What’s New in Food Technology Nov/Dec 2011 by Westwick-Farrow Media

Fill one bulk bag per week or 20 per hour at the lowest cost per bag Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements FILLER FOR PALLET JACK BAG REMOVAL Low profile version of patented TWIN-CENTREPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options.

BULK BAG FILLER USES PLANT SCALE Full length forklifting tubes allow positioning of this TWINCENTREPOST™ filler model on a plant scale as needed, allowing you to fill by weight without investing in load cells and automated controls.

FILLERS WITH AUTOMATED FEEDING SYSTEMS Every Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighing systems, as well as inlet adapters to interface with optional overhead storage vessels.

COMBINATION BULK BAG/DRUM FILLER Patented SWING-DOWN® filler features a fill head that lowers and pivots down for safe, easy bag spout connections at floor level, and a swing-arm-mounted chute for automated filling and indexing of drums.

PATENTED SWING-DOWN® FILLER Fill head lowers, pivots and stops in a vertically-oriented position, allowing operator to safely and quickly connect empty bags at floor level and resume automated filling and spout-cinching operations.

CANTILEVERED REAR-POST FILLER Offered with performance options including: powered fill head height adjustment, pneumatically retractable bag hooks, inflatable bag spout seal, dust containment vent, roller conveyor, and vibratory bag densification/deaeration system.

BASIC FILLER FOR TIGHTEST BUDGETS A lighter-duty version of the economical TWIN-CENTREPOST™ filler, the BASIC FILLER reduces cost further still, yet has an inflatable bag spout seal and feed chute dust vent as standard, and a limited list of performance options.

PATENTED TWIN-CENTREPOST™ FILLER Two heavy-gauge, on-centre posts boost strength and access to bag hooks while reducing cost. Standard manual fill head height adjustment, and feed chute vent for displaced dust. Numerous performance options. First filler to receive USDA acceptance.

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

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contents

food for thought

November/December 2011

10 Paper-based packaging method to control Listeria and E. coli

24 Genomic approach to precise pinpointing of food pathogens

packaging

testing and quality assurance

©iStockphoto.com/johnnyscriv

22 Packaging news

27 49 53 62 processing

29 Chilled food market hots up 38 New Zealand chip companies don’t grow on trees 45 Seeing beyond detection

ingredients and developments

meat poultry seafood

49 Joint health not bending to functional foods

55 Bullish on beef

50 Developments

bulk handling, storage & logistics

56 US perspective on Chinese food exports 60 The modernisation of meat inspection in Europe

www.foodprocessing.com.au

November/December 2011

This is the last issue of What’s New in Food Technology & Manufacturing for 2011, which is a rather sobering thought. I have just adjusted to writing 2011 for the year and now I’ll have to change. It is sorely tempting to move straight on to 2013, and then by this time next year, when I am finally on top of writing 2013, I will be able to sail into 2013 proper and be correct for a whole year! If I follow this system, henceforth I will be correct for at least 50% of the time - a much better success rate than I currently achieve. The last issue of the year also means it’s nearly Christmas and then it’s time for New Year resolutions. I don’t really have to worry about choosing these - I’ve kept the same ones for decades. As far as efficiency goes this is a very good stratagem. If you choose wisely, things you are never likely to achieve, you will never have to waste time thinking about New Year resolutions again. Efficiency is definitely the go in all workplaces now, even mine. Last August, after 30 years, the publisher of this magazine, Adrian Farrow, sold his business to Universal Magazines. It was a very ‘business-as-usual’ transaction with the same staff, in the same premises, trading under the same name, continuing to publish the same titles. But even such a straightforward change causes one to look afresh at how they operate. You try to see your systems and processes from a new perspective and ask “Is this the most efficient and profitable way to function from a ‘whole-company’ perspective?” Some of the answers are surprising. Old habits and established procedures are sometimes like a favourite pair of shoes - very comfortable to slip into but not necessarily the best choice to go with the outfit. Hence my question: What would you like to see in What’s New in Food Technology & Manufacturing, on www.foodprocessing. com.au and in the foodprocessing.com.au eNewsletter? Are there parts of the magazine and website that you particularly love or hate? Are there areas pertinent to your food industry business that you would like to see covered in media offerings? My usual method of selecting material for the magazine and website is based on the ‘wow’ factor. If, on reading the item, I think “wow - that’s interesting”, I give preference to the item. Not a particularly scientific approach. So, if you have any feedback for me about what gives you the ‘wow’ factor about food processing, please let me know (jwoodhouse@westwick-farrow.com.au). Now it’s time to wish you all a Happy New Boxing Day and to get on to reviewing my New Year resolutions - perhaps I should actually lose weight and exercise more ...

Crumbs from my Christmas table

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

November/December 2011

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

Woolworths Supermarkets has outlined a five-year plan to double its customer take-up of own brand products, reflecting a growing demand for value and quality. At an investor briefing in Sydney, Managing Director of Australian Supermarkets Tjeerd Jegen said Woolworths substantially lagged behind international retailers in terms of the proportion of own brand sales - Tesco in the UK, for example, has three times the penetration. He also said there is a clear opportunity to capitalise on customers’ increasing level of trust in and appreciation for Woolworths’ own brands Select, Homebrand and Macro.

image©iStockphoto.com

FOR

Fo d

standards. This policy will continue as the ranges expand. Also key to the own brand growth strategy is Woolworths’ customer evaluation program - an in-depth sensory assessment to ensure products hit the quality mark with customers. Woolworths’ sensory evaluation scheme was launched in May 2010. The scheme has been pivotal to the quality assurance of approximately 1500 own brand product recipes. Homebrand has been Australia’s leading value brand since the early 1980s. It has approximately 850 products and sales since 2000 have increased by 180%. The midrange, mass market Select brand was introduced in 2004 and carries approximately 1000 products. In the last quarter, new product launches such as Frozen Crumbed Fish and Select Sauces helped drive a significant sales increase. Macro is Woolworths’ health and wellbeing brand, encompassing approximately 400 organic, gluten-free and ‘good for you’ lines. Sales for Macro have grown 43% in the last year alone with highly successful new product launches such as Mini Macro Meat and Macro Soups.

thought nRVA monitors starch behaviour Innovation Minister Senator Kim Carr congratulated scientists at the Australian Nuclear Science and Technology Organisation (ANSTO) who worked with manufacturer Perten Instruments to develop the neutron Rapid Visco Analyser (nRVA) which will allow manufacturers to establish the best way to cook and process starches. “This discovery could mean manufacturers will be able to make food more efficiently, with lower energy input. It also gives manufacturers the power to consistently create starches with known health benefits, like those that have been proven to help counter bowel cancer. “The nRVA uses neutrons from ANSTO’s OPAL research reactor at Lucas Heights to enable manufacturers to better understand food at the molecular level,” Senator Carr said. 6

November/December 2011

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“Scientists employing neutron scattering techniques have been able to see how starches change when they’re cooked. “This is a great example of collaboration between scientists and industry resulting in a new technology with the potential to benefit Australia.” Dr Elliot Gilbert, food science project leader at ANSTO explained that the nRVA analyses small samples - often of starch under controlled test routines. “This is not a question of irradiating food but of exploring the properties of starch down to the molecular level. The nRVA could radically improve food manufacturing processes like measuring flour and grain quality for breakfast cereals, snack and animal foods,” Dr Gilbert said.

©iStockphoto.com/ Elena Schweitzer

Woolworths to increase its private label offerings

Jegen said: “Customers have told us loud and clear they love the value and quality offered by own brands. They have given us a firm mandate to deliver more of this and we will achieve it by expanding our ranges, lowering our prices, further improving our quality and strengthening our brand presence. We have three very successful and welltrusted multicategory own brands and there is a fantastic opportunity to make them better.” “Customers also tell us that whilst they enjoy getting the broad choice of brands at Woolworths, they also appreciate the fact that own brands inject additional competition into the grocery sector by offering the same or better quality as national brands but at a cheaper price.” Woolworths maintains an Australian bias to own brand sourcing, giving preferential terms to domestic suppliers who can meet the company’s benchmark quality assurance

Wiley gets expansion of smallgoods operations Food industry design and construction company Wiley has the go-ahead for the second stage of a multimillion-dollar expansion of the operations of smallgoods producer Primo Smallgoods. The project involves construction of the largest Australian factory of its kind, with a combined project floor area of 40,000 square metres on an 8.6 hectare greenfield site in Wacol, west of Brisbane. Stage one was completed recently and included construction of a raw material freezer and distribution chiller. Stage two will include construction of a ham, bacon, salami and smallgoods processing operation and corporate offices. Wiley Managing Director Tom Wiley said construction and operation of the ‘best in class’ large-scale manufacturing plant is expected to create 600 new jobs in Queensland. “Wiley will undertake all design and construction for the second stage of the Primo Smallgoods plant, having recently completed work on the first stage of the facility,” Wiley said.

“The new state-of-the-art modern facility consolidates three separate plants under one roof and will almost double Primo Smallgoods’ production capacity and markedly boost efficiency. “In addition to the many construction and operational jobs created by this project, Wiley will require additional resources, creating employment opportunities for local people and a variety of subcontract trades.” Wiley said the acquisition of this project in these turbulent economic times is a testament to the commitment and hard work of the entire Wiley team and places Wiley in a strong position both now and for the future. “The approval of stage two, of the development immediately following the successful completion of stage one, demonstrates the faith that Primo Smallgoods has in the Project Director, Graham Harvey, and his team,” said Wiley. Primo Smallgoods is the largest producer of ham, bacon, salami and smallgoods in Australia. It is a national brand with a strong presence in major supermarkets Coles and Woolworths, and a solid export market

AUSPACK PLUS heads to Sydney in 2013 One of the largest biennial packaging and processing machinery and materials exhibition in Australia, AUSPACK PLUS, will be heading to the Sydney Showgrounds, Sydney Olympic Park, from 7 to 10 May 2013. According to Luke Kasprzak, Exhibition Sales Executive, Exhibitions & Trade Fairs, “An extensive survey was undertaken earlier this year with visitors and exhibitors of AUSPACK PLUS 2011 to determine how we can offer an even more diverse and successful exhibition in 2013. “The results of the survey have guided our objectives for the Sydney show and not only will we continue to grow the processing and packaging machinery side of the event, an additional key finding

that came from the report was to focus on welcoming the materials side of the industry to both exhibit and attend AUSPACK PLUS 2013. Materials refers to all elements from film to plastics, through to components and ancillaries of packaging and processing machinery. This is a side of the industry that is sometimes overlooked and yet is critical to the success of production lines,” said Kasprzak. “Our focus and commitment to continue to develop AUSPACK PLUS in 2013 will be to incorporate a multiplatform showcase of materials and production component solutions, all under the one roof, alongside packaging, filling and processing machinery,” he said. For further information about the event, please log on to the newly designed website. ©iStockphoto.com/ malerapaso / David Gallaher

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November/December 2011

image©iStockphoto.com

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Muddy Boots wins the Coles IT vendor of the year award 2011 UK-based Muddy Boots Software, which develops quality assurance solutions for sustainable food and farming, has won the inaugural Coles supermarket IT Vendor Award 2011. This follows the implementation of a quality management solution that improves the consistency and quality of fresh produce throughout Coles’ 742 Australian stores. Muddy Boots Software has been named Coles IT Vendor of the Year 2011 - Support Category. Greenlight Quality Control, which was implemented across Coles’ distribution centres in September 2010, was recognised by the Australian retailing giant for providing a support system that created the greatest service improvement and cost saving, and enabled the greatest increase in business income over the past 12 months. Coles is a leader in Australian food retailing, with more than 11 million customer transactions a week. Jackie Healing, Head of Quality, Policy and Governance at Coles supermarkets, comments: “Greenlight QC from Muddy Boots has given Coles first-class product quality monitoring and performance reporting capability. This helps us focus our efforts in partnership with our suppliers, to achieve our objective as Australia’s leading supermarket for quality produce.” Jonathan Evans, Managing Director at Muddy Boots Software, talks about the award win: “It is fantastic to get this sort of recognition from one of our key customers and this award is proof that quality management can directly impact business efficiency. “It has been a great experience working with Coles. They have been quick to spot the opportunity to improve their quality processes and eager to use the data to drive change for the benefit of suppliers and their customers. We are grateful for this global recognition of our work and we very much look forward to developing our long-term partnership with Coles and playing our part in supporting continuous improvement.” Muddy Boots’ heritage is deeply rooted in agriculture and the company has subsequently developed a strong understanding of the dynamics of the food industry from field to fork and the challenges that companies within the food supply network face. With an expanding customer portfolio, Muddy Boots continues to expand its operations and build increased capacity, adding a further 25% to its global workforce in 2011.

Change an ongoing theme for AIFST The Australian Institute of Food Science and Technology Incorporated is currently undergoing a period of significant change, including the development of a continuing professional development (CPD) program, redesign of the official publication Food Australia and a new website. The Code of Professional Ethics has been replaced with a shortened Code of Professional Conduct. Members in the pursuit of their profession agree to observe and be bound by the code to: • act in accordance with the objects of the Institute; • c onduct themselves in such a manner as to reflect credit upon, maintain the standards of, and advance the profession of food science and technology; • aim in their work to enhance the health, wellbeing and safety of the public; • act in compliance with all appropriate statutes and authorities; • publish observations, statements and scientific research objectively, fairly and accurately, and maintain objectivity when reviewing the work of others; • m ake public statements in the name of the Institute only when authorised; • respect any confidence gained in a professional capacity, and not use confidential information for personal gain nor disclose it to third parties without permission; • avoid conflicts of interests or any appearance of impropriety, and act honestly at all times; • a cknowledge the work and contributions of others and afford to those under their direction every opportunity to advance their knowledge and experience; • recognise a responsibility towards the development of the next generation of the profession. For further details, contact (02) 8399 3996; or to view the changes, visit www.aifst.asn.au.

Australian Institute of Food Science and Technology (AIFST)

©iStockphoto.com/ SimplyCreativePhotography

November/December 2011

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Your challenge. Our pumps. Best solution. A range of pumps suitable for: • sustaining product quality and minimising waste • sensitive, highly viscous, or whole foods • accurate metering and dispensing • high pressure, flow or temperature applications • waste applications

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The recent Listeria and E. coli O157:H7 outbreaks associated with cantaloupe and raw beef in North America reveal that the current available methods and procedures for food safety are failing to achieve full control of these deadly pathogens. New packaging approaches, by Canadian researchers from the Sentinel Bioactive Paper Network, for improving food safety are ongoing and can provide solutions for biocontrol by using immobilised phage.

o try to prevent these foodborne tragedies from happening in the future, researchers Hany Anany and Mansel Griffiths (University of Guelph) are using harmless viruses called phage to kill targeted pathogens (including Listeria and E. coli) that could be present on the surface of foods. A phage, in simple terms, is a harmless virus that can kill bacteria. Phage use has received regulatory FDA approval in the United States as a safe food additive in certain food products, along with Health Canada issuing a letter stating no objection for the use of phage. An immobilised phage can take over the Listeria and/or E. coli O157:H7 bacterial cell and produce new copies of itself inside the cell. After the phage reaches critical levels, the phage breaks open the bacterial cell and destroys it, thus not allowing the pathogen to multiply on a food surface (see Image).

November/December 2011

Sentinel researchers’ published work in the journal Applied and Environmental Microbiology describes their method to stick phage onto cellulose material and explains when foods (ready-to-eat meats, raw meats) are wrapped in the package, the harmful cells of Listeria and E. coli are killed by phage that have been placed on the packaging. This packaging option works at refrigeration temperatures, at which pathogens can still grow. The packaging solution can be used for modified atmosphere and vacuum packaged meats. This is one of several technologies being investigated by the Sentinel Network, a NSERC strategic network. “This work has the potential to change the way today’s food packaging operates,” said Dr Mansel Griffiths, a Sentinel researcher and Director, Canadian Research Institute for Food Safety at the University of Guelph. “Through our research we also examined phage storage stability to further extend the use within industrial applications.” Paper-based biosensors (bioactive paper) offer one of the best approaches for food safety monitoring because of their low-cost, simplicity and rapid response time. “Sentinel is working hard with its industry partners to bring phagebased anti-Listeria and E. coli materials to the marketplace. One vision is food packaging that inhibits Listeria and E. coli growth and warns the consumer or food supplier of contamination,” said Robert Pelton, Sentinel’s Scientific Director, McMaster University Professor and a Canada Research Chair.

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©iStockphoto.com/Lauri Patterson

PACKAGING

Paper-based packaging method to control Listeria and E. coli

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

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

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

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

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

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

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

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

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

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

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

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

AUSTRALIA sales@flexicon.com.au 1300 FLEXICON

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November/December 2011

PACKAGING

Traceable laser marks and codes

Inspection software

Coding and marking lasers are easy to install, require no consumables and will readily fit onto a

Dalsa’s iNspect Express 1700 soft-

production line using encoders and detectors to monitor the speed and pitch of packages as they

ware is designed for automated

move along the packing line providing a fully automated service.

inspection and quality assurance. The

In the laser marking process, the high-intensity focused laser beam is transformed into heat en-

software interface, designed for the

ergy. This energy is absorbed very close to the surface of the material to be marked. The absorption

BOA Smart Cameras, allows users of

results either in the removal of the surface material, in the material changing colour or in the foaming

all experience levels to set up and

of some plastics. For example, on coated anodised metal, the overcoat is etched away to expose

deploy solutions with no program-

the contrasting sublayer. On glass, a shallow groove is etched into the material causing a frosted

ming required.

appearance. On certain plastics the mark on the material changes colour. In all cases, the marks are clean, precise and indelible.

This version of the software uses optimised algorithms for 360° search,

Laser technology is a consistent, high-speed, efficient manner of permanent identification. But

optical character recognition and 2D

each application requires care and consideration to ensure the most appropriate laser is selected

matrix reading, as well as improved

to permanently mark and code products. Laser permanent marking can be found on food packets,

calibration tools. Also introduced

ice-cream containers, shrink-wrapped tablets, wine cartons, glass and PET bottles and jars, clip locks,

with this release is a PC-based ap-

labels and hot drink cups. Indeed any product that requires a reliable mark or code that needs to

plication for displaying images and

be tracked is suitable for permanent laser marking.

results from multiple BOA cameras

Raymax Applications Pty Ltd

on the same screen. Operators can

Contact info and more items like this at wf.net.au/M044

monitor production, change job files and review inspection history of any BOA connected to the local network. Typical applications include: detecting missing or incorrect components in a package; verifying - label position, fill level, cap and safety seal on bottles; tracking products - barcode, 2D matrix, printed text; and locating and counting objects or features. Adept Electronic Solutions Contact info and more items like this at wf.net.au/J009

Steam valve for packaging The Flexis Steam valve is suitable for food producers of ready-to-eat meals. The custom-engineered valve allows the measured escape of steam from food packaging during microwave cooking. The self-venting valve is claimed to enable home-heated packaged foods to cook with greater consistency, more thoroughly and faster than foods in conventional steam-release packages. The valve is recommended for precooked foods that benefit from precise steam heating, including sauces, rice, dumplings and noodles. During the cooking process, the valve actuates at a predetermined temperature and allows a precise amount of steam to escape from the package. Depending on the baffle configuration designed into the valve, more or less steam will be permitted to escape. For example, a floret baffle design might be specified for a rice, vegetable and protein meal because it retains an additional percentage of moisture inside the package. An ‘X’ baffle design, which releases a bit more moisture and thereby thickens the meal’s sauce, may be better suited to a chicken and pasta dish. The valve’s precision allows food manufacturers to specify an exact time period for cooking, rather than a range of time. The steam valve system is applied at the package converting stage. Steam valves are clear and can be printed with text, graphics and logos in one colour. Avery Dennison Materials Contact info and more items like this at wf.net.au/K644 12

November/December 2011

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STOP LegiOneLLa

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Cost-effective packaging

PACKAGING

As a packaging consultant I would love the opportunity to be able to consult a reliable crystal ball to see what lies ahead for this very important industry we represent. Reaching consumers these days is difficult. No longer do traditional methods of advertising and marketing warrant the attention of consumers or their dollars. Business owners and advertisers alike struggle to come up with creative ways to grab even the smallest bit of attention for their products. Creating an effective package design is one of the simplest and most cost-effective ways to do this but requires originality, creativity and the ability to connect with consumers. Generally consumers are not readily open to changing their purchasing habits or experimenting with new products. Why fix it, if it is not broken? When introducing your product to consumers you need to display originality in your packaging design. Consumers look for packaging that is visually pleasing and representative of the actual product. The package should demonstrate the company’s ability to uniquely display the product through colour, size and/or logos. As with people, packages that are different tend to stand out. Using unusual colours, containers and a catchy phrase are all effective ways to attract the consumer’s attention. You can reap substantial rewards by using packaging design to market the same product to multiple target groups. Product packaging can give new meaning to the same product for different consumers. It is important to note, however, that creative packaging is no substitute for a great product. Therefore, your package design must demonstrate a fulfilment of a need of some sort, as well as the benefits of choosing your particular product. Consumers will purchase products because of a perceived need for them. Your package should elicit emotion from your consumer, whether it is happiness, serenity or even hunger. If there isn’t a feeling of excitement or necessity, the product will not sell. Consumers like to feel that a company is in touch with their specific needs and offers them something special. You must connect with your target audience. Effective package design keeps the consumer’s needs at the forefront while still remaining effective in demonstrating the product and its benefits. For better or for worse, your packaging design will be a significant deciding factor in whether or not your product is purchased.

Code verification products The tna intelli-scan 2 comprehensive date code assurance system and the intelli-read 3 integrated barcode scanning system can be used to accurately verify products on the tna robag vertical form fill and seal (VFFS) bagger, while retaining a high level of flexibility and simplicity for food manufacturers. The intelli-scan 2 processes images through its camera system to ensure that the date code is printed, complete and legible. Its ability to accurately and reliably find miscoded or uncoded products is facilitated by its high-speed image detection capability. The system is suitable for a range of print requirements and it can handle both light and dark texts. Furthermore, with exposure times of less than 0.5 ms and high speeds of up to 200 bpm, the scanner is able to keep up with the current speed of tna’s robag 3 series equipment, into which it is fully integrated, therefore maximising efficiency. The user-friendly settings ensure ease of operation, whatever the application. The tna intelli-read 3 full film width barcode reader automatically scans the barcode on the film and cross-checks it in order to verify that the correct product is being processed. Mounted on to the film system of the tna robag and then fully integrated into the software, the system scans the entire width, making it virtually impossible to bypass, as every barcode, regardless of where on the film it is printed, will be read. Not merely a verification system, the intelli-read 3 will also select the tna robag product program or recipe associated with the decoded barcode in order to ensure correct usage.

Pierre Pienaar MSc FAIP National President Australian Institute of Packaging (AIP)

No manual interaction from an operator is required, as the device suggests the appropriate programs for the product. It also automatically detects a splice with a different film and aids traceability. TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/M061

November/December 2011

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November/December 2011

Labeller for stretch-sleeve films The Sleevematic ES labeller is designed for handling stretch-sleeve films. Based on recyclable low-density polyethylene (LDPE), the stretch-sleeve films provide an alternative to sleeves made from PVC (polyvinyl chloride) and a high stretch rate on beverage containers. The stretch sleeves are well suited for customised containers featuring prominent contours. Due to its high stretching capability, the sleeve can be smaller and consequently requires fewer materials. Also, a shrink tunnel and a container drier are not required and this can

PACKAGING

result in energy savings. Two machine variants for stetch-sleeve films are available from Krone: the Sleevematic ES single-carousel variant, rated at a maximum of 27,500 containers an hour, and the twincarousel, rated at a maximum of 55,000 containers an hour. Krones (Thailand) Co Ltd Contact info and more items like this at wf.net.au/K570

Cap quality inspection systems The IntraVis Vision Systems CapWatcher II is a cap inspection system that can inspect up to 144,000 caps per hour for defects such as: open and closed short shots and long shots; spots; height deviations; broken tamper bands; deviations in the length of the gate; micro holes in the head plate; damage to the seal cone; colour deviations; damaged flaps; and linear inconsistencies. The system inspects the caps on a vacuum belt, using an industrial-rated CCD camera using either colour or greyscale technology to identify the defects. It can be equipped with up to five cameras that can inspect the inside and outside, including the cavity and number of the caps. IntraVis has recently added an additional option to the CapWatcher II - the inclusion of a print inspection unit that has an extra camera and an additional vacuum conveyor. The caps can be transferred to the second conveyor for presentation to the sixth camera that inspects the print quality at a speed of 1500 caps/min. HBM Packaging Technologies Contact info and more items like this at wf.net.au/J698

November/December 2011

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November/December 2011

Whole bird film packaging Cryovac BDF whole bird’s puncture-resistant, leakproof packaging ensures that supermarket shelves and shoppers’ hands stay sanitary. The barrier shrink film and hermetic seals are claimed to be able to eliminate the risk of cross-contamination by Salmonella, Campylobacter and other microorganisms to other goods. Modified atmosphere trapped in the pack is also claimed to extend the shelf life

PACKAGING

of the poultry. The 25 µm thin, multilayer, polyolefin, fully coextruded shrink film with modified atmosphere provides gas and aroma barrier properties. Highly versatile, it can be used with lightweight polystyrene, cardboard or rigid trays of many sizes and colours - or no tray, which results in packaging weight reductions. The film has a clear, anti-fog, glossy look and is

Aluminium bottles The Ardagh Group now produces aluminium beverage bottles at its facility in Taree, NSW. Ardagh took the decision to extend the Taree aluminium portfolio from aerosols to aluminium bottles after its research identified an opportunity

also fully printable and features drip-proof seals. The film is designed for a range of horizontal form fill seal systems, which can handle quick format changes and run at speeds of up to 50 packs/min.

to enter a niche, but growing, market segment. The bottles are good for on-shelf branding as they lend themselves to packaging a special promotional product - for example, for a sporting event, product launch, anniversary edition drink, or just to differentiate a product from the competition. The bottles could be suitable for a wide range of beverages, for example, beer, RTDs or energy drinks. With a premium look, feel and functionality, the bottle has the added benefits of being unbreakable which makes it is suitable for outside events or functions. The manufacturing process permits high-quality graphics with a wide range of special finishes. The 100% recyclable aluminium bottle is initially available in sizes from 330-355 mL with a crown seal closure. Plans are already being put in place to expand the product range. Ardagh Group (Australia) Contact info and more items like this at wf.net.au/K059

Cryovac Australia Pty Ltd Contact info and more items like this at wf.net.au/L447

November/December 2011

www.foodprocessing.com.au

Think you’ve seen it all in product identification…

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Coding & Marking Systems Small and Large Character inkjet coders including Low and High Resolution technology as well as Laser Coding Systems.

‘Smart technology that saves at every level’

Label Applicators Labelling Equipment from Manual to Fully Automated Solutions.

‘Its experience that delivers uniqueness’

Friction and Vacuum Feeding Equipment as well as wrapping and personalization systems.

‘Europes largest manufacturer of self adhesive labeling equipment’

Coding & Marking Systems On Line Thermal Transfer and Hot Foil coding equipment. Entry Level and High Performance systems through to multiLane integrated equipment.

Feeders & Packaging Equipment

‘Superior products with unlimited applications’

Print & Apply Equipment

Pack Functionality Systems

Variable Print and Apply Systems for Shippers and Pallets. Fully customisable, Basic Systems to 100% Electric Models.

‘Engineered to be the best with unparalleled efficiency’

In-Line and Adaptable Easy Open and Resealable Packaging Systems for any flexible Packaging from Pre-Printed to Shrink Films.

‘Making packaging easier and consumer friendly’

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November/December 2011

Barcode printer

PACKAGING

The Quicklabel Systems Plexo! 653 barcode printer includes: two-colour thermal transfer printing, electronic ribbon saving (especially important in GHS applications), a user-friendly design, high-quality rugged build with sturdy die-cast aluminium chassis, robust metal cover and a Plexo! glass window

Disposable filling systems The Bosch Packaging Technology PreVAS is a disposable filling system concept from a single source. The system is said to have a number of advantages including: lower cleaning and downtime during production, reduced sterilisation requirements and the prevention of cross-contamination.

for viewing consumables. The range is network ready with built-in ethernet and USB communication ports, slots for RAM cards, compact Flash card and USB connectors. Accessories include a cutter,

Developed in cooperation with a partner for disposable materi-

cutter/stacker, wireless card,

als, the system provides users with the benefit from the synergy

RW-P1 rewinder, compact flash

between filling system competence from a machine manufacturer

card, etc.

and a plastic manufacturer with sterilisation know-how.

The printer is suitable for

Flow behaviour, interfaces, tubing layout, distribution and connection

harmonised systems for chem-

point aspects are designed using a holistic approach. In addition,

ical labels, any label subject to

questions such as the introduction of materials into a qualified area

GHS and wide format.

like a sterile room or isolator are solved with the concept. The Bosch

Fe a t u r e s i n c l u d e : 3 0 0

mock-ups have been useful in creating operator-friendly layouts of

dpi (12 dots/mm); print

transfer ports and glove ports.

modes - batch, tear, cut,

A further development of the Bosch peristaltic pump permits a

perf/cut; media sensing -

tool-less and single-handed tubing change which is suited to isolators.

gap/notch, reflective, continu-

The pump is available, not only for volumes up to 500 mL, but

ous, adjustable from 5-53 mm;

also in an autoclavable version with a removable pump head and

range of ribbon colours.

connections made from Peak plastics. Metromatics Pty Ltd

Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/K761

Contact info and more items like this at wf.net.au/K697

Australian Made Label Applicators

November/December 2011

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Failsafe metal detection systems M e t t l e r-To l e d o S a f e l i n e h a s launched its Due Diligence Enhancement for its metal detection systems to strengthen control and security at critical control points (CCP) on food processing and packing lines. Multiple design features ensure the metal detection enhancement delivers an ality resulting in increased product safety as well as compliance with legislation and retailer guidelines. Food manufacturers also benefit through avoiding the risk of product recalls and potential damage to their brand reputation. A key focus of the Due Diligence Enhancement is on ensuring that

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

contaminated packs are properly removed from the line. This is achieved through a fully automated rejection system with multiple pack sensing

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

and control devices. The automatic reject mechanism is controlled via input from both the metal detector and the pack sensors enabling the contaminated product to be efficiently removed without stopping the production process. In the event the correct pack has not been removed, a reject confirmation sensor reports this to the system and an alarm is triggered, providing full failsafe functionality. As an additional guarantee of accurate rejection, a secondary reject check sensor further along the conveyor belt signals a fault should the rejection mechanism fail or the pack in-feed sensor malfunction. If

DiversaCut 2110® Small footprint versatile dicer

there is any failure, then an alarm is activated, stopping the machine. All activity is monitored and documented within the detector, providing additional confidence that all control measures have been taken to ensure product safety.

TranSlicer®2510 High capacity slice, shred & julienne

Mettler Toledo Contact info and more items like this at wf.net.au/M056

Shelf-ready packaging machinery Fibre King’s shelf-ready range of case packers and palletisers has been

Comitrol® Puree, granulate, paste, desicate

designed to suit the evolving shelf-ready requirements of Australian food retailers. The shelf-ready machines are robotic or mechanical, depending on the application, and available in a range of speeds to cover most needs. Each system is designed for maximum flexibility of pack sizes and formats and to easily accommodate future packaging format changes. The ordering and installation process is streamlined to avoid minimum disruption to production and minimal effort on the user’s part. Following extensive review of the application and environment, multiple layouts are designed and presented, altered if necessary and quotes provided. A final solution is customised from Fibre King’s proven designs, factoryacceptance-tested and installed in the shortest possible period, with no time lost on freighting from overseas. Installation can be completed in

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a weekend and commissioning can take as little as 8 h for a single product. Fibre King provides extensive operator training, coupled with user-friendly

Use our test facilities to determine your best cutting solution

features and local service to ensure maximum productivity. Fibre King Pty Ltd Contact info and more items like this at wf.net.au/L480

November/December 2011 www.foodprocessing.com.au Sept11_WhatsNewinFood_Urschel.indd 1

18 Aug 2011 21 11:21:46

PACKAGING

Cutting fruit & vegetables down to size

increased level of failsafe function-

Tetra Pak caps using renewable resource

image©iStockphoto.com

PACKAGING

Nestlé Brazil, in a partnership with Tetra Pak and Braskem, is launching two of its popular milk brands in a package with a polyethylene (PE) cap using a renewable resource called Green PE. The polyethylene, developed by Braskem, a Brazilian petrochemical company, is made out of sugar cane derivatives, which are polymerised in plastics for cap production. The launch represents a landmark in the use of polyethylene made out of 100% renewable raw materials in the food and beverage packaging industry.

Smart lid wins food safety OHS award The Smart Lid, a disposable colour-changing coffee lid, has won the Occupational Health & Safety 2011 New Product of the Year Award in the US. The Smart Lid won the OH&S 2011 New Product of the Year for its category of ‘Food Safety’. The awards were hosted by the Occupational Health & Safety Magazine. The hot beverage packaging lids provide a visual indication of the contents, changing in colour from a dark colour to a bright red with the application of heat. A significant selling benefit is that it shows those who first pick up the hot beverage whether or not the lid is securely attached properly to the cup. “Receiving this level of recognition within the USA occupational safety industry is huge news for an Australian

c o m p a n y. T h i s a w a r d i s particularly significant to Smart Lid Systems as the judges determination is based on safety innovation,” said Nick Bayss, Managing Director of Smart Lid Systems. “We have also implemented a high-definition video stream on our website to project these safety features.” The Smart Lid was recently included by the Australian Government in the ‘Australian Technology Showcase’ (ATS). The ATS program identifies innovative, market-ready Australian technologies with global market potential, with the aim of showcasing the product to local and international markets.

Bayss added, “Our company offers the safest delivery method of hot beverages, not just for coffee drinkers, but also for the nearly 13 million employees in the hospitality industry in the USA.” All category winners will be presented with their trophies during the National Safety Council Congress & Expo in Philadelphia in late October.

O-I partners with RMIT in glass cider bottle design Responding to cider’s recent growth in popularity among Australian consumers, leading glass packaging manufacturer Owens-Illinois (OI) developed a design brief for a 500 mL glass cider bottle. The brief was presented to first-year industrial design students at Melbourne’s RMIT University. It included a number of guidelines such as the need to produce a bottle suitable for high-speed production and filling lines, and an area for applying a label and branding and mandatory information. Students were provided with an overview of the glass manufacturing process and spent one day sketching their concepts followed by 3D modelling and rendering. “I was blown away by the intricacies of the design concepts and the level of creativity and skill demonstrated by all

November/December 2011

students,” said O-I Australia’s Senior Product Designer, Julian Ditchburn. “The collaboration with RMIT also provided us with a unique insight into emerging design techniques and technologies as well as an extremely impressive talent pool.” O-I Australia employees from the company’s design and sales and marketing departments were invited to review more than 60 student concepts. The designs were assessed on a range of criteria including their level of creativity and adaptability to glass manufacturing processes. One of the outstanding designs titled ‘Cider Bottle’, by student Dustin Bailey, was commended for its simple yet contemporary design featuring a large surface area for labelling. “I’ve always viewed glass as a beautiful material which gives products a premium look and feel,” said Dustin.

SIPA of Veneto, Italy, a global leader of stretch blow moulding machines for the production of PET bottles, has recently celebrated its involvement in producing the award-winning bottles of Ramlösa (Carlsberg) mineral water. The bottle was awarded the prestigious Diamond Pentaward 2011, one of the world’s finest packaging awards. The Carlsberg mineral water range is a popular premium Swedish drink that was previously sold in high-quality heavy glass bottles. Carlsberg was concerned that the glass bottles were expensive, difficult to handle and transport, and not environmentally friendly. It commissioned NINE, a Swedish innovative design company to work on creating a PET bottle that would maintain the customer perception of a premium range of drinks. The team at SIPA worked on many prototypes over a year to find a functional design that could provide the sharp cuts and angles in PET but would give the appearance of a premium cut-glass look. The technical experts at SIPA produced new renderings that met the marketing needs of Carlsberg and the functional requirements of the bottle. The result was a bottle that could be used for still, semisparkling and sparkling variants of the Ramlösa water range. SIPA supplied a SFR 8 EVO Rotary Blow Moulding machine that is now used to produce the Ramlösa 330 and 800 mL bottles inline with Carlsberg’s existing production line. The SFR8 EVO has eight cavities, a maximum speed of 17,600 bph and guarantees optimum container quality, simple and flexible operation, high utilisation rates and low running costs. “The successful launch of Ramlösa in a unique premium PET bottle has increased our customers by 16% and has assisted us in reducing our carbon footprint on the product by a massive 65%,” said Paul Davies, Marketing Director of Carlsberg. SIPA is represented in Oceania by HBM Plastics & Packaging Technologies.

DO THEY NEED FORMAL PACKAGING QUALIFICATIONS TO IMPROVE YOUR BOTTOM LINE?

Are you aware that the AIP can assist you with internationally accredited formal packaging training? Did you k now that you can complete a Certificate in Packaging on-line in less than two years? Did you know the AIP can offer you an on-line Diploma in Packaging Technology? The AIP can also customise half-day training courses just for your company. Ask the AIP how we can help your staff with their packaging education.

PH: 07 3278 4490 info@aipack.com.au www.aipack.com.au

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November/December 2011

PACKAGING

Beautiful PET bottles

WHO IS LOOKING AFTER YOUR PACKAGING DESIGN, IMPLEMENTATION AND SUPPLY CHAIN EFFICIENCY?

to precise pinpointing of food pathogens The ability to detect outbreaks of foodborne illness and determine their sources has become a top public health priority. Now, a new genomic approach may enable scientists to uncover smaller as well as large outbreaks and to identify the temporal, geographical and evolutionary origin of outbreaks.

ccording to Cornell University food science professor Martin Wiedmann [Oct. 14 online journal Applied and Environmental Microbiology], scientists at government agencies and food companies will soon be able to pinpoint the exact nature and origin of foodborne bacteria with unprecedented accuracy. The standard method of tracing foodborne illness involves breaking up the DNA of bacteria samples into smaller pieces and analysing their banding patterns.

The genomic approach But scientists often find that different strains of bacteria have common DNA fingerprints that are too genetically similar to be able to differentiate between them, making it difficult to establish whether the Salmonella that made one person sick was the same Salmonella that infected another person. This was the case in a Salmonella outbreak linked to salami made with contaminated black and red pepper in the US that included 272 cases in 44 states between July 2009 and April 2010. To surmount this challenge, Wiedmann and his team adopted a genomic approach. By sequencing the genome of 47 samples of the bacteria - 20 that had been collected from human sources during the outbreak and 27 control samples collected from human, food, animal and environmental sources before the outbreak - Wiedmann and his team were able to rapidly discriminate between outbreakrelated cases and non-outbreak-related cases, isolating four samples believed to be connected to the pepper contamination. 24

November/December 2011

In the process of doing so, he also found other links: a Salmonella strain that led to a nationwide recall of pistachio nuts in 2009 turned up in samples from four people - only one of whom had reported eating pistachios. Other connected cases suggested smaller outbreaks of which officials had been previously unaware. "The use of genome sequencing methods to investigate outbreaks of foodborne bacterial diseases is relatively new and holds great promise as it can help to identify the temporal, geographical and evolutionary origin of an outbreak," Wiedmann said. "In particular, full genome sequence data may help to identify small outbreaks that may not be easily detected with lower resolution subtyping approaches." Wiedmann, research associate Henk den Bakker and other lab members developed the single nucleotide polymorphism (SNP) test that is specific to the 2009 pepper-associated outbreak with the help of researchers at Life Technologies Corp. They also collaborated with researchers at Washington State University and departments of health in New York City and New York state. A similar approach has previously been used in hospital settings to trace pathogenic bacteria such as methicillin-resistant Staphylococcus aureus, but this is its first application for foodborne illness. Wiedmann said he is continuing to perfect the method and use it to test other types of bacteria. The US Food and Drug Administration and other agencies are also starting to use similar approaches.

www.foodprocessing.com.au

ÂŠiStockphoto.com/brett lamb

TESTING

Genomic approach

Top load tester for plastic bottles and containers Mecmesin has released the MultiTest xt Top Load Tester for plastic bottles and containers.

strength and eventual collapse. Top-load testing measures

Sensorex pHASE pH electrodes provide accurate and stable pH meas-

the resistance of the containers to compressive load to the

urements in dynamic process environments under wide-ranging variable

point where they deform or collapse.

temperature conditions.

Operation is simple using the touch-screen

The research-grade electrodes are specially designed for variable tem-

interface with one-touch favourite test program

perature operation process testing and provide fast, accurate and stable pH

selection and quick changeover to different

measurements even with large temperature changes. This makes pHASE

size containers making rapid testing easy.

electrodes suitable for quality control and R&D use in a wide variety of

The MultiTest xt features multiple levels of

applications including dairy products and food and beverage processing.

password-protected access. ‘Master’ users

The electrodes are available in two designs to best suit user needs:

have full access to all the test set-up and

the cost-saving, user-friendly sealed design and the Rapid-Renew refillable

reporting functions. Predefined read-only tests

design that is suitable for dirty samples.

can be used by operators preventing in-

pHASE Electrodes are offered with either epoxy or glass

advertent changes to the test parameters.

bodies. Epoxy bodies offer maximum ruggedness and good

The touch-screen tablet PC has its

chemical resistance. Breakage-resistant flat surface designs

own reporting and storage facilities, with

also have epoxy bodies without the need for bulb guards. They

automatic capturing of top load and free

are designed to make good contact with viscous materials and

height, and it can also be connected to your network via Wi-Fi and ethernet connections with results sent directly to an SPC or quality monitoring

are recommended for use with slurries. All pHASE electrodes are combination types with built-in double junction references, which prevent the electrode’s silver ions from contacting product samples. Fast-response pHASE electrodes are stable to 0.01 pH within 30 s

system. Results or raw data

when exposed to a temperature change of 35-75°C. They are accurate to

can be exported directly to

0.04 pH at a temperature range of 0-100°C. The stable, electrodes offer

Microsoft Excel.

0.005 pH or less drift per 24 hours.

SI Instruments

Envirosensors Pty Ltd

Contact info and more items like this at wf.net.au/M025

Contact info and more items like this at wf.net.au/M064

www.foodprocessing.com.au

November/December 2011

TESTING

subject to considerable vertical loading causing loss of

pH measurement in variable temperature environments

During filling, capping and storage, a container can be

Detection of GMOs, pathogens and ingredients Qiagenâ&#x20AC;&#x2122;s mericon portfolio, which encompasses products for the detection of a broad range of genetically modified organisms (GMOs), pathogens and ingredients from animals or plants, has been

TESTING

expanded with another 11 kits. The latest, ready-to-use (real-time) PCR assays include GMO kits for the quantification of

Freeze-drying moisture management Adixenâ&#x20AC;&#x2122;s Lyotrack, an online moisture measurement system for freeze dryers, is designed to monitor the water vapour concentration under vacuum conditions inside a freeze dryer. Previously, online monitoring of a freeze-drying process has been

MON810 and RoundUp Ready Soy, as well as the detection of the 35S-pat and CTP2-CP4EPSPS constructs. Additionally, other kits are designed for the identification of ingredients from cattle, chicken, turkey, corn and apricot kernels.

done by measuring temperature, pressure and time. With a careful interpretation of these three parameters it is possible to determine the end of the primary and secondary drying phases. With large production freeze dryers, placing the temperature probes and wiring up the connections throughout the freeze dryer is a protracted task. Results can vary from user to user simply through inconsistent placement of the temperature probe within the chamber or sample. Unlike temperature measurements with just a few probes spread throughout the freeze-drying chamber, the Lyotrack is able to measure the complete load, independent from quantities or the product location within the freeze dryer. The system uses ICP-OES technology (inductively coupled plasma - optical emission spectroscopy) to directly measure the water vapour inside the freeze dryer. Not only does it allow an instant measurement of product moisture levels, it also helps in the determination of process parameters such as the end of primary and secondary drying stages. Installing is straightforward - the system uses a flange connection on the freeze dryer which only involves minor modifications if not yet present. The monitoring software runs off any standard Windows PC. The system complies with FDA recommendations, including the Process and Analytical Technology (PAT) initiative recommending modern process analysis tools and resources for monitoring and controlling

Qiagenâ&#x20AC;&#x2122;s food testing offering now comprises 27 PCR assays and covers the complete workflow from dedicated sample preparation solutions for a variety of sample types through to analysis and detection.

processes and process endpoints.

Qiagen Pty Ltd

John Morris Scientific Pty Ltd

Contact info and more items like this at wf.net.au/L281

Contact info and more items like this at wf.net.au/M068

November/December 2011

www.foodprocessing.com.au

November/December 2011

PROCESSING

Chilled food market hots up Consumers love the convenience of freshly made, freshly processed and freshly cooled product, and this is driving huge growth in the chilled food sector.

ÂŠiStockphoto.com/johnnyscriv

n addition to complete ready meals, this segment primarily encompasses fresh pizza and pasta that only need to be baked or cooked, as well as kitchen-ready cleaned vegetables and salad preparations or complete, ready-to-eat salads to which only dressing needs to be added. Other examples of chilled food include sandwiches, cut and portioned fruit and even plates of sushi. Chilled beverage products include smoothies and freshly pressed juices. What all of these products have in common is that they arenâ&#x20AC;&#x2122;t preserved thermally and donâ&#x20AC;&#x2122;t contain preservatives. They are all sold in a chilled state and can be eaten after only minimal preparation. Chilled products enable food companies to create more value than is the case with conventional ready meals or refrigerated products. They also offer consumers the opportunity to enjoy freshly prepared food without needing special skills or having to spend much time preparing meals. However, these miraculously fresh products do require a certain amount of processing. In addition to needing an effectively uninterrupted cold chain, hygienic and germ-free conditions are needed during the production and packaging of chilled food.

The focus is therefore on the microbial count of the raw materials, packaging materials, processing areas and finished products.

Clean surroundings are essential A clean and nearly germ-free production environment is the primary precondition for ensuring that preservatives and heat treatment are not needed to manufacture refrigerated fresh products. In addition to strict hygiene on the part of personnel and the regular cleaning of all surfaces, machines and operating materials, such an environment can best be attained through the use of an appropriate air management system. As a result, clean rooms are slowly being increasingly used in food production. However, targeted measures can also be employed to ensure that airborne germs do not get anywhere near chilled food in normal production facilities. For example, UV-C modules can be integrated into air-conditioning and ventilation systems. These modules irradiate the air channelled into the room so that airborne germs are effectively exterminated.

www.foodprocessing.com.au

November/December 2011

©iStockphoto.com/Sean Locke

PROCESSING

sushi and salad preparations would be damaged by such packaging or lose their fresh appearance. That’s why modified atmosphere packaging (MAP) on trays is frequently used for such products. MAPs replace preservatives with a germ-free gas atmosphere that is tailored to the food in question in order to keep cut fruit, salads and vegetables fresh. But tray packaging is also useful for other applications. The merger of freshness and convenience is made perfect by all-new plastic wrapping that allows kitchen-ready chilled products to be cooked or baked in the microwave directly on the tray.

Creating clean conditions with high pressure

Air is also effectively sterilised by atomising special aerosols in the production areas. The effective components of these aerosols are substances such as benzoic acid, lactic acid or hydrogen peroxide. These substances can even be used for the production of organic products and they also are effective on the food’s surface. Although they eliminate almost all of the germs that cause spoilage, they are harmless for human beings and do not damage the product.

Everything is under control in the packaging as well Chilled food can be shrink-wrapped, which is particularly suited for pasta and fully prepared meals. By contrast, sandwiches,

High pressure preservation (HPP), a non-thermal method for preserving food, has recently become generally available. This method reduces the number of undesirable microorganisms in food in a manner that preserves the product’s properties. HPP helps to meet the increasing demand for very high quality food products lacking additives. High pressure preservation of food is generally performed at a pressure of up to 6000 bars, which destroys any harmful microorganisms that the products may contain. The highpressure treatment is employed on primary packaged food. The process causes negligible thermal stress and hardly changes the food’s structure, its taste or the valuable nutrients it contains. Protective gas packaging that is especially adapted to high pressures is used as the primary packaging to ensure that product quality remains unchanged during the food’s shelf life.

HACCP software doHACCP software can be used to prepare HACCP plans to coordinate the many details required to make food safely. The software guides users through designing a food safety system, beyond controlling cross-contamination. As a part of the HACCP process, users can create a flow of materials diagram of the process and document the hazards that ride on the materials. HACCP requires users to eliminate or reduce the significant hazards and establish critical control points for them. It then asks them to document how they will make sure that the food is prepared correctly, every time, eg, how to confirm that details are being correctly handled; that the right protocols being followed; ensuring a hazard isn’t missed; how to print the right forms and make sure the diagram makes sense. The software guides users and simplifies input for each of the sections required for a HACCP plan: the Flow of Materials Diagram; hazard identification; critical control point determination; critical control point planning; end product planning. First, the flow of materials diagram for each unique product system is created using the software. Operations and materials are dragged and dropped onto a grid from a floating toolbox, allowing users to see the diagram as it is developed. Branching to perform HACCP tasks is done directly from the diagram, critical control point (CCP) determination, CCP planning, end product planning, and procedures/recipes are all attached to the diagram. The software automatically organises the information entered in each of these categories. When entering hazards, doHACCP software prompts users for all of the information required. CCP determination asks users to carefully consider if this point in the system is a CCP and the software allows users to choose between them using a decision tree. Places where CCPs occur in the flow of materials diagram are highlighted with contrasting colours. The software allows users to enter and print administrative information, including an HACCP team roster, a statement of management commitment to HACCP and a history of amendments to the HACCP plan. The software automatically feeds information into 16 standard HACCP reports and allows users to print all or parts of the plan. Arrow Scientific Contact info and more items like this at wf.net.au/L908 30

November/December 2011

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November/December 2011

Machine guarding The Allen-Bradley Guardmaster SensaGuard range delivers a cost-effective, machine guarding solution for industry. The units provide secure safety switching, diagnostics and monitoring in one compact package. Combining the cutting-edge

PROCESSING

HACCP auditing and management

technology of RFID coding with an M23 Safety Distribution block, SensaGuard simplifies the integration of multiple sensors. RFID coding provides an additional level of security, allowing a SensaGuard

ECEFastâ&#x20AC;&#x2122;s HACCP Audi-

switch and actuator to be paired with a specific code. This enhances safety

tor is a waterproof, rug-

by reducing the possibility of other actuators being used to bypass the switch.

ged, handheld device that

The switch is paired with an actuator on initial power-up and can be locked

measures temperature

to this unit immediately. If some flexibility is required, the switch can be re-

and also provides real-

paired to another actuator up to eight times. After the 8th time, it is locked to

time Food Safety Plan

the last-paired actuator. At any time during the pairing process, the switch can

action control, automatic

be locked to a specific actuator permanently.

results recording and cor-

When multiple sensors are installed, the use of the Allen-Bradley M23 Safety

rective action if processes

Distribution block will simplify integration of the SensaGuard family of products.

are not in control. It is simply programmed on a PC

Available with either four or eight ports, the M23 Safety Distribution block fa-

using the userâ&#x20AC;&#x2122;s workplace terminology.

cilitates the direct local connection of M12, 8-pin SensaGuard safety products. The Safety Distribution block provides the

Since it is not a universal PDA device, there is little chance of unexplained loss; and with fewer

ability to connect up to eight SensaGuards to

control keys, staff training is simplified. Regular

meet Cat4/SIL3/PLe, with an individual auxiliary

actions, such as cleaning, sanitising, and tidy-

contact from each device going back to the

ing, can be scheduled and acknowledged

control panel. This provides specific diagnostic

by the logged-in operator. Temperature

information for each door or device to the con-

measurements are requested in plain

trol system. The LEDs on the distribution block

text, recorded and acknowledged.

provide additional local diagnostic information

Temperature out of tolerance will trip

for troubleshooting. Shorting plugs for unused ports, variable length 19-pin patchcords and 8-pin

and alarm and direct the user to the

cordsets are available to provide full connectivity

planned corrective action.

and circuit safety.

The Auditor can be connected to a

Suitable for guarding equipment with part- or full-

PC and data uploaded, so no time is wasted with checklists and data entry.

body access, SensaGuard switches are particularly

The HACCP Auditor can be used

suitable for applications where multiple access doors must be monitored up to safety Category 4/Safety Integrity

to assure that Food Safety Plans are

Level 3 (SIL3)/Performance Level e (PLe).

carried out according to schedule, with little supervision, and to minimise the time and

The SensaGuard RFID coding and connectivity with the M23 Safety Distribution

effort required to keep complete records that are

block offer a cost-effective solution that is suited to a wide range of industrial

easy to access in the event of an external audit

safety applications. Following certain installation requirements, the M23 Safety

of a system.

Distribution block also allows connectivity of other devices via dry contacts to products such as e-stop or OSSD transistor outputs for light curtain applications.

ECEFast

Rockwell Automation Australia

Contact info and more items like this at wf.net.au/M066

Contact info and more items like this at wf.net.au/K588

MegaWatt Heating Elements manufacture and supply industrial heating elements & controls

3/2 Industrial Drive, Somerville 3912, Victoria, Australia t 03 5977 6991 f 03 5977 6995 m 0419 507 868 e tony@megawattheatingelements.com.au

Cartridge Heaters Cartridge Heaters can be custom made to suit your application. Temperature Controllers We are the Australian agents for Arico Temperature Controllers. Thermocouple We manufacture thermocouples made from heat resistant cable and stainless steel braid for added protection.

www.megawattheatingelements.com.au 32

November/December 2011

www.foodprocessing.com.au

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 89 convenient locations Nationally, all IS09001:2008 accredited

November/December 2011

Wireless sensor logging system The Elpro Ecolog Net wireless sensor logging system combines the reliability of the original Elpro Central Monitoring System with added flexibility of wire-free sensors.

PROCESSING

The Central Monitoring system based on the Ecolog

Stainless steel ultrasonic sensor

Net range of temperature, humidity and analog data

The UMC3000 ultrasonic sensor is suitable

ing for warehouse, pharmaceutical and other critical

for use in harsh environments. The unitâ&#x20AC;&#x2122;s

applications for many years, the new wireless sensors

seamless, 100% stainless steel housing and

allow for connection of sensors without the need

chemically resistant cable system enable

for cabling between the sensor and the logger unit.

ultrasonic monitoring and control in areas

The system features easy instal-

previously considered impossible to solve.

lation as no wiring of sensors

logging units has provided reliable automated monitor-

is required and it is simple to

Two housing concepts solve a variety of applications. A smooth-barrel, food-grade design

move equipment about freely

meets the stringent standards of the food and

without relocating wires. The

beverage industry, while a 30 mm diameter

system allows users to monitor

threaded model is suitable for agricultural

equipment where no sensor cable

machinery and other outdoor installations.

can be routed. The system is GMP, GLP, GAMP5

LED indication of target presence and power is standard on all models. The completely

and FDA 21 CFR Part 11, Annex

sealed design meets IP68/69K standards

11 and HACCP compliant and has

and the sensing face and barrel are stainless

applications in monitoring room tempera-

steel. The units have a fully adjustable 200 to

tures, fridges or freezers; storage and production

3000 mm sensing range and meet EHEDG

plants and incubators.

(European Hygienic Engineering & Design

ETM Pacific Pty Ltd

Group) Hygienic Design guidelines.

Contact info and more items like this at wf.net.au/J900

Pepperl+Fuchs (Aust) Pty Ltd Contact info and more items like this at wf.net.au/K592

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

www.heraeus-noblelight.com/au

Clean Cover UV tunnel - Steribelt - Bluelight UV module

November/December 2011

www.foodprocessing.com.au

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

Web-based remote temperature monitor The range of climate monitors from IT WatchDogs can be used to protect server rooms, laboratories, cool rooms and store rooms that require climate control. The range includes the compact MicroGoose climate monitor that can be placed almost anywhere. Its built-in sensors can measure temperature and humidity while user-defined alarm points can be set to notify a system administrator when extreme conditions occur. The MicroGoose-II provides an additional digital sensor port allowing external sensors to be attached. The MicroGoose climate monitors include an internal web server that can be accessed to remotely check the status of the environment and view graphs of logged data. Support for email and SNMP allows recipients to be directly notified, or network monitoring programs such as HP OpenView or What’s Up Gold to easily add the climate monitor to their list of devices. Interworld Electronics & Computer Industries Contact info and more items like this at wf.net.au/L631

Stainless steel spring rewind reels Australian manufacturer ReCoila offers a range of stainless steel spring rewind reels suitable for food processing, washdown and manufacturing processes where hygiene is paramount. Available in a wide variety of sizes to handle pressures up to 400 bar, the SE Series of reels is strong, reliable and can be hygienically washed and cleaned when required. The reels are supplied either bare or with hose, from 3/8″ ID up to 1″ ID and are suited to air, cold water or hot water. A heavy-duty mount enables the reel to be fixed to the wall, ceiling or under a work bench. ReCoila also supplies other reels that are well suited to the food processing industry, including hand crank reels in stainless steel and PVC spring rewind reels for hot water washdown available with or without a fully insulated washdown gun. ReCoila Pty Ltd Contact info and more items like this at wf.net.au/K660

www.foodprocessing.com.au

November/December 2011

PROCESSING

Available digital sensors include temperature, humidity, dewpoint, airflow and power monitoring.

PROCESSING

Dosing oil into vegetable trays at Lea Green Foods Founded in 1997, Lea Green Foods provides a range of pastes and purees to the food service and manufacturing markets. In just 12 years the site at St Helens has grown to 835 m² and is home to 14 employees. Last year the company wanted to introduce a process that entailed repeatable, accurate and hygienic dosing of vegetable oil into trays of produce such as tomatoes and roasted peppers. “It was a fairly new concept to be honest and we were unsure of how much demand there would be,” says the company’s Engineering Manager Barry Rushton. “For these reasons, we didn’t want to outlay excessive capital designing and building a new production process.” With this in mind, Rushton decided to try replicating the required process using a trial 520 series pump from WatsonMarlow, a model designed specifically to meet the needs of the process sector. “We took a 520 series pump on trial for a month,” says Rushton. “We needed a pump which could operate at a variable flow rate depending on the volume, speed and time of our production.

November/December 2011

“We tried it using a selection of different oils and it performed very well. “I was particularly interested in achieving accurate dosing of each 300 mL volume as we have to declare a given weight for the product within ±2%.” Watson-Marlow’s 520 series pumps are fitted as standard with the 520R pump head, which accepts up to 9.6 mm bore tubing for flow rates up to 3.5 L/min. A key feature of the 520 series pump is its Memo Dose facility, which has helped Lea Green Foods to benefit from accurate and repeatable dosing capability. Another factor that impressed the team at Lea Green Foods was the design of the filling nozzle. Here, a small quantity of fluid is sucked back up into the tube to prevent any drips after dosing. “The fact that we have no drips not only means less product waste, but also creates a clean process, something that is pretty important in the food industry,” says Rushton. “We also specified food-quality 9.6 mm bore Marprene as a tubing material.” With demand beginning to rise for the new products, Lea Green Foods requested an extension to the pump trial period, keeping the Watson-Marlow 520 series model for a further three months. “Since then it’s been fabulous for us. It now runs for a few hours at least four days a week, with demand for the products continuing to grow. ” Watson-Marlow Pty Contact info and more items like this at wf.net.au/L221

www.foodprocessing.com.au

Compact safety light curtain The ReeR EOS4 compact safety light curtain has been designed for the protection of machine tools. With its small-size housing and minimal dead zone, it is well suited for applications

PROCESSING

where space restrictions exist. The unit has a very small dead zone, which is only present on one side. This allows the EOS4 to maintain resolution up to 30 mm if installed on a plan and up to 40 mm if installed at 90° against another EOS unit. The curtain can be used for the protection of presses, punches and dinking machines, cutters and shears, robotised areas, assembly lines and assembly machines, including those with a small size. The units feature selectable maximum scanning distances of 4 m or 12 m and have two PNP safety static outputs protected from short-circuits and overloads. Up to three light curtains can be connected in a master/slave set-up. The curtain is available in a variety of models, including with a resolution of 30 and 40 mm for hand detection, 50 and 90 mm resolution for presence detection in a hazardous area and 90 mm resolution with 2, 3 or 4 beams for access control. It is also suitable for complex applications with the highest safety requirements where conventional relay technology reaches its limits. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/J867

‘Turn-off’ nozzles for spray heads The PNR range of nozzles can be shut off individually to suit different requirements. In industrial and manufacturing settings where spray heads are used for distributing water or other types of liquids, it is common that sometimes not all the nozzles are required. The PNR range of nozzles has been designed to provide a solution to situations such as when the width of the product or surface being sprayed changes several times in the course of a day and so it is helpful to be able to easily turn off unneeded nozzles to eliminate wasted water or liquids. The nozzles are manufactured from brass for longlasting wear. Turning the water flow on or off through individual nozzles is simple and fast. Tecpro Australia Contact info and more items like this at wf.net.au/K009

www.foodprocessing.com.au

November/December 2011

PROCESSING

New Zealand chip companies don’t grow on trees A ‘chip off the old block’ - Heartland Potato Chips

A niche in the New Zealand potato chip market for locally grown, locally made and locally owned product has enabled a South Island potato farmer to produce his own potato chips, in his own factory, from his own potatoes.

eartland Potato Chips was formed when the Bowan family was given the opportunity to purchase the old Bluebird Washdyke factory based in Tiramu in February 2009. The family had a potato farm in South Canterbury, in the heart of New Zealand’s South Island, and had once been a supplier to a major snack food company in New Zealand. Knowing that quality control always starts at the farm, this bold and enterprising decision to go into potato chip manufacturing would change their life. A niche market in the New Zealand potato chip industry for locally grown, locally made and locally owned product was born. Timaru potatoes, well known for their great flavour and low sugar content, make the perfect potato chip and, because of this, Heartland Potato Chips wanted only the best packaging and product handling equipment to complement and add value to their raw product. With Heat and Control’s reputation in New Zealand for manufacturing and sourcing only high-quality equipment, they were approached and able to listen to the Bowans’ needs and concerns, and found a way to be flexible in their approach to provide Heartland with the packaging equipment and product handling equipment they needed to achieve their goals. 38

November/December 2011

Heartland Potato Chips were after specific equipment to complete their line. Scott Burrows from Heat and Control explained, “FastBack conveyors were an ideal choice for transporting such a delicate product as potato chips. The horizontal motion of the conveyor reduces breakages of delicate products, and also minimises seasoning loss. Bill Cockburn, Product Manager of Heartland Potato Chips, and with over 37 years in the food industry, had previous experience with Ishida multihead weighers, so this equipment had already proven its capability for accuracy, as well as longevity and reliability.” Burrows continues, “Bill’s previous experience leant him towards the Ishida equipment, unfortunately a complete Ishida packaging line was not possible. The line speed/ packaging speed required to ‘pull’ the processing supply volume did not warrant a high-speed Ishida VFFS solution. Although when the time comes, they may choose an Ishida Atlas bagmaker which has product stripping capabilities, as the specific gravity (solids) can change through the seasons and therefore the bulk density when packed.” With the experience of the sales, engineering and project management team, Heat and Control was able to provide Heartland with an Ishida computer checkweigher, Heat and

www.foodprocessing.com.au

PROCESSING

Control FastBack conveyor system and CEIA metal detector, as well as Matrix packaging machinery from the USA to complete the 300 kg/h potato chip line. The result, success! “Extreme care was taken when purchasing our equipment. Conditioning units, along with a modern fryer, were purchased overseas, but when it came to our end-of-line equipment, we looked to Heat and Control to supply us the best quality and reliability to complement our line,” said Bill Cockburn. With delivery of the equipment just one day prior to the New Zealand earthquake, and with the practical attitude of the South Island people, the Heartland Potato Chips project installation team got on with installation of the equipment into their newly refurbished factory. A sheer indication of their dedication and pride, and why they are named Heartland Potato Chips. So with a passion for a challenge and with over 40 years’ experience, Ray Bowan, farmer/ owner of Fallgate Farms and now CEO/owner of the new Heartland Potato Chip Company, finally got a chance to fulfil a lifelong dream - to produce his own potato chips, in his own factory, from his own potatoes. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/M031

Albany and Envico combine. High performance doors for every application.

Reversing Safety Edge

Sizes Up to 9 x 9

Knock-out with Automatic Relocation

High Speed Security Doors

Rapid Freezer Doors

Flexible Soft Bottom Edge

Speeds Up to 3.0 mps

Durable RollTex© Door Blade

Albany Door Systems No. 9 Mc Ilwraith Street Wetherill Park 2164 Sydney, NSW

Ph: 1300 666 232 Fx: (02) 9756 4340 Andrew.Bykersma@albint.com www.albanydoors.com

www.foodprocessing.com.au

November/December 2011

A six-month project, completed by Ovivo Australia in just 12 weeks, has enabled two large beverage companies to increase their production capacity by 420%. The joint venture between Frucor NZ and Slade’s Beverages in Thomastown, Victoria, was to increase the production of water supply by installing a nanofiltration system. This has allowed for the production of a new range of V Energy drinks and other products using water directly from the potable supply. The client required a 30 m³/h supply of consistent quality demineralised water to ensure that flavours were not affected. The nanofiltration system was recommended by Ovivo Australia due to its small filter pore size which is fine enough to remove contaminating flocculants and divalent metal ions. The process design to take feed water from Melbourne’s potable water system and treat it to remove fine flocculent particles and dissolved metal impurities was completed by Ovivo Australia with the support of Van-Der-Molen GmbH, a member of the Ovivo water group. The integrated nanofiltration plant and permeate transfer system was delivered at the end of May. As well as removing the impurities, the system also allows for a consistent quality of product water in terms of hardness, TDS and pH. This enables the client to

accurately control the flavour as well as the carbonation process in soft drink making. Analysis of local potable water samples showed TDS levels of 100 mg/L. The system was designed to reduce these to <55 mg/L and maintain a consistent pH of 6.2 to 6.5. The system was also designed for an 82-85% recovery of the potable water feed utilising a three-stage, one-pass treatment process. The nanofiltration plant utilises mains water pressure to feed through a pretreatment process which involves PID controlled dosing of antiscalant and SMBS for membrane protection. Additional cartridge filtration prior to the NF plant is in place to protect against particulates from depositing on the membrane. A 15 kW Vertical Multistage pump drives the 36 m³/h feed to the required pressure to push the water through the membranes. The generated permeate is maintained below an 80 µS/cm conductivity setpoint by a discharge conductivity meter. Permeate which is above this limit is discharged to sewer via an off-spec valve to maintain a consistent quality product in the permeate tank. The permeate is stored in a product tank being delivered to the client’s processes via two VSD controlled centrifugal pumps. An integrated recycle system is implemented to allow delivery of

permeate from the product tank back to the nanofiltration plant for use in the CIP process. As the feed water is potable water, the discharge TDS on the brine side is extremely low. TDS levels in the discharge are only 370 mg/L with a pH of 7.8, which has meant the water can be recycled. Ovivo provided an online quality control system to ensure all water delivered was within the 85 µS/cm quality specification. The integrated control system means the plant operates as a self-contained turnkey plant and HMI software includes a CIP procedure walkthrough feature to remove the risk of operator error during membrane cleaning. As well as the challenge of meeting a 12-week delivery schedule, Ovivo Australia faced a second test of having to increase the package size when product storage was added to the project scope and delivered with just four weeks remaining. An integrated automatic product transfer pumping solution, including three pumps and a secondary VSD control panel and upgrades to the existing NF control panel, were also added to the scope and delivered within 10 days. The benefits of the nanofiltration system over a reverse osmosis system for beverage production include: • S mall enough filter pore size to remove contaminating flocculants and divalent metal ions. • T he product water quality still contains vital dissolved salts so that it does not require significant remineralisation for human consumption. • T he energy required per unit of product is lower. • Lower capital expense. • T h e p r o d u c t w a t e r, d u e t o i t s high quality, can be used for both the manufacture of the beverage flavouring as well as the carbonated make-up water. Ovivo Contact info and more items like this at wf.net.au/M041

November/December 2011

www.foodprocessing.com.au

©iStockphoto.com/Plainview

PROCESSING

Nanofiltration increases water production capacity by 420% at beverage plant

Plate freezers for non-packaged product DSI plate freezers are designed for throughput of smaller product and typically for non-packaged product such as minced meat, seafood, blood, poultry and juice. Plate freezers can be designed for manual, semiautomatic

PROCESSING

or fully automatic operation. The DSI range of small vertical and horizontal plate freezers is suited to land and marine installations. The vertical plate freezers are particularly suited to the seafood industry where installations on fishing vessels provide rapid freezing of fish and shellfish of all sizes. A key benefit for plate freezing is that it provides quick rapid freezing which allows for improved product freshness and quality. The output of frozen blocks, whether from a vertical or horizontal plate freezer, also delivers savings and efficiencies to palletising and logistics operations due to uniform flat surfaces maximising space available for transport of pallet loads. DSI plate freezers can be designed to operate with CO2 to deliver faster freeze times. The units are designed for easy maintenance, low power consumption and operator health and safety. Post-installation service and maintenance is provided on all products ensuring continued optimum performance. Milmeq has been awarded the exclusive agency for DSI plate freezers in Australasia. Milmeq Pty Ltd Contact info and more items like this at wf.net.au/M038

www.foodprocessing.com.au

November/December 2011

Lubricant for bottling plants DryExx GF is a conveyor lubricant specifically designed for use with glass bottles on steel conveyor belts. It is claimed that the lubricant saves up to 80% of the water used when compared to traditional wet lubricants but still achieves the highest possible hygiene levels and does not compromise efficiency. Ecolabâ&#x20AC;&#x2122;s DryExx GF formula contains an active lubricating substance which creates a protective film on the belts. This results in reduced friction, less abrasion and consequently

PROCESSING

eliminates the need to use large amounts of water to continually wash any abrasion off the belts.

X-ray systems

Ecolab Pty Ltd

Heuft Systemtechnik eXaminer X-ray systems

Contact info and more items like this at wf.net.au/K579

can be used for the quality inspection of filled containers during the production of foods and drinks. The very low radiation exposure and the integrated filter and image analysis technologies ensure maximum detection reliability with a minimum false rejection rate. The system inspects unpackaged and packaged products lying on the conveyor for foreign objects and completeness among other things. For this they are examined by means of X-rays. The radiation is only activated for a fraction of a second when a product is actually in the inspection area. The radiation intensity is far below the permitted limit value for the inspection of food because of this. In addition, the short exposure time of this pulsed radiometric measurement ensures pin-sharp X-ray photographs. In order to analyse these precisely, the eXaminer XB is equipped with special filter technologies and the reflexx high-performance image processing sys-

3D colour camera for fruit and vegetable grading 3D imaging is ideal where height, shape or volume is of importance for the production process. However, to make a complete quality or grading decision, it is often necessary to also consider the colour of the parts produced. This is, for instance, common in grading of fruits and vegetables, shape and baking degree verification of baked goods, and fill level and colour verification in beverages. By considering both 3D and colour aspects, more reliable decisions can be made which improve the product quality and reduce waste. Sick is introducing the ColorRanger E, a high-speed 3D camera with highquality colour capability. By measuring both the 3D shape and the colour of parts, more reliable decisions can be made to allow production plants to improve their uptime, throughput and product quality. The ColorRanger E replaces the need for several different cameras for the same task, which reduces the solution cost and complexity.

tem which clearly dif-

ColorRanger combines the functionality of a 3D camera and a line-scan

ferentiate real faults from packaging structures or product inhomogeneities. This increases the detection accuracy and reduces the false rejection rate. JW Industrial Instruments Pty Ltd Contact info and more items like this at wf.net.au/H002

colour camera. With Sickâ&#x20AC;&#x2122;s MultiScan technology, the camera can be configured to provide several measurements at the same time, such as 3D shape, laser scatter, colour and monochrome, according to the exact need of each specific application. Hence, one ColorRanger can replace several other cameras, which reduces the system size as well as the cost of hardware, integration and maintenance. In addition, since the different measurements come from the same camera system, it is easier to make data fusion and combined data analysis. Sick Pty Ltd Contact info and more items like this at wf.net.au/L292

November/December 2011

www.foodprocessing.com.au

Process viscosity sensors Marimex Industries’ range of process viscosity sensors includes the ViscoMeter VP-1000,which is geared towards OEM process applications. The series VP-1000 is capable of measuring low or high viscosities with process pressures up to 10 bar and process temperatures up to 130ºC. The ViscoMeter VP-3000 sensor can be adapted to most every process application. It is capable of measuring low to high viscosities and the sensors can be constructed for pressures up to 500 bar and

Fruit fly control Insect-O-Matic has introduced the Nectar unit which can be used to discreetly control fruit flies as well as other flying insect pests. This insect control device specifically

Because of an innovative construction it is now

targets fungal gnats (commonly known as fruits flies,

possible for Marimex Industries to make the non-active

vinegar flies or bar flies).

extension any length and shape. This way the sensor can

Nectar uses melon-scented and pheromone-impregnat-

be easily adapted to specific applications and installation

ed glueboards - attractive to the fungal gnats as well as

requirements. With the neck also being able to be any

flies - together with the patented Synergetic UVA-Green

length, it is possible to use the sensor in high process

light to attract the insects. In addition, Nectar has two

temperatures. Air cooling of the sensor housing is not

trays designed to hold a liquid attractant (such as wine

required, making sure the sensor itself is kept at the

or vinegar), which further enhances the attractiveness

actual process temperature.

of the unit to fungal gnats and hence its performance.

These next-generation sensors incorporate many

Nectar has stainless steel construction and a discreet

features, making them more flexible and easier to work

design with the trapped insects being kept out of sight. It

with during installation, start-up and operation. They are

is user friendly - simply plug it in and turn it on. Changing

designed to make future updates easy.

the glueboards is quick and easy.

Rheology Solutions Pty Ltd

Insect-O-Matic

Contact info and more items like this at wf.net.au/K607

Contact info and more items like this at wf.net.au/L268

Show-Off!

Looking for an allrounder? Bürkert has it – the new multichannel transmitter/controller. MultiCELL controls up to 8 sensors with mathematical processing and datalogging all on board. It is ideal for dosing applications, water treatment systems or control loops. The standard base model, which delivers various options for measuring pH, redox and conductivity, has software and hardware expansions; eg for additional flow measurement, control functions and signal inputs. With just one device you get exactly what you need for your measuring requirements.

Want to know more? Call AU 1300 888 868 or NZ 0800 BURKERT (287 537) WNIFT Ad 201101.indd 1

16/12/2010 2:49:21 PM

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November/December 2011

PROCESSING

temperatures up to 450ºC.

Press system for joining SS pipe Victaulic has intriduced Vic-Press, a flame-free press system that joins pipe in a matter of seconds. Vic-Press is an ANSI Schedule 10S pipe sized press-toconnect system designed for off-the-shelf ASTM A-312 Schedule 10S stainless steel

PROCESSING

pipe. An industrial-grade solution for quickly and reliably joining small-diameter piping systems, Vic-Press offers increased strength and durability and improved flow characteristics compared to light-wall tube systems. It is claimed to be a safer, more efficient pipe assembly than welding, threading and flanging, and meets or exceeds industry standards. Vic-Press is used with standard Schedule 10S stainless steel pipe, which offers increased strength and durability and eliminates the need to stock specialty pipe. The pipe-wall thickness of ANSI Schedule 10S pipe is up to double that of light-wall tube. As a result, Vic-Press offers a good life cycle, up to three times the end-load performance, up to twice the bend-load performance, up to a 52% increase in available flow, and up to a 23% reduction in pressure drop per 30 m of pipe over tube-sized systems. The Vic-Press system is quick, simple and safe to install. Pipe is cut to size and deburred, marked for visual verification and inserted into a lubricated coupling, fitting or valve. The Victaulic PFT510 handheld pressing tool is used to press the component onto the pipe-end, providing a positive mechanical interlock and creating a rigid, permanent, leak-tight joint. Press detection technology enables the installer to confirm any unpressed joints as the system is filled. The Vic-Press system is claimed to require 70% fewer man-hours than welding to install and significantly reduces rework. No flame or arc is required as with welding, reducing risk to workers and surroundings. With pressure tolerances up to 3450 kPa, Vic-Press exceeds ANSI class 150 standards. It meets ASME B31.1, 31.3 and 31.9 support requirements. The system is also ANSI/NSF 61 certified for potable water up to 82°C. “Victaulic makes major investments in research and development to bring our customers innovative products such as Vic-Press,” said Gennaro Sposato, Regional Manager for Victaulic in Australia. The Vic-Press system is available for 15-50 mm Type 304/304L and Type 316/316L pipe. Vic-Press products feature Grade H HNBR gaskets, suitable for services up to 98°C. Alternative materials, including EPDM, fluoroelastomer and silicone, are available for services up to 121°C. Vic-Press is suitable for many wet and dry industrial and commercial applications, including potable water, oil, compressed air, lubricated air, non-combustible gases and general chemical services. Victaulic Australia/New Zealand Contact info and more items like this at wf.net.au/M030

November/December 2011

www.foodprocessing.com.au

©iStockphoto.com/Allen Penton

PROCESSING

Seeing beyond detection The evolution of X-ray inspection systems Terry Woolford, General Manager, Eagle Product Inspection (Formerly Smiths Detection PID)

A look at how X-ray product inspection in the food industry has advanced in recent years to meet ever-increasing consumer demands.

O ©iStockphoto.com/Kelly Cline

ver the last few years, X-ray systems for food manufacturers have matured. Gone is the day when food was painstakingly inspected by hand, which was a time-consuming process; today, technologically advanced machines identify a multitude of contaminants in a variety of foods, products and packages. With ever-changing trends in the food industry, X-ray inspection equipment has evolved to meet the new demands that increasingly innovative packaging designs are impacting on the inspection process.

Detecting contaminants in multitextured foods A growing consumer trend affecting manufacturers is the desire for multitextured foods, such as bags of mixed salad leaves. These types of packaged goods have many density levels resulting in a crowded X-ray image, posing new challenges for identifying contaminants. As such, extra demands are being

made on image analysis software to find contaminants. Material Discrimination X-ray (MDX) technology, which is especially useful with variable density ‘busy’ images, is a good solution to this new-found problem. Originally pioneered for use in the security sector, MDX technology is able to discriminate materials by their chemical composition and allows the detection and rejection of historically undetectable inorganic contaminants such as glass shards, rocks, rubber and plastic. New product inspection systems now come equipped with MDX dual-energy algorithms that increase contaminant detection of foreign bodies previously unseen by X-ray or any other conventional means in difficult product applications.

Problems caused by innovative packaging designs New and innovative packaging designs, such as fold-out cardboard sandwich packaging and corrugated card encasements,

www.foodprocessing.com.au

November/December 2011

PROCESSING have also led to their own challenges. Machines previously calibrated to scan standard types of packaging have had to adapt to be able to accurately analyse new shapes, sizes and materials such as flexible packaging and pouches. Recent advancements in technology now enable X-ray inspection equipment to simultaneously perform a wide range of inline quality checks such as verifying fill level, measuring headspace and verifying component presence and absence to alert manufacturers to over- or under-fulfillment to avoid waste. The blind spots that had previously occurred at the bottom of upright containers such as glass jars, bottles and composite lines are also easier to inspect today with machines that use enhanced contaminant detection technologies, such as MDX.

Contaminant detection in foil pouches and tin cans Goods in tin cans or foil pouches have also posed a problem for manufacturers when inspecting for metal contaminants within the container. Detection of metal and foreign contaminants in food packaged within foil and metal is impossible with a conventional metal detector and so the development of X-ray metal detection technologies has made this achievable. Food and drug safety regulations, along with the requirements of large food retailers, have also been a driving force in the industry to improve X-ray inspection machinery. Although there are no legal requirements to use X-ray inspection, guidelines such as Hazard Analysis Critical Control Point (HACCP) have put the onus on manufacturers to establish reliable and fully documented product inspection programs. The HACCP management system addresses the inspection of food by analysing and controlling biological, chemical and physical hazards. It is used by manufacturers at all stages of food production and preparation processes including inspection, packaging and distribution. 46

November/December 2011

As packaging continues to evolve to appear attractive to consumers, X-ray inspection machines will continue to progress in order to meet these ever-changing demands. Equally, as retailers demands increase and food and drug safety regulations intensify, compliance and traceability through every stage of a productâ&#x20AC;&#x2122;s life cycle will grow in importance. Eventually all product inspection equipment will need to be tailored to dually function as a management tool and food safety measure.

The Eagle Product Inspection (Formerly Smiths Detection PID) line of X-ray inspection systems evaluates in process and finished products for contaminants such as metal, glass, stone and bone while also having the ability to check mass, evaluate compartmentalised fill level,and analyse fat content. With its headquarters in Tampa, Florida, and local offices across the globe, Eagle Product Inspection machines meet todayâ&#x20AC;&#x2122;s HACCP certification requirements to ensure that food and beverage manufacturers and their customers in turn are well protected. Eagle Product Inspection was acquired by MettlerToledo in March 2011. The business adopted the Eagle brand which has been used for its products since 1998. The Eagle business joins the Mettler-Toledo Product Inspection family of brands: Garvens, Hi-Speed, Safeline and CI-Vision. Eagle Product Inspection equipment is distributed in Australia and New Zealand by Food Processing Equipment.

www.foodprocessing.com.au

Energy management Carlo Gavazzi Energy Meters - the WM30 and WM40 along with their respective range of optional add-on modules - feature modular

PROCESSING

communications options, including: BACnet IP, MODBUS TCP/IP, MODBUS-RTU and iFIX SCADA. The BACnet

IP69K-rated safety light curtains and grids

and MODBUS options are also available with or without onboard memory. With the large LCD that can be user configured, all of

A range of IP69K-rated safety light curtains and grids has been

the most critical parameters are available at a glance.

introduced by ifm effector.

Combined with the touchpad, navigation through the

The safety light curtains and grids are designed to provide a

comprehensive parameter list including energy, currents,

protective optical barrier between plant personnel and unsafe equip-

voltages, frequency, power, power factor and harmonic

ment and dangerous areas. The curtains can be used for perimeter

analysis is user friendly.

guarding, access prevention and point-of-operation guarding.

Complete with Class 0.5 (kWh) accuracy, phase asym-

Housed in a robust PMMA transparent tubing, ifm's safety light

metry measurement, temperature input and harmonic

curtains and grids carry an enclosure rating of IP69K and are

analysis up to 32nd harmonics, these energy meters can

resistant to high-pressure cleaning and steam.

be integrated into Carlo Gavazzi’s plug ‘n’ play trending

The units feature a heater element coupled with sealing O-rings

and analysis software - PowerSoft.

to prevent moisture build-up inside the tubing and easy mounting

NHP Electrical Engineering Products Pty Ltd

using the integrated tabs. Highly visible LEDs provide status, set-up

Contact info and more items like this at wf.net.au/L215

and troubleshooting indication and an attached PVC cable enables quick connection. The light curtains are shipped fully assembled, bringing down total installation costs. For application flexibility, products offered include safety light curtains with 14 or 30 mm resolution and light grids with 2, 3 or 4 beams. Both Type 2/SIL 2 and Type 4/SIL 3 versions are available. ifm efector pty ltd Contact info and more items like this at wf.net.au/M032

Programmable panel meter The Series SPPM Smart Programmable Panel Meter is a configurable, full-colour display that can be used in a variety of applications. Utilising a USB connection, the panel meter can be configured with downloadable software, using any computer running Windows-based software. It is available with either a 2.4″ or 2.8″ screen which features graphics that can easily be customised to read and/or graph pressure, temperature, humidity, gas concentration or many other parameters. Up to two transmitters or transducers can feed the panel meter’s user-scalable inputs. The Series SPPM meter includes a gasket and mounting clip for quick installation into a panel. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/L193

www.foodprocessing.com.au

November/December 2011

Biodegradable, phosphate- and bleach-free cleaner for food production facilities Crystal Simple Green is a biodegradable, phosphate- and bleach-free cleaner for food production facilities. It has been designed with no added colour or scent and is suitable for cleaning all areas including factory and food preparation surfaces. Crystal Simple Green rinses residue free so the risk of product tainting is also minimised. The product is non-hazardous and readily biodegradable, without containing bleach or ammonia. This makes the product safer for workers as they will not be exposed to toxic cleaning chemicals

PROCESSING

either through direct exposure or indirectly through residue. It is also beneficial for employees with allergies who have to avoid industrial

9-port IP67 switch Belden has extended its Hirschmann product range with a 9-port version of its Octopus OS20 series. The Hirschmann basic software is installed on this layer-2 switch, which meets the requirements of protection class IP67. This software supports both various management and security functions and fast redundancy methods such as HIPERRing, MRP and RSTP.

cleaners that contain bleach. Crystal Simple Green can degrease as well as clean and is suitable for all steel surfaces. Chemical solvents and non-degradable detergents found in many common industrial cleaners can also inadvertently find their way into stormwater systems, which is why Crystal Simple Green has been designed to clean in a safe and responsible way without damaging the environment. The cleaning agent is also non-abrasive and non-corrosive so it won’t scratch or damage surfaces, making it suitable for

The Fast Ethernet ports (10/100 BASE-TX) have

use over all surfaces. It’s safe for the user, safe to

vibration-resistant M12 connections in D-coding.

store and safe to transport. As it is non-flammable,

Further features include a robust metal housing

there is also no risk of fire, which is particularly

and an extended temperature range from -40

important if used around hot cooking and food

to +70°C.

processing equipment.

As the switch can be cascaded in any way,

Crystal Simple Green is available in five sizes

decentrally structured automation networks with

ranging from a 710 mL trigger bottle right up

short transmission paths can be implemented with

to a 1041 L tote suitable for the largest food

the respective terminal devices. The Octopus's

processing and handling facilities. The highly

redundancy method and a redundant voltage

concentrated product is diluted 1:30 for light

supply ensure high network availability.

cleaning and degreasing so 20 L of concentrate

The switch, whose compact housing (184 x

makes 600 L of cleaning solution - saving pack-

189 x 70 mm) is designed for wall mounting, can

aging, time and money. This is simply an afford-

be quickly put into operation with plug-and-play.

able and efficient, eco-friendly, industrial-strength

Configuration is possible either via Command

cleaner that will allow users to clean and degrease

Line Interface (CLI), DHCP relay agent option

food processing and handling equipment, floors,

82, HiDiscovery or the ACA11-M12 EEC auto-

walls and counters, stainless steel, grills, faucets,

configuration adapter. Belden Australia Pty Ltd Contact info and more items like this at wf.net.au/M024

backsplashes and more. CIPL Pty Ltd Contact info and more items like this at wf.net.au/M050

Quality ISO 9001

November/December 2011

www.foodprocessing.com.au

Joint health not bending to functional foods in maintaining active lifestyles, joint health remains a very underdeveloped area of the functional foods market as a whole. While there has been considerable activity in dietary supplements for joint health, the mainstream food and drinks market has seen relatively few developments in this area.

he Innova Database (www.innovadatabase.com) records that introductions with a joint health positioning accounted for less than 1.5% of global food and drinks launches on an active health platform in the 12 months to the end of August 2011. This represented just over 0.1% of launches as a whole. Furthermore, the vast majority of this activity was in pet foods, which accounted for over 85% of total joint health launches. If pet foods are excluded, beverages, including both soft drinks and hot drinks, accounted for almost all of the launch activity. According to Innova, the USA has seen by far the highest levels of activity in this area, particularly for soft drinks, although many still take a hybrid-type positioning as supplement-style products. Joint Juice is one of the earliest examples of this, having become the first ready-to-drink glucosamine supplement in 2001. It contains glucosamine, chondroitin, vitamins D and C and green tea extracts.

The original drink was extended with a Fitness Water, later relaunched as a Performance Water, and, more recently, with a dose-delivery shot variant. A rival brand arrived in 2007 with Elations Healthier Joints liquid supplement containing glucosamine, chondroitin, calcium in CCM (calcium citrate malate) form and boron. The Osteo Bi-Flex brand of supplements also has a liquid Joint Aid product on the market, and the Assure range of juice drinks was extended in March 2011 with a Peach Mango drink for women containing calcium for bones and glucosamine for bone and joint health. A review of joint health product launches on the Innova Database shows that, apart from glucosamine, other ingredients positioned for their joint health benefits include collagen and a whole raft of botanicals. Collagen was first used in Japan in the mid-1990s for products with a joint health positioning, as well as for skincare lines, but a recent European Safety

November/December 2011 www.foodprocessing.com.au

INGREDIENTS AND DEVELOPMENTS

Despite an ageing population and a growing interest

INGREDIENTS AND DEVELOPMENTS

The role of saturated fat re-examined

Authority (EFSA) rejection of an EU health claim submission seeking to link collagen consumption and joint health may prevent its use spreading into new markets. Meanwhile, natural, traditional and herbal remedies continue to be marketed in different countries, although often only via specialist outlets and in many cases supported by largely anecdotal evidence. In the hot drinks market, Innova Market Insights records that herbal teas have also seen some activity in this area, with a number of arthritis teas available, including the TooTeaz Arthritis Blend launched in Australia in 2010 containing alfalfa, meadow sweet, nettle, celery seed, devil’s claw, ginger, silver birch and jasmine. Nearby, in New Zealand, the longpromoted health benefits of Manuka honey resulted in the launch of Nelson Honey’s Nectar Ease Plus Special Manuka Honey with bee venom and glucosamine. South Africa has also seen a number of joint health herbal lines launched on the market, with 2011 introductions including Herbal Power Arthritis Tea, Cayenne Pepper and Black Sesame Strips. While there has been ongoing, if fragmented, activity in joint health food and drinks, the joint health market currently remains largely confined to supplements of various kinds, according to Innova Market Insights Research Manager LuAnn Williams. She contends, however, that there appears to be a clear opportunity for this type of product to be developed into the mainstream food and drinks arena, particularly in light of the growing awareness of the relationship between glucosamine and joint health. Developing convenient products with a good taste profile may perhaps be the key to tempting consumers, particularly in the USA, away from dietary supplements and into joint health food and drinks. On the local scene, Vic Cherikoff, a co-formulator of Kakadu Complex, a wild food nutritional, says “Anti-inflammatory ingredients are rife in the Australian range of functional foods. They include mountain pepper, pepperberries, anise myrtle, Kakadu plums, Illawarra plums and more. It makes sense to also co-formulate joint health ingredients with other support aims, not only for humans but for dogs and cats too. For example, appetite, energy or nutrient absorption enhancers might be targeted since compromised joints can also reduce these stimuli and compound problems. I expect we’ll see increasing emergence of non-therapeutic but still functional products over the next few years.” Innova Market Insights (Australasia) Pty Ltd

For the past three decades, saturated fat has been considered a major culprit of cardiovascular disease (CVD) and as a result dietary advice persists in recommending reduced consumption of this macronutrient. However, new evidence suggests that saturated fat intake has only a very limited impact on CVD risk causing many to rethink the ‘saturated fat is bad’ paradigm. Results from a research review conducted by Dariush Mozaffarian, MD, MPH, Department of Epidemiology and Nutrition at Harvard University School of Public Health, found that the effects of saturated fat intake on CVD risk depend on simultaneous changes in other nutrients. For example, replacing saturated fat with monounsaturated fat yielded uncertain effects on CVD risk, while replacing saturated fat with carbohydrates was found to be ineffective and even harmful, especially when refined carbohydrates such as starches or sugars were used in place of fat. Replacing saturated fat with polyunsaturated fat gave a small reduction in CVD risk, but even with optimal replacement the magnitude of the benefit was very small. According to Mozaffarian, it would be far better to focus on dietary factors giving much larger benefits for CVD health, such as increasing intake of seafood/omega-3 fatty acids, whole grains, fruits and vegetables, and decreasing intake of trans fats and sodium.

A recent meta-analysis of epidemiological and intervention studies of milk fat conducted by Peter Elwood, DSc, MD, FRCP, FFPHM, DUniv, Hon DSc, Honorary Professor at the School of Medicine, Cardiff University, found that milk and dairy consumption actually was associated with a decrease in CVD risk. “It is clear that we have barely scratched the surface in our understanding about the biological effects of saturated fatty acids,” said Cindy Schweitzer, PhD, Technical Director, Global Dairy Platform. “Scientific meetings where researchers from different disciplines within the field of nutrition share information are extremely important to identify both the gaps in our knowledge and the studies that are needed to answer the important questions about diet and health.” All of these recent research advances add to the growing body of science reassessing the role of saturated fat in the diet. Whether it’s nutrient replacement or better understanding the role certain foods can play in CVD risk, saturated fat may not be as bad as once thought.

Contact info and more items like this at wf.net.au/M063 50

November/December 2011

www.foodprocessing.com.au

Functional phosphate replacers Ulrick & Short has developed a range of functional phosphate replacers that can improve the overall texture and moistness of meat and poultry. The company’s Ezimoist range of phosphate replacements is suitable for brine solutions used for cooked and cured meats in either injected or tumbled products and whole muscle or reformed meat products. The complex functionalities of original phosphates, such as maintaining yields and maintained in the products. The Ezimoist range enhances the eating quality by maintaining

Olive oil standard

consistency, texture and taste of meats that

Standards Australia has approved a new olive oil standard for both imported and

go through harsh processing conditions.

domestic oils. The standard will promote and protect authentic products and put

Derived from both tapioca and maize, Ezi-

consumers in a much stronger position when it comes to making informed choices.

moist comes with a clean product label dec-

The voluntary standard was developed with input from the entire supply chain.

laration and can help to extend merchandise

The Australian Standard for Olive and Olive-Pomace Oils clearly outlines different

appearance due to its ability to enhance and

grades of oil - whether fresh or refined; unambiguously defines what constitutes Extra

retain succulence in meats such as burgers,

Virgin Olive Oil; includes the most current and effective testing methods for quality

sausages and hams.

and authenticity; provides a technical basis for ‘best before’ claims; and provides

Ulrick & Short www.ulrickandshort.com

labelling requirements to minimise consumer confusion. There will be a crackdown on misuse of the words ‘premium’, ‘super’, ‘pure’, ‘light/lite’, ‘extra light/lite’ and words describing country/region of origin will require substantiation as will processing methods (eg, cold pressed, first extraction). The natural variations that occur in different countries, olive varieties and regions will be accommodated, without compromising the ability to test and verify quality. SAI Global Limited Contact info and more items like this at wf.net.au/L478

Strain HN019 improves digestive symptoms A collaborative study by Danisco and Fonterra Co-operative Group on the effects of Bifidobacterium lactis HN019 on colonic transit time (CTT) and digestive symp-

Shelled hemp seeds

toms has just been published in the Scandinavian Journal of Gastroenterology. The results of this study found that daily consumption of Bifidobacterium lactis

Manitoba Harvest Hemp Foods & Oils has

HN019 (also known as HOWARU Bifido and DR10) decreases CTT and improves

rebranded its shelled hemp seeds product

functional gastrointestinal symptoms in otherwise healthy adults.

which is now known as Hemp Hearts.

“Gastrointestinal disorders are both common and complex. The results of this

The shelled hemp seeds are heart healthy,

study will help us to validate the roles and benefits of consuming probiotics in

and omega, protein and fibre rich with a

patients with mild gastrointestinal disorders,” said Dr Pramod Gopal, Principal

pleasant nutty flavour. They boast the ideal

Research Scientist, Digestive and Immune Health, Fonterra Research Centre.

ratio of healthy fats omega-3 to omega-6,

Poor gastrointestinal health and its complications are often linked to variances

making them beneficial to cardiovascular

in CTT - the time it takes food to be swallowed, digested, absorbed and ex-

health. Hemp is also the only food source

creted. Functional gastrointestinal symptoms can affect the quality of daily life

for the rare omega-6, gamma-linoleic acid

and include pain, bloating, diarrhoea and constipation.

(GLA), claimed to support healthy skin, hair

In addition, published studies independent of this study indicate that slow

and nails as well as helping balance hormones

CTT and functional GI symptoms may be associated with an increased risk of

and control weight.

gallstones, and possibly bowel and breast cancer. Probiotic consumption may

The protein found in hemp seed is comparable to soybeans and has higher levels

benefit people with mild gastrointestinal disorders by improving slow CTT2 and reducing associated GI symptoms.

of protein compared to other seeds, nuts,

According to European Food Safety Authority (EFSA) guidelines for digestive

dairy products and meats. Hemp Hearts are

health claims, transit time, frequency of bowel movements and stool bulk are

a whole food vegetarian source of complete

appropriate outcome measurements for claims on bowel function.

protein that does not contain carbohydrates. Manitoba Harvest Hemp Foods & Oils www.manitobaharvest.com

Danisco Australia Pty Ltd Contact info and more items like this at wf.net.au/K694 www.foodprocessing.com.au

November/December 2011

INGREDIENTS AND DEVELOPMENTS

moisture through various cooking cycles, are

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November/December 2011

The longer-term outlook for the Australian beef market looks promising as drought continues to affect our major competitor.

levated currencies, global economic uncertainty and climate risks might be posing short-term obstacles for global beef markets; however, the longer-term outlook remains bullish, according to a recently released industry report, the Rabobank Beef Quarterly. Australian markets will also feel some ongoing pressure through to the first quarter of 2012; however, a number of factors should provide support for prices in the second half of next year, the report says. One key factor will be the reduction in the cattle herd due to the severe drought taking place across the US, which is a key competitor in Australian beef export markets. The Australian live export market looks strong with the potential to reach record prices this quarter. Through to quarter one 2012, Rabobank expects an increase in global beef competitor meat supplies. This will take place amidst a backdrop of uncertain economic growth. However, cattle prices are likely to reach record highs later next year as markets transition from a short-term supply bulge - primarily in the US where herds are diminishing due to drought - to materially lower supplies. Report coauthor Wendy Voss says the longer-term view is that global meat protein supplies will continue to lag income and population growth in important emerging markets. “This places pressure on supply, increasing prices throughout the supply chain, from feeder cattle buyers, processors and all the way through to consumers,” Voss says.

Australia Voss says a number of factors combined to drive prices down in Australian markets during quarter two and three of 2011; specifically, a very high Australian dollar, the effect of the tsunami in Japan and a seasonal easing of demand from Korea and Russia. By late third quarter, however, Voss says a number of these pressures eased and prices began to recover. Live cattle exporters also faced a turbulent quarter three due to uncertainty surrounding the resumption of trade with Indonesia, the report highlights. The suspension of live ex

ports by the Australian government was lifted in early July, yet exports did not begin until August as it took time for the government-required supply chain audits to be conducted. Once the shipments resumed, prices rose sharply, reaching record highs for September. “The rise in prices has been due to the restriction on availability of cattle that meet Indonesian market requirements; in particular, the 350 kg maximum live weight limit,” Voss says. “Given the north of Australia is fast approaching the wet season, which will seasonally reduce supplies, prices for live export cattle are likely to remain high during quarter four and may even exceed these record levels.” Rabobank expects prices for southern Australia’s finished cattle, which have risen rapidly in recent weeks, will ease during the upcoming quarter. Spring pasture offerings are expected to increase. However, demand will remain curtailed by eroding export returns from a strong Australian dollar and the uncertain global economy’s impact on consumer confidence in some key Australian beef markets.

US drought a major factor in 2012 The report highlights that 25% of US beef cows live in the drought-stricken states of Texas, Oklahoma and New Mexico areas that are experiencing the worst drought on record following the heels of another extreme drought in 2006, causing 84% of ranchers to reduce their herd. Drought is driving aggressive cow slaughter rates on an already-low herd. As a result, US beef production will surge in early 2012, but rapidly decline later in the year and production will remain low until at least 2014. “For Australian cattle producers, a decline in US beef production in 2012 will likely be a support for higher farm gate prices. The US is a major export market for Australia and a key competitor in a number of significant overseas markets,” Voss says. Rabobank Australia Contact info and more items like this at wf.net.au/M043

www.foodprocessing.com.au

November/December 2011

MEAT POULTRY SEAFOOD

Bullish on beef

MEAT POULTRY SEAFOOD

US perspective on Chinese food exports As food imports increase and FDA demands more detailed disclosure and tracking, foreign seafood manufacturers and suppliers will undoubtedly feel the pressure from both government agencies and US importers. Benjamin England discusses the major challenges.

Speed vs quality “One of the toughest parts about FDA compliance from a manufacturing standpoint is that there’s always a tension between speed and quality control,” said England. “Chinese companies are having to produce larger shipments, faster than ever before to stay competitive. When you do that month after month there is a risk that quality control is diminished because the rules are getting more complicated and production outpaces your ability to stay on top of it.” England predicts that more and more food shipments from China will be facing FDA detention and FDA import examination, especially as FDA begins implementing the new Food Safety Modernization Act requirements.

Complexity, not simplicity “I’ve seen FDA law change over the years and I know how complex it can become,” said England. “The new regulations, FDA restructuring and FDA’s compliance standards are becoming more complex instead of simpler. However complex they appear to American companies, simply double or triple the potential for confusion for foreign manufacturers and importers. Regulatory compliance is at a level now where you either have to be an expert, know an expert or have uncanny good luck.”

Increased role of private third parties England also predicts an increased role for private third parties in the future. “Under the FSMA, FDA is directed to 56

November/December 2011

change its position with respect to private third parties, such as private laboratories and private inspection organisations, from one of critical reviewer to one of accreditor. But this is not an area where FDA has had much success in the recent past. FDA has even stated that the agency does not consider the Department of Commerce, Seafood Inspection Program to be an ‘appropriate third party’.” England further commented that getting United States government agencies to interact together was hard enough, let alone third parties and extra-government entities. “US Congress had to force FDA, in the FSMA, to work with its sister agencies just to get the governmental parties together to work on inspections of foreign seafood processors,” he said. “Although Congress requires FDA to implement third-party programs, I expect FDA will be reluctant to make much progress.” As food imports increase and FDA demands more detailed disclosure and tracking, foreign seafood manufacturers and suppliers will undoubtedly feel the pressure in the coming months from both government agencies and US importers … and they will have to pay for it both financially and from a labour perspective. Benjamin L England is a former 17-year veteran of the FDA and served as the Regulatory Counsel to the Associate Commissioner for Regulatory Affairs. Currently, he is founder and CEO of FDAImports.com, LLC, a firm of consultants and affiliated attorneys practising at the intersections of complex administrative law and regulations that impact international traders in highly regulated commodities.

www.foodprocessing.com.au

n the US, industry leaders are preparing to tackle emerging food import issues and discuss how manufacturers and importers are bracing for the coming changes in FDA regulation. Benjamin England predicts three major trends in regard to Chinese seafood exports.

November/December 2011

Crossflow hygienic spiral freezer The CRYOLINE XF crossflow hygienic spiral freezer allows food producers to achieve increased value in their processing operations. The freezer is suitable for a wide range of high-quality food products such as meat proteins, ready meals, seafood, poultry and bakery products.

MEAT POULTRY SEAFOOD

It is claimed that the spiral freezer delivers increased line production rates while lowering cryogen cost per kilogram of product. The spiral freezing technology makes the system suitable for difficult high-temperature and highmoisture products, such as cooked poultry, seafood and prepared meals. Freezing with cryogens allows for a very low operating temperature and thus a very fast freezing action. This preserves the quality and shape of the product and provides increased product yield. The CRYOLINE XF freezer improves cryogen efficiency while reducing overall freezer size. The freezer provides twice the heat transfer rate of conventional spiral freezers, making it a freezing or chilling solution with the ability to process a wide range of products and production volumes in relatively small floor space. The CRYOLINE XF has a small footprint, a high production capacity and a high efficiency. The freezers are designed for hygiene and ease of sanitation. The simplicity of the design enables the user to maximise productivity by reducing cleaning and maintenance downtime. The CRYOLINE XF is currently available in 760 mm belt width. The product line will be expanded to include a 1066 mm belt width model. BOC Limited Contact info and more items like this at wf.net.au/M052

Delivering DSI Vertical Plate Freezers Milmeq - exclusive agency for DSI Plate Freezers in Australasia. The DSI range of small vertical and horizontal plate freezers compliment the large scale horizontal plate freezers Milmeq have designed and manufactured for over 30 years. The plate freezers can be either manual or automatic depending on process requirements, application and installation location. The range of DSI models include; Model: Plate Size: DSI V3 1070 x 530mm DSI V4 820 x 800mm DSI V5 820 x 600mm DSI V7 1220 x 500mm DSI V16 1070 x 530 mm DSI V20 1070 x 530mm • Plates can be designed to operate with CO2 • Land or marine installations • Easy to clean and ergonomic design

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

Offices in New Zealand & Australia. Partners worldwide. Installations worldwide.

Brisbane, Australia Auckland, New Zealand Dunedin, New Zealand

www.milmeq.com

info@milmeq.com

November/December 2011

www.foodprocessing.com.au

Vacuum packaging for meat FreshCase packaging is a material technology from Curwood for case-ready meats. It is claimed to deliver flavour, quality and extended shelf life of vacuum packaging; the fresh red colour consumers prefer; and cost advantages. The packaging is an FDA- and USDA-approved technology engineered to maintain the fresh red colour in a vacuum package. The leak-proof packages are easy to open; freezerready; and can be stored in the refrigerator, ready to cook, until the use-by date. The hermetic packaging offers a shelf life of more than 30 days for whole muscle beef and extends typical retail display life up to 28 days compared to 3-5 days for tray overwraps. This advancement leads to cost savings from

MEAT POULTRY SEAFOOD

reduced markdowns, spoilage, waste and labour costs for repackaging. The packaging is claimed to decrease packaging and logistic costs - as well as material waste and energy usage - compared to MAP packaging. The vacuum packages use up to 75% less packaging material than MAP packages. By eliminating MAP gases, FreshCase packaging can nearly double the amount of meat transported per truck. Vacuum packaging is a good format for case-ready meats because it allows meat to age properly, while offering significantly longer shelf life and reducing loss due to spoilage. Since vacuumpackaged meats require no headspace for gases, the package fits the product and does not look overpackaged. Meats also retain their juices, so there is little, if any, purge. Soaker pads can typically be eliminated. In addition, the format does not turn bones black like gas-flushed packaging can. It also eliminates the cost of gas, oxygen absorbers and master packs. Developed for fresh beef, materials are available for many formats including forming and non-forming films, vacuum skin packaging, trays and semi-rigid films with VSP and ground beef chubs. The films run on horizontal, VSP and chub equipment. An EZ Peel opening feature can be added which allows even the most form-fitting package to open effortlessly without knives or scissors. Bemis Flexible Packaging Australasia Contact info and more items like this at wf.net.au/K640

www.foodprocessing.com.au

November/December 2011

MEAT POULTRY SEAFOOD

The modernisation of meat inspection in Europe The European Food Safety Authority has commenced assessing the strengths and weaknesses of the EU's current meat inspection methodology so it can provide a scientific basis for the modernisation of meat inspection across the European Union. It has released its first reports covering the inspection of swine. 60

November/December 2011

Biological hazards The main recommendations on biological hazards are to: • omit the use of palpation and/or incision techniques in post-mortem inspection of pigs subject to routine slaughter because of the risk of bacterial cross-contamination. • introduce a comprehensive pork carcass safety assurance framework, combining a range of preventive measures applied on-farm and at-abattoir in an integrated way as this is the only means to ensure an effective control of the main hazards. • collect and analyse food chain information (FCI) at herd and abattoir levels to enable a more location-specific assessment of risk.

Animal health and welfare In the area of animal health and welfare, it was noted that the abolition of palpation and/or incision would lead to a reduction in detection of some diseases, but that in cases where several organs are affected, this effect was likely to be minimal. To mitigate the reduced detection probability of the proposed modified system, experts recommend that palpation and/or incision should be conducted as a follow-up to a visual inspection showing abnormalities. The necessity of meat inspection, both ante- and post-mortem - as shown in the 2001 UK Foot and Mouth Disease outbreak - in the overall surveillance system for swine health and welfare

was also highlighted. However, the experts recognised that surveillance information is currently underutilised.

Contaminants In the area of contaminants, dioxins, dioxin-like polychlorinated biphenyls and the antibiotic chloramphenicol were identified as chemical substances of high potential concern in pork, based on predefined criteria. However, it was concluded that chemical substances at the concentrations found in swine meat are unlikely to pose an immediate or shortterm health risk for consumers. The experts recommend: • the development of risk-based sampling strategies that differentiate between farms producing pigs under conditions of fully implemented HACCP-based protocols and with complete FCI, and farms with less stringent quality control procedures. • the encouragement of ad hoc amendments to sampling plans to take account of emerging substances in the food chain. • the inclusion of ante- and post-mortem inspection criteria to identify illicit use of substances and encourage analysis at farm level.

Harmonisation of epidemiological indicators for food-borne hazards EFSA also proposed harmonised epidemiological indicators for food-borne hazards that are covered by existing meat inspection procedures as well as the highlighted biological hazards. The indicators would be particularly useful in the context of the proposed pork carcass safety assurance framework, enabling the categorisation of farms, herds and slaughterhouses according to risk as well as the setting of targets for final chilled carcasses. They would also help risk managers in the European Commission and Member States to decide whether adaptations in inspection methods may be relevant.

Future reports The five remaining sets of opinions and reports will cover poultry; bovine animals over six weeks old; bovine animals under six weeks old; domestic sheep and goats; farmed game and domestic solipeds. Harmonised epidemiological indicators relate to the number of cases in a given group at a given time (prevalence) or the likelihood of being exposed to (incidence) a hazard at a certain stage of the food chain that correlates to a human health risk caused by the hazard. The European Food Safety Authority (EFSA) is the keystone of European Union (EU) risk assessment regarding food and feed safety. In close collaboration with national authorities and in open consultation with its stakeholders, EFSA provides independent scientific advice and clear communication on existing and emerging risks. The following two Scientific Opinions and Scientific Reports: • Scientific Opinion on the public health hazards to be covered by inspection of meat (swine) • Technical specifications on harmonised epidemiological indicators for public health hazards to be covered by meat inspection of swine can be accessed in full on the EFSA website - www.efsa.europa.eu.

www.foodprocessing.com.au

November/December 2011

MEAT POULTRY SEAFOOD

n May 2010, the European Commission asked the European Food Safety Authority (EFSA) to deliver a series of Scientific Opinions on public health hazards – biological and chemical – to be addressed by meat inspection. The authority was also requested to provide a summary of comparable data on specific food-borne hazards in the Member States that would enable risk managers to adapt meat inspection procedures to national requirements. EFSA’s experts were asked to consider the implications for animal health and welfare of any proposed changes to current inspection practices. To fulfil this complex mandate, EFSA has drawn on its expertise in a wide range of fields within its scientific remit and has broken up the work into six sets of Scientific Opinions and Scientific Reports. The first set, covering the inspection of swine, has been released. As well as identifying and ranking the main risks for public health, the scientific experts on EFSA’s panels were asked to: assess the strengths and weaknesses of the current inspection methodology; recommend methods that take into account the hazards not addressed by current meat inspection; and recommend adaptations of methods and/or frequency of inspections based on the hazard rankings and harmonised epidemiological indicators. In the area of biological hazards, the food-borne hazards Salmonella, Yersinia enterocolitica, Toxoplasma gondii and Trichinella were identified as priority targets in the inspection of swine meat at abattoir level, due to their prevalence and impact on human health. It was concluded that current inspection methods do not enable the early detection of the first three of these hazards and, more broadly, do not differentiate food safety aspects from meat quality aspects, prevention of animal diseases or occupational hazards.

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Bundaberg Brewed Drinks solves end-ofline packaging challenges Bundaberg Brewed Drinks has installed an OCME Pegasus Robotic Palletiser with manipulator infeed. The family-owned brewery in Bundaberg, Queensland, is renowned for its Bundaberg Ginger Beer product and other brewed beverages that are exported to over 30 countries around the world. All of the drinks are shipped in high-quality cardboard sleeves in a 3x2 format and are a popular choice on supermarket shelves. Bundaberg was looking to improve the efficiency of its ‘end of line’ and to improve the handling of its bottles, as its previous machinery was susceptible to carton damage and struggled operating in the high humidity experienced during Bundaberg’s summer months. The primary objective in the purchase of a new palletiser was to find a machine that could create layered patterns of cartons containing lightweight glass bottles that were filled with hot liquid without damaging them. The company reviewed a number of palletiser technologies such as traditional split type, roller deck handling and full layer robotic handling. OCME conducted extensive testing on the Bundaberg product at its facility in Italy and was able to alleviate Bundaberg management’s concerns, as this technology had never been trialled in Australia before without the use of support under the cartons. The OCME robotic Pegasus palletiser fulfilled Bundaberg’s rigorous product handling criteria. Combined with an OCME Altair N60 wraparound case packer and a TechnoWrapp B150 stretch wrapper, the complete installation h a s e x c e e d e d B u n d a b e r g ’s expectations. “The installation, commissioning and training phases of the project were executed extremely well and to a very high standard. The palletiser has increased our capacity from 20 to 66 cartons/ min and efficiency has increased due to the reliability and ease of changeover from product sizes,” said Darren Smith, Engineering Manager at Bundaberg Brewed Drinks.

Palletising system The Symach palletising system is suitable for operators wishing to increase stacking efficiency and optimise the presentation of pallets for distribution. The palletisers are built to create tight and uniform layers of bags, boxes, crates and sequentially stack these layers to form a stable and well-presented pallet. Speed and accuracy are the key benefits of the Symach palletisers. They can handle 13 to 50 bags/min depending on layout. The gripper, which receives and positions the packaged material, has a small axis of movement allowing rapid and efficient operation. From an accuracy perspective, these machines are equipped with a centralisation unit, a squeeze collar and pneumatically controlled sliding doors. These features ensure that the bags, crates or boxes (all can be handled with one machine) are placed and squeezed for optimal fit on the pallet, thereby maximising use of storage and shipping space. The Symach palletisers can also overlap bags and are equipped with a stacking cage to enhance pallet appearance and stability. Symach specialises in customised palletising systems for the industrial, chemical, food and agricultural industries. Wrapping machines for plastic and stretch net film, pallet and slipsheet dispensers and machines to place protective corners and straps around the finished pallets are also offered in order to provide a fully auto-

HBM Packaging Technologies

mated solution.

Contact info and more items like this at wf.net.au/M034

Wyma Engineering (NZ) Ltd Contact info and more items like this at wf.net.au/M021

November/December 2011

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November/December 2011

Hygienic pneumatic drives Anthropomorphic industrial robot for bakery automation The Tecnopack IRB 2400 is an anthropomorphic industrial robot, with 6 axes. It is suitable for

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general product pick-and-place operations, especially when it is necessary to handle many components at the same time. The robot is available in three versions, with a managing capacity from 5 up to 16 kg.

Festo has released two hygienically safe, corrosionresistant pneumatic drives: the easy-to-clean ISO standard cylinder DSBF and the guided drive DGRF. The drives offer dirt no hiding place and are unaffected by normal commercial cleaning agents. Thanks to their high level of corrosion protection, these two units are suitable for use in the food, beverage and packaging industries. The guided drive DGRF has a compact design and combines precision with torsional rigidity. Its smooth surfaces, large radii and ease of cleaning mean dirt deposits and corrosion are a thing of the past. The preci-

Tecnopack has developed a variety of robotic feeding solutions which have been

sion guide makes

integrated with their horizontal flow wrappers and cartoners to automate the loading

it suitable for many

of product and eliminate the labour component.

applications in the

Thanks to its operating range, it can be used on more pick-and-place applica-

food industry wher-

tions. The versatility of the S4C+ robot is enhanced by using the conveyor

ever high force and

tracking function. This function allows the robot to operate on moving

accuracy are required.

elements, which offers more freedom during the layout planning phase

Aluminium castings used in

and during the design of the plant.

the splash zone must have a special

The IRB 2400 uses PickMaster software and Cognex technology to pick

coating to give the necessary resistance to

up products from a moving transport system and deposit them onto the moving conveyor/infeed of a wrapper or onto preformed trays. It can manage, in real time, the distribution of the load among many robots.

cleaning agents. The DSBF has been designed for this area. To meet food production requirements there

Perfect Packaging

must be no chemical contamination, which is

Contact info and more items like this at wf.net.au/M036

why the sealing materials and lubricating grease are FDA approved for use with food. There is also the option of a dry running seal, which

Magnetic grab heads

has a long service life even when subjected to

The magnetic grab heads from Goudsmit Magnetics hold steel objects

intensive cleaning.

in a firm grip. Once a grab head magnet has been switched on it does

Suitable proximity sensors are available that

not let go again, even if the air pressure drops or if there is a power cut.

are resistant to cleaning agents, heat and mould.

The magnets are suitable for picking up or gripping stamped or perforated

Just as easy to clean is the cylinder sensor

steel objects, punched steel materials or wire mesh parts.

SMT-C1, which can be mounted directly on both

They are also suitable for transport and transfer operations in automatic

drives using the sensor rail.

production lines, press-to-press transfers and robot pick-and-place systems.

Festo Pty Ltd

Romheld Automation Pty Ltd

Contact info and more items like this at wf.net.au/M039

Contact info and more items like this at wf.net.au/L512

Do you need flooring for your

Food Facility?

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November/December 2011

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

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

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

Spill containment for palletised goods Pallet racking Colby Drive-In Rack is a versatile solution for high-density pallet storage that maximises the use of warehouse space. Designed and manufactured in

Bund-A-Rack is a spill containment system specifically designed to contain any liquids leaking from palletised goods on standard racking. Its use will to reduce the likelihood of cross-contamination due to ice melt, in products stored on racking.

Australia by Dematic, the racking system can be tailored to meet

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individual needs depending on pallet configuration and load and warehouse design requirements, including product range and stock movement rate as well as the type of materials handling equipment. Dematic’s Rackman design software can be used to configure the best and most costeffective racking solution, ensuring safety integrity and compliance with Australian and International design standards. Heavy-duty bracing connects symmetrically to the big strong racking upright, increasing strength and load-carrying capacity. The systems also include onepiece, formed cantilever brackets that wrap securely around the upright. These are available in double-sided or single-sided applications. The modular design of Colby Drive-In Rack is highly configurable for individual needs, and single-sided cantilever brackets even allow for different pallet levels in adjacent bays. A variety of forklifts including counter-balanced and reach trucks can operate effectively in Colby Drive-In Rack. All Drive-In Rack solutions incorporate a complete, integrated system of safety elements designed to provide good conditions for safe work practices and increase the life of the storage system. Backstops are positioned at the end of the storage rails to prevent pallets from being pushed too far into the racking, reducing potential damage to spine bracing. Heavy-duty, purpose-designed floor channels help to guide forklifts into Drive-In Rack bays, making pallet alignment quicker, easier and safer, as well as reducing the risk of rack damage. For added protection, the Colby Protect-a-Rack wraps around the base of the racking uprights. Their angled profile deflects impacts, minimises damage and maximises clear bay entry. As the rack components are standardised and there are fewer of them, installation is quick and simple.

Suitable for use in freezers, coolrooms and food storage and distribution centres, Bund-ARack is a valuable tool in the HACCP process. The system not only reduces the crosscontamination hazard, it also helps maintain goods in prime condition, avoiding the wastage and disposal costs incurred by soiling. The patented design eliminates point loading and is easy to clean, with no sharp corners. Designed to ANZFS 3.2.2, the Bund-A-Rack is Australian made and nests for storage when not in use. Drumsafe

Dematic Pty Ltd Contact info and more items like this at wf.net.au/M062

Contact info and more items like this at wf.net.au/M037

Pallet truck scale Adam Equipment’s sturdy PTS Pallet Truck Scale gives industrial users an easy way to weigh heavy loads. The pallet truck scale is suitable for use on the production floor or in the shipping department. It has a sleek, low-profile design and non-marring wheels ensure floors stay clean and unmarked. Heavy-duty reinforced steel pallet forks provide durable lifting capabilities and a zero-radius pivoting handle gives good manoeuvrability in tight spots. The PTS manages overloads with ease. The capacity tracker shows exactly where you are in the weighing range. The display monitors the weight value and warns if the load is reaching the scale’s capacity. Included with the PTS is Adam’s AE 402 indicator, providing a wide range of different features and functions for fast and accurate results. The AE 402 is sealed for dust. Large keys are colour-coded to clearly identify the more frequently used buttons. Weights are quickly and easily read on the large backlit LCD. An internal rechargeable battery with auto-off power-saving function lets operators use the PTS in many areas, without needing to plug it in. Adam Equipment (SE ASIA) Pty Ltd Contact info and more items like this at wf.net.au/L143

November/December 2011

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Side flexing conveyor belt belts that can handle high loads and high

Wulftec has FAST, a film

speeds, combined with a small side flex-

feeding system which ac-

ing radius for optimum product handling.

curately delivers film to the

The belts are suited to conveying smaller

pallet without reacting to demand. FAST stands for Force

packaged goods, such as cluster packs

Anticipation Stretch Technology, which is the best way to

and plastic tubs to packaging machine

control film failure, film ripping and breakage.

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1â&#x20AC;ł pitch is a series of versatile side flexing

Film feeding system

The System Plast 2256 series belts with

As the FAST technology eliminates excessive stress

in/out feeds. The Side Flex belt has a 3â&#x20AC;ł increment

on the film it can be used to its full potential. Using

across the width. This belt is bi-directional

conventional methods, users often reduce the film ten-

making left and right turns simple and

sion to a point where the film does not break and can

S-curves a reality. The belt is available

waste up to 35% film force. With FAST, all the force in the

with several clips and guiding systems

film can be used and film consumption can be reduced

to accommodate any requirements users

while achieving the same containment. The FAST system is suitable if loads have sharp edges,

may have.

protruding objects or if the product is very light, out of

Dotmar EPP Pty Ltd Contact info and more items like this at wf.net.au/K603

shape or fragile. Australian Warehouse Solutions Pty Ltd Contact info and more items like this at wf.net.au/J806

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November/December 2011

NEW White Papers BULK

now available online!

HACCP, AQIS and BRC certified flooring for casings company

How to minimise losses in converter-fed induction motors This study presents a technique developed to minimise losses in totally enclosed fan-cooled (TEFC) induction motors fed by frequency converters in applications with constant torque loads, especially at low speeds, in which the ventilation system is inefficient.

Control systems and operational security - are you properly covered? Security has always been a relevant concern during the design and deployment of automated control systems. But recent worldwide events, combined with technological and industry trends of the last decade, have significantly raised the visibility and public awareness of this issue.

Lowering costs and improving safety at sewage pumping stations Pumping raw sewage or any kind of wastewater can be expensive, with many hidden costs and safety issues. Download this white paper to find out how you can lower costs and improve safety at sewage pumping stations.

Reduce energy costs with predictive load management (PLM) Power factor is an important aspect that drives up energy costs so improving this, controlling the demand charge and reducing peak consumption during ON peak times will result in substantial savings.

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

November/December 2011

Almol Casings is one of Australia’s leading producers and suppliers specialising in natural casings. The iconic Australian company was established 40 years ago and is committed to be the ‘best of breed’ in every aspect of the business. A key requirement of the company’s new state-ofthe-art, multimillion-dollar factory in Sydney was that its floor coatings met strict food hygiene and OHS standards, and demanding cleaning regimes as well as provide extensive longevity. The client chose Roxset SE 1 as a tailored solution to optimise the traffic demands of every area of the facility. A major need was a system with aesthetic appeal that was extremely tough and able to withstand forklift and trolley traffic, so Roxset SE was installed over 2000 m2 at an increased thickness of 4-6 mm. The mezzanine storage area needed an anti-slip coating for extra safety and protection while the processing and washdown areas needed a seamless waterproof floor which could withstand very wet conditions, high-pressure cleaning and forklift and trolley traffic. The client also called for each working area to be colour delineated using a block pattern with the epoxy resin - this is not only practical but adds interest and appeal for staff and customers. Roxset SE1 is suitable for wet processing zones such as food manufacturing, food preparation areas and chemical processing plants. The coating delivers an easy-to-clean and -sterilise antislip surface, which offers good thermal protection. In the coldroom areas Roxset SE4 was applied. The seamless flooring was enhanced wall-to-floor coving installed at 100 mm, to ensure a monolithic surface. The flooring complies with all the requirements of HACCP and AQIS and BRC certification. Roxset Contact info and more items like this at wf.net.au/M045

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Pneumatic gain-in-weight filling system The Flexicon Pneumati-Con is a pneumatic gain-in-weight filling system for free-flowing bulk solids. It conveys and weighs the material, and discharges it into bulk bags. The filter receiver of the vacuum dilute-phase pneumatic conveying system is mounted on load cells, enabling the system controller to weigh incoming material at high rates, and then at steady trickle-feed rates, stopping the flow

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once an accurate batch weight has been reached. Pressing a ‘fill’ button on the control panel actuates a bag inflation blower on the Twin-Centrepost bulk bag filler to remove creases in the bag and opens a slide gate valve at the outlet of the filter receiver, allowing the weighed batch to gravity discharge into the bag at high rates, as a vibratory deck densifies the material to stabilise the bag. A secondary set of load cells mounted beneath the bulk bag filler allows the system to confirm the final weight of the filled bulk bag. A port within the discharge spout vents displaced air and dust to a remote bag house. The controller then releases the bag straps and deflates the spout seal, allowing the operator to tie off the spout and remove the filled bag. Connecting an empty bag consists of attaching the bag straps, pulling the spout over the inflatable collar and pushing a spout inflator button. While filled bags are being removed and empty bags attached, a subsequent batch is being conveyed to the filter receiver and weighed, ready for another fill cycle. Flexicon Corporation (Australia) Pty Ltd Contact info and more items like this at wf.net.au/M049

Let our Ultra Pallecon

- meet all your food and ingredient transport needs CEVA’s market leading Ultra plastic container is the ideal choice to ensure the quality of your bulk food and liquid ingredients, including poultry, small goods and meat products, when being transported or stored. Ultra is manufactured from 100% recyclable food-grade polypropylene material. It is easily assembled by a one person operation and features an hygienic, efficient bag-in-box system with a drop gate for ease of access and removable, tamper evident lid. Ultra even has a graduated sight glass to provide a clear view of the level and quality of product at all times. For further information about CEVA’s full range of innovative materials handling solutions, and our flexible rental options: call 1300 133 133 or email: palinfo@cevalogistics.com

www.cevapallecon.com

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November/December 2011

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Vacuum-assisted lifting aids productivity Eighteen months ago Kockums Bulk Systems was contracted by Zetco to supply Tawi vacuum-assisted lifting systems for improved handling of boxes and cartons of valves. Zetco wanted to improve handling operations when a shipping container arrived into the warehouse for unloading. The main purpose was to minimise the dangers during the manual lifting of these boxes, and to improve productivity. Typically, when a container is unloaded, the packing list needs to be checked to confirm model and part numbers. There are generally 20 pallets in the container, each holding 30 boxes and each box weighing an average of about 26 kg. For this purpose a Tawi system was installed at the unloading location to move the boxes from the pallet. The vacuum- Floor-mounted column, lifting boxes, assisted lifting system offers great ease when with vacuum pump mounted on the picking a carton and relocating it quickly, wall behind. without any physical effort. An impressive outcome from the introduction of the Tawi system for unloading containers was the improvement in productivity. Previously it had taken two staff members two days to achieve the task and now one person completes the job in about a day. The contrast in staff attitude is also uplifting, as all seek the task, instead of being â&#x20AC;&#x2DC;busyâ&#x20AC;&#x2122; on other work with the previous laborious manual system. Apart from the lifting protection afforded the staff, Steve McAndrew the Warehouse Manager advised that another great outcome was that urgent product requests were 100% able to be delivered the day the container arrived, creating an improvement of generally two days. Another system was also installed at the dispatch location. The recently introduced Cobra model suits these applications best, allowing highspeed grab and movement. Particularly when there are differing masses to lift, the Cobra balance is automatically controlled by the Further down the line, valves are operator. being repacked into Zetco boxes, then Other safety upgrades in the facility have stacked on a pallet. The twist and turn motions required identified a further led to the replacement of ladders by Crown application for vacuum-assisted lifting. Wave machines. Here we see a 40 kg lift model with a Here we have an example of a health and 5 m swing arm. safety upgrade, and productivity increase working hand in hand. Kockums Bulk Systems Contact info and more items like this at wf.net.au/M040

November/December 2011

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March 2011 total CAB audited circulation (Aust + NZ): 6743 readers (93% personally requested) Printed and bound by SOS Print & Media +61 2 9549 2100 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.

WILERYT REPO

2011

November/December 2011