of water and aerobic polishing - to enhance water discharge purities while converting waste to methane, to be burned to power boiler and hot water systems, for example, or to power generators and permanently replace fossil fuels. On average, the removal efficiency of GWE’s anaerobic wastewater treatment installations is as high as 90-95%, 70

May/June 2012

bringing the organic load down to regulatory discharge standards for most types of wastewater. GWE CEO Jean Pierre Ombregt says the concept of using wastewater to create green energy is much more widely applicable than often realised. “Any factory with a biological waste stream or wastewater with high COD (Chemical Oxygen Demand) can easily use this model to generate energy - particularly the dairy industry, for which technologies such as GWE’s Flotamet system, combined with its Dissolved Biogas Flotator (DBF), are specifically designed to take the high levels of fats and oils prevalent in dairy factory effluents,” said Ombregt. So far, most industries have mainly been focussing on treating their effluent to meet local discharge standards. By doing so, wastewater treatment installations have only generated additional costs and have never been seen as potential revenue generators in their own right. “However, applying anaerobic wastewater treatment sheds a whole different light on the cost structure of wastewater treatment infrastructure. It can now actually become a substantial, additional source of income for many processing plants,” said Bambridge. Dairy wastewater is actually well suited to anaerobic treatment. It can be followed by an aerobic polishing treatment if direct river discharge is required. There is no such thing as a standard dairy factory, nor a standard dairy wastewater treatment. There are different types of dairy factories with different products, all with very

www.foodprocessing.com.au

©iStockphoto.com/Grant Shimmin

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Green energy from wastewater


Power from effluent Wastewaters from the dairy industry are typically highly loaded with organic pollutants that can be treated advantageously by means of anaerobic processes. Closed anaerobic reactors generate large quantities of methane (CH4), from the organic materials in the wastewater, that can diminish or even completely replace the use of fossil fuels in the production process. To bring some perspective to the value, one tonne of COD digested anaerobically can result in 350 Nm3 of methane, equivalent to 0.15 MW of power. For specific industry applications with high organic loads, enough biogas can be generated to fully cover a factory’s energy needs and still have a biogas surplus to feed into power generators and sell electricity to the national grid, often generating carbon credits, where these apply, as well as profit.

For a greener footprint But it doesn’t end there. The GWE closed anaerobic process systems prevent large quantities of CH4 being emitted into the atmosphere. With CH4 being 21 times more harmful than CO2, GWE’s anaerobic wastewater solutions can also qualify for Emission Reduction Certificates for projects in countries listed under the United Nations' Kyoto Clean Development Mechanism (CDM) and Joint Implementation (JI) programs. Besides the economic advantage of efficient anaerobic wastewater treatment, there is clearly also an environmental advantage, significantly reducing factories’ carbon footprint. Benefits include: supplying renewable energy and thus reducing, or even eliminating, the use of fossil fuels; replacing more traditional, CH4-polluting open lagoons; and replacing

power consuming and sludge producing traditional aerobic wastewater treatment plants.

Can I also apply it to my factory? The main criterion for energy generating projects to become viable is the COD loading rate. The higher the organic load of the wastewater, the more biogas, and thus renewable energy, can be generated from it. Cost of fuel also plays a significant role. As the world is learning to live with higher energy prices, choosing anaerobic technology now holds the key to immediate and future safeguarding of power supply for many industries.

Choosing the right technology When selecting a suitable technology provider for wastewater treatment with biogas utilisation, it is crucial to partner with a reliable, experienced team, such as GWE/CST Wastewater Solutions. Between them, the two companies provide a solid track record in this field, complemented by more than 20 years of hands-on local wastewater experience. From the design to implementation stage and beyond, it is important to look at the feasibility of a biogas project, both technically and economically. It is extremely important to choose the right reactor configuration. Each industry has specific wastewater characteristics, requiring thorough analysis and subsequent careful selection of the most suitable reactor design for these characteristics. “Too often we have seen companies left disillusioned, after trying to implement anaerobic wastewater treatment with biogas reuse, in the past. Although anaerobic technologies have improved significantly in recent years, the world is still littered with too many examples of how it is NOT supposed to be done,” said Ombregt. A significant part of GWE revenue comes from customers who had bad experiences with anaerobic treatment in the past and are often left with empty hands. This is a shame, as it sheds a negative image on the technology when, in the right hands, it has so much to offer for a broad range of industries. Environmental initiatives such as green energy generations from wastewater treatment do not always get as much attention as the more traditional renewables, such as solar and wind. But in fact there is a huge, often hidden, potential in using wastewater as a source of renewable energy. CST Wastewater Solutions Contact info and more items like this at wf.net.au/M913

Michael Bambridge is the owner and director of CST Wastewater Solutions. With a background in chemical engineering, Bambridge founded the company in 1984 as Contra Shear Technology, supplying specialised, patented wastewater screens for the industrial and municipal wastewater markets. Since then, the company has flourished to become a premier provider of innovative wastewater treatment solutions throughout Australia and equipment supplier around the world. For clients requiring comprehensive solutions, CST constructs complete wastewater treatment plants in partnership with major specialist companies.

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different wastewaters, and also different levels of product recovery. In the end, the type of production determines the wastewater characteristics. The COD of dairy wastewater can be anything between 2000 and 10,000 mg/L and for cheese factories much more: 50,000 mg/L in case of no whey recovery. Also very important is the amount and type of fat, oil and grease (FOG). In case of ice cream and butter, there is a lot of FOG in the wastewater, but it can be easily removed by DAF (Dissolved Air Flotation). The Anubix-B system, sensitive to excess FOG in the wastewater, is most suitable. In other cases, particularly in the case of milk processing, the FOG in the wastewater is basically dilute milk and the fat is very much emulsified, so that a DAF cannot always remove it properly, even after chemical treatment. For this scenario, GWE offers two anaerobic systems that can treat dairy wastewater without or with limited FOG removal: the Anubix-C system and the Flotamet system. Although more expensive, those systems are often the best choice, to be preferred over a high-rate UASB or EGSB system, if the FOG removing pre-treatment (by DAF, with chemicals) results in problematic and expensive sludge disposal. The cost of this depends much on local possibilities for sludge disposal. Both the Anubix-C and, especially, the Flotamet system can effectively degrade moderate amounts of dairy fat, thereby avoiding big DAF sludge disposal problems. The Flotamet system degrades FOG best but requires a high operating temperature, in case of a high FOG/COD ratio.


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

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




©iStockphoto.com/Dragan Grkic

Packaging leads to 25% increase in beer sales

Packaging NEWS

AIP National Conference to host 34 speakers Thirty-four guest speakers from nine countries will present at the 2012 Australian Institute of Packaging (AIP) National Conference. The conference, held over 14-15 June at Surfers Paradise, is open to both members and nonmembers of the AIP and is ideal for those in the food, beverage, manufacturing and packaging industries. Keynote speakers include: Terry O’Brien, Managing Director, Simplot; Rick Fox, Chairperson of the Packaging Machinery Manufacturers Institute (PMMI); Peter Alison, General Manager of Brandpack; David Carter, Director of Environmental Strategy and Sustainability, Lion; Rachel Bermingham; and Thomas Schneider, President of the World Packaging Organisation. The conference will feature 12 international speakers, including: Morten Torngaard, PBI Dansensor; Erwink Vink, NatureWorks; Maxence Vanderlynden, Sidel; and Andy Sweetman, European Bioplastics Association.

The Australian Packaging and Processing Machinery Association (APPMA) in conjunction with the Australian Institute of Packaging (AIP) are pleased to announce that submissions are due on Friday 11 May for the fourth annual scholarship program, which will enable a packaging engineer the opportunity to complete a Diploma in Packaging Technology. According to Mr Mark Dingley, Chairman of the APPMA: “The Diploma in Packaging Technology is a Level 5 qualification which is internationally recognised for those wishing to pursue a career in the packaging industry or for those who are already in the industry and who wish to extend their knowledge and expertise. It has been offered by the AIP continuously since 1980 and has an exemplary record of successful students.” “The Diploma prepares students to take responsibility for packaging operations at any level through the supply chain. The qualification is comprehensive and provides an opportunity to study the principles of packaging, packaging materials and packaging processes.” There are two broad target groups for the scholarship: 1. People currently employed in parts of the packaging industry who want to broaden their knowledge and understanding and take on greater levels of responsibility. Due to the diverse nature of the packaging and related industries, it is difficult to define this target group in terms of precise job functions. 2. People who are currently employed in the industry, who may be following courses in associate subject areas such as packaging design, food science/technology, materials science/engineering and logistics, will find that this program broadens the scope of their studies. In designing the course, the principles of constructive alignment have been employed, eg, the intended learning outcomes, which reflect the requirements of industry, clarify the course objectives. Pierre Pienaar, FAIP, National President of the AIP, added that the Institute is grateful that associations like the APPMA recognise the importance of education and training and are contributing to the growth of the packaging industry as a whole in Australia. Submissions are now open for the APPMA 2012 Scholarship program.

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O-I’s Vortex bottle has played a major role in a sales boost for Western Australia’s Gage Roads Brewing Co. The company has reported a 25% year-on-year increase in its Wahoo Premium Ale sales, since the introduction of O-I’s Vortex bottle and changes to the beer’s label and secondary packaging. In June last year, Gage Roads became the first company in the Asia Pacific to launch the new internal-embossed Vortex bottle, featuring distinctive grooves on the inside of the bottle’s neck while providing a smooth exterior for easy labelling. Gage Roads Brewing Co’s CEO, John Hoedemaker, said the changes to Wahoo Premium Ale’s packaging had a significant impact on sales. “The introduction of the Vortex bottle and colour changes to the brand’s label and secondary packaging had a positive impact on sales,” said Hoedemaker. “We’re delighted this innovation in glass packaging has led to more consumers experiencing Wahoo and its awardwinning great taste.” The Gage Roads Wahoo Vortex bottle was designed in Melbourne and is manufactured at O-I’s Sydney plant. Other internal embossing designs are available.

APPMA 2012 Annual Scholarship - Submissions now open


©iStockphoto.com/ José Luis Gutiérrez

PACKAGING

Accurate and efficient barcode inspection Simon Webb, Product Support Engineer, Micromax Sensors & Automation

Standards for product and ingredient quality are continually being raised due to stringent agency regulations, increasing the importance of barcode reading, verification and grading in many inspection processes. Historically used in the pharmaceutical industry for traceability purposes, barcodes are now commonly used for a similar function in food and beverage applications, allowing a recalled product to be rapidly identified and traced back to its manufacturing source, easing the recall process.

M

achine vision is often used for barcode inspection in the food and beverage industry, as the appropriate combination of vision sensor hardware, software and lighting can deliver efficient and effective analysis in these applications. When utilised for barcode reading (BCR), a vision system can ensure each product on a packaging line contains the proper barcode - which in turn contains the proper manufacturing location and product identification data. For instance, UPC symbols include five digits of data about the specific product and five digits about the product manufacturer. The ECC 200 Data Matrix, a two-dimensional barcode symbol type, can significantly increase the amount of data stored within a code; a single data matrix symbol can encode up to 2335 numbers of 1555 ASCII characters. In both of these cases, vision sensors capture an image of the barcode on the inspected product and then analyse the captured image to ‘decode’ the symbol, thus ‘reading’ the code to verify its contents.

Barcode grading Vision sensors may also be applied to grade barcodes. Grading is used to ensure each product contains a clear, high-contrast and complete code that can be successfully read during the manufacturing process. Barcodes also must be successfully read once the product reaches shipping, retailers and finally, consumers. This provides a trail of product information, from origin to expiry details. Grading is performed on an A to F scale based on a number of parameters, including ‘Symbol Contrast’, which involves how well the black and white portions of a barcode 76

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can be distinguished from one another. If the barcode does not exhibit sufficient contrast between these two elements, it may be illegible downstream. A successful vision inspection, which is paramount to maintaining food safety and efficient data collection, will not only grade a barcode but will also reject a product if it fails the inspection. Irregularities or defects present within the codes can be detected, thus preventing future rejected products and avoiding costly returns and recalls. Barcode grading can also indicate when a system’s barcode marker needs replacement or repair. For instance, information that the device marking the barcodes may be low on ink allows companies to address the concern immediately to avoid further rejected products.

Barcode inspection through vision Most vision sensors with BCR capabilities can distinguish a barcode placed at any orientation, on the condition that the entire code falls within the camera’s field of view. The barcode symbol’s overall size is often not a concern. Some data matrix symbols can consist of cells as small as 0.025 mm on a side, yet such marks are decipherable by a vision sensor with the proper lens. However, in order to be successfully read, the barcode must meet certain resolution requirements. For most applications, the narrowest bar in a linear code must be at least three pixels wide in order to be legible. This parameter also applies to the cells within a data matrix. Just as contrast is a crucial factor in effective barcode grading, the contrast between the barcode symbol and the material on which it is located is just as essential to a vision inspection’s success.

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Machine vision software The final element of a vision system is the vision software, which includes all programming and image algorithms required to monitor, analyse and control an inspection. This component establishes whether a barcode is present, if it contains the correct data and if the physical barcode symbol is legible. The BCR tool allows the vision sensor to capture the full barcode as an image containing both light and dark patterns for analysis. The sensor is then able to compare these light and dark patterns to the barcode symbol standards stored in

PACKAGING

Ambient light within a factory environment frequently does not illuminate a product’s barcode evenly enough for a vision sensor to constantly obtain a clear image of the code. Even if ambient lighting is plentiful, plant windows or skylights often cause it to be inconsistent. Poor lighting affects the vision sensor’s ability to read a barcode consistently from product to product, leading to unreliable results. A dedicated vision lighting solution produces the necessary contrast to acquire accurate, repeatable results from a vision inspection. Of the numerous varieties of vision lighting types and techniques available, ring lights are the most commonly used illumination solution for barcode inspection. Mounted directly to the camera, ring lights surround the camera lens and aim light towards the barcode. This dedicated lighting method provides adequate and uniform lighting, allowing the vision sensor to consistently obtain an image with high accuracy. For long-lasting illumination, ring lights are available utilising LEDs, which offer a usable life of 100,000 hours. Lighting is one of several components that constitute vision sensor hardware, which also includes the camera, processor and lens. For BCR applications, selecting vision hardware should be based on the size of the barcode and how it is positioned within the camera’s field of view. The size of a barcode symbol can vary greatly, from several centimetres to less than a millimetre wide. The field of view provided by the lens should accommodate the barcode’s size, as well as the entire product region on which the barcode may be placed. For applications where barcodes are mechanically stamped or applied in precisely the same location each time, a smaller field of view is generally sufficient, enabling the use of a standard resolution camera in many cases. If the barcode is hand-placed, the field of view must be expanded to include the entire product region on which it may appear. In these instances, a high-resolution camera should be used to ensure the code’s narrowest bars or cells, when captured by a camera, are at least three pixels wide. The key to how a vision sensor interprets a barcode is the sensor’s operation as, essentially, an electronic light meter. The vision sensor’s imager chip comprises photosites - light-sensitive elements that generate an electronic signal proportional to the amount of light to which they are exposed. Each photosite on an imager chip is linked to a pixel, which portrays the obtained light value from dark to bright - ranging from 0 to 255 - on an 8-bit grayscale. In these terms, when contrast is created, it yields a greater numeric difference between pixels in the dark and bright portions of the barcode, making these variations easier to detect.

Mustard bottles on a production line are inspected to ensure each bottle contains the correct bar code data. the software. If the light/dark line and space variations can be recognised as a known barcode symbol type, the data can be decoded. After this determination has been made, the vision sensor uses communication tools to send inspection data via serial or ethernet communications to a PLC or PC. Sensors that offer configurable I/Os do more than share the collected inspection data - they apply it by categorising products according to the data that each barcode contains, as well as diverting any incorrect or illegible barcodes from the line. While the results of a vision inspection are comprehensive, the selection, set-up and programming of the sensor can be complex. Prompted by the explosion in touch-screen-driven consumer electronic devices from recent years, some vision sensors now offer an all-in-one solution that provides the same comprehensive inspection capabilities within a selfcontained design. This type of sensor features an integrated touch screen for on-site programming but also offers a USB port to upload and download inspection parameters and results to and from a PC. A simple-to-apply design accelerates operator training and decreases the programming time required for setting up a barcode inspection, all while allowing users to monitor and control the inspection in real time on the plant floor, with no external PC or other components required. With the combination of these innovations, a wide range of hardware options and sophisticated BCR capabilities, machine vision delivers a reliable, repeatable solution for barcode inspections to the food and beverage industry. Micromax Pty Ltd Contact info and more items like this at wf.net.au/N783 www.foodprocessing.com.au

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Self-adhesive label applicator The Herma 400 form, fill and seal self-adhesive labeller can be integrated to apply self-adhesive labels for reseal tabs, promotional messages or to add or correct information on the pack. Herma claims its compact label

PACKAGING

applicator can be easily integrated into a form, fill and seal or flow wrap machine. A range of modules and accessories enables mounting in a range of applications or machines - vertical or horizontal. Full motion control allows the speed of the labeller to

Fairytale ending for compostable packaging film

be matched to the speed of

Innovia Films’ compostable cellulose-based material, NatureFlex, has been selected by Miss Muffet & Co, to wrap its range of fairytale- and nursery rhyme-inspired premium confectionery. Miss Muffet & Co is a UK-based company, set up by Sarah Cadman, who has a philosophy of using natural ingredients wherever possible. Outlining why she chose NatureFlex to wrap her range of quality sweets, Sarah stated, “It was really important for Miss Muffet & Co that our packaging had the lowest possible impact on the world around us and it had to clearly show the contents. We chose Innovia Films’ transparent NatureFlex, primarily due to its environmental credentials. At the same time, it keeps our sweets tasting and looking good.” NatureFlex films are certified to meet the European EN13432, American ASTM D6400 and Australian AS4736 standards for compostable packaging. The wood-pulp is sourced from managed plantations from referenced suppliers operating Good Forestry principles (FSC or equivalent). The renewable bio-based content of the films is typically 95% by weight of material according to ASTM D6866. The film has been confirmed as suitable for emerging ‘waste to energy’ techniques such as anaerobic digestion, aiding the diversion of organic wastes from landfill. Transparent NatureFlex NE is used to flow wrap the sweets, which are then packed in beautifully designed, storybook-shaped ‘keepsake’ boxes, with drawings by children’s illustrator Rosie Brooks. The titles (stories) of sweets in the range include: Three Blind Sugar Mice, Oranges and Lemon Drops, Jack and the Jelly Bean Stalk, Goldilocks and the Jelly Bears, and Tom Thumb Drops. “This is an excellent example of a company planning its packaging to meet their ethical product strategy,” said Paul McKeown, Innovia Films’ UK sales manager. NatureFlex was an obvious solution for the packaging in this application as the film begins life as a natural product - wood - and breaks down at the end of its life cycle in a home compost bin (or industrial compost environment) within a matter of weeks. It also offers advantages for packing and converting such as inherent deadfold and antistatic properties, high gloss and transparency, resistance to grease and oil, good barrier to gases and aromas, print-receptive surface and a wide heat-seal range.

panel and an unwind unit giving

Innovia Films Pty Ltd Contact info and more items like this at wf.net.au/N241

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the film. The applicator runs in continuous or intermittent modes with a clearly laid out operating consistent web tension.

On valve applications such as coffee, steam release or two-way air release valves, it has automated synchronisation of labelling and punching to specified production speeds. Various shapes and patterns can be placed into webs at speeds of up to 2400/min. With no external control box or cables, it has easy PLC connection to line control systems or individual machinery. The built-in servo control system removes the need for interconnecting cables. Result Packaging Pty Ltd Contact info and more items like this at wf.net.au/N200


meet

phil egglestone

customer service & logistics coordinator tna australia pty ltd

delivering the ultimate customer experience. At tna, we constantly look to improve and acknowledge excellence in customer service and are committed to delivering the ultimate customer experience. Phil Egglestone is this years winner of the Asia Pacific customer service award. It’s people at tna, like Phil, that take the time to understand your challenges and apply innovative thinking to exceed your expectations. We would love to hear from you. Come and join in the discussion at our blog on your customer experience tnasolutions.com/news/blog or contact us at info@tnasolutions.com. Stay in touch with tna Follow us @ tnasolutions

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Universal low migration inks The production of legally compliant food packaging requires that the right choice of Flexographic inks and varnishes is used. With recent developments, the SLM Series of UV inks and coatings offer a range of EuPIA food packaging compliant formulations with special features. Jet Technologies now offers this new generation of UV shrinkable low migration (SLM) inks used in the

Horizontal casepacker

manufacture of food packaging and labels. The SLM series has excellent shrink characteristics (more than

The Econocaser is a horizontal casepacker that is designed to handle a variety of case styles. Its solid construction accom-

PACKAGING

modates corrugated and folding board materials including full flap, economy flap and butting end flap case constructions. The casepacker operates by automatically pulling cases from the supply magazine and erecting them onto a single load station. Product may then be manually or automatically loaded. Following loading, the machine cycle begins and the loaded case is transported to the closure section for either gluing or taping.

70% with good retained adhesion) and these products distinguish themselves with their low migration formulation and good printability, steam or hot air shrink. Benefits include: no requirement for primer or protective lacquer; excellent adhesion on a range of other synthetic substrates, such as PP, PE, BOPP coated paper; printing speeds of 150-200 m/min (dependent on lamps); resistance to chemicals - good, subject to laboratory testing; and shrink films - typically PVC, PET, PET-G, OPS. Due to the diverse nature of different substrates, it is essential that each grade/application is tested thoroughly prior to commercial production. To achieve compliance it will be necessary to carry out a suitable evaluation. It must also be remembered that manufacturers of packaging and fill are responsible for the properties of the food packaging and its compliance with legal requirements. The packaging ink suppliers are not able to issue certificates or declarations of compliance which cover the legal responsibility of others in the packaging chain. It is important to note that the EuPIA guideline recognises that the requirements are challenging and that there will be a need for a continuous improvement strategy to control potential migrants from packaging inks. It is envisaged that a significant period of time will be required in order to test and, where the required limits are not achieved, to generate an action plan that sets out a program to ensure compliance within an agreed and manageable timescale. Regulations include: European Commission Regulation (EC) 2023/2006 on good manufacturing practice (GMP) for materials and articles intended to come into contact with food. This has an annex referring to printing inks; Regulation (EC) 1935/2004 in Article 3 requires that

Perfect Packaging

materials and articles in contact with food, do not transfer their constituents to food in quantities that could

Contact info and more items like this at wf.net.au/M141

endanger human health or bring about an unacceptable change in the composition of the food or bring about a deterioration in the organoleptic characteristics. Jet Technologies Contact info and more items like this at wf.net.au/N276

Film offers shelf-life extension for fruit and vegetables Shelf-life extension of between two and five days has been reported for fruit and vegetables using Sirane’s Sira-Flex Resolve wrapping film. Retail trials using the film have reported four additional days of shelf life for potatoes and similar results with other fruit and vegetables. Sira-Flex Resolve has been developed to have the optimum balance between humidity control and O2 and CO2 permeability. The permeability is temperature dependent so that the ideal atmosphere is maintained inside the pack even if the storage temperature is variable. There is no condensation on the inside of the film and the product does not dry out. As there will be no ‘fogging’, mould or bacterial growth will be minimised. The film is suitable for all types of vegetables including salads as well as many types of fresh fruit. It is a natural biopolymer made from plants and is sustainable and fully compostable. The permeability is controlled by the property of the film itself. Due to the structure of the film material, the permeability to humidity, O 2 and CO 2 is different in each case. This has allowed Sirane’s team of scientists to balance the permeability of each component to achieve the optimum result. CMActive Contact info and more items like this at wf.net.au/N745 80

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tna unsticks CTC’s sweet packaging problem

Lidding films for MAP applications

PACKAGING

Linpac Packaging has released three films for the protein industry. The LINtop Star lidding films, for use in modified atmosphere packaging (MAP) applications, have been designed to work with Linpac’s LINfresh EPS MAP and Rfresh/Fresh PET/PE trays, as well as all standard high-barrier EPS and rigid trays. The films are available with either

Output has increased and waste reduced at Australian sweet and snack distributor Confectionery Trading Company (CTC) of New South Wales since the company installed the tna robag vertical form fill seal (VFFS) bagger to address issues of burst bags and failing seals. CTC packs high volumes of hard-boiled lollies, jubes, gummy sweets and jellies using tna packaging lines. After installing the tna robag 3, tna customised its flagship VFFS to handle the sugary confections being packed. Loose sugar making its way into the seals was hampering the sealing process. By installing a dust extraction unit on the robag 3, sugar was kept away from the seals and tna had resolved the problem. A second challenge at CTC was that the high sealing temperatures were causing the bottoms of the heavier (2 kg) bags to open. To overcome this, tna installed multidumping and stagger delay technology from tna-Yamato, which allowed the jaws sufficient time to cool. “We had used tna equipment in the past so were familiar with their solutions-focused approach and quality after-sales service,” explained Dean Theouli, Director of CTC. “tna took the time to understand our business, carefully assess our needs and assess where we could improve and economise along our packaging line. We now have three of the tailored tna robag systems installed on site and are reaping the benefits.” Additional benefits for CTC include a reduction in film use during changeovers thanks to a smaller film system, with total film waste having halved since the latest tna installation. In terms of speed, throughput levels now reach 140 bpm, with product rejects remaining under 1%. Operators at the CTC plant also responded positively to the upgrade, finding the controls and interface extremely user friendly.

a PE or PP sealant. Their oxygen

TNA Australia Pty Ltd

Linpac Packaging

Contact info and more items like this at wf.net.au/N700

www.linpac.com/

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barrier properties may extend shelf life to help retailers and consumers reduce food waste and spoilage. The LINtop Star HB range comprising LINtop Star PE HB, PE CXI and PE CXO - has a thinner gauge and has been designed with good optics, controlled shrink and good antifog properties. Longer reels result in 33% less machine downtime, claims Linpac. They have been designed to work with existing manual and high-speed automatic tray sealers, from small to fully equipped thermoforming lines, and will seal through contamination.


Laser perforating system for modified atmosphere packaging The PerfoTec PT-100 laser is a perforating system that adjusts the number of laser perforations per package according to feedback from testing product in a respiration meter. In this way, variations can be made to the perforations to meet the specific respiration requirements of individual fresh products to be packaged, making this system particularly suitable for modified atmosphere packages. The system comprises two parts, a laser perforation unit with moni-

PACKAGING

toring camera that checks the hole size, ensuring continual accuracy, and a respiration meter. The meter measures rates of respiration, sends data to a website and within 4 h the results are entered into the automatic Oxygen Transmission Rate software determining the size and number of perforations to be used on the plastic film. Recent research findings indicate that film permeability must be considered as a critical control point for quality and shelf life. With this online system it is possible to finetune the fresh produce requirements making variations in permeability at the point of packaging. The PerfoTec laser has been developed to integrate with either vertical or horizontal packaging machines, used by professional fresh produce processors, as well as flexible film converting machines. One key advantage of the laser is the ability to make very small holes, down to 30 - 40 Âľ in diameter, achieved by a special laser beam equaliser. With this instrument, the very small micro perforations are made with high consistency, which is especially important for salads and ready-meal salads because of the low respiration of these products. Due to the improvement in quality and extension in shelf life being achieved from 1 to 7 days, along with the option for full traceability labels, this laser system has seen a good uptake amongst European fresh produce processors. It is now available in Australia. Raymax Applications Pty Ltd Contact info and more items like this at wf.net.au/N266

High Speed Bundle Wrapping at Affordable Prices

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Plastic tube decoration system The Moss Digitube digital transfer machine is a plastic tube decoration system. The machine uses a new transfer technology for decorating containers with high-quality images. The images are pre-printed on a Xeikon printer at 1200 dpi on rolled-up silicon paper. The rolls are then used by the machine to transfer the high-quality images onto

PACKAGING

the containers plastic substrate. This transfer is achieved by a combination of heat, pressure and synchronisation. A lacquering device and optional UV drying feature improve the scratching resistance and appeal for the final product. Production costs are minimal, particularly on small runs, as offset plates and/or silk-screens are not required. This provides manufacturers with fast turnaround, production flexibility and low set-up costs. HBM Packaging Technologies Contact info and more items like this at wf.net.au/N237

Stretch blow moulding machine The Contiform 3 is the latest generation of Krones’ stretch blow-moulding machine series. The blow-moulding module has been entirely revamped. The linear oven of the Contiform S/H series has been design-enhanced and optimised in regard to its energy consumption. The blow-moulding station enables plastic containers to be produced at a speed of up to 2250 containers/h and cavity. A flexible electromagnetic stretching system is used which enables any required machine speed to be linked to a perfectly matched stretching speed. The integrated Monotec drive concept, featuring servomotors, operates synchronously at all times, thus ensuring accurate transfers. Elimination of transfer belts means there are no longer any mechanical efficiency losses and there is less wear and tear. Fewer cavities for the same total output ensure shorter changeover times. With the option for integrating a MouldXpress system, mould replacement time is additionally reduced to less than one minute per blow-moulding station. If PET preforms with a different neck finish are to be run, the optional quick-change handling parts in the oven of the Contiform 3 ensure reduced machine standstill times for a changeover routine. A series of functions contribute towards significant savings in compressed air consumption. Electromagnetic stretching of the preforms using a linear drive instead of a pneumatic system means that compressed air is no longer required here. A dead space volume significantly downsized yet again reduces the compressed air consumption to an absolute minimum. With the Intermediate Pressure system, compressed air recycling inside the machine is dramatically increased. The compressed air recycling system inside the machine, the Air Wizard Plus, automatically adjusts itself to the optimum proportion of recycling. The machine’s total air consumption has been reduced by a third. The machine has been developed in sizes ranging from 8 to 36 blow-moulding stations, thus enabling outputs to be achieved of up to 81,000 containers/h. Krones (Thailand) Co Ltd Contact info and more items like this at wf.net.au/M896

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UHT white milk production process The Tetra Lactenso Aseptic with OneStep technology incorporates UHT white milk production within a single process. Tetra Pak claims OneStep technology eliminates the need for pasteurisation pretreatment and intermediate storage of raw milk. Raw milk is preheated, clarified, separated, standardised and homogenised before undergoing UHT treatment and regenerative cooling; it is then transferred to two aseptic buffer tanks. The company says this can shorten processing time to a few hours.

High-performance thermal transfer coder The Markem-Image SmartDate X60 thermal transfer coder features a high-speed/high-quality printhead. The long-life, high-speed

simplifies and may accelerate the production process.

printhead is designed to meet the needs of users in demanding,

The line includes several pieces of equipment. The Tetra

high-volume production environments.

Therm Aseptic Flex is a UHT unit that integrates heat

Combining fast performance with the SmartDate legacy of

treatment with separation and standardisation. The Tetra

reliability, the SmartDate X60 can print at pack speeds of up to

Spiraflo is a tubular heat exchanger with good energy

1000 mm/s at full 300 dpi resolution. The X60 is also capable of

recovery. It incorporates the Floating Protection System, a

full resin printing at up to 600 mm/s. That means codes will not rub off and makes thermal transfer a viable option in a wider range

thermal-stress-absorbing design. The line also includes a Tetra Centri AirTight Eco, a hermetic

of situations. The SmartDate X60 is suitable for manufacturers of

direct-driven separator. An integrated unit for milk and cream

baked items, biscuits, cakes and pasta, as well as chocolate and

standardisation, the Tetra Alfast prevents fat content deviation

sugar confectioneries, where single-size packs on lines running at

in the final product. The Tetra Alex homogeniser achieves the same

very high speeds require high-speed coders. The coder minimises

product quality at lower pressure than conventional homogenising devices,

waste and optimises uptime on the packaging line. A standard

Tetra Pak claims. Also included in the system are the Tetra FlexDox, Alcip

1100 m ribbon provides up to 20% more prints per roll, resulting

and PlantMaster.

in 20% less waste and reducing the frequency of changeovers.

Tetra Pak Marketing Pty Ltd

Markem-Imaje

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

Contact info and more items like this at wf.net.au/N693

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PACKAGING

In essence, the OneStep technology combines heat treatment, separation and standardisation into one step, which


Biological indicators test system The 3M Attest rapid readout biological indicators (BIs) test sterility by challenging the steriliser with a highly resistant dry bacterial spore strip (Geobacillus stearothermophilus) in a plastic vial.

TESTING

The 3M Attest 1291 BIs are designed to monitor the 132ºC

Digital refractometer for sucrose The Hanna HI 96801 digital sucrose

gravity displacement steam sterilisation process, providing results

refractometer offers a specific analysis

within one hour. The 3M Attest 1292 BIs are designed to monitor

to determine accurate sugar concentra-

the 132ºC vacuum assisted process, providing results in 3 h.

tion. It measures the refractive index to

The BIs are incubated in the compact 3M auto-reader, which

determine parameters pertinent to sugar

displays a red light to indicate a failed sterilisation or a green

concentration analysis and is designed

light to indicate a successful process. The automatic readout

for analysing food such as fruits, energy

from the auto-reader means an unambiguous pass/fail result.

drinks, puddings, soy milk juices, syrups,

The system, available from Arrow Scientific, includes rapid readout BIs, disposable

jam, marmalade, honey, soups, jelly, tofu

test packs, auto-readers and record keeping. The self-contained BIs consist of a Ba-

and condiments. It is rugged, portable

cillus stearothermophilus spore strip and sealed glass ampoules with growth medium

and water resistant, making it suitable for

and dual indicator system.

taking measurements in the lab or field.

Being self-contained, the risk of false positives due to contamination is reduced. The system conforms to ISO 11138. Arrow Scientific Contact info and more items like this at wf.net.au/N228

Gluten test kits Romer Labs has released two test kits for gluten. The AgraStrip Gluten G12 is a lateral flow device for on-site factory testing and the AgraQuant Gluten G12 is an ELISA for quantitative testing in the laboratory. The test kits use Romer Labs’ gluten detection technology, which employs a next-generation antibody called G12. The method targets the most immunotoxic proteins for those intolerant to gluten. The G12 antibody is suitable for processed food such as biscuits or baby food, as it determines the pathogenic component of the sample, regardless of whether the ingredients have been modified during processing. The AgraStrip kit has an adjustable cut-off level for qualitative screening at either 5, 10 or 20 ppm gluten while the AgraQuant ELISA quantitates levels of gluten between 4 and 200 ppm. Australasian Medical & Scientific Ltd Contact info and more items like this at wf.net.au/N544

The actual measurement of refractive index is fast and simple and provides the operator with a standard accepted method for sugar content analysis. Samples are measured after a simple calibration with deionised or distilled water. The refractometer measures the refractive index of the sample and converts it to degrees Brix within seconds. The HI 96801 may eliminate the

Determination of ginsenosides in Panax ginseng

uncertainty associated with mechanical refractometers. The meter features au-

Asian ginseng (Panax ginseng) traditionally is used as a tonic to reduce the effects of

tomatic temperature compensation for

stress, counteract fatigue and increase stamina. The main bioactive ingredients found

accurate measurements.

in Panax ginseng and a related species, Panax quinquefolius (American ginseng),

The HI 96801 utilises internationally

are triterpene saponins, commonly referred to as ginsenosides. Most methods for the

recognised references for unit conversion

analysis of ginsenosides use gradient elution reversed-phase high-performance liquid

and temperature compensation and em-

chromatography (RP-HPLC) with low-wavelength UV detection (203-205 nm) because

ploys methodology recommended by the

the ginsenosides do not strongly absorb above 205 nm. This often results in strongly

ICUMSA, the internationally recognised

sloping baselines that complicate integration and interferences from minor components

body for sugar analysis.

that have stronger UV chromophores than the ginsenosides.

Temperature is displayed simultane-

An analytical method using the Thermo Scientific Dionex Corona CAD Charged Aero-

ously with the measurement on the large

sol Detector is able to provide a reliable alternative to low-wavelength UV detection.

dual-level display along with icons for low

Customer Application Note (CAN) 112: Determination of Ginsenosides in Panax ginseng

power and other relevant messages. The

by HPLC-CAD demonstrates that charged aerosol detection does not over respond to

meter is supplied with a battery and an

strong chromophores, thereby reducing interferences. Baseline slopes are not as pro-

instruction manual.

nounced or as variable, making peak area determinations more reliable. Thermo Fisher Scientific Contact info and more items like this at wf.net.au/N703 86

May/June 2012

www.foodprocessing.com.au

Hanna Instruments Pty Ltd Contact info and more items like this at wf.net.au/M268


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

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

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

SwabSURE ListeriaP

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

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

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

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

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

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


Food Chemicals Codex The 8th edition of the Food Chemical Codex (FCC) includes specifications for the identity, quality and purity of more than 1100 food ingredients, test methods to verify specifications, and guidance on issues such as impurities testing for metals.

Fluid-handling system The VWR carboy is an advanced fluid-handling system. The ergonomically designed carboy and versatile cap technology provide the user with an easy-to-use and easy-to-clean system. The carboy includes design features that

TESTING

allow the user to easily hold and manipulate it during lifting, filling and pouring. Leakproof even when placed on its side, the carboy is suitable for field work and allows for sterile sample collection and transport of sterile solutions to any location. The leakproof cap adapters enable users to quickly change the top connectors of each carboy to match their application needs. The 20 and 40 L carboys are available in a widemouth version for easier filling and cleaning.

The FCC is a compendium of internationally recognised standards for the authenticity of a variety of ingredients. It provides a combination of specifications for the authenticity and quality of each ingredient and test methods to verify these specifications, as well as reference materials suitable to confirm that the test methods are executed appropriately and measurement results therefore can be trusted. The FCC provides more than 1100 monographs, which include chemical formula and structure, chemical weight, function, definition, packaging and storage, labelling requirements and test procedures. Fourteen appendices detail more than 150 tests and assays, with step-by-step guidance for the analysis of enzymes, impurities such as metals and pesticides and markers for authenticity testing, among others. The FCC also contains general information, including relevant information on a variety of topics including Good Manufacturing Practices (GMP) Guidelines for Food Chemicals, a compare-and-contrast table of food and drug GMPs, AOAC ISO and IUPAC method validation guidelines and helpful introductions into a variety of different analytical test methods. The codex includes the complete contents of USP’s upcoming Food Fraud Database, which features more than 1300 entries on adulterants reported for specific ingredients and the corresponding analytical detection method. It can be a useful risk management tool for industry, regulators and other stakeholders. FCC is available in two-year print and online subscriptions. A subscription includes the main edition and three update supplements. US Pharmacopeial Convention www.usp.org

Electronic pinch door force tester The FM100 pinch door force

Top and bottom handles allow users a secure grip, while a sturdy shape helps

tester from DriveTest, available in

maximise footprint and volume capacity. Avail-

Australia through SI Instruments, is

able in sizes from 2 to 40 L, the carboys are

an electronic pinch force measuring system

constructed of BPA-free co-polyester, HDPE

for power-driven doors and gates. Typical applications include final inspection of new installations and periodic conformance

or polypropylene - FDA and USP Class VI materials. Colour options include clear, opaque

testing of existing equipment. The company claims the tester continues to provide accurate measure-

and amber. The carboys are available with and without spigots and taps, while sanitary spout

ments even after years of use in an industrial environment. It is of rugged construction and has been tested and certified by the German TÜV.

options are available for use with standard

Sites with multiple doors and gates require rapid and easy performance

seals and clasps. The company’s versatile

of repetitive measurements. DriveTest claims its product streamlines the

cap technology allows interchangeable con-

measurement process and may reduce documentation effort. Measure-

nectors to be used.

ments made on a complete site can be entered, printed as a table and

VWR International Pty Ltd Contact info and more items like this at wf.net.au/M935

88

May/June 2012

stored in a database with minimal user entries. SI Instruments Contact info and more items like this at wf.net.au/M372

www.foodprocessing.com.au


Analytical balance Adam Equipment has available the PW analytical balance that measures to 0.1 mg.

New Look

With durable solid metal construction, standard internal motorised calibration, the balance has a large, easy-to-read backlit dual display that shows text prompts to help balance.

for 2012

The intuitive user interface is ergonomically

HI93501NS digital thermometer

designed and has highlighted tare keys. Other

$188

buttons access set-up functions, turn the balance on or off, calibrate, send data to a printer and change modes and

plus gst

weighing units. The bidirectional RS232 interface enables data transfer from the balance to printers or computers. Other features include built-in applications for density, percentage, comparison and checkweighing, plus counting and dynamic or animal weighing. The balance offers 16 weighing units, including a custom unit. With models from 120 to 250 g and readabilities at 0.1 mg, PW analytical balances are suitable for a range of applications. Adam Equipment (SE ASIA) Pty Ltd Contact info and more items like this at wf.net.au/M451 HI2211 bench pH meter

$658

plus gst

HI96821 refractometer for NaCl

$255

Listeria test

plus gst

Hygiena InSite is a quick and easy presumptive environmental Listeria test that has been designed to monitor presence of Listeria in environmental samples from the food processing environment. The test contains a liquid media formulated with antibiotics, growth enhancers and colour-changing compounds specific to the growth of Listeria species. A colour change from yellow to light brown/black is considered presumptive positive.

HI96801 refractometer for Brix

$255

plus gst

Applicability of Hygiena InSite is limited for selected common Listeria spp (Listeria monocytogenes, L. innocua, L. ivanovii,

RESELLER ENQUIRES WELCOME

and L.welshmeri) on selected common surface types. The test can maximise sample collection by the use of a premoistened sponge swab. The Listeria detection system is an AOAC approved method and can provide presumptive positive results in 30 h, at levels as low as 1-10 CFU/mL. The Listeria kit doesn’t require any measuring or subculturing and the selfcontained system is safe to use even if you don’t have a pathogen laboratory. The only equipment needed is a 37°C incubator. Key Diagnostics Pty Ltd Contact info and more items like this at wf.net.au/M940

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

May/June 2012

89

TESTING

the user set up the


Gutter oil TESTING

Out of the sewer and into the frying pan

Alice Richard

I

magine there’s a 1 in 10 chance that your dinner is cooked in oil skimmed from the gutter or even the sewer. Still hungry? Restaurant patrons in China face these stomach-turning odds, thanks to the illegal trade in ‘gutter oil’ - used cooking oil that’s dredged from gutters and sewers, reprocessed and sold back to restaurants to be used as cooking oil again. Called “distilled sewage” by one commentator, the oil can also contain oil refined from animal offal and deep-frying oil that’s past its prime. If the source of this oil isn’t enough to quash your appetite, there’s more. Far from a green approach to dealing with kitchen waste, gutter oil - or “digouyou” - is treated with chemicals to clarify it and deal with the odours that inevitably accompany a product with such shady origins. It begins life as a chunky, putrid stew and is ‘purified’ with calcium bicarbonate and neutralised with alkali to the point that it looks the same as good-quality oil. Chemical dyes and bleaches are other appetising additives used to disguise its origins. Most alarming, though, is the presence of the carcinogen PAH and aflatoxin, a highly carcinogenic mycotoxin. Not only that, but the animal and vegetable fat in gutter oil can undergo rancidity, oxidation and decomposition, as well as producing toxic substances like arsenic, according to Zeng Jing, a nutrition expert. Despite the Chinese authorities running a campaign to crack down on gutter oil production, they admit they have no way of distinguishing legitimate cooking oil from gutter oil. Unless companies are caught in the act, there’s no way of determining whether a restaurant is using new or used oil. Gutter oil production is clearly big business in China: a 2011 crackdown on gutter oil production saw police deal with 128 cases and 60,000 tonnes of gutter oil over a period of four months. It’s frequently referred to as an “open secret” in the restaurant industry in China. And it’s no wonder, when profit margins are so high. According to Xinhua, the official government press agency in China, raw gutter oil can be purchased for around 6000 yuan a tonne and sold for 8000 yuan a tonne after processing - nearly a third higher than the original price. Another expert, He Dongping, said, “The profit margin is almost 200%. It’s easy to understand why the business is so hot.” Used cooking oil can legally be used to make biodiesel or animal feed in China, but, according to an article by Xinhua, it’s easier and cheaper to make cooking oil than biodiesel. According to one journalist, the combined factors of Chinese cooking styles using plenty of oil and consumer demand for cheap restaurant food creates a market for gutter oil. Reducing the profit margin of gutter oil by adjusting the price of recycled oil for industrial use is one possibility for reducing the allure of processing gutter oil. The current approach taken by the Chinese government, however, is to threaten those who trade in gutter oil with the death penalty. Qiu Baochang, head of the China Consumers’ Association, said “This shows that the country attaches great importance to ensuring food safety.” This move has been questioned by some, with a legal expert from the Chinese Academy of Social Sciences suggesting that the death penalty should be handed down “with care” to gutter oil criminals as it is technically a non-violent crime. The good news is that the government’s recent food safety campaign has resulted in legal oil processing businesses seeing a growth in the volume of raw material coming in, which means the used cooking oil is going where it’s meant to and not back onto people’s plates. But with no accurate testing procedure available to differentiate good-quality oil from this ‘distilled sewage’, and no definite figures on just how rampant the industry is, eating out in China is still apparently a game of chance. 90

May/June 2012

www.foodprocessing.com.au

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

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


INTEGRATED FOOD PROJECT DELIVERY Creating outstanding food facilities with our clients since 1918.

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