What’s New in Food Technology Nov/Dec 2012 by Westwick-Farrow Media

CEOS KNOW GLASS BUILDS POWERFUL BRANDS. “Consumers like to see what they’re getting,” says Edson Auricchio, CEO of OLÉ Foods. “We package quality foods, and glass demonstrates that quality, quite literally. Seeing is believing. I would say that glass is more than packaging for us, it’s a form of advertising.” GlassIsLife.com makers of strong, bold, clearly different glass packaging

contents

November/ December 2012

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food for thought

traceability 10 Machine vision for quality assurance

testing and quality bulk handling, assurance storage & logistics

27 48 52

processing .

29 What ‘foodies’ think about when investing in new technology 36 Applications for UV light in the food industry

meat & seafood .

48 Meat consumption and stress reduction 50 Blast chilling methods could change meat tenderness

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14 Finding fresh food contamination sources faster

packaging .

52 Resealable packages: a frustration-free alternative

51 Cattle vaccine 38 Third-party audits and works to reduce food safety E. coli O157:H7

www.foodprocessing.com.au

Nov/Dec 2012

Cooking your goose

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Christmas is coming, the goose is getting fat … and if you haven’t fulfilled your 2012 New Year’s resolutions you might as well concede that that goose is cooked for 2012. What themes do you suppose will pervade the food industry in 2013? I am guessing that ‘the obesity epidemic’ will still be ubiquitous and food processors and retailers will continue to be held responsible for everything consumers choose to eat. In cahoots with this will be continuing drives for ‘natural’, ‘free-from’, ‘ethical’ and ‘wellness’ products. It is possible that your goose won’t fit well into this scenario, certainly your pâté de foie gras won’t. And while the mainstream media will continue to bemoan the wantonness of the food industry in its complicity in undermining the health of the entire population by only manufacturing “processed” foods that are “full of chemicals”, no-one will look at the reality of the situation. Take this “full of chemicals” malarkey - just tell me any physical object that isn’t made of something and every ‘something’ is a chemical even if it’s water or air. Really, every natural, free-from-any-additives foodstuff is made of a mixture of chemicals just the same as every highly processed food. The emotive association of the word ‘chemical’ with ‘bad’ is ludicrous. And, while I’m on my high horse, let’s also mention preservatives. In environments where food contamination is likely, access to refrigeration is dodgy, access to clean water uncertain - in other words all developing countries - food preservation is one of the most important contributors to public health. Preservatives have certainly saved more lives than they have harmed. I will be interested to watch how sugar and alcohol fare next year. Both regularly get very bad press and I sometimes wonder if wine will end up going the same way as cigarettes. My adult children watched people smoking on Mad Men with fascination. They found it hard to believe that there could ever have been a society where every living room had at least one ashtray and that an invisible wall could separate smokers from nonsmokers on aeroplanes. In fifty years will people watch ‘period pieces’ about the early 21st century and be amazed that people drank wine with their meals, beer with their sport, cocktails for pleasure … that society accepted the consequences of drunkenness as an everyday part of life? Ah, but that’s all in the future. Now I am just thinking about the end of 2012. In fact, wondering which wines will go best with the roast goose I am thinking of serving for Christmas. After that? Bring on 2013 with a whole new lot of resolutions to ignore. May 2013 be the year the goose lays the golden egg for us all.

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

Nov/Dec 2012

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Macleay River Meats has won the 2012 Prime Minister’s Water Wise Award. The company, which trades as Eversons Food Processors, was congratulated by Senator Don Farrell, Parliamentary Secretary for Sustainability and Urban Water, on winning the award. Senator for Victoria Jacinta Collins presented the award on behalf of Prime Minister Julia Gillard at the savewater! awards gala dinner in Melbourne on 26 October. The prestigious Prime Minister’s Water Wise Award showcases commercial and industrial innovation in water efficiency. It is open to all commercial and industrial water users. Farrell said Eversons Food Processors received the award due to its strong

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Food processor wins 2012 Prime Minister’s Water Wise Award

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commitment to water efficiency and sustainability. “I congratulate Eversons Food Processors for recognising the need to minimise its impact on the environment and for taking action to reduce both its water usage and disposal of waste to landfill,” Farrell said. “The company has reduced its water usage by close to 95%, which is an amazing achievement. “Eversons’ water savings were particularly commendable, given the need to use drinkingquality water in the food production process for health and safety reasons. “A major focus of Eversons’ water-saving strategy was the construction of three onsite wastewater ponds - two aerobic and one anaerobic - and the commissioning of a wastewater treatment system.” The other finalists in the Prime Minister’s Water Wise Award were Serco Australia which was highly commended - Cameron’s Nursery and Sakata Rice Snacks.

Salt-reduction campaigns not affecting new product launches, Mintel finds Campaigns to reduce salt levels in processed foods have had little effect on new product launches of low/no/ reduced sodium foods, Mintel says. Research from the market analyst has shown that global launches of foods with low/no/reduced sodium claims actually declined by 5% over the 2010/2011 period, with only 2% of food launches in 2011 sporting sodium claims. “A large percentage of the global food industry remains wary of the commercial impacts of reducing salt in their products. This anxiety is well founded, with many products positioned as low sodium forced off the shelves prematurely in recent years due to poor sales,” said Chris Brockman, Global Food and Drink Analyst at Mintel. “Manufacturers struggled to find workable salt substitutes, forcing many to rapidly pull them from the market. Efforts are being made to offer consumers alternatives to sodium. However, existing salt replacements have not caught the imagination of consumers. Consumers are concerned about salt intake, but are not willing to compromise on taste.” Europe is said to be the most active region in terms of product innovation, with 35% of new product launches sporting low/no/reduced sodium claims in 2011. 26% of North American new product launches carried sodium claims, while in the Asia-Pacific region, only 19% of new product launches carried a low/no/ reduced sodium claim.

Nov/Dec 2012

New Zealand leads the pack in the Asia-Pacific region, with 3% of new food products carrying sodium claims, while Australia follows with 2%. Taiwan, China and Vietnam had the lowest number of sodium claims, with 0.7, 0.5 and 0.4% respectively. Changing consumer attitudes to low-sodium products could prove difficult. Mintel found that 49% of British consumers say that taste is more important than calories and 46% of US consumers think low-sodium alternatives don’t taste as good as their higher-sodium counterparts. In the UK, only 22% of consumers say they’ve purchased low-sodium products. “Brands will need to dispel widely held perception about low sodium or salt alternatives to be successful,” Brockman said. “Fortunately, this is possible. “Many food brands are already introducing step-bystep salt reduction programs that gradually reduce the salt content of their products - a strategy often called ‘stealth health’, as the incremental removal of sodium can be carried out over a period of time to help the consumer to become accustomed to the changed flavour profile, without the need to flag that up prominently on-pack and thus deter consumers who may perceive ‘less taste’. “Other brands are also steering clear of the health issue by experimenting with different flavour profiles, such as strong spices and vinegars, to enhance taste while eliminating sodium,” said Brockman.

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Reduced-sodium cheddar successfully manufactured Reducing salt in cheese has historically proven difficult. Recently, however, researchers from the University of Minnesota have been successful in manufacturing a cheddar-style cheese using mineral salt replacers. The researchers claim that previous studies into reducing sodium in cheese have used mineral salt replacers at levels too low to produce equal water activity (a w ) in the finished cheese, compared with a standard, full-sodium cheese. Higher aw can result in differences in cheese quality due to differences in the effective salt-to-moisture ratio, creating differences in biochemical and microbial reactions during ageing. Hypothesising that targeting replacer concentrations to produce the same a w as full-sodium cheese would minimise changes in quality, the researchers manufactured a

range of stirred-curd, cheddar-style cheeses. The control cheese was salted with naturally reduced-sodium sea salt, while others were manufactured with blends of sea salt with KCl (potassium chloride), modified KCl, MgCl2 (magnesium chloride) or CaCl 2 (calcium chloride). Unfortunately, CaCl2 and MgCl2 produced a range of unpleasant flavours, such as bitter, metallic, unclean and soapy. However, bitterness ratings for cheese with KCl and modified KCl were not significantly different from the full-sodium control. The researchers concluded, “Potassium chloride can be used successfully to achieve large reductions in sodium when replacing a portion of the NaCl in cheddar cheese.” The research has been published in the Journal of Dairy Science.

Water recycling in food production Increasing the use of water recycling in food production and manufacturing is among new research being undertaken by the Australian Water Recycling Centre of Excellence. Led by CSIRO Animal, Food and Health Sciences, the project will collaborate with industry to demonstrate higher-value water recycling opportunities that deliver economic, environmental and social benefits to the agrifood industry and community. The research will examine opportunities for water recycling across the agrifood chain with particular focus on food manufacturing, dairy and meat industries. Project Director Jay Sellahewa said the project will focus on current industry challenges, including regulatory and policy pressures, and the value proposition (an analysis of all factors to determine if water recycling stacks up as the best option). It will also develop strategies to increase acceptance by consumers and enhance the sustainability positioning with customers. “The ultimate goal is to reduce the reliance of fresh water throughout the agrifood supply chain,” Sellahewa said. “This could be achieved by increasing the amount of water used for irrigation of crops by treating effluents from food processing plants and by increasing the amount of water recycled within food manufacturing plants. “Outcomes of this work will include the development of fit-for-purpose water recycling guidelines for industry, a tool to enable industry to make decisions on recycling water based on the value proposition and available

technologies, and communicating positive messages in consuming foods associated with recycled water to help increase consumer confidence.” Centre CEO Dr Mark O’Donohue said the project was a good example of the multidisciplinary work being done by the centre. “This project is using rigorous science-based research in partnership with some of the biggest and most credible industry organisations in Australia, such as Meat and Livestock Australia, Dairy Australia and the Australian Food and Grocery Council,” Dr O’Donohue said. “As a centre focused on water security, the applications of this research for food security are very exciting.” More than $2.3 million has been committed to this project, which has linkages with the centre’s other work in examining public attitudes to and perceptions of water recycling. The linkages between projects were examined at a recent workshop where project leaders had the opportunity to engage and discuss common themes of their individual projects. The workshop’s focus was to ensure the centre’s research outcomes have the greatest impact on a national scale - enhancing efficiency, expansion and adoption of water recycling in Australia. Other new research being undertaken by the centre includes the use of nanotechnology to recover phosphorous, which could in turn be used in fertiliser products, and a study into the importance of micropollutants in water, including an analysis of whether the right chemicals are currently being monitored and regulated.

www.foodprocessing.com.au

Nov/Dec 2012

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thought

Cyanocobalamin; pyridoxine hydrochloride; calcium pathothenate: consumers reading these terms on a food label could be forgiven for thinking the product is full of artificial ingredients. A new resource from the US is helping consumers interpret food labels so they can see these particular ingredients for what they are: B vitamins. ‘What’s in Our Food: Understanding Common Food Ingredients’ is a resource that aims to take the mystery out of common food ingredients by explaining why they are used in food products. Developed by the International Food Information Council (IFIC) Foundation, the guide is free to download and will be available in some nurse practitioner clinics in the US. The resource includes a quick reference guide

that outlines common food ingredients and their functions in food, as well as providing more familiar terms for ingredients and examples of food that contains these ingredients. “Our Food & Health Survey results show that nine out of 10 consumers give thought to what’s in their food and pay attention to ingredients listed on food labels,” said Marianne Smith Edge, IFIC Foundation Senior Vice President, Nutrition and Food Safety. “For this reason, it is important to bring clarity to those unfamiliar ‘chemical’ sounding names of ingredients that are really quite common, readily found in nature and play important roles in keeping our food safe, affordable and delicious.”

LycoRed receives full approval for premix operation in China

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Demystifying food ingredients: new consumer resource

LycoRed has received full approval for its new premix plant in Changzhou, China, which is said to be one of the largest premix factories in Asia. The new site is now fully operational and will serve processors of infant formula, beverages, baby food and other food products in the Asia-Pacific region. “We recently received our Halal MUI certificate for our new vitamins D3, E and K1 formulations,” said Ilan Ron, LycoRed’s Vice President of Sales & Marketing. “These vitamins are made with a proprietary spray-drying process to ensure complete solubility of vitamins. They can be used in premixes for infant formula and baby food, as well as in dry blends for beverages. “Our formulations are manufactured under the most stringent specifications in the market for delivering the safest premixes. We are proud to have received all necessary certifications and can ensure our customers will receive the highest quality blends possible.” The company also recently appointed Jason Foo as Sales and Business Development Manager, covering Malaysia, Singapore, Indonesia, Vietnam and the Philippines.

First phage for food safety approved Food Standards Australia New Zealand (FSANZ) has approved Listex P100 as a processing aid against Listeria monocytogenes, making Listex the first phage for product safety approved in Australia and New Zealand. The phage is produced by Dutch company Micreos. According to FSANZ’s approval report: • The safety assessment did not identify any public health and safety concerns associated with using Listex P100 to treat food. • I t is effective at reducing levels of Listeria monocytogenes on the surface of solid RTE foods evaluated. • T here is no appreciable ongoing technological function when it is applied to the surface of various solid RTE foods, therefore it fits into the category of

Nov/Dec 2012

processing aids. This is consistent with international approaches. • There were no measures that would be more cost effective than Listex P100. “FSANZ’s decision marks an important step in the acceptance and appreciation of phage technology,” said Mark Offerhaus, CEO of Micreos. “The review process was thorough, transparent and involved all stakeholders; an example of how new - and suitable technology should be brought to market.” Following approvals in the USA, Canada and the Netherlands, Micreos applied for approval of Listex in Australia and New Zealand. Easy to apply, Listex is sprayed onto the surface of food products during processing, killing Listeria without any sensory or other effects.

www.foodprocessing.com.au

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Machine vision for quality assurance Glenn Johnson, Editor, What’s New in Process Technology

achine vision (MV) is the technology and techniques used in industrial environments to provide imaging-based automatic inspection, detection and analysis. The most common uses for machine vision are automatic inspection and industrial robot guidance, while in recent times, vision-based sensors for detection purposes have become available to replace sensors such as photoelectric sensors. Common MV applications include quality assurance, sorting, material handling, robot guidance and optical gauging.

Machine vision outputs The most common output from a machine vision system is a pass/fail decision. Such an output may in turn trigger mechanisms that reject failed items or sound an alarm. Other common information that can be provided by an MV system includes object position and orientation information, which is commonly used for guidance systems, as well as numerical measurement data, data read from codes and characters, displays of the process or results, stored images, alarms from automated space monitoring MV systems, and process control signals.

General operation The first step in the MV sequence of operation is acquisition of an image, typically using cameras, lenses and lighting that has been designed to provide the differentiation required by subsequent processing. For example: • Different types of lighting (different colours or infrared for example) render different qualities of objects that may be of interest for detection or inspection. • Strobe lighting synchronised with the rate of flow of objects past the camera allows fast snapshots to be taken of each object without motion blur. MV software packages then employ various digital image10

Nov/Dec 2012

processing techniques to extract the required information and often make decisions (such as pass/fail) based on the extracted information. While conventional 2D visible light imaging is most commonly used in MV, alternatives include imaging in various infrared bands, line scan imaging, 3D imaging of surfaces and X-ray imaging. 2D visible light imaging can be performed in monochrome or colour, and various resolutions. The use of colour and the depth of resolution affect the performance requirements of the image processing hardware and software, and therefore the cost of the solution. The imaging device (usually a camera) can either be separate from the main image processing unit or combined with it, in which case the combination is generally called a smart camera or smart sensor. When separated, the connection may be made to intermediate hardware, such as a frame grabber, using either a standardised (Camera Link) or custom interface. There are now also digital cameras available that are capable of direct connections (without a frame grabber) to a computer via FireWire, USB or gigabit ethernet interfaces.

Processing methods After an image is acquired it is processed. Machine vision image processing methods include: • Pixel counting: Counting the number of light or dark pixels. • Thresholding: Converting an image with grey tones to simply black and white or using separation based on a greyscale value. • Segmentation: Partitioning a digital image into multiple segments to simplify or change the representation of an image into something that is more meaningful and easier to analyse. • Blob discovery and manipulation: Inspecting an image for discrete blobs of connected pixels (such as a black

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Quality assurance applications The main uses of vision systems for quality assurance are to analyse images to perform appearance inspection, character inspection, position detection and defect inspection. Some of the main applications are: • Detecting the presence, position and formation of a code such as a date code or barcode • Validating the presence and positioning of labels • Checking closures for tamper seals, correct caps by colour and dimensions • Inspecting product for fill levels, product content or other parameters • Sorting products based on marking

Advantages for quality assurance The major benefits of machine vision inspection solutions are: • Cost savings due to reduced rework, more reliable product quality and less wasted product • Automation of quality to provide more objective QA compared with manual inspection • Greater transparency throughout the inspection process and improved process control • Real-time quality metrics can be made available for OEE data

Examples of QA applications Code validation Machine vision solutions for code inspection are used to verify code presence, position and formation, and sometimes to also provide code reading and matching. Such systems can also automatically identify and reject containers or packages with missing, incorrect or unreadable codes to ensure only properly coded items are produced. Examples of the use of code validation are the validation of date codes, batch codes, barcodes and 2D data matrix codes. Date code verification verifies that a code is present and is completely formed in the correct location, while batch code verification checks the quality of the printed batch information, ensuring it cannot be misread, possibly resulting in product recalls. Barcode verification checks that barcodes are readable and correct, helping to ensure correct product tracking through the supply chain. 2D data matrix validation verifies that information which is not human readable is still valid, and is properly decoded and understood by the quality system. Label inspection and validation High-speed labelling of products, of all types, shapes and sizes, can result in a wide variety of possible defects. These defects can lead to label errors that can be harmful to a brand

or even present liability issues for a brand owner. Labels can be inspected for label presence, wrinkles, tears, skewed labels, double labels, flagged or missing labels, as well as incorrect label pairs on containers and packages. Machine vision technology for label inspection can be set up to help ensure perfect product presentation and correct labelling. Packages and containers with incorrect or defective labelling can then be automatically rejected in the production line.

The main uses of vision systems for quality assurance are to analyse images to perform appearance inspection, character inspection, position detection and defect inspection.

Label presence and pairing can be checked, both to ensure labels are present and also that front and back labels are paired correctly with each other. Skewed and dog-eared label detection ensures that labels are applied correctly and straight, and in the correct position, while double label inspection can make sure that only one label has been applied to the same location on the package. Overwrap alignment is another form of label inspection in which wraparound labels are checked for straightness and proper position. With appropriate MV system design, a 360-degree inspection on round bottles can be performed. Confirming that the correct label has been applied is often performed using graphical label verification (in which a unique graphical item on the label is used to confirm that the proper label has been applied) or by using 2D data matrix code verification where 2D dm codes are being used on the labels. Similarly, barcode verification: confirms that the proper label has been applied by verifying that the correct barcode is present. Closure and seal validation Obviously the integrity of closures and seals on bottles and other containers is important for the quality of the product and the safety of the consumer. MV systems can be used to visually check the closures and seals for integrity. Checking the closure’s colour and dimensions verifies that the right closure has been applied to the container, while visually checking liner formation and placement ensures the product is properly sealed and protected from contamination and leakage. In the same way, tamper seals can be checked to make sure they are not broken. Packaging and filling Machine vision systems can inspect filled bottles, trays, pouches, cases, cartons and other packages to verify that the packaging process was completed to the specifications required. Bottles can be inspected to ensure that they are properly filled, labelled and capped to minimise product spoilage and ensure perfect product presentation, and case quality inspection can also be performed to verify that cases are properly sealed and undamaged, to allow fast and reliable palletising and packing. MV technology can also be used to check the content of products made of discrete items, confirming that the specified contents are present, thereby demonstrating due diligence and reducing the costs associated with missing or additional components, parts or other items.

www.foodprocessing.com.au

Nov/Dec 2012

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hole in a grey object) as image landmarks. These blobs frequently represent optical targets for machining, robotic capture or manufacturing failure. • P attern recognition and template matching: Finding, matching or counting specific patterns. This may include the location of an object that may be rotated, partially hidden by another object or varying in size. • Barcode, data matrix and 2D barcode reading: Reading codes for data input or simply to check correct labelling on finished products or shipping boxes and pallets. • Optical character recognition: The automated reading of text such as serial numbers. • Gauging: The measurement of object dimensions (in pixels or millimetres). • Edge detection: The finding of object edges to detect their presence and orientation.

Metal detector for wet and dry products Mettler-Toledo Safeline’s Profile Select metal detector offers sensitive detection for both wet and dry products on food production lines. The inclusion of variable frequency technology offers accurate inspection regardless of the moisture content of the product or packaging material. Traditionally, only dry products can be successfully inspected at metal detectors’ maximum sensitivity setting. This is because wet

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or ‘conductive’ products create an electrical signal called a ‘product effect’ that can disguise the signal generated by metal contaminants. Until now, contaminant detection in

Handheld HACCP auditing device The Comark N5001 HACCP Auditor is a handheld instrument for logging, monitoring and managing data. The Auditor has been specifically designed for food and pharmaceutical applications and use in HACCP, due diligence and health and safety systems. The instrument can be fully programmed using the Auditor software to suit the application, providing the flexibility and recording functions of palm-held organisers. The Auditor software has been specially developed for the N5001 and has broad programming capability. It enables the collection of temperature of event data and the management and control of processes. This is achieved through the logging of location/product/suppliers and other parameters, together with pro-

wet and dry products used metal detectors with tuned frequency technology. These metal detectors can be configured to have a number of operating frequencies to address specific products. However, this can restrict inspection flexibility in cases where manufacturers produce a wide range of products. The detectors have true variable frequency technology that automatically selects the most suitable frequency for each application. The machine’s autoset function selects the optimum frequency for the product being inspected, providing maximum product quality, enhanced process flexibility and optimised equipment performance. Profile Select allows the operating frequency to be adjusted in 1 kHz increments, ensuring precise tuning for each application. This allows a variety of products with differing size, moisture content and packaging material to be inspected on the same production line without sacrificing inspection accuracy. Profile Select rectangular detectors are designed for easy integration with conveyorised systems to fully automate inspection processes. Manufacturers can choose between various automatic reject mechanisms depending on the line and pack speed, pack weight and dimensions and the nature of the packaging material. Mettler Toledo Contact info and more items like this at wf.net.au/R384

grammed corrective actions for out-of-limit temperatures and events. enables the user interface to be customised

RFID system for production and conveying

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Nov/Dec 2012

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Tracking down the source of fresh food contaminatiotn can be difficult and time-consuming. Adequately characterising connections and product flows among producers, distributors and suppliers can be problematic and contribute to significant uncertainty in assessing the risk of foodborne illness. This can present a serious problem when there is an outbreak of food poisoning in a particular region and the authorities cannot quickly trace the source of the outbreak.

hen an outbreak occurs, epidemiologists must interview affected people to track down where foodborne exposures happened. Often those interviews take place weeks after the exposure, leading to inaccurate or incomplete information and making it difficult to pinpoint a likely food culprit. Once the tainted food has been identified, investigators must trace up through the food distribution supply chain to locate the source of contamination. This means that epidemiologists involved in traceback have to reconstruct the pathway the contaminated food has travelled through the distribution network well after the fact. Even at the supply chain level, investigating how food moves through the system is daunting as supply chains vary widely from one food marketing system and agricultural sector to another. Some supply chain parts change frequently. Even within a single agricultural sector, some parts of the food supply chain may be characterised by enduring supplier/customer relationships, while others may be market based and highly transitory. Even industry insiders may not understand the supply chain map. Many only know ‘one up and one down’ - that is, they know only their direct supplier and direct customer. Also, some information about customers and suppliers can be proprietary and therefore hard to get. In 2011, sprouts were the focus of a serious E. coli outbreak in Europe, but tracing contaminated products to their source proved difficult. But now, uncovering the sources of fresh food contamination could become faster and easier thanks to analysis done at 14

Nov/Dec 2012

Sandia National Laboratories’ National Infrastructure Simulation and Analysis Center (NISAC). A study, in the International Journal of Critical Infrastructures, demonstrates how developing a probability map of the food supply network using stochastic network representation might shorten the time it takes to track down contaminated food sources. Stochastic mapping shows what is known about how product flows through the distribution supply chain and provides a means to express all the uncertainties in potential supplier-customer relationships that persist due to incomplete information. If this approach is used on a larger scale, such methods also might assess the vulnerability of food supplies to wide-scale, deliberate contamination. Sandia researchers applied the stochastic mapping technique to test data from the fresh sprout sector in a single state in the US, using a case study of the edible seed sprout distribution system as the basis of their computational model. The method enables effective risk analysis and the design of robust food defence strategies because stochastic network representation can incorporate and express the uncertainties using probability maps. Future work for the team will include scaling the analysis up to the company or industry level as well as mapping commodity flows into, out of and within a geographic region. Ultimately, NISAC intends to work with partners in business and federal and state agencies to ascertain whether the agencies have a business case for adopting the method. If there is, the team will seek to help achieve wide acceptance of using data analysis to assess risk.

www.foodprocessing.com.au

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Finding fresh food contamination sources faster

TRACEABILITY

A leading rigid plastics packaging manufacturer is ensuring authenticity and traceability with an unusual product: invisible ink. RPC Containers Llantrisant is using special UV-readable ink from Linx Printing Technologies on its range of bottles. The Linx Clear UV-readable ink goes on clear and is used to code both the bottles and their caps inline using Linx 4900 continuous ink jet printers. The code includes a batch number, date and time, and the line on which the bottle was produced. “The ink produces a completely invisible code which is nevertheless very clear and easy to read under the appropriate conditions,” said Jon Bedgood, RPC Llantrisant’s manufacturing manager In the event of any problem or quality issue, the complete pack can be traced back through the entire filling, supply and manufacturing chain using the ink code. RPC Llantrisant manufactures bottles in eight sizes, from 25 to 200 mL. The bottles are injection blow moulded and then fed into a capping machine. Both the cap and bottle are coded simultaneously by two Linx 4900 printers. “We have been delighted with the performance of both the Linx 4900s and the UV-readable ink,” said Bedgood. RPC selected the Linx printers based on their speed and reliability. The 4900s can easily cope with line speeds of around 3200 bottles/h. RPC operates two lines, with a third line available to meet peaks in demand. The portability of the Linx 4900 means the printer can easily be moved as required, depending on production requirements. “The printers have been extremely reliable and we have had no issues since they were installed - we literally only have to start them up and away they go. Our operators like them and Linx provided full training, which means everyone is familiar with how they work,” Bedgood said.

©iStockphoto.com/Dmytro Kozlov

Invisible ink ensures traceability and authenticity

Matthews Intelligent Identification Pty Ltd Contact info and more items like this at wf.net.au/R652

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Nov/Dec 2012

High-speed centrifuges VWR Australia has extended its VWR Collection range with the VWR Ultra and High Speed Centrifuges. The centrifuges are easy to use and have many protective features. VWR’s Automatic Rotor Life Management accurately logs the actual percentage of rotor

Satellite data logger

life used. The company claims its Automatic Rotor Life

TESTING

Halytech has released a low-power solution for remote monitoring and data logging which uses the Iridium satellite network Short Burst Data

Extension will gives longer use from the rotor. Safety features such as automatic rotor locking and imbalance protection are included. The systems can be adapted to a range of applications.

(SBD) service for automated data

VWR International Pty Ltd

delivery.

Contact info and more items like this at wf.net.au/R973

The microSpider satellite is suitable for applications such as environmental, industrial and infrastructure monitoring where other forms of communication are not possible. To reduce the cost of remote site data acquisition to an affordable level, the company has developed a highly compressed data format which it claims enhances the performance and reduces the cost of data delivery using the Iridium SBD service. The microSpider satellite’s configurable I/O combined with Modbus and SDI-12 compatibility provide good flexibility for use with a range of instruments. The satellite includes an onboard web server which allows the user to view and configure all

Listeria detection system ANSR for Listeria is the second test available for Neogen’s ANSR pathogen detection system and provides results after 20 minutes of reaction time. In comparison, other commercially available molecular amplification tests require up to 3 hours’ reaction time. The test’s approval from the AOAC Research Institute is pending. Combined with ANSR’s single enrichment step, Neogen’s pathogen detection method for Listeria can provide definitive results in as few as 16 h from the time the sample is taken. Neogen’s ANSR is an isothermal amplification reaction test method that exponentially amplifies the DNA of any bacteria present in samples to detectable levels in minutes. According to the company, the system was designed to combine molecular-level accuracy with a scalable low-cost instrument and a methodology that can be easily incorporated into a testing laboratory’s existing workflow. The system’s small benchtop footprint and simple procedure make it an easy fit in laboratory settings.

parameters without special software

Cell Biosciences Pty Ltd

or licences.

Contact info and more items like this at wf.net.au/R187

Halytech Pty Ltd Contact info and more items like this at wf.net.au/R133

Allergen test for soy Australasian Medical and Scientific has announced that the Romer AgraStrip for Soy is now available. Soy is a very common allergen in foods, presenting a problem for children in particular, but also in adults. Soy can be present in many food, beverage and pharmaceutical items due to the common practice of using soy-based ingredients and additives. The AgraStrip for Soy provides manufacturers and laboratories with a fast and simple test to screen for soy in raw ingredients, finished product and manufacturing environments. No special equipment or laboratory is required to perform the test, and results are available in less than half an hour, making it suitable for on-site testing. The AgraStrip for Soy offers a high level of sensitivity, with a limit of detection as low as 1 ppm, and has been validated with a variety of food matrices. Australasian Medical & Scientific Ltd Contact info and more items like this at wf.net.au/R968 16

Nov/Dec 2012

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

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

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

SwabSURE ListeriaP

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

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

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

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

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

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

Laser particle counters The Spectrex PC-2200 in-situ laser particle counter and PC-2300 portable laser particle counter are designed to permit thorough inspection of bottled and flowing liquids without consuming the sample. The sample is placed in a specialised glass bottle or beaker and inserted into the instrument for counting - eliminating sample flushing and making handling clean and simple. Oil immersions and other liquids can be counted by adjustments made by

TESTING

SuperCount software. The PC-2200 can also count particles inline using a flow-through cell. Using the principle of ‘near angle light scatter’, a revolving laser beam passes through the walls of the beaker or flow-through cell. When directed through a central ‘sensitive zone’, the particle counters not only count the particles in suspension, but tabulate their size, from 0.5 to 100 µm in diameter. The analog signals generated by the light pulses are routed to a computer and digitised. In the PC-2300, a scanning laser beam automatically quantifies small particulate matter, presenting the results on a digital display. A minimum size selector is provided for this measurement and is normally set to 1 µm. The direct connection to a computer with the company’s interface card, cable and software gives full automatic sizing and particle counts. The counter is ruggedly constructed with all the optical members mounted on one solid aluminium base plate. The units come with three sealed calibration standards, each containing a precise number of NIST traceable polymer spheres of known concentration. The suspensions are sealed with inert argon gas and have proven stability. Novasys Group Pty Ltd Contact info and more items like this at wf.net.au/Q824

Method for determining catechins in tea

Know the

Thermo Fisher Scientific has announced a quick and easy method to determine catechins in various

TRUE

teas after a simple solvent extraction. Application Brief 150: Rapid Separation of Catechins in Tea Using

Content

provide protection against certain diseases, such as cardiovascular disease and cancer.

Core-Shell Columns demonstrates use of a high-performance liquid chromatography (HPLC) core-shell column and absorbance detection to separate and detect catechins in tea. Catechins are flavonoid phytochemical compounds found primarily in green tea and - in smaller

Sodium

amounts - in grapes, black tea, chocolate and wine. Catechins are considered potent antioxidants that In North America, the consumption of green tea products has increased due to the reported health benefits. However, commercially available teas show a high variability in catechin content; therefore, simple and rapid methods are needed to evaluate product quality.

New: Direct Analysis of Sodium in

The application note can be found at www.thermoscientific.com/dionex under the Documents tab.

Foodstuffs by Thermometric Titration: It’s cost efficient, precise and fast.

Thermo Fisher Scientific

Call or email for details and free applica-

Contact info and more items like this at wf.net.au/R909

tion note.

Metrohm 859 Titrotherm Sodium Analysis

Pipette filter sleeve Particulates in a liquid sample can be a problem for several reasons, such as clogging pipette tips, or interfering with a sample analysis. The Nasco Pipette Filter Sleeve overcomes these problems by fitting over a standard 10 mL pipette and extracting the sample

available at

through a 330 µm polyethylene filter. The sleeve is made from strong, sterile polyethylene materials used in Whirl-Pak products. The sleeves are arranged into bags of 25 which can be closed

MEP Instruments Pty Ltd Australia Tel 1300 720 485 New Zealand Tel 09 912 1330 www.mep.net.au

after each use. The pipettes are available in boxes of 500. Australasian Medical & Scientific Ltd Contact info and more items like this at wf.net.au/R376 Nov/Dec 2012

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BULK HANDLING, STORAGE & LOGISTICS

CHEP helps growers take a bigger bite of the export cherry In an industry traditionally dominated by wooden crates and cardboard hat-bins, taking a chance on plastic has paid off for a cherry exporter. The Caernarvon Cherry Co, based in Orange, NSW, made the switch after contacting CHEP for a solution. CHEP recommended the FB3 foldable plastic bins, which were designed specifically to preserve the integrity of softer fruits and vegetables. The Australian-made CHEP FB3 bin allows air TO flow through specially designed air vents and raised platforms, ensuring good air circulation even when the crates are stacked. Prior to export, the cherries must undergo a cold disinfestation treatment for 14 days. However, the pulp temperature must be at least 1.11°C before the disinfestation process can begin. Co-owner of the Caernarvon Cherry Co Fiona Hall says using the FB3 bins means the cherries cool faster. “The quicker the cherries cool, the longer the shelf life of the produce, the better they present in store and the sooner we can start the cold disinfestation process,” said Hall. “Ultimately, it means we can export a better quality product, sooner.” An additional benefit of using the FB3 bins is that they can be hosed and washed out, unlike wooden crates, which has helped the Caernarvon Cherry Co achieve its Freshcare Certificate for Food Quality & Safety. The CHEP FB3 bins are making quite an impact on the fresh produce industry, says Martin Rees, CHEP Business Development Manager. “Made from high-quality, food-grade plastic, the FB3 lasts longer, is more durable and retains the integrity of the fruit better than wooden crates or the one-trip cardboard alternatives,” Rees said. “As with other products in the CHEP pool, the bins provide customers with total flexibility. For example, growers have to purchase cardboard hat-bins in large quantities to be cost effective, whereas FB3 bins can be picked up on demand. This eases the uncertainty of overordering and being left with a need to store them or underordering that can cause issues down the supply chain.” In addition, Rees says, the FB3 bins provide multiple transport efficiencies for local growers. “The FB3s have a superior stacking configuration over their wooden or cardboard alternatives, and can be stacked up to five high in transport and 10 high in static storage,” Rees said. “This not only decreases the need for third-party storage but, in transport, substantially improves supply chain costs by reducing the number of trucks needed to move product.” The Caernarvon Cherry Co has found the FB3 bins easier to manage compared to the wooden crates. “They have made it easier for us to streamline our processes, have saved us capital outlay and reduced our labour and handling costs,” Hall concludes. CHEP Australia Contact info and more items like this at wf.net.au/R480

Postgasser and heat sealer for bulk bags To reduce or eliminate product deterioration and prolong the shelf life of fat-containing dairy powders, it is important to close bulk bags immediately after filling to minimise exposure of the powder to atmospheric air. Historically known as Bulkpak 600, the Postgasser - Heat Sealer by Tetra Pak is designed for powder deaeration and replacement of ambient air with an inert gas, followed by hygienic closing of the bulk bags. The Bulkpak 600 comprises a single station capable of handling a wide range of plastic liners suitable for modified atmosphere packaging (MAP) and heat sealing. To minimise exposure of the powder surface to atmospheric air, the heat sealer would be usually located in the immediate vicinity of a filling station. The filled bulk bag is conveyed to the Bulkpak 600, where the operator puts the plastic bag liner onto the heat sealer bars and secures both ends of the liner with the assistance of pneumatic bag grippers. Once the cycle has been initiated by the operator, postgasser probes go down into the powder and replace ambient air with an inert gas, such as nitrogen. This achieves residual oxygen levels typically under 3% after

Level transmitter for non-contact measurement of solid levels Dwyer Instruments’ Series ULL Ultrasonic Level Transmitter for Liquids is a direct-install level transmitter designed for non-contact measurement of solid levels. The ULL uses ultrasonic technology paired with automatic temperature compensation to provide reliable and accurate measurements in most conditions. An integrated LCD screen and four responsive push-buttons allow for quick and easy programming on a simple menu structure. Diagnostic capabilities and a fail-safe output signal make the ULL a suitable choice in critical applications. Dwyer Instruments (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R864 20

Nov/Dec 2012

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seven days from closing. Optionally, the operator can perform selected stages of the cycle, such as only deaeration or only heat sealing. All stages of the cycle are timed and automated. An extensive range of testing and indication features provide the operator with comprehensive feedback on process flow at each step of the cycle. Tetra Pak New Zealand Ltd Contact info and more items like this at wf.net.au/R861

PLANT WIDE SOLUTIONS FROM FRESCO SYSTEMS We are dedicated to the design, manufacture, installation and commissioning of Bulk Materials Handling and Processing Equipment. engineered and manufactured in house. We strive to ensure our customers receive the latest proven technology while aiming to reduce costs, improve operations and increase quality. Visit our website to learn all about our comprehensive range of Fresco Systems designed, manufactured equipment and systems, all supported by international technologies. www.foodprocessing.com.au

www.frescosystems.com Nov/Dec 2012

Nonmetallic rotary peristaltic pump The portable, nonmetallic Flex-I-Liner rotary peristaltic pump from Vanton Pump and Equipment Corp evacuates drums and totes containing acids, caustics, salts, chlorides and reagent-grade chemicals, without corrosion of the pump or contamination of the fluid. The self-priming design has no seals to leak or valves to clog and can run dry for extended periods without damage. Compact

BULK HANDLING, STORAGE & LOGISTICS

in size with an integral handle, it fits on drum lids without protruding and has sufficient lift characteristics to operate from the floor, skid or stand. Only two nonmetallic parts come into contact with fluid: a thermoplastic body block and an elastomeric flexible liner that can be replaced in the field without special tools. The rigid body block is of solid polypropylene, UHMW polyethylene or PTFE, and the moulded flexible liner of natural rubber, Neoprene, Buna-N, Hypalon, Viton or Nordel elastomers, eliminating corrosion or contamination associated with metal pumps. The range of thermoplastics and elastomers in which these pumps is available permits their use over the full pH range and for an extensive list of corrosive, volatile and viscous fluids. A rotor mounted on an eccentric shaft oscillates within the flexible liner, imparting a progressive squeegee action on the fluid trapped in the channel between the liner and the body block. Flanges on the flexible liner are pressed to the side of the body block by concentric grooves on the bracket assembly and the cover plate, isolating the fluid to the channel. The pump is suitable for flows from 1.25 to 151 L/h and pressures to 310 kPa at temperatures to 121°C. Acromet (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R894

Vacuum-mounted vibrator Using vibrators to move product usually involves some welding to the hopper to give the best results. Vibration Systems & Solutions has a method which eliminates welding by using vacuum to securely attach pneumatic vibrators to the hopper wall. The VacMount is useful when suppliers send product to the end user in their own containers, on which no welding is allowed. This method is also useful for hoppers and products with infrequent ‘hang-up’ problems, which may be caused by product differences or temperature changes. The vibrator is supplied mounted to an aluminium plate, on the other side of which are vacuum suction cups. The size and quantity of these cups varies with the strength of vacuum required for specific vibrators. Vacuum generators are built into the plate, with the vacuum being generated from the same air supply as is used for the vibrator. Linear vibrators from 14 to 8000 N can be carried on various sized VacMounts. Vibration Systems & Solutions (Australia) Pty Ltd Contact info and more items like this at wf.net.au/R917

Nov/Dec 2012

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Heinz-Golden Circle picks single-robot depalletising solution BULK HANDLING, STORAGE & LOGISTICS

New Zealand manufacturer Scott PHS Limited has come a long way since its beginnings as CBS Engineering in 1955. At its inception, the Auckland-based company provided packaging lines primarily to the beverage industry. Scott PHS now designs, manufactures and supports an extensive range of package handling equipment including palletisers, depalletisers, conveyors, pallet handling and other associated equipment. It services industries such as food processing, dairy, wine and beverage, handling a wide range of products including bottles, cans, cases, trays, shrink-wrapped collations, pails and bags. Scott brought its innovative approach to a recent installation in Melbourne. Heinz-Golden Circle was looking for an economical solution to depalletise a range of empty PET bottles from two different-sized pallets simultaneously and provide bottles in single file to two separate filling lines. The challenge for Scott was to develop a system that had the flexibility to handle the customerâ&#x20AC;&#x2122;s product range automatically and deliver it into a compact footprint but maintain good operator accessibility. The conventional approach would have been to have two independent layer-style depalletisers, each dedicated to its own filling line. The Scott PHS solution, however, involved a single ABB IRB 660 180 kg robot picking layers from two pallet stations and delivering each of the layers to separate mass flow conveyors. Each product is then placed on a pressureless single filler directly into each filling line. The robot also stacks layer boards, top frames and empty pallets automatically. Scott Package Handling Systems Contact info and more items like this at wf.net.au/R910

www.foodprocessing.com.au

Nov/Dec 2012

Beef City gets a lift from Toyota Materials Handling

BULK HANDLING, STORAGE & LOGISTICS

One of the largest feedlots in Australia is getting a lift thanks to Toyota Material Handling Australia (TMHA). Beef City feedlot, owned by JBS Australia, recently commissioned 18 new pieces from TMHA’s forklift range on long-term hire from the company’s Brisbane branch. With a staff of 950, a feedlot, meat processing facilities for 260,000 head per year, a farm and more than 26,000 cattle in the feedlot at any one time, Beef City definitely has a need for quality materials handling machinery. The handover of 18 new pieces of Toyota Material Handling equipment at Beef City. The new complement of forklifts includes three Toyota internal combustion forklifts, one Toyota electric three-wheel forklift, two Toyota electric reach trucks, two Raymond reach trucks, three BT hand-pallet jacks and six Raymond pallet trucks, both walkie and ride-on. Beef City General Manager Justin McCormick said the company selected Toyota as it is the best brand available to suit its business needs. “They are the best forklifts on the market and the service from Toyota’s Brisbane office has been first class,” McCormick said. “The relationship with Toyota has grown with support from TMHA Queensland Major Accounts Manager Martin Gross and the Brisbane office being on hand 24/7 when required.” The internal combustion Toyota forklifts are used in the Beef City feedlot main yard, rendering section and maintenance lifts. Four of the battery electric machines are used for cold-room operations and are set up to serviceracking profiles. Toyota Material Handling Australia Pty Ltd

Low-maintenance wrapped wedge belt Optibelt has introduced Red Power 3 belts, which, once installed to manufacturer’s recommendations, are claimed to require no maintenance or re-tensioning throughout their lifetime. Constructed of high-quality raw materials, the wrapped wedge belts are claimed to produce up to 97% efficiency with up to 50% higher power ratings when compared to Optibelt’s standard V-belt. The belts are available in lengths from 1200 to 12,065 mm in a range of V-belt and Kraftband profiles. A high power rating can also mean fewer belts on a drive, resulting in narrower pulleys with significant space and cost savings. In addition, they require no matched set coding. The belts have been developed for applications such as compressors, pumps, presses, fans and heavy-duty drives for industries such as mining, timber, quarrying and recycling. They are less sensitive to shock loads and are able to operate successfully in heavily contaminated environments. All belts in the range are heat resistant to 100°C, oil resistant and antistatic in accordance with ISO 1813. They are compatible with ATEX and come dust protected as standard. Optibelt Australia Pty Ltd Contact info and more items like this at wf.net.au/R822

Contact info and more items like this at wf.net.au/R576

Nov/Dec 2012

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Scanner for measuring volume and mass flows Sick’s Bulkscan can measure volume and mass flows without contact, increasing system availability and

Portable splice press Flexco’s Novitool Aero portable splice press allows users to splice a conveyor belt in 7 to 12 min.

avoiding mechanical wear. It also prevents wear by transmitting data on uneven belt loads and belt drift. A laser scanner mounted above the conveyor belt uses laser pulses to continuously detect the height profile of the bulk materials passing by. The laser beam is eye safe and corresponds to Laser Class 1. The two-dimensional height profile obtained is combined with supplementary information, such as the third dimension of belt speed or density information, and the sensor autonomously determines the transported volume or mass per time unit. At the

good splice repeatability, as well as

same time, the height distribution can be used to

temperature control and integrated

reliably detect tilting or any one-sided loading so

air cooling.

that a warning signal can be transmitted.

The all-in-one unit has no external

The Bulkscan uses multiecho technology, whereby

components and requires no hoses,

the software algorithm can reliably determine the

couplings, air pumps, control boxes or

correct signal from among the various reflected laser

water tanks. A flight case is included

pulses and dependably suppress the measurement

with the splice press.

of interfering echoes caused by mist or rain.

The splice press is available in

Rapidly moving transport belts with speeds of

five sizes, from 300 to 1500 mm. It

up to 30 m/s can be measured as a result of the

is available with a range of power

device’s rapid scan frequencies of up to 75 Hz and

cables, both 1- and 3-phase, from

fast response times. For the further processing of signals, the Bulkscan

230 to 460 V. A workshop stand is available

system offers six switching outputs that can be indi-

for use with the 900, 1200 and

vidually occupied as well as continuous outputs such as transmission of measurement values via TCP/

1500 mm models.

IP (ethernet). The processing and preparation of measurement values takes place directly in the sensor,

Flexco (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R188

which also has two inputs. No supplementary measurement value computer is required. Sick Pty Ltd Contact info and more items like this at wf.net.au/R377

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

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Nov/Dec 2012

BULK HANDLING, STORAGE & LOGISTICS

It is easy to operate and offers

Motor series Swiss company LinMot has released a motor series that can be run from most three-phase brushless servo drives. The P10-70 series of motors can provide peak forces up to 2500 N, velocities up to 8 m/s, accelerations up to 90 g and provide long wear free of force, velocity or position control. LinMot stators are nickel-plated iron, while the slider surface is stainless steel for longer life and corrosion protection. The series has a stator body diameter of 70 mm, with available strokes from 180 to 500 mm. The motors use non-contact, integral position feedback using 1 Vpp sin/cos signals. This enables 10 µm resolution, ±20 micron repeatability and good linearity. Options include mounting flanges and cooling mounting flanges, and blower

BULK HANDLING, STORAGE & LOGISTICS

kits to extend motor performance. LinMot motor systems can be retrofitted into existing applications. Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/R987

Compact industrial robot ABB has expanded its robot technology range with the release of the IRB120T, a variant of the IRB120. Like the IRB120, the IRB120T is compact, agile and lightweight, but the six-axis IRB120T variant delivers an increase in the maximum speeds of axis 4, 5 and 6, which ABB claims results in cycle time improvements of up to 25%.

Bulk bag conditioner for loosening solidified material Flexicon’s Block-Buster

The faster variant is suitable

Bulk Bag Conditioner has

for pick and place applications,

a hydraulically-actuated,

particularly in the food and bever-

variable-height turntable

age packing industries. ABB says

for automated in-frame

it may also be suitable for as-

bag rotation and con-

sembly applications for electrical

ditioning of bulk bags

and electronics and automotive

at varying heights. The

parts manufacturers.

number and pressure of

The IRB120T has a repeat-

hydraulic ram actuations,

ability of 0.01 mm. It can also

the height of the turntable

be mounted at any angle, either

and the degree of rotation are user-programmable.

in a cell, on top of a machine

Two hydraulic rams with specially-contoured end plates press

or close to other robots on the

opposing sides and corners of bulk bags, loosening material

manufacturing line. The robot comes with the ABB IRC5 Compact control, including good path motion, user-friendly FlexPendant programming, RobotStudio offline programming, flexible RAPID language and strong communication capabilities.

that has solidified during storage and shipment, enabling bulk bag unloaders to discharge it through bag spouts. A cantilevered I-beam with motorised hoist and trolley allows loading and unloading of bulk bags without the need for a forklift. The system controller and hydraulic pump can be mounted

ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/Q373

on the exterior of the safety cage or remotely. The conditioner is fully enclosed on all four sides for operator safety and includes full-height doors that are interlocked to prevent operation of the system when the doors are open. The conditioner is recommended for bulk bags containing hygroscopic chemicals, certain spice blends, heat-sensitive products and other materials prone to solidifying to the point at which pneumatically-actuated flow promotion accessories integral to bulk bag dischargers can be inefficient or ineffective. The conditioner is also offered without a variable-height turntable, in which case the bag is raised and lowered using the motorised hoist and rotated manually for conditioning of the bag at any height and any degree of rotation. The conditioner is offered as a standalone unit or integrated with the company’s Bulk-Out bulk bag discharging systems. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/R637

Nov/Dec 2012

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©iStockphoto.com/Dmitry Gool

PROCESSING

What ‘foodies’ think about when investing in new technology It is good to know that the food industry still considers quality improvements and new product development to be the main objectives when investing in new technology.

recent Leatherhead Food Research survey in the UK asked the food and beverage industry what objectives are currently the most important when considering investment in new technology. And, despite big moves within the industry to improve sustainability and resource efficiency, 55% of respondents said the primary technology innovations needed remain focused on the product - either to deliver better quality or new products. ‘Health and wellness’ was considered as less of a priority, maybe indicating a tide of change in the focus of development teams for the coming years. This also suggests that ‘health and wellness’ is no longer the domain of the innovators but is a mainstream trend that is considered the core of any development activity since it is a still a priority agenda item across the industry. However, when asked to consider a range of issues or themes and whether an emerging technology was the only way of achieving a step change in that area, an interesting picture emerges. When asked “which of these objectives are currently the most important when considering investment in new technology?”, “product innovation” was the clear winner. Some distance behind, in second place, was “product quality” followed by “energy and resource efficiency”. Necessity is the mother of invention so it is important to identify where emerging technologies could be most effectively implemented to achieve that all important step change.

Two main themes emerged – ‘efficiency, productivity and sustainability’ and ‘salt and fat reduction’ (Figure 2). These groupings suggest that it is generally believed that ‘green’ agendas cannot be met by the current manufacturing platforms and that the reductions in salt and fat that are possible by existing strategies are at their maximum. This echoes research conducted by Leatherhead Food Research earlier in 2012 that suggested that maximum salt reductions had been achieved within the current landscape. With ever-challenging targets such as salt reduction, it is possible that the industry will have to look at alternatives, such as nanoparticles, to achieve new levels of functionality and delivery. The implementation of new and emerging technology is not thought to be key in further improvements to taste texture and market share - the product-centred and market-driven innovations. Yet product-centred objectives were at the heart of investment policy. Around 60% felt that new and emerging technology would be key in the successful delivery of strategic objectives compared to existing technology; only 4% felt this would not be the case. Putting it into context of whether the greatest financial gains would be made from renovation or innovation, the population was evenly split with only 2% difference reflected between the opinions, interestingly falling in favour of renovation. It could be considered that the reasons behind this reflect the need for speed to market and return

www.foodprocessing.com.au

Nov/Dec 2012

PROCESSING

©iStockphoto.com/Dmitry Gool

Figure 1. Which of these objectives are currently the most important when considering investment in new technology?

Figure 2. Commercialisation of emerging technology is the only way of achieving a step change in "...".

on investments; two-thirds requiring a product to market within two years and 87% needing to launch within three years. The return on investment would need to be realised within three years by 62%. To achieve success with a fledgling technology, less than 10% considered that their exclusive use was important with 36% rating sole rights as very or extremely important. In summary, the survey showed that ‘product’ centred innovations outweighed ‘greener’ agendas for investment in emerging technology, yet the same population conceded that new technology was more important in achieving the step change required on those issues. While emerging technologies were seen as being key to meeting strategic objectives - often the greener agenda - opinions were generally split as to whether greatest commercial gains would be from new or existing technologies; and with an expectation of product launches and return on investment coming within two to three years, it is easy to see why renovation is seen as the easier option. Extending beyond the scope of the survey a little and considering the wider context of the questions, it may be

fair to suggest that key issues such as fat and salt reduction are at the limit of the capability when considering existing technology. Health and wellness is being seen as a lower priority in terms of new technology, or that legislation has stifled the appetite for innovation in these areas. It is more likely, however, that salt and fat reduction are actually no longer considered part of the ‘health and wellness’ agenda but more of a more generic continuous improvement activity. Wider objectives such as ‘sustainability’ and energy efficiency may also be considered ‘out of scope’ for many NPD and R&D teams, possibly even unattainable even though the need is recognised to achieve the shift into next-generation ‘greener’ technology. The markets (and marketing investment) are still driven by product innovation and quality, which is achievable through incremental improvement and renovation of existing technology. Such investment is much lower risk, and can achieve the required product launch and ROI expectations. With the need for exclusivity also being considered of importance to retain competitive advantage, this allows for progress and its associated knowledge to be retained in-house.

Uninterrupted power supply system The Caterpillar Critical Protection Module (CPM) is an uninterrupted

Stainless steel electric motors

power supply (UPS) system that combines a CAT Flywheel UPS, CAT

Lafert Electric Motors has released the

diesel generator and an Automatic Transfer Switch (ATS) packaged

Third Generation range of Scorpion

in a sound-attenuated and factory-tested ISO standard container.

Stainless Steel electric motors.

A UPS system protects computers, data centres, telecommunica-

The motors are a solution

tions equipment and other electricals where an unexpected power

for problem areas, from

disruption could cause serious business disruption or data loss.

wet areas in food pro-

The product is designed to provide seamless continuous power

cessing factories to en-

in a simple and complete package, delivering constant power

vironments with corrosive

protection against surges, sags and power interruptions that can

gases. According to Lafert,

halt operations or cause loss of data or system capacity.

the stainless steel motors outlast

The Caterpillar CPM uses robust digital components and is

conventional motors, saving downtime and increasing productivity.

claimed to require a quarter of the floor space of battery-based

The motors have been upgraded with improved sealing and an IP67

UPS systems. Its ability to operate at higher temperatures may

rating that certifies the motors can withstand submersion in water to a

also reduce air-conditioning and electricity costs over the life of

depth of 1 m. The motors are designed with ‘tap-on’ flanges that can

the product.

be bolted on without disturbing the integrity of the seals on the motor.

Caterpillar of Australia Ltd

Lafert Electric Motors

Contact info and more items like this at wf.net.au/R212

Contact info and more items like this at wf.net.au/R866

Nov/Dec 2012

www.foodprocessing.com.au

Cogeneration system fires up Geelong brewery PROCESSING

The soon-to-be-completed Little Creatures Brewery in Geelong will feature a 1200 kWe natural gas fired cogeneration system, which will significantly reduce the brewery’s energy use and carbon emissions. Simons Green Energy has been awarded the contract to supply and install the system. The system’s heat waste will provide hot water for the brewery’s process heating applications. The units will be configured to run parallel to the grid, so the brewery will only purchase energy over and above what the engines can supply, which is expected to be very little. The system will provide up to 1200 kWe of electrical power and 1282 kWt of thermal power. “The cogeneration system to be installed at the Little Creatures Brewery will be a great platform for other breweries and food and beverage manufacturers to follow,” said Simons Green Energy CEO Derek Simons. “The system is technologically advanced and very efficient at about 85% conversion efficiency, compared with 30% efficiency for conventional grid-supplied electricity.” The Simons Green Energy cogeneration plant comprises two off-sized units, which allow for greater modulation of output. They consist of an 800 and 400 kWe system with reciprocating gas engines from MWM. The system is supplied as complete factory-tested packaged units made up of engine and generator sets housed inside purpose-built containers. “We knew that we wanted to do something special for this project, in particular implement an environmental technology that would be a step change for us,” said Alex Troncoso, Head of Brewing Development for Little Creatures. “Cogeneration seemed to be a natural fit as breweries have a high thermal energy demand - we knew that we could use the waste heat effectively for a number of applications.” Other energy-efficient equipment will also be installed, such as energy recovery systems in the brewhouse, as well as automated cleaning regimes and variable speed drives on motors. Brewery owners Little Creatures, plant suppliers Krones AG and Simons Green Energy’s engineering team are working together to ensure a smooth installation. Brewery production is due to commence mid-2013.

Vision sensor Sick has launched an addition to its Inspector family of vision sensors. The Inspector P150 allows users to easily build their own interfaces, as well as operate the sensor from any computer or operator panel that contains a standard web browser. The P150 is suitable for applications such as positioning control in commercial goods production and integrated quality control in packaging machines. The integrated web server means any user can operate the P150 from a computer or operator’s panel that contains a standard web browser. Advanced users can completely build their own operator’s interface with the sensor’s flexible web API. The API provides commands to design customised functions. The PI50 contains an expanded toolbox for object location and positioning based on a taught-in pattern, free-form and line/polygon object shapes. In addition to the positioning tools, it provides tools for quality inspection such as blob, pattern, edge and pixel-counting inspection. The sensor supports extended results and control handling over EtherNet/IP and TCP/IP. This enables easy communication with dedicated PLCs, or simply a PC host using value-based results for machine control and customised trend design, image triggering, external teach and reference object selection for centralised device control and parameter modification for customised configuration handling. The calibration feature supports image translations to ensure results are exactly aligned with the external machine environment. It also provides reliable images even in tight and tilted set-ups where the image could otherwise be distorted. The PI50 is available in a white or IR ring light option. Both are designed with the company’s easy ‘Flex’ housing - providing a fast method to exchange lenses, filters and Dome accessory for different optical needs.

Simons Green Energy Contact info and more items like this at wf.net.au/R622

Sick Pty Ltd Contact info and more items like this at wf.net.au/S006

Nov/Dec 2012

www.foodprocessing.com.au

Getty Images

Total food safety confidence with NEVASTANE

TOTAL NevAsTANe food grade lubricants For food safety and dedicated services.

Ensure total food safety for your customers with NEVASTANE Food Grade lubricants. TOTAL goes the extra mile, providing optimum protection and long service life for your equipment, with enhanced security and efficiency. All NevAsTANe Lubricants are NsF H1 registered.

For more information or to locate your nearest TOTAL lubricants distributor: Phone Toll Free: 1800 TOTAL OIL (1800 868 256), email: lubricants.au@total.com or visit: www.totaloil.com.au

The right choice in lubricants www.foodprocessing.com.au

Nov/Dec 2012

Simplot gets an ‘A’ with IBP

PROCESSING

Simplot Australia manufactures some of Australia’s most iconic food brands, including Chiko, Birds Eye and John West. A wholly owned subsidiary of US company JR Simplot, the company has a turnover of more than $1.5 billion and employs over 3000 people in Australia and New Zealand. Simplot recently rolled out Oliver Wight Integrated Business Planning (IBP) across the business to help it stay ahead of the pack. The company has been recertified as Oliver Wight Class A standard for Capable Planning & Control using the Sixth Edition Checklist and has also received Class A accreditation for Capable Integrated Business Planning. Having rolled out Integrated Business Planning across its organisation, Simplot’s service levels are now up at 98% and inventory has been significantly cut. “Our service levels are so good because IBP allows us to forecast the business two years out and we now have a much better process of identifying risks and opportunities,” said Deahnne Spencer, Simplot’s Strategic IBP Manager. “With weather conditions affecting the levels of raw material, controlling inventory levels has been a constant challenge, but we are now much better equipped to manage these volatile market conditions.” The company has also improved its product portfolio management. “We have a really good forum for prioritising projects; readdressing every month if we’re on track and if not, why not, and where we can put our efforts to drive innovation and profitability,” Spencer said. Simplot is ranked as one of the top food companies in Australia, Spencer says, and plans to keep it that way. “The Class A journey is part of a continual commitment to become a world-class company, provide excellent customer service, drive innovation and retain competitive advantage,” she concludes. Oliver Wight Asia Pacific Contact info and more items like this at wf.net.au/R953

Brewhouse for small and mid-tier breweries To enable brewers to concentrate solely on their brewing process, Krones supplies

The APC-3792P Stainless Steel Fanless Waterproof

breweries with complete systems

Panel PC is totally sealed to IP69K specifications on

for the beer production process,

all sides. IP69K is required for applications where

from raw-materials reception

high-pressure, high-temperature washdown is used

on to the brewhouse, then the

to sanitise equipment.

fermentation and storage cellars and

The APC-3792P combines an embedded PC and a

the bottling hall, as well as packaging,

17″ 550 cd/m2 LCD in a thin stainless steel enclosure

intralogistics and full-coverage automation.

measuring only 432 x 358 x 68 mm. The APC-3792P

With the CombiCube F for the filter cellar, Krones

uses an Intel Atom N455 1.66 GHz processor and

says it has progressed the modularised concept of the

supports up to 2 GB of 800 MHz DDR3 memory.

CombiCube series for another section of the brewing process:

The 17″ LCD provides a maximum resolution of

the CombiCube F is also a TFS filter.

Waterproof IP69K stainless steel fanless waterproof panel PC

1280 x 1024 pixels and is supplied with a protective

The twin-flow principle has been retained, enabling the filtrate flow to be

capacitive touch screen. Rear panel waterproof sealed

reduced down to 30% of the nominal output. All the other advantages of the TFS

I/O connectors include two USB 2.0 ports, two COM

filter can also be used in the lower output range.

ports, one RJ45 LAN port and DC input power.

The mid-tier filter is divided into five separate modules, which can be com-

The APC-3792P provides a long-term reliable

bined to suit the requirements of individual breweries. It is suitable for small and

computing solution for industrial process control, food

mid-tier breweries.

processing and marine environments.

Krones (Thailand) Co Ltd

Interworld Electronics&Computer Ind

Contact info and more items like this at wf.net.au/R566

Contact info and more items like this at wf.net.au/R496

Nov/Dec 2012

www.foodprocessing.com.au

Innovative valve automation

The Bel Cheese â&#x20AC;&#x2DC;Mini Babybelâ&#x20AC;&#x2122; plant

Type 8681 Control Head There are 180 Type 8681 Control Heads in the Bel Cheese plant. The head is designed to fit all hygienic ball, butterfly, single, and double-seat hygienic valves - so Bel Cheese simplified things, using it run-of-site on production and service lines. It is the sole head required for any dairy, food, or other hygienic processing plant. Call now. www.burkert.com.au | 1300 888 868

We make ideas flow

PROCESSING

Applications for UV light in the food industry UV light is used for a large variety of applications in the food industry. With high-performance UV light sources and equipment, water, air and surfaces can be reliably disinfected, cleaned and treated. The use of chemicals can be reduced or even avoided in an economical and environmentally friendly way.

V light has been shown to be effective on most bacterial microorganisms, as well as viruses and moulds. Ultraviolet light at wavelengths of 254 nm destroys the DNA of all microorganisms so viruses, bacteria, yeasts and fungi are disabled in seconds. For a whole series of microorganisms, the lethal dose of UV radiation is known: this is the dose after which the cells can no longer maintain their metabolism and can also no longer multiply. Because of the cell structure, the lethal dose for different pathogens varies. Consequently, bacteria such as Salmonella, Listeria and E.Â coli, which have a comparatively thin cell wall and can thus only slightly block the UV radiation, are extremely vulnerable and are very easily destroyed. On the other hand, mould spores protect themselves against UV radiation with a thick cell wall, which can even be pigmented. To kill these, a UV dose which is 10 to 100 times higher than that required for bacteria is needed. On surfaces such as conveyor belts, particularly in the meat and meat processing areas, UV light can be used to provide continuous decontamination in the form of a module designed to expose the belt to UV as it passes. The module is completely watertight and can be incorporated into CIP best practices. The intense germicidal action of UV light acts on microorganisms on the belt surface, rendering them inactive. This treatment can reduce the number of complete washdowns required during processing, thereby saving resources such as water and energy costs. In the dairy industry, UV disinfection is used especially for the packaging of fresh milk products, such as yoghurt, cream 36

Nov/Dec 2012

cheese and dips, which are kept in the cool chain, in order to improve shelf life. This means that the dairy processor has significantly fewer returns of spoiled product. In baking, mould spores in the processing environment contribute to significant wastage, reducing shelf life and costing money. In most cases, the installation of a UV tunnel over the production line can provide an effective solution. In addition, pre-packaged fresh vegetables and fruits can be treated and the packaging exposed to UV light to decrease the incidence of spoiling. An assessment of the possible sources of mould spores in the processing environment usually indicates a build-up of material in the air supply. In order to treat the incoming air, a simple, economical and effective step is the installation of UV light in the air duct. Installing UV light at the cooling coils keeps the coil fins free from â&#x20AC;&#x2DC;bio-filmâ&#x20AC;&#x2122; build-up, which is the breeding ground for contaminants that are then circulated through the processing environment. Not only can UV light in the ducting contribute to a reduction in spoilage, the HVAC system needs manual cleaning less often and can be shown to work more efficiently, thereby saving on maintenance and energy costs. UV light at 185 nm facilitates the creation of ozone, which is used to destroy odours and grease deposits associated with cooking and food processing. In the meat processing and rendering industry, ozone lamps can be used to effectively control odours that would otherwise disperse into the surrounding area causing concern to local residents. Heraeus Amba Australia Pty Ltd Contact info and more items like this at wf.net.au/S086

www.foodprocessing.com.au

Finally, your plant can perform at its full potential

Introducing PlantStruxure architecture, the collaborative process automation solution that improves efficiency with plant wide visibility. Is your processing plant operating at its full potential? If you donâ&#x20AC;&#x2122;t have a collaborative architecture for monitoring and control, this question may be difficult to answer. And yet, quick access to precise information is exactly what you need to achieve optimised business performance.

Produce effectively with PlantStruxure architecture PlantStruxure provides you with a global view across your entire facility, closing the gap between the field and enterprise, delivering real-time information to users as and when they need it.

Ensuring a safe and sustainable working environment

PlantStruxure is a collaborative solution that allows manufacturing facilities to meet their automation needs whilst simultaneously addressing growing energy management requirements. The integration of software, hardware, networking and communication forms the backbone for information transparency from field to enterprise.

Software CitectSCADA and CitectHistorian deliver critical production related information to those who need it, while dedicated configuration software such as Unity Pro reduces engineering and maintenance time.

With PlantStruxure architecture, you can finally meet your automation requirements, reduce capital and operating expenses, and optimise energy usage without lowering standards or compromising safety.

Hardware From Modicon controllers to RTUs, drives and motor

PlantStruxure - the foundation you need to yield a holistically optimised facility.

Networking and communication Based on Ethernet

starters, our hardware is flexible, reliable, and highly efficient.

and with support for standard devices and process buses, the networks help to ensure high availability and transparency of valuable plant data.

Learn more about PlantStruxure architecture! Download our PlantStruxure Solutions brochure today. Visit www.SEreply.com Key Code 52808K ÂŠ2012 Schneider Electric. All Rights Reserved. Schneider Electric, PlantStruxure and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. www.schneider-electric.com.au CLIPCOM25395

©iStockphoto.com/Sheryl Griffin

PROCESSING

Third-party audits and food safety Part III: The role of the auditor and the difference between certification and accreditation A thorough and probing certification process can only be led by auditors with in-depth knowledge and sectorspecific expertise, and who are able to help organisations minimise risks, improve systems and processes and deliver confidence for stakeholders throughout the food supply chain.

artin Bucknavage, member of the Department of Food Science at Pennsylvania State University, reviewed two of the audits conducted at the Georgia Peanut Factory plant (see Part 1). His findings included: • Manufacturers need to be more critical of audits, including determining “What are the credentials of the auditor?” and • “Are they familiar with the type of processing operation they are auditing?” and finally • “Did they evaluate all of the risks associated with that type of operation and the type of product they make in performing the audit?” The integrity of the audits and the integrity of the certificate are of the utmost importance. As Cor Groenveld, Global Product Manager Food Services at LRQA, recently commented; “Firstly, I truly believe that these can only be delivered by a trained auditor who knows audit skills but also who knows the sector. I think that this is often a weak spot and we have seen too often with other companies in other certification bodies that auditors do not have enough knowledge of the sector they are auditing, so making sure that the auditor has that knowledge is crucial that is a starting point.” The second thing that is really important is that an auditor has to ensure that he really looks in depth at the corporate objectives and strategies and understands the vision of the company. From there the auditor needs to find out what are the real risks in the organisation and the processes and try to focus on these risks. It has to be a risk-based approach, which is the only way that an auditor can do an effective audit. Essentially an effective auditor needs to be ‘bilingual’ - they need to be able to speak the language of the shop floor as well as that of the board room to achieve a complete understand of an organisation. 38

Nov/Dec 2012

Thirdly, the certification process has to be linked to driving improvement. Again, the technical expertise of the auditor and the certification has to support the company to drive continuous improvement. An auditor can challenge the organisation, without being a consultant of course, and support the organisation by doing a robust and in-depth audit. Finally, and with criticism being levied at the auditing process that sparked the cantaloupe Listeria outbreak last year, the point needs to be made that what happened at Jensen Farms was a second-party audit. There is widespread lack of understanding on the difference between a second-party and a third-party audit. The official definition according to the International Register of Certified Auditors (IRCA) is that a 2nd Party Audit relates to audits of contractors/suppliers undertaken by or on behalf of a purchasing organisation. IRCA goes on to define 3rd Party Audits as audits of organisations undertaken by an independent certification body or registrar or similar third-party organisation. What happened at Jensen Farms was not a third-party assessment but a second-party audit because it was done to a Primus standard, not a certification standard or scheme.

The role of certification The responsibility for driving positive change across the food supply chain is not solely the responsibility of regulators, retailers and manufacturers. Certification bodies have a vital role to play in bringing confidence to the stakeholders of assessment and certification. With organisational objectives focused on delivering safe food, at LRQA we take our responsibility seriously as do many of our counterparts within the certification industry. We are actively driving change by putting in place the mechanisms to effectively train our existing assessors to ensure that their sector and technical expertise is maintained and enhanced. In parallel,

www.foodprocessing.com.au

Nov/Dec 2012

PROCESSING

we are continuing to invest in recruiting new assessors to ensure “Using GSFI recognised certification delivered by licensed and that we can meet the ‘stakeholder demands of tomorrow’. accredited certification bodies is the way forward. But who governs the certification industry? Well, ISO/IEC “Although certification will never be a guarantee things will 17021: 2011 - the standard for certification bodies - ensures that not go wrong, the controls put in place by using GFSI and acthe regional or country-specific accreditation bodies assess the creditation enlarges the level of integrity of the audits themselves certification industry against a consistent standard. and in turn the certification.” It has also extended the competence requirements to encompass all staff engaged in the certification process. ISO/ IEC Conclusion 17021 has clear benefits for certification bodies that are looking At LRQA, we believe that the auditing processes, which were to set themselves apart through their transparency, expertise and essentially checklist driven, coupled with the alleged lack of independence. For these reasons ISO/IEC 17021 offers tangible, relevant experience of the auditor, were complicit in producing consistent benefits that translate into increased trust and confi- a less than effective report. This approach contributed indirectly to both the 2009 Peanut Factory crisis, as well as the 2011 Jensen dence for all stakeholder groups. In parallel, there are many legislative controls in countries Farms crisis. The systems and processes of both organisations throughout the world that add another layer of protection for were clearly ineffective. A robust assessment approach, one consumers in terms of regulating the food supply chain. Yuri that looked at their systems and processes, embedded continual Cosco, from LRQA, explained further: “In Belgium, we have a improvement as a fundamental component and featured a risksystem which is called Self Checking Guides, which is government based methodology, would certainly have mitigated the risks to regulated. The different food sectors can set up guidelines that all of the stakeholders of both organisations to a greater extent, including, most importantly, the have to be used as a basis for the consumers whose lives and health Food Safety Management System were put at risk. of the companies in the sector. Certification bodies have a vital role to play in bringing LRQA have proactively worked The government then authorises confidence to the stakeholders of assessment with food safety stakeholders, inCertification Bodies (CBs) (after cluding manufacturers, retailers, and certification. accreditation and the necessary suppliers and industry experts, to paperwork) to audit the compamove the food sector away from nies with the specific guide as a a checklist-based approach to aubasis. There are several advantages diting towards a process-based management systems approach. for the companies: This approach looks at the underlying systems and processes • Financial incentive that organisations have in place rather than the ability of that • Fewer government audits plant or factory to convince an auditor on a given day that they • For some sectors, it facilitates export comply with a series of items on a checklist. It is not enough to “This approach means that the government then can focus have a strong standard or scheme, organisations need registrars on companies that are not assessed by CBs and that are thus or certification bodies that: considered as higher risk. • offer auditors that have extensive experience and proven “The government has already done studies that point out that competence in the sectors they are auditing in, companies having a certified system have fewer nonconformities • can provide a robust process-based management systems from the government during official inspections.” approach to auditing, Influential organisations in food are helping to position food • stand up to the client when nonconformities are found, safety management systems firmly on the corporate and regulaand finally, tory agenda. LRQA’s key alliances with organisations such as • help the organisations being audited to reduce risks, improve the GFSI and the Foundation for Food Safety will deliver added food safety performance and link their food safety managevalue to clients through technical insight and enable us, along ment systems objectives to their overall corporate objectives. with other major certification bodies, to extend their sphere What is clear is that organisations across the food supply of influence. Referring to the calls by the FDA for reforms to chain, including some of the world’s leading manufacturers and third-party auditing, Vel Pillay, Food Safety Programme Manager retailers, are increasingly recognising the benefits of independLRQA Americas, made an insightful remark: “There is a general ent assessment and certification, not only in terms of the cost lack of understanding in the difference between certification and savings, but also in terms of the benefits and value it brings. accreditation. If we take the FDA as an example: initially, the Those organisations that are prioritising potential auditor CVs FDA indicated that they wanted to become a certification body and certification body methodologies and credentials, rather than to grant certification to third-party auditors or audit body. They focusing on price, have clearly understood what is at stake. This since have changed their statement to becoming an accreditation approach is helping to drive consumer and other key stakeholder body to certify third-party auditors and audit bodies. Fortunately, confidence as well as ultimately helping to safeguard the lives there is a group of very powerful people from the industry curof people around the world. On the road to food safety, this can rently working with FDA to educate them on the role of audit only be seen as a positive step. bodies and, as the FDA does not have the resources to inspect Lloyd's Register Quality Assurance all food manufacturing institutions, this may be a way of getting Contact info and more items like this at wf.net.au/Q413 more resources from the government akin to the Belgium model.” Commenting further on the calls for reform, Cor Groenveld, said: This is the third part of a three-part article. See also Part I and Part II.

Process automation technology Schneider Electricâ&#x20AC;&#x2122;s PlantStruxure process automation technology allows industrial and infrastructure companies to transparently connect field, process and enterprise levels within their business - creating time, decreasing cost and driving energy efficiencies. PlantStruxure is a key building block of Schneiderâ&#x20AC;&#x2122;s energy management portfolio,

PROCESSING

EcoStruxure, focused on the process automation domain. EcoStruxure connects five domains of business expertise - power, data centres, process and machines,

Siphon-fed atomising spray nozzles

building control and physical security - within an open and flexible technology architecture that delivers up to 30% savings in energy efficiency. Schneider says its PlantStruxure system is based on tested, validated

Exairâ&#x20AC;&#x2122;s siphon-fed spray nozzles atomise fluids in a

and documented architectures for process and energy management, and

range of spray patterns for a wide variety of uses. The

offers complete solutions from field to enterprise.

nozzles require no liquid pressure and can be used

It offers energy management solutions to help achieve energy optimisation,

with gravity-fed liquids or lift liquids from siphon heights

from device level to enterprise level. Operating and monitoring solutions

up to 91 cm. They combine liquid and compressed

enable users to prioritise, act and operate their processes more efficiently.

air to create a thin coating of liquid that can be easily

High-availability solutions offer the flexibility to choose the level of avail-

adjusted to meet the needs of particular applications.

ability at all levels of the architecture, including operator stations, data

With the nozzles, users can coat, cool, treat and

servers, controllers and networks. Safety process solutions ensure that

paint a variety of products using compressed air and

the process is safe and efficient while also meeting safety best practices

liquids with a viscosity of up to 200 cP. Used with

as defined in the IEC 61511 standard.

water, atomising nozzles are an efficient way to evenly cool hot items in an automated process.

Networking solutions, based on ethernet, allow transparent communication among field, process, plant and enterprise. Network technologies and

The stainless steel construction of the nozzles adds

web services ensure the efficient sharing and distribution of information

to their durability and corrosion resistance. All Exair

between sensors, instrumentation, devices, controllers, operator work

atomising nozzles are adjustable and are available in

stations and other third-party systems.

a variety of flow patterns and rates to meet a range of requirements. Internal and external mix atomising nozzles are also available.

Modernisation solutions to migrate to PlantStruxure are easy and customisable. Schneider Electric (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R860

Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/R575

Nov/Dec 2012

www.foodprocessing.com.au

Larger-size valve range BĂźrkertâ&#x20AC;&#x2122;s Element range of valves has been extended into larger-format valves and drives, with orifices up to DN50 and actuators to 130 mm. This expands the application area of the valve types, enabling their use at higher process pressures and larger flow rates.

Process calibrator

Element is a modular valve concept that delivers single-unit controlled valves, with a choice

Fluke Calibration has introduced the 7526A

in valve style, feedbacks, positioner or process controller needs. It has a high-quality stainless

Precision Process Calibrator, which is a single

steel housing with intelligent and flexible system architecture. The range further extends to

benchtop process calibrator. The 7526A simplifies calibration of temperature

flow, level and analysis chemistry sensors.

and pressure process instrumentation by incorporating an isolated measurement channel, letting

angle-seat and 2301 globe valves, and the on/off and proportional control 2103 diaphragm

users source and measure simultaneously. With

valve family. All valves are available with

the calibrator, users can easily calibrate RTD and

50 to 130 mm actuators, with orifice sizes

thermocouple readouts, pressure gauges, tem-

DN8 to DN50.

perature and pressure transmitters, digital process

The valves control fluids, steam, caustic

simulators, data loggers, multimeters and more.

solutions and chemicals, as well as abrasive

In todayâ&#x20AC;&#x2122;s competitive global markets, precise

or high-purity substances in many applica-

pressure and temperature process control is re-

tions and process environments. A robust

quired to maintain product quality, reduce waste,

IP65/67 construction suits the range to

cut manufacturing costs and ensure compliance

arduous conditions, from hygienic process

to regulatory standards. Fluke says the 7526A

caustic washdown areas (FDA and EHEDG

puts all the necessary tools for regular process

certification) to high-dust mineral process-

instrumentation calibration into one box.

ing areas. Element on/off and proportional

The calibrator simulates and measures nine

control heads offer network interfaces, push-

RTD and 13 thermocouple types, accurately

button commissioning, super-bright LED

measures pressure to within 0.008% of reading

status indicators and numerous feedbacks

when combined with Fluke 525A-P Series Pressure

and options.

Modules, sources and measures DC voltage from

The drive design facilitates integration

0 to 100 V to within 0.004% of reading, sources

of automation units at all levels of the modular valve system. Valve positioners and process

DC current from 0 to 100 mA, accurately measures

controllers link seamlessly with sensors for a monitoring and control system, for complete

DC current to within 0.01% from 0 to 50 mA and

decentral automation of complex systems with minimal expense for cables and hoses.

supplies 24 VDC loop power.

Burkert Fluid Control Systems

Fluke Australia Pty Ltd

Contact info and more items like this at wf.net.au/R962

Contact info and more items like this at wf.net.au/R984

www.foodprocessing.com.au

Nov/Dec 2012

PROCESSING

The expanded Element line of larger-size valves and drives encompasses on/off Types 2100 angle-seat and 2101 globe valves, the corresponding proportional control Types 2300

Air handling units for food processing applications Hurll Nu-Way has expanded its HVAC range with the Phoenix Hygienic Air Handlers, which are designed for critical process applications such as food processing facilities, including meat, poultry, seafood, fruit and vegetables, juice, nuts, dairy, eggs and frozen and prepared food. Used in food processing plants, hygienic air handlers supply fresh, filtered, humidified and cooled or temperature-controlled air to pressurise food processing rooms. Room pressurisation can inhibit airborne contaminants from entering the processing space from other

PROCESSING

areas. Controlling humidity is crucial to reducing free moisture and condensation, which fosters the growth and spread of bacteria. Roof- or indoor-mounted hygienic handlers are used instead of air cooling units that are mounted inside the processing rooms. By eliminating in-room equipment and mounting hygienic air units outside the processing room, washing and disinfecting the process rooms is faster and easier with fewer growth surfaces for bacteria. The air handlers are suitable for a range of applications, including: meat processing; dairy processing; fruit, vegetable and nut processing; and ready-to-eat and frozen food production. Hurll Nu-Way Pty Ltd Contact info and more items like this at wf.net.au/R960

RFID controller Balluffâ&#x20AC;&#x2122;s BIS-V RFID controller is a compact evaluation unit that enables simultaneous connection of up to four read/write heads. Both HF 13.56 MHz (in accordance with ISO 15693 and ISO 14443) and LF 125 kHz read heads can be connected on the front with plug connectors and are automatically detected. The controller also allows IO-Link capable sensors or actuators to be directly connected. W i t h a n I P 6 7 r a t i n g a n d m e t a l h o u s i n g , t h e c o n t r o l l e r i s i n d u s t r y- r e a d y. It is equipped with Profibus interface and with USB as the service interface to the PC. There are many typical application areas for the combination of RFID controllers and sensors. For identification tasks for material flow control in production systems, the user may benefit from the low hardware usage and low installation costs. The controller is suitable for areas like conveyor systems in mechanical engineering, assembly lines, electric suspension systems and the intralogistics field. Balluff-Leuze Pty Ltd Contact info and more items like this at wf.net.au/R558

Nov/Dec 2012

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Integrated pneumatic actuator range Norgren has launched a high-performance range of cylinders designed to reduce energy usage and operating costs for OEMs and end users in a range of process-

PROCESSING

ing applications. Conventional pneumatic control involves an arrangement of valves or valve islands, actuators, flow controls and sensors, along with connectors and accessories. In typical applications, up to 13 different components can be required for each actuator function. This complexity presents some intrinsic disadvantages and performance constraints. Norgren has developed IVAC (integrated valve and actuator control) - an integrated unit which combines the valve, flow controls, cushioning and sensors in a single actuator package. IVAC is a weight- and space-optimised actuator, suitable for a range of bore sizes from 40 to 80 mm, with an integrated valve and magnetically operated switches for complete actuator control. Able to be retrofitted or integrated within new systems, each unit requires only one pneumatic and one electrical connection, eliminating the need for multiple valve islands, components, tubing and accessories. A number of options and varieties are available including cleanline versions for industrial cylinders, industrial slave cylinders and easy washdown, helping OEMs comply more easily and cost effectively with hygiene regulations. The design of the integrated actuator is based on modularity to allow all components to be easily assembled and disassembled. The IVACâ&#x20AC;&#x2122;s modular concept includes a special pilot module which is placed directly at the end of the actuator barrel, and the integration of a pneumatic interface, position sensing, display for status and electrical connection. Norgren Pty Ltd Contact info and more items like this at wf.net.au/R859

Optical distance sensor Even with extraneous light of up to 100,000 lux the ifm efector O1D series optical distance sensor provides reliable performance. The sensor detects all distances, even in direct sunlight, irrespective of whether the target is fully exposed to the light or only the sensor, or both. Even reflective and shiny polished metal surfaces of stainless steel or aluminium are claimed to be reliably detected. The company claims the sensor is insensitive to reflective surfaces such as reflective strips on safety vests or reflectors and can be used in outdoor applications for position monitoring such as portal lifters on loading stations. As well as the optical distance detection of up to 10 m range, this product has two switching outputs, one of which can be set as an analog output. The detection zone is scalable and has a window function. The sensor can also be used in applications with background suppression. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q331 www.foodprocessing.com.au

Nov/Dec 2012

Two-wire magnetic flowmeter Yokogawa Australia has released an upgraded version of the ADMAG AXR two-wire magnetic flowmeter. According to the company, the two-wire flowmeter exhibits a level of performance comparable to that of the ADMAG AXF four-wire magnetic flowmeter in terms of measurement accuracy and low noise characteristics. The ADMAG AXR has been certified for use in SIL2 applications typically encountered in the oil, petrochemical, chemical

PROCESSING

and other industries, and can be installed in areas that require functional safety. By pairing two ADMAG AXR flowmeters, SIL3 applications can be supported.

Customisable vibratory conveyors

In addition to HART 5, the product supports HART 7, the latest

Heat and Control’s customisable vibratory conveyors

HART protocol, eliminating the need for converters to connect

have been designed specifically for the food industry. The

with HART-compliant control systems. HART 7 also supports and

conveyors can be customised for multiple applications,

enables the automatic issuance of alarms when the device’s set-

such as grading, alignment, dewatering, spreading and

tings are modified or a problem is detected by self-diagnostics.

bidirectional distribution.

The flowmeter uses the dual frequency excitation method, with

The rugged conveyors are low-maintenance and their

low-frequency excitation that ensures stable measurement of flow

construction makes sanitation easy. One-piece stainless

rates and high-frequency excitation

steel pans with large-radius corners are easily cleaned.

that delivers high noise resistance,

Open support frames and columns facilitate cleaning of

realising stable measurement in

floors. Multiple options for drives, supports, pan configura-

a wide range of fluid conditions.

tions and accessories are available.

The device can be used in

Variable-speed electromagnetic drive conveyors handle

both monitoring and control

dry, wet, free- and non-free-flowing products for sorting,

applications. Its installation and

spreading, laning and fines removal for a single product type.

maintenance costs are lower

Direct drive conveyors are suitable for fixed-speed sort-

because two-wire magnetic

ing, grading and bidirectional conveying. The direct drive

flowmeters do not require

conveyors are suspended from a floor-mounted frame or

a dedicated power supply

the ceiling.

unit and use only a single

Fixed-speed indirect drive conveyors provide efficient

pair of cables. The low

transfer, dewatering, spreading, laning and fines removal

power consumption also

for a single product type. The underslung design saves

reduces running costs.

floor space.

Explosion-proof types suit-

For operators wanting to convey in two directions, the

able for installation in hazardous

conveyors can be customised to instantly alternate the

areas are now available for the entire product range, covering

conveying direction for product distribution or accumulation

bore diameters from 25 to 200 mm.

using one space-saving direct drive conveyor.

Yokogawa Australia Pty Ltd

Heat and Control Pty Ltd

Contact info and more items like this at wf.net.au/R529

Contact info and more items like this at wf.net.au/R192

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Affco NZ has been producing prime meat products since 1904. At its Wairoa site, a large rendering addition was made to avoid trucking offsite. During the design phase, and with energy conservation in mind, one of the key components was to ensure condensate was recycled to the boiler house. The site’s existing 11.3 MW coal-fired boiler had sufficient capacity to supply the new rendering process equipment. The majority (12,000 kg/h) is used for two rotary driers, drying meat and bonemeal from approximately 70% to 10% moisture for end use as dry chicken feed or dog biscuits. At differential pressures (between steam use in process and the backpressure of the condensate) higher than 4 bar, a conventional condensate pump return system is not very effective, wreaking more than 6% flash steam energy in the condensate lines and often boiling the boiler feedtank water. “I’ve worked with another operation where we couldn’t control the flash steam - it just went to waste,” said Plant Engineer Paul Sullivan. “We worked with Spirax Sarco to ensure that we had minimal wasted energy in the steam and condensate loop.” The solution has paid off in just over a year and, according to Sullivan, “The project achieved all of our expectations, plus more.” After several site visits and a review, Spirax Sarco put forward a proposal. Spirax suggested splitting condensate into high- and low-pressure systems and utilising energy from the dryer condensate at high pressure by installing a flash vessel. In addition, flash steam energy would be recovered and used

for a new ‘on-demand’ hot water system comprising two heat exchangers in series using low-pressure condensate for preheating and high-pressure flash steam. This was ideal as the existing hot water system was due for an upgrade. Excess flash steam beyond hot water demand was used to heat the make-up water storage tank, while all spent condensate was returned to the vented receiver and pumped back to the boiler. “Dropping the pressure and temperature of the condensate to 80°C was ideal. All the flash steam is run through the main heat exchanger and serves almost the entire washdown hot water requirements,” Sullivan said. “The only time we use direct boiler steam for hot water is at start-up from 6.00 to 9.00 am and it is minimal as the storage tank is preheated to about 65°C from the prior day from excess flash steam.” Controlling the condensate return temperature at 80°C (subcooling) ensures maximum energy recovery. All spent condensate is returned to the condensate receiver and pumped to the boiler feedtank, enabling a reduction in boiler chemicals and make-up water required. Spirax’s solution combined Affco’s need for condensate return and a hot water system upgrade into a large energysavings project. Sullivan is enthusiastic about the project’s success: “We are not wasting energy; we are saving in the order of $100K per year and could not have asked for a better turnout.” Spirax Sarco NZ Contact info and more items like this at wf.net.au/R902

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Nov/Dec 2012

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PROCESSING

Flash steam recovery delivers large energy savings

PROCESSING

Optyx is the Key to quality for cranberry producer

Mechatronic flow sensor series ifm efector’s SBT series mechatronic flow sensors can be used for flow ranges from 0.3 to 25 L/min at pressure ranges of up to 15 bar. The sensors function on the principle of the spring-supported piston: the piston, located in the valve seat in the housing, is lifted by the flowing medium against the spring resistance. The mechatronic measuring principle enables response times of less than 10 ms. At the same time, the spring resistance forces the piston to return to its original position with decreasing flow. This ensures positionindependent installation of the flow sensor, preventing backflow. Due to the temperature decoupling of the transducer from the electronics, some versions of the sensor are suitable for media in high-temperature applications of up to 180°C. The sensors can be set intuitively and provide an analog output signal. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q326

Clean Cover UV tunnel - Steribelt Bluelight UV module Germ-free packaging and conveyors with Fast and Effective UV disinfection. Less waste, improved quality, reduced risk of re-contamination.

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

www.heraeus-noblelight.com/au

Nov/Dec 2012

Inspired by seeing an Optyx sorter in action at an Ocean Spray plant, L&S Cranberry installed its own Optyx sorter - and has increased its production from one shift a day to two, six days a week. With help from Key Technology, the cranberry grower says it has maximised productivity while maintaining the highest product quality and food safety. “Prior to having our own packing plant, we shipped our fresh cranberries to an Ocean Spray packing plant, which had Optyx sorters,” said L&S Cranberry General Manager Kevin Connolly. “In 2008, we decided that we had grown large enough to justify having our own packing plant. We installed an Optyx sorter because we saw how successful it was at Ocean Spray.” Using a combination of colour cameras and lasers, the Optyx 6000 series sorters inspect up to 5400 kg of fresh cranberries per hour. The cameras analyse size, shape and colour, while the lasers detect differences in structural properties, identifying and removing foreign material, defects and soft berries called ‘poppers’ that spoil quickly. “In 2011, we went from operating one shift per day to two shifts per day, six days a week,” said Connolly. “At that time, we added RemoteMD to allow us to monitor and access the sorter remotely.” RemoteMD is a real-time monitoring and diagnostics tool for the Optyx sorter. L&S Cranberry farms and packs about 3.6 million kg of fresh cranberries each year during the four-month season, making it one of the largest growers supplying Ocean Spray. But even for such a busy company, high staff turnover is a common problem. “We usually begin every year with new people,” Connolly said. “Optyx reduces our reliance on labour because it automates sorting, and RemoteMD helps us maintain the highest product quality and line productivity even if the most fully trained person isn’t in the plant.” With high staff turnover comes increased staff training. Fortunately for L&S Cranberry, Key’s PROliance protection plan includes access to Key’s online training program - a self-paced, interactive curriculum that covers hardware, software and user interface topics. “Key’s online training program frees me up from having to train everybody myself. When employees are better trained, they lean on me less to get involved in the operation,” Connolly said. “With online training, we’ve trained more people, which is a good thing, and we didn’t have to spend thousands of dollars to bring in technicians to do the training. Online training is available any time, on-demand, which is especially valuable given our high turnover. “At L&S Cranberry, we’re focused on producing the highest quality fresh cranberries. Given how short our season is, it’s important that we achieve perfect accuracy from the moment we start up in September,” concludes Connolly. “Optyx helps us achieve our high-quality standards. Online training helps us be prepared and RemoteMD is like having an insurance policy.” Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/Q605

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Upgraded hygiene monitoring system software 3M Food Safety has announced software enhancements to its 3M Clean-Trace Hygiene Monitoring System, a family of products that helps food and beverage processors easily track and monitor cleaning and sanitation within their manufacturing environments. 3M Clean-Trace Data Trending Software Version 5.03 allows easy identification of cleanliness and continuous improvement in sanitation programs after samples are taken from the production line. The updated software is available in 20 languages and includes: newly formatted, audit-ready reports; customisable trend analytics and a sophisticated graph wizard; and tools for development and implementation of company-specific sample plans and master For food and beverage manufacturers and processors, the software improvements are claimed to go beyond the ability to conveniently store data that has been collected. By using the full capabilities of the software to transform data into robust trend analytics, hygiene managers can track cleaning effectiveness, bring about improved sanitation processes and standards as well as address audit requests that originate internally or externally. The system consists of a sampling medium and easy-to-use hardware and software. The sampling medium - 3M Clean-Trace ATP Test Swabs - is wiped on suspect surface areas to collect residues that may contain adenosine triphosphate (ATP), an energy molecule prevalent in organic materials. The 3M Clean-Trace NG Luminometer rapidly evaluates the sample and determines the presence and magnitude of potential contamination. The handheld luminometer, which delivers a result in mere seconds, allows users to pre-select their own ‘pass, caution or fail’ levels. Once the sample data is downloaded to the software, users gain full trend analysis capabilities, allowing them to quickly make business decisions and comply with audit requirements. 3M Safety Products

Tamper-proof safety switches Euchner’s CES and CET series safety switches have been designed for use on decentralised machine systems. The safety switches from both series are based on transponder technology and are claimed to offer maximum protection against tampering. They are suited for protecting safety doors, even in harsh industrial environments. The switches also feature mechanical guard locking, allowing them to be used safely on machines with over-travelling machine movements. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/Q667

Contact info and more items like this at wf.net.au/R041

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Brolton Group Pty Ltd

69 Princes St, Riverstone, NSW, 2765, Australia Sydney Ph: +61 2 98381311 Perth Ph: +61 8 6263 4426 Fax: +61 2 9838 3113 E: sales@brolton.com.au www.brolton.com.au www.sanddryer.com.au www.foodprocessing.com.au

Nov/Dec 2012

PROCESSING

sanitation schedules.

MEAT & SEAFOOD

Meat consumption and stress reduction Consuming greater amounts of choline - a nutrient found in meat and eggs - during pregnancy may lower an infant’s vulnerability to stress-related illnesses, such as mental health disturbances, and chronic conditions, like hypertension, later in life.

n an early study in The FASEB Journal, nutrition scientists and obstetricians at Cornell University and the University of Rochester Medical Center found that higher-than-normal amounts of choline in the diet during pregnancy changed epigenetic markers - modifications on our DNA that tell our genes to switch on or off, to go gangbusters or keep a low profile - in the foetus. While epigenetic markers don’t change our genes, they make a permanent imprint by dictating their fate: if a gene is not expressed - turned on - it’s as if it didn’t exist. The finding became particularly exciting when researchers discovered that the affected markers were those that regulated the hypothalamic-pituitary-adrenal or HPA axis, which controls virtually all hormone activity in the body, including the production of the hormone cortisol that reflects our response to stress and regulates our metabolism, among other things. More choline in the mother’s diet led to a more stable HPA axis and consequently less cortisol in the foetus. 48

Nov/Dec 2012

As with many aspects of our health, stability is a very good thing: past research has shown that early exposure to high levels of cortisol, often a result of a mother’s anxiety or depression, can increase a baby’s lifelong risk of stressrelated and metabolic disorders. “The study is important because it shows that a relatively simple nutrient can have significant effects in prenatal life, and that these effects are likely continue to have a long-lasting influence on adult life,” said Eva K Pressman, MD, study author and director of the high-risk pregnancy program at the University of Rochester Medical Center. “While our results won’t change practice at this point, the idea that maternal choline intake could essentially change foetal genetic expression into adulthood is quite novel.” Pressman, who advises pregnant women every day, says choline isn’t something people think a lot about because it is already present in many things we eat and there is usually no concern of choline deficiency. Though much more research has focused on folate - functionally very

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Nov/Dec 2012

MEAT & SEAFOOD

similar to choline and used to decrease the risk of neural cortisol-regulating genes. Higher choline lessened the exprestube defects like spina bifida - a few very compelling sion of these genes, leading to 33% lower cortisol in the studies sparked her interest, including animal studies on blood of babies whose mothers consumed 930 mg per day. the role of choline in mitigating foetal alcohol syndrome Study authors say the findings raise the exciting posand changing outcomes in Down sibility that choline may be used syndrome. therapeutically in cases where A long-time collaborator excess maternal stress from ... a relatively simple nutrient can have significant with researchers at Cornell, anxiety, depression or other Pressman joined a team led prenatal conditions might make effects in prenatal life, and that these effects are likely by Marie Caudill, PhD, RD, the foetal HPA axis more reaccontinue to have a long-lasting influence on adult life. professor in the Division of Nutive and more likely to release tritional Sciences at Cornell, in greater-than-expected amounts studying 26 pregnant women in of cortisol. their third trimester who were assigned to take 480 mg per While more research is needed, Caudill says that her day, an amount slightly above the standard recommendation message to pregnant women would be to consume a diet of 450 mg per day, or about double that amount, 930 mg that includes choline-rich foods such as eggs, lean meat per day. The choline was derived from the diet and from and beans, and cruciferous vegetables like broccoli. For supplements and was consumed up until delivery. women who limit their consumption of animal products, The team found that higher maternal choline intake which are richer sources of choline than plant foods, she led to a greater amount of DNA methylation, a process in adds that supplemental choline may be warranted as chowhich methyl groups - one carbon atom linked to three line is generally absent in prenatal vitamin supplements. hydrogen atoms - are added to our DNA. Choline is one “One day we might prescribe choline in the same way of a handful of nutrients that provides methyl groups for we prescribe folate to all pregnant women,” notes Pressthis process. The addition of a single methyl group is all man, the James R Woods Professor in the Department of it takes to change an individual’s epigenome. Obstetrics and Gynecology. “It is cheap and has virtually Measurements of cord blood and samples from the no side effects at the doses provided in this study. In the placenta showed that increased choline, via the addition future, we could use choline to do even more good than of methyl groups, altered epigenetic markers that govern we are doing right now.”

MEAT & SEAFOOD

Blast chilling methods could change meat tenderness A recent study looked at the tenderness and other meat quality traits of pork longissimus muscle, comparing different stunning methods and carcass chilling rates at slaughter facilities.

he pigs used in this study came from one barn on The researchers found no loin quality advantages from a commercial finishing operation. Pigs were taken blast chilling. They did find a 13-fold increase in excessively to one of three slaughter facilities. Plant A used tough samples from blast chilling. This research shows that CO 2 stunning and conventional spray chilling; differences in chilling systems among pork packing plants Plant B used CO 2 stunning and blast chilling; and Plant can have a strong influence on loin chop tenderness. C used electrical stunning and blast chilling. “This study showed that blast chilling can have a very “Blast chilling is a rapid cooling of the muscles for at substantial negative impact on tenderness. So there are least 45 minutes at less than -23°C,” said Steven Shackelford trade-offs that must be considered,” said Shackelford. of US Meat Animal Research Center (USMARC). The findings are surprising because past literature sugBlast-chilling systems are gests that blast chilling had litused to increase packing plant tle importance. The researchers throughput, enhance food safety believe this is due to changes They did find a 13-fold increase in excessively tough a n d i m p r o v e m e a t q u a l i t y, in genetics and production samples from blast chilling. particularly water-holding casystems, which can affect chillpacity of muscles from stressing rate. The researchers also susceptible pigs. found that regardless of chilling After slaughter, carcasses were cooled by blast chilling method, CO 2 stunning resulted in darker longissimus muscle or conventional spray chilling. The researchers used a loin lean colour and greater longissimus muscle water-holding from the left side of the carcass for evaluation. They sent capacity than electrical stunning. the loins to the USMARC, where the loins were refrigerFor the future, the researchers would like to see studies ated and weighed for purge loss. Purge loss is the loss of that determine whether differences exist consistently across fluid from meat. conventional and blast-chill plants over multiple seasons At 15 days post mortem, the meat was cooked and the of the year and multiple production systems. researchers measure the longissimus muscle slice shear “Given the real and perceived advantages of blast chilling, force. Slice shear force is a measurement of meat tender- we think that more research is needed to determine optimal ness. The higher the shear force, the tougher the meat. blast-chilling conditions for a balance of all meat quality traits They also tested the meat samples for marbling, muscle and other economical issues,” said Shackelford. fibre length, moisture content, colour, the breakdown of This research has been published in the Journal of Animal Science. proteins and intramuscular fat content. 50

Nov/Dec 2012

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Cattle vaccine reduces E. coli O157:H7 A commercial vaccine for cattle can effectively reduce levels of E. coli by more than 50% according to a Kansas State University study. The vaccine is also effective using two doses instead of the recommended three doses, which can help cut costs for the beef industry. “We didn't want it to be any different than the way somebody would use the products in a commercial feedlot.” The researchers found that the vaccine reduced the number of cattle that were shedding E. coli O157:H7 in faeces by more than 50%. E. coli shedding was reduced by more than 75% among cattle that were high shedders of E. coli. While the vaccine label suggests that it is given in three doses, the researchers found that two doses of the vaccine significantly reduced E. coli. “Showing that level of efficacy with two doses is really important because a shift to two doses from three could significantly cut costs for the beef industry,” Renter said. The researchers also discovered that the low-dose, direct-fed microbial product did not work as well as the vaccine. Renter said while the study used a lower dose of the direct-fed microbial and could find no evidence that it reduced E. coli shredding, it is possible that the direct-fed microbial product is more effective at a higher dose. “This vaccine is an option for reducing E. coli,” Renter said. “We have shown that this vaccine works and that it is a tool that could be adopted in the industry.”

www.foodprocessing.com.au

Nov/Dec 2012

MEAT & SEAFOOD

avid Renter, associate professor of epidemiology, is the principal investigator on a project that researched the effectiveness of products used to prevent the shedding of E. coli O157:H7 in cattle. The research appears in an online version of the journal Vaccine and helps improve current preventative methods for addressing food safety concerns. While E. coli O157:H7 does not affect cattle, it causes foodborne disease in humans. Vaccines and other products may be given to cattle to help prevent the spread of the bacteria. “We wanted to test how well these products work to control E. coli O157:H7 in a commercial feedlot with a large population of cattle that were fed in the summer and may be expected to have a high level of E. coli O157:H7,” Renter said. Using a commercial feedlot setting, the researchers studied more than 17,000 cattle during an 85-day period. They studied two products: a vaccine and a low-dose, direct-fed microbial. “What's unique about this study is the number of animals we used, the research setting and that we used commercial products in the way that any cattle producer could use them,” Renter said.

PACKAGING

Resealable packages: a frustration-free alternative

Glenn Woodworth, Managing Director, Blue Sky Packaging representing Zip-Pak in Australia and New Zealand

As everyday consumers, we are all too familiar with the frustration that accompanies a hard-to-open package. Clamshell packaging is notoriously difficult to open, but other formats like candy packets or frozen meat products can be equally challenging.

urveys over the years have found a significant and growing number of consumers have trouble opening packages, with many requiring assistance and others injuring themselves in the process. Inevitably, consumers are left feeling helpless and frustrated. This experience has been termed ‘package rage’ and refers to the anger and frustration experienced by consumers resulting from their inability to successfully remove contents from a hard-to-open package. Coffee packaged in metal containers, shrink-wrapped cheese and cereal bags are amongst common complaints. The trend of consumers shying away from hard-to-open packages suggests they are turning to competitor products that feature better openability and accessibility instead. Brands take note: packaging is an important marketing tool and should be 52

Nov/Dec 2012

a key consideration during product development. Specifically, food packaging should be designed with the young and elderly in mind, since they represent a large proportion of today’s populations, in both emerging markets like China and more mature markets like Australia and New Zealand. These two age groups also influence other consumers’ purchasing decisions, as parents and working adults seek out products that their young children or elderly family members can easily access and consume. The growing population of older individuals is also increasingly independent, with many living on their own and doing their own grocery shopping. Besides the ageing demographic, Australia is also concerned with providing accessible packaging for consumers with disabilities. It has been found that one in three healthy Australians over the age of 50 struggles with packaging, in

www.foodprocessing.com.au

Nov/Dec 2012

PACKAGING

addition to the 6.4 million Australians living with arthritis options because, in addition to portability, these packages or disability. The Ease-of-Use program was established by Ar- enable them to conveniently store unconsumed contents. thritis Australia and Arthritis New Zealand back in 2009 in a Resealable packaging also provides portion control options bid to promote user-friendly products. Since then, NestlĂŠ has and lets shoppers indulge in their favourite snacks without also joined the program to evaluate the packaging of many of fear of overconsumption. its major products and has invested in designing packaging that is easy to open for various demographic groups. This Battle of the food packages move shows that companies like NestlĂŠ are starting to hear Today, conservative estimates suggest that 70 to 75% of all the voices and demands of their consumers, and innovation purchasing decisions are made at the point of purchase - conis a necessary investment for companies that seek to retain sumers decide between the brands in front of them at the store itself. This means that packaging should attract and engage consumer loyalty and win new consumers. Increased convenience is always appreciated by those with the often overwhelmed consumerâ&#x20AC;&#x2122;s attention in the space of arthritis or disability, as these consumers may not be able to a few seconds. Shelf impact is especially important in Asian as easily open and use packages. When manufacturers consider marketplaces as these are crowded and competitive landscapes this group, they should think about creating a universal pack- with brands increasingly investing heavily in graphics and age design that can be opened by consumers of all ages, from innovative technology for their packaging. In order to stand out, manufacturers must offer children to the elderly. This will something unique to consumers ensure convenience in terms of in order to encourage them to Brands take note: packaging is an important portability, easy storage, opening select the product. and closing. marketing tool and should be a key consideration The best way for a package to during product development. The rise of snack culture stand out is through improved Increased income levels across functionality - packaging that the Asia-Pacific region have creis functional and intuitive tends ated a greater demand for food products that are convenient, to fare better in the competitive shelf landscape. Contrary to particularly in the snack category. Products consumed out of popular belief that packaging should be fanciful and intricate home have become a major area of growth because modern to attract the consumer, simplicity is frequently preferred. consumers are spending less time at home and more time Ideally, food packaging should be simple and still able to on the go. Research has also found increased snacking in fulfil the basic function expected of any food package: to keep the workplace in both developing and developed economies contents fresh even after opening. However, good packaging around the region. With spending on these convenience foods accomplishes this and simultaneously responds to the trends rising, manufacturers must accurately identify and address and demands of consumers while prompting sales. The best consumer needs in order to remain competitive with other packaging keeps contents fresh but also addresses openability, brands in the market. portability and convenient storage options. Packaging should be a key consideration for snack brands. Manufacturers need to make sure the package matches the Enhancing your brand product: if the product is supposed to be easy to consume, Many brands have found that a simple packaging modificathe packaging should also be easy to open. Resealable pack- tion can revive a product. Value-added resealable closures ages, in particular, address the need for portability and are proven and effective ways to refresh existing packaging convenience. Consumers appreciate packages with resealable and maintain the current market share. At the same time, the

PACKAGING

obvious convenience afforded by such packaging also attracts new consumers to purchase the product. In spite of the obvious benefits of resealable packaging, however, many manufacturers are still unsure about how to integrate zippers into their packaging. It is a common belief that easy-open and other valueadded features can add extra costs to packaging. However,

Difficult packaging threatens brand loyalty because package rage may lead consumers to competing easy-open brands.

flexible packaging holds an overall total cost of ownership advantage in terms of reduced shipping and material costs, lowering production costs in the long run. In fact, it has been estimated that one truckload of flexible film equates to 20 truckloads of rigid containers. Likewise, studies conducted by Purple Research and commissioned by Zip-Pak have found that consumers are willing to pay more for convenient packaging with a press-to-close or slider zipper. The cost associated with implementing resealable technology depends largely on manufacturer needs and requirements. There is a wide range of resealable products and value-added features that have been developed to suit almost any application. It is important to match the need with the zipper, as powdered products, frozen applications, bulk goods or hightemperature applications like retort and microwave require very different solutions.

Avoid cutting corners: how to adopt resealable technology Almost any flexible package can benefit from a resealable closure, whether or not incorporating a zipper was part of the initial packaging design. There are two ways to make the switch. Manufacturers can either invest in new machinery or opt for the more popular option of retrofitting existing packaging lines with zipper applicator equipment. To achieve the best results, it is important to work with a provider who can consult on machinery, materials and package design to allow for the seamless integration of resealable technology. The biggest problems with adding closures lie in working with inexperienced operators and implementing faulty package designs. Many consumers also experience frustration with value-added resealable closures that fail to work after even a single use. Most often, this is due to machinery that is not properly set up to apply the zipper. Further, for a closure to work effectively over the life of the product, the package must be designed specifically to accommodate the feature. As the only zipper supplier with an in-house equipment division, Zip-Pak is equipped to work directly with manufacturers 54

Nov/Dec 2012

to ensure machinery is properly installed and operators are adequately trained. Further, the company employs experts in package design to assist food brands in producing a package with a premium zipper that works once consumers bring it into their homes. For businesses looking to make a successful transition, here are a few tips on what to consider: • Keep it simple: Don’t crowd your package with marketing messages - minimalistic packaging can effectively indicate quality. Highlight the convenience of your package with an instantly recognisable resealable closure. • Match the zipper to the application: Zippers behave differently with various films and the products they package. Make sure you are choosing the right closure for your product. • Understand your packaging system: Additional training and knowledge is required for operators on zipper-capable packaging systems. While operators are generally reliable and knowledgeable, they may lack the expertise to correct closure application issues. Make sure your supplier is also a specialist who can work with and consult your operators to ensure smooth operations. • If you are producing a premium product, make sure you back that up with premium packaging with value-added features that work every time. • Employ universal design: If your package can be opened and resealed by children and the elderly, it will be easily accessed by everyone else in between.

Simplicity is key Today’s consumers live in a world of convenience and choice. For any given product, they are faced with a variety of options and differentiation is largely attributed to branding and packaging. Brands must realise that consumer satisfaction goes far beyond product. Difficult packaging threatens brand loyalty because package rage may lead consumers to competing easy-open brands. Packaging innovations can significantly improve consumer experiences, and with today’s advancements in technology, there really is no reason why consumers should experience such frustration. After all, no one has ever complained that a package kept food too fresh or was too easy to open. Blue Sky Packaging Ltd Contact info and more items like this at wf.net.au/S186

www.foodprocessing.com.au

PACKAGING

Automatic strapping machines with ultrasonic technology MOSCA’s range of Stainless Steel Automatic Strapping Machines use ultrasonic technology for sealing that allows immediate

Conscience-free Canadian coffee

use of machine on start-up, gives high seal strength and increases strapping speed by up to 50%. No fumes or smells are produced and the dangers of hot surfaces are eliminated.

Canadian coffee drinkers can now enjoy their morning brew with a clear conscience. Pistol & Burnes, a Canadian coffee roasting company, has introduced a fully compostable pack for its Farmer First brand which incorporates cellulose-based NatureFlex from Innovia Films. The Fair Trade organic coffee is packed in a paper bag laminated with transparent NatureFlex film. The film begins life as a natural product - wood - and breaks down in a home compost bin or industrial compost environment in a matter of weeks. It is also confirmed as suitable for emerging ‘waste-to-energy’ techniques such as anaerobic digestion. “Most roasted coffee sold in the world is packaged in either foil bags (coated in plastic) or paper bags (with a plastic liner),” said Roy M Hardy, President of Pistol & Burnes. “These usually end up going straight to landfill as they can prove difficult to recycle. However, our enviro-friendly coffee bag can be organically recycled (composted), which means it breaks down in a home compost bin.” NatureFlex films are certified to meet the American ASTM D6400, European EN13432 and Australian AS4736 standards for compostable packaging. The wood pulp is sourced from managed plantations. The renewable biobased content of NatureFlex films is typically 95% by weight of material according to ASTM D6866. Genpak, a Canadian converter, developed the bags for Pistol & Burnes. “We recommended NatureFlex to Pistol & Burnes for several reasons,” said Billy Reilly, Technical Manager for Genpak. “First and foremost, the film performs well technically, having high barrier properties and good seal integrity that enhance shelf life, keeping oxygen out and aroma in - very important for packaging coffee. Secondly, NatureFlex is perfectly aligned with the ethos of their Fair Trade, organic Farmer First brand.” “Continued success with partners such as Genpak and Pistol & Burnes means that our NatureFlex films are well positioned to provide solutions to converters and brand owners, especially those seeking to meet consumer demand for packaging made from renewable resources,” said Joe Piccione, President of Innovia Films Americas.

These corrosion-resistant machines are constructed of stainless steel or non-oxidating materials and have a sealed splash-proof control cabinet and operation panel rated at IP56. The machines offer fully automatic strap threading, automatic strap loop ejection and strap end detection with ejection of remaining strap. The IP56 washdown machines are built around MOSCA’s series 3 sealing head and brushless DC direct drive technology. Able to be integrated into most production lines, the machines have PLC control and an operator panel that allows quick setup of operating methods, strapping positions and strap tension. Mosca Contact info and more items like this at wf.net.au/S072

Innovia Films Pty Ltd Contact info and more items like this at wf.net.au/R967

Nov/Dec 2012

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CIP sensor system

Reseal, reclose and easy-open packaging systems

demands of the food, chemicals,

Packaging formats that are difficult to open or not used for

packaging, pharmaceutical and

anything more than the trip home from the retailer reduce the

similar industries. The Wenglor

interaction consumers have with a brand. This has prompted

InoxSens products come as a modular clean in place

many FMCG companies to look at introducing reseal, reclose

(CIP) system of sensors.

or easy-open systems.

The Wenglor InoxSens System

The system’s self-draining, gap-free surfaces make for

External value-added processing enables Result Packaging to add either a reseal,

easy cleaning. There are no edges to attract contamination.

reclose or easy-open feature to users’ packaging materials between the packaging printing

On the outside, the system is constructed entirely of

and filling stage, or add application technology to existing filling or forming machinery.

food-safe, FDA-approved materials. Its corrosion-free V4A

Options include: a self-adhesive label applicator from Herma or a tape application

stainless steel exterior is resistant to cleaning agents and

system from SealStrip to apply the functional element to film on Result’s Vertical or

with its IP68 and IP69K rating it is waterproof, allowing

Horizontal Flow Wrapper or Vacuum Packaging System and Carton erector loader. These

it to be cleaned with high-pressure water. The system

can be combined with self-adhesive labels and Finger Lift Tapes.

also provides mechanical protection for all cable types.

Result Packaging’s systems include: Peel&Seal, a simple and resealable tape that

In accordance with EHEDG directives, the system has

acts as an easy fold-over based reseal; FreshPak, a true easy-open, tamper-evident

an inspectable seal.

and resealable packaging system; and Bend-Seal, a memory-based fold reseal device.

Treotham Automation Pty Ltd

These can be easily adapted to any type of pack and machinery to deliver a consumer-

Contact info and more items like this at wf.net.au/R827

friendly feature. Result Packaging Pty Ltd Contact info and more items like this at wf.net.au/R865

DFC Packaging Proud Suppliers of Nicholl Smooth Wall Aluminium Trays & Lidding Films

Call us today to discuss a trial sample of our new peelable PET Antifog Dual Ovenable Lidding film. DFC Packaging Vic. 20 Summit Rd Noble Park , 3174 03 9701 2000 sales@dfc.com.au www.dfc.com.au

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

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Nov/Dec 2012

PACKAGING

is designed for the high hygienic

>>> Continuous ink jet printer Shelf friendly packaging - is there a problem here?

PACKAGING

While shelf friendly packaging (SFP) has been part of the Australian retail landscape for nearly 10 years, it is a process and a function that few understand. The core of SFP is waste and cost reduction; topics familiar to many of us. The Australian supply chain for FMCG goods is long and many hands touch the carton or pack. One of SFP’s key targets is minimising labour at each work station. For secondary packages, the accepted task of safe transport has not changed. It is just more challenging when it needs to look good on the shelf, attract a buyer and complement the primary pack. The big three retailers are driving SFP. The shared presentation at the AIP National Conference by Rod Evenden (Woolworths) and Matt Swindells (Coles) clearly demonstrated common goals, which are summarised in the mantra of ‘five easies of SFP’: easy to identify; easy to open; easy to replenish; easy to shop; and easy to dispose. There are three elements to find the optimal SFP solution: Size, shape and format of the secondary packaging. The question asked of brand managers and packaging professionals is “what is the item’s rate of sale?” If 24 items per week are sold in each store, a carton of 24 can be adapted. However, if the weekly rate of sale is six, the value of continuing with a slow-moving product must be analysed. Structural. Secondary shippers are becoming smaller. Corrugated board C flute is outdated, with E and the newly-developed R as alternatives. Folded board packs are finding a niche with their exceptional printing qualities. Regular-slotted and wraparound carton formats are no longer the only choice. Tray and shrink are generally chosen for rigid cans and glass. Communication. Having transported the primary packs successfully to the shelf, the shipper must now be point-of-sale material and communicate directly to the shopper. The choice of message and how it is printed is vital to success. As was the case with introduction of barcodes on shippers many years ago, SFP is part of doing business today and is not going away. No-one would consider removing barcodes; in time, SFP will be as important as barcoding. If you look you will find problems, but if you are committed you will find solutions. Ralph Moyle MAIP National President Australian Institute of Packaginginfo@aipack.com.au www.aipack.com.au

Nov/Dec 2012

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Matthews Australasia has released the Linx CJ400 continuous ink jet (CIJ) printer. The CJ400 prints up to three lines of information such as lot codes, dates, times, text and symbols onto most surfaces. With a special print-head, it can print four to five lines, dependent on font size. The printed code can be quickly changed without lengthy set-up procedures. The CJ400 can print characters from 2 to 20 mm high, making it suitable for both product and carton printing. The printer’s Easi-Change Service Module can be changed within minutes using on-screen prompts, allowing scheduled maintenance to be completed without the need for a trained technician. On-screen troubleshooting can solve most operating issues without having to consult manuals or engineers. The Easi-Change is designed so that all serviceable parts are housed in an easily removable box, with no wires or pipes to disconnect and reconnect, and no need to expose other critical printer components during servicing. There are no electronic components to replace when the module is changed, reducing cost and waste. Extended print-head cleaning intervals (typically three months) further reduce maintenance requirements. The Linx CJ400’s autoflush process means there is no need for printer or conduit flushing for shutdowns of up to four weeks, so fluids aren’t wasted and start-up is easy after extended shutdown periods. Weighing 13.5 kg complete with fluids, the CJ400 can be easily moved around a factory, which may increase productivity and reduce coding costs. It can store settings for up to four production lines and 1000 typical messages. Set-up can be completed by following simple prompts on an easy-to-use touch screen. The system offers step-by-step message creation and editing. Matthews Intelligent Identification Pty Ltd Contact info and more items like this at wf.net.au/R391

Bosch modifies its Elematic case packer to handle jars

Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/R190

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Nov/Dec 2012

PACKAGING

Bosch Packaging Technology has developed a new application for its Elematic 3000 S case packer. Designed by Bosch for Rapunzel Naturkost, the German manufacturer and supplier of organic products, this version of the machine is engineered to handle and place glass jars into tray and hood secondary packaging. Any machine parts that come into contact with product are constructed of plastic to protect glass jars and reduce the risk of downtime. The Elematicâ&#x20AC;&#x2122;s wraparound technology ensures jars are gently but tightly packed, which minimises the risk of product damage during transport. It can handle a range of jar sizes, including 250, 400, 500 and 750 g jars. The case packer can be adjusted to match the preceding filling machineâ&#x20AC;&#x2122;s speed without affecting efficiency on the production line. Jars are transported from the filling machine to the Elematic via two lanes, with each lane carrying up to 95 jars per minute. A special grouping system includes an accumulation area to help regulate delivery of product to the machine and ensure consistent product flow. Combining a packaging tray with lid and a full wraparound system, the Elematicâ&#x20AC;&#x2122;s modular design enables the operator to quickly switch between the two formats, speeding up changeovers. A transparent design means operators can quickly identify issues if they arise. All parts of the machine are reachable, making repair work easier. In addition, the MIS (maintenance information system) alerts the operator to pending maintenance jobs.

PACKAGING

Earthbound Farm automates clamshell packaging with ClamPAC Earthbound Farm is America’s largest grower, packer and shipper of organic produce and is widely regarded as an innovative industry leader. When looking to change its clamshell packaging presentation to a more environmentally friendly version, Earthbound also decided to automate its clamshell case packing operation, which had previously been manual. The system needed to be gentle enough to handle its new packaging format while increasing efficiency. In April 2012, the company installed four Adept ClamPAC robotic systems from Adept Technology to case pack clamshells. “We explored several suppliers offering robotic systems. Adept was the only one we found that had a product that could withstand our rigorous sanitation routine,” said Joe Torquato, Director of Engineering at Earthbound Farm. “Our new robotic packaging systems improve the consistency of our throughput, which helps position us for continued growth. “The technology is gentle and accurate; it reduces product damage and enhances the presentation of our clamshells in the case,” Torquato said. “It helps improve our work environment by eliminating a highly repetitive task.” Adept says the ClamPAC is the first fully integrated robotic solution in the world to be pre-engineered to case pack clamshells. Adept’s packaging solutions group modifies each standardised modular system to specific client needs before delivery. The company says this reduces the client’s total cost of ownership by minimising integration complexity and deployment time while providing the flexibility, dexterity and speed of a world-class robotic solution. “Food processors like to find a single source supplier that handles the entire process,” said Torquato. “Adept took on that accountability. “They handled everything including our empty boxes. They learned all our SKUs and became very intimate with our process. They set the systems up to handle our clamshells and each case packing configuration. They integrated their systems with our plant control network so we can control the operation remotely and gather data for reporting purposes. The integration went very smoothly.” Torquato says the ClamPAC handles the clamshells more gently than the labourers ever did and much more gently than Earthbound’s old drop door case packers. The new clamshell lids are sonically welded to the tub and feature an easy-open perforation. The ClamPAC is gentle enough to lift the clamshell by its lid and not break the easy-open perforation. This is due, in part, to the machine’s SoftPIC grippers. The grippers are selected specifically to suit each client’s product range and are made of soft silicon that conforms to the shape of the clamshell and provides a direct vacuum path to the product. “The ClamPAC systems nest the flanges of the clamshells during case packing. This keeps the clamshells in a better position so they are less prone to damage during transportation. It also allows us to put the same number of clamshells into a smaller box, which reduces packaging materials,” explained Torquato. The first four ClamPAC systems at Earthbound Farm are case packing 5 oz clamshells filled with an assortment of washed lettuces into six- and eightcount cases. “The Adept ClamPAC systems have been very successful,” concluded Torquato. “We wanted an integrated, turnkey system that would be easy to start up. We wanted the systems to be easy for our technicians to operate. And we wanted to achieve significant speeds and experience exceptional uptime. The Adept systems have delivered.” Adept Technology International Ltd Contact info and more items like this at wf.net.au/R972

Nov/Dec 2012

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September 2012 total CAB audited circulation (Aust + NZ): 5889 readers (90% personally requested) Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP247345/00010 ISSN No. 1039-8414 NOTICE: All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.

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

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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.

AUSTRALIA sales@flexicon.com.au 1 300 FLEXICON

+1 610 814 2400 +44 (0)1227 374710 +27 (0)41 453 1871 +56 2 415 1286

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