What’s New in Food Technology Sep/Oct 2013 by Westwick-Farrow Media

contents September/ October 2013

packaging

10 Making ice-cream more nutritious with meat leftovers

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food for thought

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fruit & vegetables

Five decades of 31 Making frozen broccoli training and education better excellence for 34 Invisible, colourless, packaging technologists odourless, tasteless and 22 What to do with 1.31 covering your ready-to- trillion plastic beverage eat fruits and vegetables bottles each year

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36 47 84 bulk handling, storage & logistics 36 Dust: an explosive risk 40 Another reason to be scared of aflatoxins

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processing

ingredients

49 Beer is booming - 2 billion hectolitres to be sold worldwide in 2013

84 Putting the bite in the bubble in the soft drink

88 Bindaree Beef beats 54 Heat-resistant chocolate the carbon tax 64 Flame pasteurising sizzles 72 Don’t let your business go to the rats 81 Frankenburger vs farmed meat: which would you choose?

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Sep/Oct 2013

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You’ve probably all forgotten about the federal election by now. But I am still perplexed at how the community, apparently, responds to ‘industry’. Rumour has it that the large swings away from the Labor Party in Victoria and South Australia were fuelled by community response to the Labor government not providing sufficient support to the car manufacturers. Now, I’m sorry, but I really don’t get why the government has to pour billions of dollars into the car industry. We’ve been pouring billions into this sector for decades as the manufacturers threaten to take their industry offshore if we don’t. Everyone gets up in arms because of the effect this withdrawal would have on employment or, perhaps even more weirdly, concern that if the country goes to war without having car manufacturing set-ups we won’t have the technology or engineering skills to build tanks or planes. Really? It seems to me that if we can’t manufacture a Ford or Holden that is good enough to capture local market share, the likelihood that we can manufacture tanks and planes good enough to take to battlefields is pretty fanciful. But what I really want to get to is why does the car industry elicit this type of response but the food industry doesn’t? For that matter, how can the car industry score billions of dollars of government support but the food processing industry only a fraction of this? If we go to war I rather have a food industry that can feed its citizens and its soldiers than a Holden, Ford or Mitsubishi factory attempting to fabricate tanks! Maybe the answer to all of this is that so far, in spite of substantial international pressures, the food industry is able to function without having to rely on government assistance. So now the question is does that make us smart or foolish? I’m opting with smart. While it would be nice to receive nice boosts to cashflow from government handouts, it would be awful to have bureaucratic ‘advisers’ looking over your shoulder. I am not against government supporting industry per se. Its support of the fledgling renewables energy sector has enabled businesses in this arena to establish themselves and ultimately become taxpayers. The workforce has become trained and proficient in a new sector that is becoming self-sufficient - a worthwhile and sensible investment by the government. Interestingly, the media is not full of stories about these businesses threatening to move offshore if they don’t continue to garner government funds! So, my post-election message is: “Well done food processing industry.” In spite of governmental indifference you manage to survive and, in many cases, thrive. Now can someone pass me the bully beef and a tin hat, I’m off to build a tank!

Food over cars any day

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

NZ research links kiwifruit to mood

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Correct storage key to reducing food waste Learning to store fresh produce correctly could help consumers extend the life span of their food, helping to reduce the amount of food that is thrown out each year. A new study commissioned by KitchenAid shows that Canadians spend around $40.80 each week on fresh produce, but will throw out close to 10% of this.

Sep/Oct 2013

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Of the Canadians surveyed, 39% were not aware that certain fruits and vegetables should be stored separately to keep them fresh. Apples and green onions emit ethylene gas, which speeds up the ripening process in other produce. Spinach and sweet potatoes are particularly sensitive to this gas and should be stored separately, KitchenAid says. “With more than half of Canadians (55%) willing to pay more for premium fruits and vegetables, be it organic, locally grown or fair trade, it’s important to know what they can do to extend the lifespan of their food,” the KitchenAid report said. Lettuce is the most frequently thrown out produce, followed by bananas, tomatoes, grapes and celery. KitchenAid has developed a refrigerator range that it says deals with humidity, ethylene gas and odours, which can all contribute to over-ripening. The refrigerators have separate systems, one which absorbs ethylene gas and an air filter that reduces odours. The study was conducted by Leger and surveyed 1501 Canadians in May 2013.

The path to happiness may travel via an unexpected stopover: the fruit bowl. Researchers at the University of Otago, Christchurch, (UOC) have found that eating two kiwifruit each day can improve mood and boost energy. Over a six-week period, 54 healthy young males ate either two kiwifruit a day or half a kiwifruit daily and were then assessed on their mood and energy levels. The subjects generally ate little fresh fruit and had lower-than-desirable vitamin C levels as a result. Those on the two-kiwifruit dose reported significantly less fatigue and depression than those in the other group. They also felt they had more energy. The researchers have suggested that the changes could be related to the optimising of vitamin C intake with the two-kiwifruit dose. “The two kiwifruit per day ensured that the study group’s vitamin C levels were optimal, and this was needed to see an effect on mood and energy,” said Professor Margreet Vissers, whose team at UOC’s Centre for Free Radical Research carried out the research as part of a larger study. “The amount of vitamin C required for this is higher than the current recommended intake. Our study provides good evidence to support the view that there are measurable health benefits to be obtained from eating a good amount of fruit and vegetables daily. “For best benefit, it is important to include high vitamin C foods in your daily diet.” Vitamin C helps activate a number of enzymes in the body that enhance the levels of metabolic energy and different neurochemicals in the brain, Professor Vissers says. This means taking in more vitamin C could decrease feelings of fatigue and increase physical and mental energy. The findings were published in the Journal of Nutritional Science.

New research tracks consumers’ perceptions of vegetables ©iStockphoto.com/ClarkandCompany

New research commissioned by AUSVEG will track consumers’ perceptions of vegetables. The research will be released as monthly reports, the first of which has just been released. “Measuring purchasing habits, consumer knowledge of vegetable varieties, new product launches and how Australians prepare their vegetables, Project Harvest will track consumer trends across a number of key vegetables on a monthly basis over a three-year period in order to identify opportunities for growers to better meet consumers’ needs,” said AUSVEG Manager of Industry Development and Communications Andrew White. “There is an increasing need in the Australian vegetable industry to monitor and gauge consumer perception and behaviour in relation to vegetables. “Understanding consumer purchasing behaviour will be critical to identifying

ways in which vegetable growers and retailers can best meet the needs of Australian consumers.” “ To c o n t i n u e t o m a x i m i s e t h e opportunities for Australian vegetable growers it is imperative that we are able to evaluate consumer trends. For instance, if Australians are moving away from traditional meat-and-three-veg to Asianinspired cooking we may discover a raft

of opportunities to supply new varieties of vegetables to the market.” The research will also monitor new product releases from around the world. An online panel of 500 consumers, representing all Australian states and territories and metro and rural areas, will be surveyed to identify opportunities for vegetable growers to better meet consumer needs.

Tasmania smiles as Cadbury invests $30 million in its Claremont site

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Tasmania’s largest exporter by value, Cadbury, has announced an aspirational goal to increase its production from 42,000 to 70,000 tonnes/year. A recently announced $30 million investment into Cadbury’s Claremont facility in Hobart will help the company realise its goal. Back in 2008, Cadbury invested around $135 million in Australia and New Zealand to develop three sites into ‘Centres of Excellence’. In Australia, the Claremont site was to specialise in producing moulded chocolate blocks and Ringwood was to concentrate on chocolate bars, while in NZ, Dunedin was to focus on manufacturing boxed assortments. It was hoped that this specialisation would bring the economies of scale to each site and justify the upgrading of a chocolate moulding plant for Claremont and boxing machinery for Dunedin. All plants automated their packaging systems. Cadbury now claims a 51% share of the Australian and New Zealand chocolate block market and its Claremont site employs around 600 people directly and 350 indirectly. The decision to invest more into this site is good news for the local community and also good news for Tasmanian dairy farmers who supply the milk to the plant.

www.foodprocessing.com.au

Sep/Oct 2013

image©iStockphoto.com

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Keeping salad in the dark may make it healthier

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You’d be amazed what plants get up to at night. US researchers have found that by manipulating the circadian clocks of fruits and vegetables, they were able to improve the amount of antioxidants they contain. “Vegetables and fruits don’t die the moment they are harvested,” said Rice University biologist Janet Braam, lead researcher of the study published in Current Biology. “They respond to their environment for days, and we found we could use light to coax them to make more cancer-fighting antioxidants at certain times of day.” In a collaboration with the University of California at Davis, Braam’s team used light to simulate day-night cycles to control the internal clocks of fruit and vegetables including cabbage, carrots, squash and blueberries. The research follows on from Braam’s award-winning study into how plants use

their circadian clocks to defend themselves against insects. They found that Arabidopsis thaliana begins to increase production of insect-fighting chemicals several hours before sunrise, the time that insects begin to feed. These chemicals are known to be beneficial to human health, Braam said, so there could be health benefits to eating vegetables when they’re producing these chemicals. The team began by ‘entraining’ cabbages’ internal clocks. Entrainment is similar to the process of overcoming jetlag, where the circadian clock resets itself over several days to the day-night cycle of a new location. Using controlled light, study lead author Danielle Goodspeed found she could entrain the circadian clocks of postharvest cabbage in the same way she did in the 2012 Arabidopsis study. Having succeeded with cabbage, Goodspeed and co-authors John Liu and Zhengji Sheng studied spinach, lettuce, zucchini, carrots, sweet potatoes and blueberries.

Australians willing to pay extra for Australian made products

Sep/Oct 2013

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Consumers prefer to buy local, even if it costs more, according to new research from Roy Morgan, commissioned by the Australian Made Campaign. Buying Australian made matters more to consumers now than it did 12 months ago, the research shows, and Australians regularly buy locally made products. Of the respondents surveyed, 55% said that buying Australian made had become more important to them in the last 12 months. Just 12% said they would not buy Australian products if they were more expensive. “The research confirms that people are becoming more conscientious about buying local,” said Ian Harrison, Australian Made Campaign chief executive. “They are aware of the benefits of buying Aussie products, and of the impact that their purchasing behaviour has on jobs, local business and future opportunities. “Concern is mounting over job prospects in this country, but research like this indicates a proactive effort by consumers to turn things around.”

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FLEX YOUR OPERATION

C O N Ta C T U S F O R a F R E E O N S I T E L U B R I C a N T S U R V E y

Making ice-cream more nutritious with meat leftovers Most of the animal proteins found in the meat industry waste have, until now, been underutilised. The challenge is to transform such waste into food of higher functionality and added value.

p to 50% of the animal weight processed in the meat industry is discarded as leftovers and ends up composted or incinerated, despite being rich in proteins and lipids. Turning the lipid fraction of such waste into biodiesel has proven too expensive. So the focus is now on re-using proteins. Today, only 22% is converted by the food industry into feed and barely 3% is consumed as food. The problem is that recovery methods are energy intensive. They also convert the source proteins into meals with poorer digestibility and nutrient properties as well as a low commercial value. Thanks to the findings of the EU-funded ProSpare project, it is possible to re-use the protein and lipid fraction of disused food, according to project co-ordinator Arnaldo Dossena, who is the head of the food science department at the University of Parma, in Italy. Thanks to a process involving enzymes to digest food, poultry leftovers such as bone and meat trimmings can be converted into proteins dubbed functional animal proteins hydrolysates. They differ from existing protein hydrolysates, from eggs, buttermilk or fish already on the market in that they have a higher content of nutritionally useful amino acids. They can be used as supplements for a sports diet, to help build up muscle tissue, and as additives in processed food, for example. So far, some of their properties - namely prebiotic, antimicrobiotic, antioxidant and hypotensive - have been demonstrated in vitro. The technology developed under the project is now being tested by a Belgian food company, called Proliver. It is hoping to enhance the nutritional quality of its protein hydrolysates, already sold in dietary, health and sports food supplements. One of the project partners, Mobitek-M, which is a Russian company specialising in production of protein-enriched foodstuffs, is also planning on including these products in ice-cream, under the follow-up Rosano Project. They have built a plant in the Belgorod region of the Russian Federation, which is about to 10

Sep/Oct 2013

start transforming functional animal protein at a capacity of 100 tonnes per day. Some see a real advantage in this approach. “I think in Europe the most important part of such an approach is to reduce the impact of the [food] production on the environment,” explains Vegard Segtnan, senior researcher at the Norwegian Institute of Food, Fishery and Aquaculture Nofima, located in Tromsø. He also believes that there is a market for these specialised protein products that are easily assimilated by the body for sick people, the elderly and athletes. “The materials have a one up to two years shelf life; [they] can be used to increase the protein count where there is a protein deficit since they contain many free amino acids [which are therefore easily absorbed],” according to Dossena. These products aim to complete the gamut of protein-based products present on the market. However, there is currently no EU-wide specific regulations for them. Instead, they are approved on a case-by-case basis in individual EU countries. Protein hydrolysates approved in national EU markets need to qualify as a specific food product category, according to Karin Verzijden, a food regulatory expert at law firm Axon Lawyers, in Amsterdam, the Netherlands. For example, these products might qualify as dietary supplements. “It really depends on the emphasis that is put on their ability to be digested much quicker than regular proteins for instance,” explains Verzijden. In addition to qualifying as food dietary supplements, experts disagree as to whether they might either qualify as novel foods used as food ingredients or as additives. It partly depends on whether they were not already used for human consumption within the EU market prior to 1997, when the EU novel food regulation entered into force. Until gaining further clarity regarding the food category these applications would be considered under by the food regulator at EU-wide level, it may be a while before they reach their potential users.

www.foodprocessing.com.au

©iStockphoto.com/kupicoo

and education excellence for packaging technologists

he Australian Institute of Packaging (AIP) was established on 12 September in 1963 when 14 men had a vision to create an institute that would provide a professional identity for packaging technologists in Australia. The founders of the AIP wanted to ensure that packaging technologists were recognised as professionals in their fields and that their training was acknowledged on par with other degrees and accreditation. Noel McLennan, Arthur Harris, Frederich M Flentje, Edward R Dann, William A Ross, Marcus Heselev, Leslie Buck, Ray Cox, A Hislop, J Trotter, G Jeudwine, W Smith, FH Ottaway and EG Davis have long been recognised as the official foundation members of the AIP, and without their vision, the institute would not be as relevant today. AIP mission statement: • To serve as an independent professional body of packaging specialists. • To promote professional standards of competency through education and training. • To advance and promote the standing of packaging specialists as a profession. • To serve and establish the confidence of the community in the packaging profession. • To aim towards professional qualifications for all Members. • To uphold professional integrity and ethics within the profession of packaging. Fifty years on, the AIP remains the only professional body designed to educate, train and develop packaging technologists and other individuals involved within the packaging industry throughout Australasia. The only difference today is that the AIP is much wider in its reach and has opened up its membership to all fields within the industry (marketing, sales, designers and engineers to name a few) and

is also assisting New Zealand and parts of Asia through its educational programs. The AIP is now a member of the World Packaging Organisation (WPO) and works closely with many other international packaging organisations. As a part of the 50-year celebrations, the AIP accepted the responsibility to host the prestigious World Star Packaging Awards and the event saw 230 people from 26 different countries come together in Sydney for the celebrations earlier this year. “The Australian Institute of Packaging celebrates its 50th anniversary this year and achieving this milestone is proof that the institute has provided relevant and meaningful support to the Australian packaging industry,” said Keith Pearson, Secretary General, World Packaging Organisation. “The WPO values the AIP membership and participation in contributing to the WPO vision of providing better quality of life through better packaging for more people. The AIP is a respected member of WPO and is directly involved in the WPO education initiatives that are planned to take place in Africa and South East Asia. Its fifty years of packaging experience will continue to make a major contribution in accelerating the transfer of packaging knowledge and foster the improvement of social upliftment, an important dimension of true sustainability.” The AIP today provides professional and personal development to all levels of the packaging industry - educational offerings include the Diploma in Packaging Technology, the Certificate in Packaging, in-house corporate training programs, more than 20 different half-day training courses, the biennial national conference, the biennial national technical forum, site visits, seminars and technical dinners. The institute has divisions in New South Wales, Victoria and Queensland and also has regional programs in South Australia and New Zealand.

www.foodprocessing.com.au

Sep/Oct 2013

PACKAGING

Five decades of training

PACKAGING

The AIP offers a range of educational opportunities to individuals and packaging departments seeking to expand their knowledge and commercial opportunities across the breadth of the packaging industry. These courses are internationally accredited by the Packaging Industry Awarding Body Company (PIABC) in the UK and are the benchmark for training worldwide. Graduates of AIP courses are recognised internationally, expanding their global employment opportunities. The AIP also offers a program of half-day training courses that provide key up-to-date information on specific areas within the packaging industry. The AIP’s flagship course is the Diploma in Packaging Technology, which has been developed to provide in-depth understanding of the packaging industry. It is aimed principally at technologists and managers in jobs with a packaging focus. The Diploma in Packaging Technology is a Level 5 qualification, which is internationally recognised for those wishing to pursue a career in the packaging industry or for those who are already in the industry and who wish to extend their knowledge and expertise. It has been offered by the AIP continuously since 1980 and has an exemplary record of successful students. It has been revised, updated and offered online. It is accredited by PIABC, which is in turn accredited by OfQual (Office of Qualifications and Examinations). The Certificate in Packaging is a Level 3 qualification designed to meet the training needs of a wide variety of people involved in packaging. From the new entrant to

Fifty years on, the AIP remains the only professional body designed to educate, train and develop packaging technologists and other individuals involved within the packaging industry throughout Australasia.

the industry who wants the best possible preparation for a career in the industry, to design, production, management, sales and marketing or purchasing staff who need to deepen their understanding of this vital and complex discipline. It is also an entry qualification to the diploma and offers the opportunity for fast tracking. “At IOM3 and the Packaging Society we are delighted to join with colleagues at the Australian Institute of Packaging in celebrating its 50th anniversary,” said Gordon Stewart, IOM3 (the Institute of Materials, Minerals and Mining). “Our long association with the AIP, in our present guise and formally as the UK Institute of Packaging, has brought benefits to both our organisations, especially in the field of packaging education. The AIP has shared with us developments in this area over many years as we have both been the standard-bearers for enhancing the skills and expertise for the packaging industry in our respective countries. “Long may the AIP continue.” Australian Institute of Packaging www.aipack.com.au

Depositors keep food dips flowing

Lancashire-based Riggs Autopack, a market leader in volumetric depositors and filling machines, transfer pumps and conveyor filling lines, recently installed an automatic depositor line and transfer pumps for Zorba Delicacies, an established UK manufacturer of chilled dips and deli products. Three Riggs Autopack twin-head automatic depositors were installed to fill three-portion plastic trays with hummus, salsa and guacamole products. The company then invested in three Riggs Autopack transfer pumps, which

Sep/Oct 2013

pump the different products from holding tanks into the depositor hoppers, enhancing the continual production process. The machines are working at a rate of 60 packs per minute. The low-level, twin-head automatic depositors were designed specifically for single or multi-portion pot, tub or tray filling for producers of products such as dips and deli fillers. They provide precise depositing of hot or cold liquid and semi-liquid products such as salsa, guacamole, hummus, dips and sauces. The horizontal transfer pumps provide damage-free transfer of products and efficiently pump products direct from tote bins, cooking kettles or mixing vessels, and transfer into low- or high-level hoppers and holding tanks. These robust food industry pumps provide continuous food production and negate the need for manual loading of hoppers by using tubs or buckets. Riggs Autopack also has depositors that can fill hot and cold liquid, semi-liquid and suspended solid goods, including a wide range of ready meal products such as stews, mashed potato, casseroles or curries and are able to deposit fragile vegetables and cooked meats in sauce with particulates up to 38 mm cubed as standard. HBM Packaging Technologies Contact info and more items like this at wf.net.au/T286

www.foodprocessing.com.au

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

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

Phone: 1300 467 446

Email: sales@insignia.com.au

Web: www.insignia.com.au

PACKAGING

Craft brewery installs CoMac equipment Oxygen analyser Michell Instruments has extended its range of oxygen analysers with the introduction of the compact XZR200 oxygen analyser. According to the company, it is capable of measuring percentage oxygen to better than 1% of span (or 0.5% O2) with ranges of 0-25% and 0-100% available. The analyser is easy to install and integrate into existing systems as no specialist software is required; the RS232 output can be accessed via a PC. The analyser offers four configuration options, with two choices of probe length and two temperature ranges. The lower temperature range (up to +25°C) is suitable for relatively low-

the sensor. The life span of the zirconium dioxide sensor is

CoMac has installed its machinery at the Three Taverns Brewery’s new brewery in Atlanta, Georgia. The brewery produces traditional Belgian-style beer with an American twist. The Three Taverns team brewed the company’s first keg of beer in the new state-of-the-art brewhouse recently using a CoMac 1T SA Semi Automatic Keg Washer/Filler, which has a speed of up to 18 kph. The CoMac team is currently installing a 1212-1 bottling monoblock for Three Taverns with a speed of 3000 bottles/h for 330 mL bottles. The automatic filler has 12 rinsing nozzles, 12 filling heads and a single head capper.

between 1 and 7 years, depending on the temperature and

HBM Packaging Technologies

type of gas measured.

Contact info and more items like this at wf.net.au/U889

temperature applications such as food and drink packaging, while the higher temperature range of up to +400°C serves combustion control and metal treatment applications. Depending on the application, the analyser may also be configured to measure in either 0-25% or 0-100% oxygen concentrations. The first configuration gives the highest accuracy of 0.5% O2 in the combustion process range. In the 0-100% range the accuracy is 1% O2. A 3.3 V DC logic output is used to monitor the sensor for diagnostic purposes. It is a way of listening to the sensor’s ‘heartbeat’ and enables the operator to check on the health of the sensor, providing a warning if there is a fault with

AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/U879

Sep/Oct 2013

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Mini titrator and pH meter Hanna Instruments’ HI 84532 digital automatic mini titrator and pH meter is designed for measuring the concentration of titratable hydrogen ions contained in fruit juice samples according to the official methods of analysis of AOAC International. The system uses neutralisation with a strong base solution to a fixed pH. The mini titrator improves upon the titrant delivery system and measuring ranges compared to previous models. Features include: precise piston dosing system; dynamic dosing for speed and accuracy; a clear and intuitive user interface; real-time graphing of the titration curve on the LCD; logging of up to 200 samples; on-screen helplrear USB outputs for PC connection and to save data to a USB drive.

Carton taping machines Rhino brand carton taping machines, available from AWS, are

The titrator is also designed to be used as a benchtop pH/mV meter. When used in this mode, it has many features of a professional-grade benchtop instrument. The titrator includes comprehensive GLP data and the company’s Cal-Check feature.

FlexiFruit, What‘s New in Food Technology, 150 x 195 mm, CC-en24-AZ013_02_12 Hanna Instruments Pty Ltd

Contact info and more items like this at wf.net.au/U928

fast (covering 23 m/min and 12-20 cartons/min) and efficient. The Rhino 103SD applies tape to a fixed size box but can be used for a variety of different sized boxes. To change over to a different box size, a simple no-tool adjustment is made by the operator. The Rhino 105SDR Side Drive seals any size carton. It senses the box size and automatically adjusts to that size before taping commences. The machines have a rugged steel construction and are built on tough industrial wheels that provide easy mobility. They can fit into existing conveyor or packaging lines. Both machines have a cassette tape loading system that eliminates stoppages for tape changes. The tape sealer features easy access to all moving parts and an optional safety cover is available. The machines are supplied ready for immediate use, needing only to be plugged in and switched on. A range of Rhino taping machines is available, including stainless steel models for the food industry and models that include safety cages and automatic carton closing. Rhino Tape Jumbo 1000 m rolls save frequent roll changes. The tape’s natural rubber formulation is effective on both conventional and recycled boxes, in a range of climates and temperatures. Australian Warehouse Solutions Pty Ltd Contact info and more items like this at wf.net.au/U537

krones FlexiFruit – doses fruit

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

Fonterra chooses Tetra Pak equipment for $100m plant

PACKAGING

Consumers less likely to recycle ‘distorted’ packaging

According to a new study published in the Journal of Consumer Research, consumers are more likely to throw a dented can or cutup piece of paper in the bin than recycle them. “Although products that have changed shape are still recyclable, the likelihood of a consumer recycling a product or throwing it in the trash can be determined by the extent to which it has been distorted during the consumption process,” authors Remi Trudel, of Boston University, and Jennifer J Argo, of the University of Alberta, wrote. The authors looked at how consumers treat products that have gone through physical changes during and after consumption that ‘distort’ the product, but do not affect its recyclability. They found that people are less likely to recycle distorted products than products that held their original shape after consumption. In one study, participants were asked to evaluate a pair of scissors. One group was asked to cut one or two pieces of paper into smaller pieces; another was asked to evaluate the scissors without cutting the paper. When asked to dispose of the paper, consumers recycled the whole sheet of paper more often than the smaller pieces, regardless of the total amount of paper. The authors say these results could help companies and public policymakers find novel ways to encourage consumers to recycle. “These findings point to important outcomes of the post-consumption process that have been largely ignored and provide initial insight into the psychological processes influencing recycling behaviour,” the authors wrote. The study will be published in the December 2013 issue of the journal.

Sep/Oct 2013

Packaging NEWS

Fonterra has announced it will fit out its NZ$100 million UHT greenfield plant in Waitoa, New Zealand, with Tetra Pak processing and packaging equipment. The new plant will contain five new UHT lines that will produce a range of products including UHT white milk and UHT cream for the foodservice sector, and double Fonterra’s UHT production capacity. It is planned to start producing its first milk by the middle of 2014, with products from the new plant exported throughout Australasia. “In choosing Tetra Pak, we know we can count on the highest standard of food safety and quality,” said Fonterra Managing Director for New Zealand Milk Products, Gary Romano. “A long-standing partner of Fonterra, Tetra Pak offers both equipment and service that ensures we get our products to consumers safely and efficiently.” The plant will produce long-life milk for the growing Asian market.

Plain packaging for high-calorie foods won’t work, experts say

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Australian food industry experts have resolutely dismissed the idea of plain packaging for high-calorie foods as a solution to the nation’s obesity epidemic. Debating the topic at the 46th Annual Australian Institute of Food Science Technology (AIFST) Convention, the panel concluded that plain packaging is inappropriate and unlikely to work. Instead, the panel offered a range of other concepts that address the complex issue of obesity. “Despite the rise of the celebrity chef, we are seeing a deskilling in cooking,” said dietitian Professor Sandra Capra, University of Queensland. “It’s led to a general disconnect with food, poor knowledge of what’s in a dish and the amount we should be eating. We desperately need to improve food education.” “The industry needs to put more investment into tertiary education to ensure Australia’s universities are producing the graduates the food industry needs to drive the innovation that will address Australia’s future food issues, including obesity,” added James Thomas, Kelly Scientific Resources. Vijay Rajendram, CEO of Neptune Bio-Innovations, voiced his support for the new front-of-pack labelling system, calling it “an initiative that will motivate the industry to develop innovative solutions for high-quality, nutritious food products”. “When we are eating high-calorie, low-nutrient foods, there may be a risk that we are overeating in an attempt to meet our nutritional needs,” said Vic Cherikoff, winner of the 2013 AIFST Food Industry Innovation Award. “We need to look at maximising nutrient content of foods - both processed and those at the farm gate - to meet our needs and reduce the risk of overeating.” More information about the AIFST Convention is available from www.aifst.asn.au/convention.htm.

www.foodprocessing.com.au

Packaging system The OCME DryBlock packaging system combines the entire dry part of the production filling line into a single, integrated and synchronised monoblock. The system has various modules including a labeller, packaging machine (shrink wrapper, trayformer, wraparound, pick and place) and a palletising module that typically consists of a layer forming unit and one or more robots or, alternatively, traditional palletisers.

PACKAGING

According to the company, the combined efficiency of a line of DryBlock is greater than the sum of the efficiency of the individual units. It can

Laminating adhesive range HB Fuller Company has introduced two adhesives to help

reduce costs as a single operator can control the entire line.

customers get food products packaged and shipped faster. Joining the Flextra Fast family of products are SFA8605 Solvent Free Laminating Adhesive and SB7200/XAS2283 Solvent-Based Laminating Adhesive - both designed to safely increase efficiency and reduce working capital. Flextra Fast SFA8605 Solvent Free Laminating Adhesive is suitable for snack applications including stand-up pouches for dry snacks and offers line speeds up to 1200 fpm. The adhesive enables shipping of goods in as little as two days, slitting in as little as 6 h, pouching/zipping in as little as one day and PAA decay in as few as two days. The adhesive adheres well to most substrates including foil, nylon, metallised films and high-slip sealants and offers good appearance. Flextra Fast SB7200/XAS2283 Solvent-Based Laminating Adhesive has high green bond strength and is suitable for demanding food packaging applications, including triple-layer

The system reduces energy consumption by up to 36%, the company

and greater laminations. The adhesive offers a high level of

says, and reduces space due to the elimination of buffering/accumulation

heat resistance for use in microwave, boil-in-bag, hot fill and

conveyors. The reduction of components and accumulation reduces noise.

pasteurisation applications, as well as a high level of product resistance to withstand aggressive-filled goods. Flextra Fast SB7200/XAS2283 enables shipping of goods in as little as three days, slitting in as little as 4 h and pouching/ zipping in as little as 24 to 48 h. The adhesive adheres well to most substrates, including foil, nylon, metallised films and high-slip sealant films.

bottle shapes and sizes. The system can be retrofitted to most existing lines and can be integrated with a wide range of labellers and/or sleevers. DryBlock logic enables rationalisation of the product flow, leading to the elimination of accumulation, thereby minimising friction and contact between containers. This reduces the risk of product damage, even when dealing with light, fragile, delicate and unstable containers.

HB Fuller Company Contact info and more items like this at wf.net.au/T819

Format changes are automated and made quickly for a wide range of

Sep/Oct 2013

HBM Packaging Technologies Contact info and more items like this at wf.net.au/V160

www.foodprocessing.com.au

BASF creates a new way to drink coffee

BASF Australia Ltd Contact info and more items like this at wf.net.au/U519

www.foodprocessing.com.au

Sep/Oct 2013

PACKAGING

BASF’s compostable bioplastic ecovio has found its first production application in a system solution for coffee packaging. BASF has collaborated with the Swiss Coffee Company to develop a coffee capsule with aroma-tight outer packaging. This is also the first application for the injection moulding grade ecovio IS1335. The material is used in combination with an ecoviobased multi-layer system with specific barrier properties. The packaging protects the product during transport and storage, and withstands use in high-pressure coffee machines. Once the capsule has been used, it can be composted. BASF launched the plastic ecovio six years ago. It is biodegradable and compostable as defined by Standard EN 13432. It is predominantly based on renewable resources and is proven in a variety of film applications. It is primarily used to produce bags for collecting biodegradable waste and mulch film for cultivating fruit and vegetables. In late 2012, the Swiss Coffee Company launched a range of coffee in compostable plastic capsules in an aroma-type barrier packaging, together with a range of coffee machines, under the brand name beanarella. The company’s founders came up with the product idea

in 2011, and after a record completion time of only 13 months, the beanarella biodegradable coffee capsules were on the market. Not only is the ecovio plastic certified as biodegradable, compostable packaging to Standard EN13432, the coffee capsules themselves are, too. The barrier packaging is also made of biodegradable components. The capsule structure consists of three functional layers: the outer paper-based carrier layer is followed by a thin barrier film as a middle layer and an inner sealing layer based on ecovio. All three layers are certified as biodegradable, compostable packaging to Standard EN 13432. The layers are bonded together with BASF’s compostable laminating adhesive Epotal Eco. Leomat, an office furnishings provider in eastern Switzerland, supplies the complete beanarella system to its customers and also collects the waste. An internet ordering system for private customers is being developed. The Swiss Coffee Company will arrange for the return of the used capsules and packaging once the consumer has finished with the product. BASF has conducted in-house research that confirms degradation of the used coffee capsules in an actual composting environment. During the pilot phase, the Swiss Coffee Company will itself handle composting of the capsules under industrial conditions in Switzerland. Leomat will transport both the capsules and the outer barrier packaging to the company for composting. In May 2013, the Swiss Coffee Company received the IDEE SUISSE Golden Idea Award 2013 for the compostable coffee capsule concept. The company now plans to introduce its product and concept in Germany, Austria and the US.

What to do with 1.31 trillion plastic beverage bottles each year What sounds like fun in the sandpit is, in fact, a new idea in recycling: take lots of PET bottles, fill them with sand and put their lids on. In an ambitious project in Nigeria, the sand-filled bottles are then stacked, joined together with mud and cement and being used to build houses. All kinds of ideas, some highly unusual, are being tried out for re-using PET beverage containers, whether as roofing tiles or to build entire houses and greenhouses. Designers are using them in trendy bags, home accessories and art objects. However, the majority of these plastics still end up on waste dumps or in thermal processing facilities.

ÂŠiStockphoto.com/powerofforever

Sep/Oct 2013

www.foodprocessing.com.au

PET in the overtaking lane According to Euromonitor, 446 billion PET containers were used worldwide for beverage packaging in 2011. That’s over 100 billion units, or 30% more than in 2006. Half of them are for mineral water and over one quarter for soft drinks. By 2015, Euromonitor expects a further rise in the global beverage packaging market to 1.31 trillion units, with the PET proportion increasing again to 42%, ie, 500 billion PET containers. PET recycling will become obligatory for ecological and economic reasons. The starting gun for the recycling of PET bottles sounded back in 1977. By 2007, according to Indian market researchers BizAcumen, around 3.7 million tonnes of PET containers were being recycled each year, and in 2015 this figure is set to come in at over 12 million tonnes. Three quarters of this total recycling happens in the Asia-Pacific region, where the containers are ‘down-cycled’ into secondary materials for use in items like fleece pullovers. In 2011, however, only around 455,000 tonnes of PET bottles were processed into 350,000 tonnes of food-grade PET. Nevertheless, the big players in the beverage industry are aiming at an ever higher recycling proportion in newly produced PET containers. The bar is being set very high. By 2020, the idea is to increase the recycling quota for PET containers to as much as 60%, and to aim at using an average to up to 25% of recycled material in new containers. The machinery manufacturers are reacting to this, as Dr Thomas Friedländer of Krones AG explains: “Although until now a considerable proportion of the recovered PET plastics have been downgraded to the non-food grade RPET, and in particular in China processed into textile fibres and other utility items, the trend now is increasingly towards using this valuable material again in the food sector. That’s why we are seeing increasing dynamism worldwide in the recycling of PET for use in food-grade packaging material.”

Great potential for bioplastics Perhaps the future lies in the use of bioplastics - market research institute Ceresana Research has forecast in a recent report that the global bioplastics market will expand by almost 18% per year. In 2018, global sales will come in at more than US$2.8 billion: packaging made from renewable raw materials such as polylactic acid (PLA) and PET from plant-based sources is highly popular because of its better eco-balance as compared to plastics based on oil. Yet the use of agricultural raw materials is in direct competition to the production of food and that represents a serious ethical conflict, in view of the undersupply of food to parts of the world population. Possible solutions lie in the use of waste materials as a base, or in the creation of integrated recycling processes in which containers made from bioplastics are reused in food packaging.

Plants into bottles PepsiCo recently presented a bottle made entirely from plant material, including switchgrass, pine bark, corn husks. The bottle is fully recyclable. Coca-Cola’s PlantBottles contain at present 14% renewable plant-based materials and 35% recycled plastic. Here, too, the plan is to develop bottles made from 100% plant materials that can be fully recycled. For bio-based plastics it could be possible in future to use corn husks and waste products such as orange or potato peelings, or wheat chaff, as well as sugars. In the manufacturing and recycling processes, ‘biological’ PET behaves like conventional PET. It can be produced using existing machinery and integrated into existing closed-loop recycling processes.

PEF instead of PET? The manufacture of 100% plant-based bottles from polyethylene furanoate (PEF) is now possible, thanks to the new YXY technology developed by Avantium of the Netherlands. A big advantage is that any carbohydrate-containing source material can be used to produce them. Commercial production is planned to start in 2015. Agreements with Coca-Cola and Danone will ensure mass production of PEF bottles in future. The functional qualities, combined with a low weight and the excellent barrier properties, could make PEF a viable alternative to PET. According to a report by the Copernic Institute, PEF has a 50 to 60% smaller eco footprint than oil-based PET. A dedicated PET display, PETpoint, at drinktec 2013 gave attendees more information on the many new technologies being employed by beverage manufacturers and their suppliers in both recycling and alternative bioplastics. Further information: www.drinktec.com

www.foodprocessing.com.au

Sep/Oct 2013

PACKAGING

he European Commissioner for the Environment, Janez Potocnik, thinks this is “an enormous waste of valuable resources. It’s like tipping 12 million tonnes of crude oil each year onto our waste dumps.” He made these remarks at ‘Polytalk’, a sector gathering of plastics manufacturers which took place in September 2012. A mere 24% of PET containers are being recycled so far on average in Europe: “Far too little,” says Potocnik. “In the medium term, we cannot accept the dominance of waste incineration over recycling.” What we can be sure of with political statements of this kind is that they are generally followed up by encouragement in the form of a legislative cudgel.

PACKAGING

In-house PET production saves more than just time Changing its outlook on new technology has led to Coca-Cola Amatil (CCA) investing heavily to tighten its supply chain. The $620 million Project Zero initiative involves several key investments, including changing over to in-house production of PET containers, preforms and closures. “We have to see new technologies as profit-boosters, not merely as a cost factor,” said Bruce Herbert, Durector Supply Chain of CCA at its Sydney headquarters. Project Zero will see CCA install more than 30 Krones blowmoulder/filler monoblocs between 2007 and 2015, while also offering one of the lightest 600 mL PET containers ever produced by Coca-Cola. These changes will have positive effects for both the company’s cost structure and the environment. Fourteen of CCA’s production facilities are located in Australia, with the blow-moulder/filler monoblocs installed in the six largest of these, all of which are operationally self-sufficient. CCA’s decision to make major investments in old PET lines happily coincided with Australian Government-supported investment projects offering tax incentives. “What we wanted was to find investments helping us to reduce our cost basis,” said CCA’s Bill Mossati. “What we opted for was to make group-wide use of blow-moulder/filler monoblocs.” CCA’s new ability to design PET bottles in-house made lightweighting development easier. In 2000, 600 mL Mount Franklin water bottles weighed 29 grams. By 2004, they weighed 21.5 g; by 2010, 16.6 g. Once the first blow-moulder/filler monoblocs from Krones were commissioned in 2011, the ‘EasyCrush bottle’ was developed, weighing just 12.8 g without closure. The total lightweighting of 56% since 2000 has won the Mount Franklin bottle the Global Packaging Award World Star. “We’re convinced there’s still scope left for further lightweighting,” Herbert said. The Coca-Cola bottle has also been reduced by 33% from 2000 to 2012; it now weighs 20 g. Along with Mexico, Australia now has the world’s lowest-weight 600 mL Coca-Cola bottle within the Coca-Cola corporate matrix. In the company’s Northmead plant, which uses three Contiform Bloc systems, monobloc-synchronising the blow-moulder and filler has reduced water consumption by 8%. This water saving was essentially what had previously been used to rinse the containers prior to filling them. The CO2 footprint of each container was reduced by 22%, while 15-23% less PET raw material is used for container production, 33% less PET is used for closures and

Sep/Oct 2013

30% less energy is required for blow-moulding the bottles from preforms. An estimated 65,000 km of annual truck transport has been eliminated. In all, CCA estimates it will save more than 9000 tonnes of PET raw material each year once all production lines are equipped with the blow-moulding/filling technology. CCA reduced its CO 2 footprint further in 2012 when it commissioned its own $57 million preform and closure factory, eliminating the need for transport of these components. The Eastern Creek Preform Plant has an annual capacity of more than 3 billion units. By the end of 2013, once all lines have been commissioned, CCA will have a total of 18 blow-moulder/filler monoblocs from Krones in Australia, 13 in Indonesia, three in New Zealand and one in Papua New Guinea. To meet main-season peaks, increase the number of SKUs and offer more consumer-specific packages, CCA has installed three flexible canning lines from Krones, plus two hotfill lines. “Project Zero has enabled CCA to expand its product portfolio while also cutting its costs and improving its service support and delivery capabilities for its customers,” Herbert explained. “In the period from 2001 to 2012, we increased the number of different SKUs from 194 to 1100, we upped our proportion of DIFOTAI consignments (delivered in full on time accurately invoiced) from 83 to 97% and our ROIC (return on invested capital) from 7 to 24%. Our target is to use the measures initiated to save costs of 30-40 million dollars annually over the upcoming three years, starting in 2013. “Not only will CCA in the future be utilising further options for automation and goods logistics, it will also aim to deploy new technologies for filling and packaging,” said Herbert. “For us, innovative packaging is just as important as the product it contains.” JL Lennard Pty Ltd Contact info and more items like this at wf.net.au/U485

www.foodprocessing.com.au

High-resolution printer Matthews Australasia has released the Viacode L-Series High Resolution Printer in Australia. The coder uses the patented Lexmark delivery unique drop system. According to Matthews, it is the only coding solution in the Australian market with the system. The technology is claimed to offer improved reliability, features and performance over existing thermal inkjet technologies. Optimised drop control gives the high-speed L-Series high-quality print quality, and a large range of industrial inks make it suitable for almost any substrate - both porous and non-porous. The L-Series print

PACKAGING

heads perform in a range of challenging packaging and industrial environments and can print up to 480 m/min. The system’s scalability means the L-Series can grow as a manufacturer’s coding requirements grow. Further features can be added as needed, so manufacturers only need to purchase the core system once, then adjust the options to meet their changing needs. The Viacode L-Series can print alphanumeric text, barcodes and graphics, as well as TrueType fonts, scalable from 1.98 mm to 162.56 cm. The controller can manage multiple production lines and print-head groups from a single interface. It has 7, 12 and 15″ touchscreen displays and an EZ Touch user interface allows for simple and intuitive message creation and selection. Images can be displayed for each production line. The Viacode L-Series integrates with Matthews’ own iDSnet enterprise-wide software solutions, making integration with ERP, MRP and WMS systems effortless. Matthews Intelligent Identification Pty Ltd Contact info and more items like this at wf.net.au/T974

www.foodprocessing.com.au

Sep/Oct 2013

Water-based dry bond hybrid laminating adhesives for flexible packaging HB Fuller Company has introduced a family of water-based dry bond hybrid laminating adhesives for flexible packaging in the food and industrial markets. The Flextra water-based line-up, PD2243, PD2167 and PD2207, is designed for high clarity, clean machining and good cell release. The company says that together, the water-based adhesives offer converters three options to help maximise performance while balancing cost. With these products, users can laminate, pouch, ship and fill packages in as few as two days, the company says.

PACKAGING

Flextra PD2243 offers the highest performance of HB Fuller’s water-based line with good clarity on various films, high bond strength, high chemical resistance and high heat resistance. The adhesive is suitable for stand-up pouches. Its clean machining helps minimise production line shutdowns for clean-up. Within the line, Flextra PD2167 provides the widest window of performance for its cost with good bond strength on a variety of films. It has good clarity and gravure cylinder cell release, leading to good adhesive transfer and easy clean-up. The base product in the family, Flextra PD2207, is suitable for bakery, snack and confectionery packaging, offering good economics for a waterbased adhesive. HB Fuller Company Contact info and more items like this at wf.net.au/T812

Film range

READY MEALS FILLING MACHINERY Volumetric Fillers for difficult to handle products including cooked rice & pasta

Depositors for sauces, soups and ready meal components

Ph: +61 2 8814 3100

Sep/Oct 2013

www.hbm.com.au

The Pentafood film product line has been extended to include Pentafood BPET films. The films are claimed to offer outstanding thermoforming, better cutting and no brittleness. A lower thermoforming temperature is required with the films, saving energy. Designed to be used in conditions as cold as -20°C, the films can be used for frozen food applications. Suitable for deep-draw, tray and blister thermoformed applications, the films are offered in mono- and multilayer structures of BPET, BPET/ PE and BPET/EVOH/PE, as well as BPET light films. Available in a wide range of barriers to moisture, gas and aromas, Pentafood BPET films have good sealing properties and multiple sealant options, such as permanent or easy-peel seals. Sealants that enable sealing through contaminants are also available. The films are offered in a range of standard opaque colours, are suitable for modified atmosphere packaging (MAP) and run on standard thermoforming and form/fill/seal equipment. All Pentafood BPET films comply with respective EU regulations and directives, as well as the applicable national legislations and international standards. Pentafood light BPET films reduce package weight while maintaining physical properties comparable to standard materials, the company says. The films reportedly offer greater than 30% density reduction compared to non-foamed PET products. Their scratch-resistant surface and enhanced denesting provide additional benefits. These light films are designed to be used in conditions as cold as -40°C for frozen food applications. As with standard Pentafood BPET films, they offer high production efficiency, superior formability and cost savings, the company claims. They are available in mono- and multilayer structures with PE and EVOH/PE. Klockner Pentaplast (Australia) Pty Ltd Contact info and more items like this at wf.net.au/U486

www.foodprocessing.com.au

Keeping a lid on quark

Ready. Set. Code

“Chadwicks was a pleasure to work with and offered support and advice throughout the process to ensure that our needs and deadlines were met,” said Claire Irvine, Brand Manager at First Milk. “Achieving the best shelf appeal possible is crucial to retail sales and we are delighted with the outcome.” Part of the Flexible Packaging Division of the Clondalkin Group, Chadwicks works with its sister company Nyco, a shrink sleeve manufacturer based in Switzerland, to provide a joint service to multisite European buyers. Together, Chadwicks and Nyco can provide a wider range of print processes including UV flexo, gravure and offset litho.

PACKAGING

First Milk’s recently released new product, Lake District Dairy Co. Quark, is available in three flavours: original, lemon and vanilla. High in protein and low in salt and sugar, quark is a naturally fat-free dairy ingredient that is suitable for cooking, baking and mixing. Chadwicks produced high-quality pre-cut lids for First Milk’s quark products, working closely with the company to develop a colour-matched lid that is consistent with the existing pot labelling, which is printed using a different print process. Chadwicks produced the lids on 50-micron polyester on the MPS-EP410 UV flexo press for the range. Each lid features five colours. “In isolation, this job may not be viewed as a particularly challenging lid,” said Claire Adams, Chadwicks Sales Manager. “However, the important requirement was to ensure that clarity of colour was maintained and consistent with the in-mould labels used on the pots. We produced a number of trials to ensure that the match was precise and the results we have achieved are excellent.”

Chadwicks Contact info and more items like this at wf.net.au/U221

the new SmartLase C Series Power up your packaging line. Experience the new SmartLase C Series. Re-engineered for your industry giving you ultimate control of your coding quality and production costs at the speed you need whatever the rate, size or substrate.

High contrast coding at 100,000+ products per hour

99.9% availability rate with seamless integration

Dedicated versions for food and beverage industries

Designed to last 30% longer than the rest

AP SMARTLASE (GB) 180x135mm.indd 1

6/02/13 15:30:11

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Sep/Oct 2013

>>> Interview with Ralph Moyle, National President of the Australian Institute of Packaging

PACKAGING

I have been a member of the AIP since: 15 August 2004. What the AIP means to me: The most powerful [feeling] is to be a member of a group of like-minded individuals acting as volunteers who can maintain and grow a not-for-profit organisation for 50 years and take it to world organisations and be respected for their professionalism and endeavour. I am so proud to be a member of this group of wonderful people. Education in the industry is: The force that drives growth, success and personal fulfilment of all who accept its core need. My strongest memory of change within the packaging industry: The only constant is change. In Australia (and most of the western world), retailers forcing change back through the supply chain is the most significant in the past 10 years and this is demonstrated by the requirements for shelf-ready packaging, which challenges many of the criteria for sound packaging performance. In the third world, the changes due to population growth increase the challenges of protecting against food waste. Advice to those starting in the industry: Stay alert, stay focused, listen to and learn from those around you. Find a person with passion and drive for packaging, and work with them. My mentor: I have been fortunate to have many. In packaging, George Ganzenmuller, who coerced me into the Queensland branch and provided quality leadership; Llew Stephens for his alwaysbalanced views and dedication; and Harry Lovell for proving you can fire on all cylinders at any age. In management, Barry Collet, the Danes at Plumrose and Fletcher Jones. In life, my father. My greatest achievement in the industry: To have the passion to learn new aspects and influences that packaging can bring to our society.

Ralph Moyle, National President, Australian Institute of Packaging info@aipack.com.au www.aipack.com.au

Recyclable ultrahigh barrier packaging Plantic Technologies has developed what it says is the first renewable and recyclable ultrahigh barrier packaging format, Plantic eco Plastic R. The material format combines PET and Plantic biodegradable film to provide a packaging material which has ultrahigh gas barrier properties and is made from up to 60% renewable materials. The material can be fully recycled with the PET recovered in the traditional recycling streams with Planticâ&#x20AC;&#x2122;s barrier material dissolving and biodegrading in the process. Plantic eco Plastic R trays and roll stock require no investment in new processing or packaging technology and can be directly substituted for existing materials into the supply chain, the company says. They are a drop-in replacement for a range of traditional plastics used in modified atmosphere and ultrahigh barrier packaging. The rigid trays and roll stock are offered in a high-clarity transparent form as well as a variety of colours and multicolour formats. According to Plantic, every 1000 MT of Plantic eco Plastic R used in place of traditional barrier plastics saves 5.4 million kWh of energy and 2700 MT of CO2. Plantic Technologies Ltd Contact info and more items like this at wf.net.au/U015

Steam and water mixing valve The Dynafluid 2000 steam and water mixing valve, available from TecPro Australia, combines steam with cold water to deliver a constant flow of hot water without the need to install water heating and pumping systems. The steam inlet valve is controlled directly by the cold water pressure, opening only when water is flowing into the chamber. As soon as cold water pressure in the chamber drops below 1 bar, the steam valve shuts off completely, ensuring that steam cannot escape through the outlet. The valve is available in four different sizes from 15 to 40 mm, for flow rates up to 350 L/min and operating pressures from 0.5 to 6 bar. The two smaller valve sizes are suitable for hose washdown stations; the two larger valve sizes are suitable for tank filling and multipoint applications where higher flow rates are required. A range of sizes is available, including stainless steel for hygienically controlled environments. The internal parts are constructed from robust, heat-resistant thermoplastic polymers, giving the valves good operating life even in harsh environments. Should maintenance be necessary, the valve is easy to service without removing any pipework, and a full range of spares is available. An optional temperature gauge and a hose rack are also available. Tecpro Australia Contact info and more items like this at wf.net.au/U947

Sep/Oct 2013

www.foodprocessing.com.au

Cereals

Confectionery

Simple Weighing Solutions for difficult to handle products

An integrated calibrated standard is mounted on each weigh cell to automatically and continually calibrate each weigh bucket during production. this ensures extremely high levels of accuracy, preventing costly give-away, and eliminating tedious manual calibration.

Meat, Fish and seafood

Powder, spices and Granulated Material IQF Products

Pet Food Dried fruit and nuts

www.multipond.com

Vegetables, salad Greens and Mushrooms

Fresh Fruit

Multipond weighers are designed and manufactured in Germany and sold, service and fully supported in Australia and New Zealand by Jl lennard.

Dry soup Mixes

Multipond’s combination mode also allows accurate mixing of multiple components for shelf-ready packs or ready-to-eat meals such as mixed salad greens, mixed vegetables or freshly cut fruit salad.

Cheese

Multipond’s patented ‘stepped profile’ prevents product sticking to the surface of the weigher, allowing precise and accurate dosing of fresh produce such as vegetables, salad greens, mushrooms and freshly cut fruit.

AustrAliA

NEW ZEAlAND

1800 777 440

09 572 8084

www.jllennard.com.au

www.jllennard.co.nz

Non-Food

tobacco, Coffee and tea

ready Meals

Whether your product is fresh or frozen, sticky or dry, Multipond has a weighing solution to suit.

Phyllis Picklesimer

Broccoli has long been lauded for its health-giving properties, not least of which is the cancer-fighting phytochemical sulforaphane. So it was bad news when University of Illinois broccoli researchers discovered that frozen broccoli lacks the ability to form the phytochemical. However, a second study by the same group has demonstrated how the food industry can act to restore the frozen vegetable’s health benefits.

“W

e discovered a technique that companies can use to make frozen broccoli as nutritious as fresh. That matters because many people choose frozen vegies for their convenience and because they’re less expensive,” said Elizabeth Jeffery, a U of I professor of nutrition. “Whenever I’ve told people that frozen broccoli may not be as nutritious as fresh broccoli, they look so downcast,” she added. As little as three to five servings of broccoli a week provides a cancer-protective benefit, but that isn’t true for bags of broccoli that you pluck out of your grocery’s freezer, she noted. The problem begins when soon-to-be-frozen broccoli is blanched, or heated to high temperatures, to inactivate enzymes that can cause off-colours, tastes and aromas during the product’s 18-month shelf life, she explained. The extreme heat destroys the enzyme myrosinase, which is necessary to form sulforaphane, the powerful cancer-preventive compound in broccoli, she said.

“We know this important enzyme is gone because in our first study we tested three commercially frozen broccoli samples before and after cooking. There was very little potential to form sulforaphane before the frozen broccoli was cooked and essentially none after it was cooked as recommended,” said Edward B Dosz, a graduate student in Jeffery’s laboratory. In the second study, the researchers experimented with blanching broccoli at slightly lower temperatures instead of at 86°C, the current industry standard. When they used a temperature of 76°C, 82% of the enzyme myrosinase was preserved without compromising food safety and quality. Sulforaphane is formed when fresh broccoli is chopped or chewed, bringing its precursor glucoraphanin and the enzyme myrosinase into contact with each other. The researchers first thought that thawing frozen broccoli in the refrigerator might rupture the plant’s cells and kickstart the enzyme-substrate interaction. It didn’t work, Dosz said. But they had previously had success using other food sources of myrosinase to boost broccoli’s health benefits. So the

www.foodprocessing.com.au

Sep/Oct 2013

FRUIT & VEGETABLES

©iStockphoto.com/Givaga

Making frozen broccoli better

you can cook frozen broccoli in the microwave and it will retain its cancer-fighting capabilities,

FRUIT & VEGETABLES

researchers decided to expose frozen broccoli to myrosinase from a related cruciferous vegetable. When they sprinkled 0.25% of daikon radish - an amount that’s invisible to the eye and undetectable to our taste buds - on the frozen broccoli, the two compounds worked together to form sulforaphane, Dosz said. “That means that companies can blanch and freeze broccoli, sprinkle it with a minute amount of radish, and sell a product that has the cancer-fighting component that it lacked before,” he said. One question remained: would sulforaphane survive the heat of microwave cooking? “We were delighted to find that the radish enzyme was heat stable enough to preserve broccoli’s health benefits even when it was cooked for 10 minutes at 49°C. So you can cook frozen broccoli in the microwave and it will retain its cancer-fighting capabilities,” Dosz said.

Jeffery hopes that food processors will be eager to adopt this process so they can market frozen broccoli that has all of its original nutritional punch. Until they do, she said that consumers can spice up their frozen, cooked broccoli with another food that contains myrosinase to bring the cancer-fighting super-food up to nutritional speed. “Try teaming frozen broccoli with raw radishes, cabbage, arugula, watercress, horseradish, spicy mustard or wasabi to give those bioactive compounds a boost,” she advised. Jeffery and Dosz of the U of I’s Department of Food Science and Human Nutrition co-authored both studies. Commercially produced frozen broccoli lacks the ability to form sulforaphane was published in the Journal of Functional Foods and is available online. USDA and the National Institute of Food and Agriculture funded this research. ‘Modifying the processing and handling of frozen broccoli for increased sulforaphane formation’ appears in the Journal of Food Science and can be viewed online. Sakata Vegetables Europe supported this study.

Slow-release genistein, lycopene and vitamin D3 formulation LycoRed has launched Lyc-O-Fem, a slow-release formulation containing genistein in a proprietary composition for bone health. The formulation is claimed to also alleviate menopause symptoms. Lyc-O-Fem is the first in the company’s line of products combining slow-release technology with genistein, tomato lycopene and vitamin D3. The company says all three are clinically proven nutrients to support bone health. The genistein in the product is a phytoestrogen derived from Sophora japonica, the Japanese pagoda tree, and is standardised to 98% purity and specially formulated for slow release. The compound has been shown in research studies to support bone health and reduce vasomotor symptoms. Studies

develop a strain of non-genetically modified tomatoes rich in

back the positive effect of genistein on bone metabolism in

lycopene - up to four times the amount found in regular to-

post-menopausal women, without the harmful estrogenic activity.

matoes - conventional crossbreeding methods were used and

However, genistein is rapidly metabolised, requiring a twice-daily

a proprietary method for extracting the tomato lycopene from

administration of the supplement. The slow-release technology

these tomatoes was developed. The formulation is available as

in the company’s preparation provides a continuous exposure,

a (drum-to-hopper) premix, in hard-shell capsules or as a bulk

allowing once-a-day supplementation.

or fully packed product.

Lycopene is a bright-red carotenoid pigment; the formulation contains lycopene from an all-natural extract of tomatoes. To

Sep/Oct 2013

LycoRed www.lycored.com

www.foodprocessing.com.au

Invisible, colourless, odourless, tasteless and covering your ready-to-eat fruits and vegetables

ÂŠiStockphoto.com/Sean Locke

Sep/Oct 2013

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Minimally processed fruits and vegetables currently account for about 10% of all produce sales, with sales exceeding $10 billion annually according to the International Fresh-cut Produce Association. The large, and growing, market share of ready-to-eat fruits and vegetables has been made possible by the development of invisible, colourless, odourless, tasteless, edible coatings. In 1986, the key discovery by the ARS researchers was that certain calcium salts protected apple slices from colour, taste or texture changes. “When you cut an apple, many physiological changes occur to the fruit tissue, including browning and the breakdown of cells. But this new treatment slows the process for at least two weeks. This time is crucial to allow for packaging, shipping, and marketing,” Pavlath explained back then. The technology his group pioneered enabled refrigerated, packaged apple slices to last 2-3 weeks without turning brown or losing crispness and also without leaving a detectable residue. Today, edible film technology has progressed even further the films allow exchange of gases and have other features that maintain freshness, flavour, aroma, texture and nutritional value. They generally provide the same protection against bacteria as the natural skin if the foods are handled under sterile conditions when they are cut in the factory. Workers either spray on the films or immerse the foods in the liquid coating after cutting. The finished fruits and vegetables then go to consumers in sealed containers.

Challenges still remain In the US, more bananas are consumed each year than apples and oranges combined but a coating that makes fresh-cut sliced banana a commercial reality is still elusive. Likewise, coatings for avocados, which are notorious for discolouring quickly after peeling, are still under development.

Why do we need edible films? While some products can be eaten in their original form, in most cases they need to be pared, cored, sliced and diced for immediate household use. If this is done in a factory before reaching the consumer, products start to dehydrate, deteriorate and lose appearance, flavour and nutritional values. Without special protection the product becomes immediately more perishable. The damage can occur within hours or days, even if this damage is not immediately visible. This can be prevented if after the processing the natural skin is replaced with an edible film. The right edible films can prevent moisture losses while selectively allowing the controlled exchange of important gases, such as oxygen, carbon dioxide and ethylene, involved in respiration processes. Proteins, carbohydrates and fats can fulfil requirements for edible films. The general rule is that fats reduce water transmission, polysaccharide films control oxygen and other gas transmission and protein films provide mechanical stability. These materials can be added separately or mixed, provided they do not change flavour. The major deciding factor is whether the protecting films have the necessary physical chemical properties to maintain the transmission of the various gases and liquids at the same rate as the natural protection does. Each of these components has different properties, which are efficient in controlling one type of transmission while sometimes have detrimental effect on others.

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Sep/Oct 2013

FRUIT & VEGETABLES

hese formulations can extend the shelf life anywhere between 7 and 21 days without compromising the fresh quality. They can: • inhibit enzymatic browning, • maintain the product’s natural texture, • prevent sliced product from dehydrating, • retain natural liquids in produce. Now you may have thought that the skin on fruits and vegetables already provides natural protection against drying out, discoloration and other forms of spoilage. But consumer demands for convenience mean they want their produce to be ready to eat. They want to purchase it already peeled and sliced. Unfortunately, the acts of cutting and peeling remove the natural protection, allowing deterioration and spoilage to begin - everyone is familiar with the browning of apples within minutes of having their skins breached. The use of edible films to protect produce is not new - at least as early as the 1100s, merchants in citrus-growing regions of southern China used wax to preserve oranges shipped by caravan to the emperor’s table in the North. In Europe, fresh fruit has been preserved by ‘larding’ - coated with melted fat from hogs - for centuries. In both of these cases the coatings sealed off the fruit, preventing the exchange of gases with the air, which is essential for sustaining good quality. A thin layer of carnauba wax, obtained from the leaves of palm trees, has long been applied to apples to replace the natural wax coating on the fruit that is lost in post-harvest washing. The same wax is used to make many chocolate confections shiny. Other common edible coatings include starch, alginate, carrageenan, gluten, whey and beeswax. Attila E Pavlath, PhD, is the scientist who turned fresh-cut apple slices into a today’s convenience food, available ready to eat in grocery stores, school cafeterias and fast-food restaurants. At a recent meeting of the American Chemical Society, Pavlath presented an address about his research into edible coatings, where he pointed out that the use of edible films has grown dramatically since the mid-1980s. Then only 10 companies were in the business, whereas today more than 1000 companies with annual sales exceeding $100 million are involved. And, the use of edible films will probably continue to expand dramatically in the future - especially for fruits and vegetables - as healthconscious consumers look for more foods that require minimal preparation, like cut fruit and premixed salads. Pavlath, a scientist at the US Department of Agriculture’s Western Regional Research Center, began working on edible films in the 1980s. The first formulation was created specifically to maintain the taste, texture and colour of sliced apples and pears. Pavlath and his Agricultural Research Service (ARS) team has continued to work on shelf-life extension technology and continues to add new formulas and technologies to its broad portfolio.

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Dust: an explosive risk History is littered with incidents of catastrophic dust explosions. It is possible, however, to minimise the risk by identifying and mitigating contributing factors.

ver the centuries, dust explosions have claimed many lives and caused significant injuries and property damage. And the food industry is not immune. Typically occurring in contained environments such as mills and storage facilities; the range of food industry dust types that are combustible includes such common foodstuffs as grain, flour and sugar. To many, dust can seem harmless - but if certain conditions prevail, it can pose a deadly problem. “For a dust explosion to occur, several contributing factors must be present,” said Graeme Cooper, Managing Director of Tecpro Australia. “First of all, there must be airborne, combustible dust in high concentrations. The environment will also contain an oxidising agent such as oxygen, and the explosion is triggered by a source of ignition such as a flame or static electricity. “When a product is broken down into dust particles, its total surface area increases dramatically,” said Cooper. “This makes it much more flammable.” Cooper said one of the biggest problems is that it is sometimes difficult to perceive dust as a real threat to safety. “In settings where there is the odour of gas or flammable vapours, it’s obvious that there is an explosion risk and people are usually quick to respond and combat the problem,” he said. “In contrast, where there is a large build-up of dust, it may not necessarily make people in the area think about the possibility of an explosion risk.” Lower grade dust explosions where there is no damage to people or property can also create a false sense of secu36

Sep/Oct 2013

rity. “If relatively minor dust explosions occur, sometimes people feel complacent and that the problem is more or less manageable. However, this doesn’t necessarily mean that future explosions won’t escalate into a larger disaster,” said Cooper. “Smaller dust explosions can unsettle dust elsewhere, causing rolling explosions which can, of course, do great damage. It’s best to be vigilant and proactive by eliminating or minimising the factors that can contribute to a dust explosion.” Tecpro Australia is routinely called on to offer advice and solutions regarding dust control and risk mitigation. “We’ve developed a large number of dust suppression solutions for a range of environments including transfer stations and grain storage facilities,” said Cooper. “We look carefully at each situation and customise a dust suppression solution to match the nature of the dust and its setting.” Tecpro’s expertise was recently acknowledged when the company won the 2012 Australian Bulk Handling Review Award for Dust Control, Technology, Application or Practice in partnership with the University of Wollongong. “There have been many horrific dust explosions throughout the world over the years and we’re keen to make people stop and think about whether there is a risk of this occurring in their work environment,” said Cooper. “Tecpro has the skills and experience to advise on solutions that can greatly reduce the risk.” Tecpro Australia Contact info and more items like this at wf.net.au/U550

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Mobile powered workstation For efficient inventory management and a multitude of other tasks in warehouses, distribution centres and other retail/manufacturing facilities, the PC Series Mobile Powered Workstation from Newcastle Systems has onboard power to run a computer, a printer and other devices simultaneously. Generous shelf space provides room for products and other items. The workstation is highly portable. With 6″ rubber swivel casters and no cord trailing behind, a PC Series Workstation can be easily rolled and positioned for optimal productivity. The casters can be locked for stability once the workstation is in place. All models have a load capacity of 500 pounds. The unit’s rechargeable battery offers integrated, seamless power for up to 12

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h of normal use. Carts are available with 30 or 48″ deep shelves and five different battery/inverter/charger packages. A typical use of a PC Series Mobile Powered Workstation is the recording of inventory in real time, printing a label as each product is handled, with access to WMS, ERP and automated data collection. In a receiving department, inbound products can be inspected, labelled and rerouted at the same workstation, eliminating unnecessary foot travel and paperwork. Newcastle Systems www.newcastlesys.com

Automated material handling system

Bulk bag unloader systems

National Bulk Equipment (NBE) has available an automated

National Bulk Equipment (NBE) bulk bag

material handling system for moving fragile food product

unloader systems have been designed and

through multiple process operations into bulk storage for

built for food and pharmaceutical processing

temporary holding prior to final packaging.

and packaging operations to help ensure

At a process rate of 5400 kg/h, bulk totes of the food

compliance with domestic and international

product are nestled into a lift carriage; the tote is sealed

sanitary standards.

to a custom-designed discharge hood.

Application-specific construction, including

The tote is vertically conveyed, using a 3.81 cm solid 304

304-2b stainless steel framework with continu-

stainless steel track and cam rollers to a 7 m discharge

ous weld seams ground to a No. 4 finish,

height. During tilting of the tote, optical sensors ensure a

enables clean-in-place sanitising. Tool-less

maximum product discharge drop distance of no more

component disassembly speeds cleaning and

than 12.7 cm through the entire 150° rotation. Additional material handling occurs as three stages of

simplifies inspection.

vibratory conveyor move the fragile food product through

The systems’ 32 Ra component surface finishes and food-grade non-metal components provide good mate-

two stages of high-speed image processing and sorting

rial release and resistance to corrosive foods, pharmaceuticals and

to ensure the material maintains its original characteristics

cleaning chemicals. The systems also support process practice pro-

throughout processing.

tocols where 3-A Accepted Practices of other cGMPs are necessary.

The finish-processed food product is then moved into a

The bulk bag unloader systems use integrated automation to

storage tote using a reverse-tilt fill method to, again, ensure

optimise uptime availability. NBE system-wide process control,

the product drop does not exceed 12.7 cm during filling.

communication, sensing, monitoring and reporting are centralised

The final take-away conveyor section includes an integrated

to a single touch-screen HMI. High-speed ethernet communications

NTEP-certified weigh system to ensure the filled tote weight

deliver information to UL-listed panels designed and built by NBE.

is accurate to ±0.01% of the tote’s 1814 kg total capacity.

NBE custom panel configurations include UL 508A, Class I and II,

Conveyor and container routing is directed from a single,

Divisions 1 and 2, Groups A-D, F and G, and NEMA 12 enclosures

menu-driven HMI designed and built by NBE. According to

with Type X purge.

the company, its integrated automation and construction increase material processing rates while reducing material

National Bulk Equipment Contact info and more items like this at wf.net.au/V044

reject rates. Mercer Technologies Contact info and more items like this at wf.net.au/U830

Sep/Oct 2013

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Depend on us for the best in blast chilling. Irinox technology enables users to cool, thaw, freeze, proof, pasteurise and low temperature cook almost any type of food products, without compromising on freshness, flavour, moisture and aroma. Improved food safety Better food management Improved kitchen organisation Reduced labour costs Better food quality Longer shelf life HACCP approved Total sanitising system

For inspirational ideas and to view Irinox case studies download the Project Portfolio portfolio.skope.com

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Another reason to be scared of aflatoxins The fungi Aspergillus flavus and A. parasiticus produce aflatoxin - a toxic substance that has been linked to liver damage and related cancers; but its role in the spread of infectious disease could make it even more deadly.

bout 4.5 billion people worldwide are exposed to aflatoxin at unsafe levels as it is widely found coating much of the stored corn, wheat, rice and nuts in developing countries, especially those near the equator. In a recent paper published in the World Mycotoxin Journal, Pauline, Jolly, PhD, professor in the Department of Epidemiology within the School of Public Health at the University of Alabama at Birmingham (UAB), explained: “Our work suggests study that aflatoxin exposure may be taking an even greater toll in areas where millions are infected with HIV, including Africa and Asia, the latter with a fast-growing HIV population and rice storage areas contaminated by fungi.” Jolly and her colleagues recruited 314 HIV-positive people who were not yet on antiretroviral therapy for the study in Kumasi, Ghana. They divided patients into four groups based on their level of aflatoxin exposure and found that those in the highest exposure group were 2.6 times more likely to have a high HIV viral load than those in the lowest exposure group. Higher viral load translates into higher rates of HIV transmission and the potential for earlier progression to the opportunistic infections of AIDS. 40

Sep/Oct 2013

“Previous studies by our team had looked at the possible interaction of aflatoxin and HIV on immune suppression, and this study examined twice as many patients as previous studies,” said Jolly, the study’s corresponding author. “It also was structured to eliminate factors such as opportunistic infections and antiviral combination therapy in clarifying the relationship between aflatoxin exposure and HIV for the first time.” Leading theories suggest that the fungal toxin may suppress the immune system by reducing the production of certain immune cells or the proteins that activate them. The toxin also may increase the expression of genes that result in more copies of the virus, but more study is needed to confirm the mechanisms. “We have done a series of studies now confirming a link between HIV viral load and aflatoxin exposure, but the problem has not yet been recognised or addressed,” said Jolly, an HIV immunologist who does most of her work in Ghana. “While this study was larger than our previous study, a fungal contribution to HIV transmission will only be proved once and for all by larger randomised studies for which there now is no funding. The scientific and world-health communities need to decide soon whether or not this question is worth answering.”

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Fluidisers for removing powder from silos A common problem when removing powder from hoppers or silos is that the powder can pack down. The finer the powder, the more difficult it can be to remove. Solimar fluidisers offer a solution to this problem. They are suitable for applications including

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difficult-to-handle products like cement, talcum powder, gypsum, flyash, titanium dioxide, calcium carbonate, carbon black, sugar, flour, etc. The fluidiser can be installed totally externally, from the underside of the cone. A 50 mm hole is cut in the hopper and the fluidiser is shaped to pass through the hole, with the use of a trailing lead to keep the fluidiser captive. Silo fluidisers promote the discharge of dry products from storage silos, dust collectors, weigh bins and IBCs. Solimar fluidisers enable a uniform flow of most dry bulk materials through aeration and slight hopper wall vibration that helps prevent common problems such as bridging, rat holing and compacting. Correct installation will enable a regular feed of powder for process work, particularly where a constant flow pattern is desired. Kockums Bulk Systems Contact info and more items like this at wf.net.au/U672

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Sep/Oct 2013

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ALDI adopts new-generation CHEP crate ALDI Australia has adopted CHEP’s new-generation re-usable plastic crate. The Gen 3 crate was developed in consultation with the retailer and was launched at ALDI’s Salisbury store in Brisbane. “The Gen 3 crate is a one-touch solution that will create efficiencies within the ALDI fresh produce supply chain, and in the future will streamline processes and systems for our suppliers given it has the capacity to be a whole-of-industry solution,” said Viktor Jakupec, ALDI Queensland managing director. “The new crate allows products to be packed directly on farm before being delivered to our warehouses and subsequently to stores, which reduces the amount of repacking and speeds up the process. The crate design allows it to fit directly into our new fresh produce display on the shop floor, which means less product handling and therefore a higher level of product quality. “Instead of store staff having to pack products on tables within the produce area, the majority of products will remain displayed within the crates, which will assist with better product rotation and minimise damage to the products through less handling.” The re-usable crates use best-in-class latching technology and are fully compatible with the previous-generation crate and existing infrastructure. “The Gen 3 crate family is a game changer,” said CHEP Australia and New Zealand President Phillip Austin. “It’s not only an industry-wide solution, it offers world-leading return logistics; with a folded height of 25 mm, the Gen 3 outperforms all other crates on the market by up to 29%.” CHEP says both growers and retailers will benefit from the reduced fold-down height, with up to 29% more crates fitting into a truckload than previous-generation crates, meaning fewer trucks will be required to transport an equivalent number of crates when empty. An independent life cycle analysis of CHEP’s re-usable plastic crate system conducted by RMIT in 2010 showed that compared with a single-use corrugated cardboard system, CHEP crates produced 70% less greenhouse gas emissions, used 85% less water and produced 95% less solid waste to landfill, even if the cardboard was recycled. The crate has the ability to cross and column stack on pallets for improved transport stability. It allows for improved cooling/ ripening efficiencies through crate venting. The venting design also makes produce quality inspections easier to conduct. The Gen 3 crate is not affected by coolroom moisture and rain, and produce in the crates can be sprayed and watered as it moves through the supply chain. CHEP Australia Contact info and more items like this at wf.net.au/V032

Sep/Oct 2013

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Cloud-based supply chain planning and optimisation software The Supply Chain Company has announced the release of JDA eight, which brings together more than 30 different products on a single platform, unifying supply chain planning, optimisation and business analytics for deployment in the cloud. JDA eight offers a comprehensive framework to address challenges impacting key business processes across the extended supply chain including forecasting and planning, procurement planning, promotion, transportation management, production planning and scheduling, network and inventory optimisation, and supplier collaboration. The product is designed to deliver business value through innovative supply chain solutions that address the integration problems and long implementation times that can be associated with applications offered on disparate platforms. Delivered in the cloud, JDA eight allows users to make procurement, production, inventory and logistics decisions faster through planning, optimisation and analytics. Its optimisation algorithms and inline analytics better prepare users to respond to market dynamics in real time. Users can increase productivity and effectiveness, the company says, through the use of task-based, cross-functional workflows, configurable by role. The intuitive user interface offers a consistent look and feel, reducing training time and alleviating operational silos. Powered by efficient in-memory processing, JDA eight allows users to realise rapid scenario planning and what-if analysis through an interface that delivers precise, actionable information and analytics to the user in real time. JDA Software Australia Pty Ltd Contact info and more items like this at wf.net.au/T778

Sanitary piston pump Graco has added the SaniForce 2:1 piston pump to its SaniForce line of FDA-compliant sanitary transfer pumps for product evacuation out of drums and bins. With its lightweight, durable construction, the piston pump is portable, weighing 10.8 kg for the standard drum length and 11.7 kg for the extended length. It fits through a standard bung hole and can be easily mounted using the included FDA-compliant bung adapter. The pump can transfer low to medium drums and totes, including food products such as syrups, oils and sauces. It can reach a fluid pressure of 200 psi with continuous duty flow rates from 5.7 L/m at 60 cpm and 9.5 L/m at 100 cpm. All SaniForce models are FDA compliant and meet CFR Title 21.

Force displacement drives FastBack FDX Force Displacement drives are reportedly 40% smaller than comparable inertia drive horizontal motion conveyors and convey up to 1100 kg. This makes the FastBack FDX suitable for transfer runs up to 30 m long, and product accumulation of up to 8.5 m3. Like previous FastBacks, the patentpending FDX inertia drive provides the same clean horizontal motion conveying that reduces product

Graco Australia Pty Ltd Contact info and more items like this at wf.net.au/U515

damage and transmitted vibration The FDX can be re-used with different pans when line layouts change. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U933

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Sep/Oct 2013

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viscosity materials (up to 50,000 cps) from

Oil-free centrifugal compressor range Atlas Copco has launched an energy-efficient centrifugal compressor range which it claims saves up to 7% on specific energy at full load and up to another 9% at part load. Delivered as a plug-and-run package, Atlas Copco’s ZH+ oil-free centrifugal compressor range employs advanced aerodynamics to reduce energy consumption in the core. All components of the package are designed based on computational flow dynamic (CFD) analysis to reduce pressure drops in the package. The result, the company says, is a reduction of specific energy up to 7% at full load compared to the previous model. Inlet guide vanes (IGVs), which are part of Atlas Copco’s standard scope of supply, further reduce energy cost by

BULK

9% at part loads as compared to a throttle valve control. According to the company, as energy consumption constitutes 80% of the life cycle cost of a compressor, the product reduces overall total cost of ownership. The compressors employ features such as milled impellers and servocontrolled IGVs to ensure maximum uptime. The ZH range provides clean air that complies with ISO 8573-1 Class 0 (2010) certification. A fail-safe sealing system prevents the possibility of contamination of the air with oil, without the need of any external buffer air. Oil fumes from the gearbox are captured by a motorised demister, thus eliminating the risk of ingestion of oil fumes along with the intake air. This safeguards the end product against oil contamination. Atlas Copco Compressors Australia Contact info and more items like this at wf.net.au/V039

Desiccant High temperatures and humidity create ‘cargo sweat’ within a container, which in turn can become ‘container rain’. This creates mildew, rust and sodden cartons. As a result, cargo may arrive in a condition not suitable for sale. MBD99 desiccant from Australian Warehouse Solutions can protect container shipments by keeping cargo dry. The clay-based desiccant comes in a variety of sizes to protect shipments as small as boxes or individual pallets, through to full container loads. Australian Warehouse Solutions Pty Ltd Contact info and more items like this at wf.net.au/U685

Sep/Oct 2013

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Supplement producer mixes with the best

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Belgian company Manumixx is a leading private label supplier of food supplements and nutritional products. In 2004, the company was producing around nine tonnes of product per week, with seven operating personnel. Looking to aggressively expand its operations, Manumixx purchased an IBC Blending & Discharge System from Matcon. Within months of the first installation, production levels had reached their limit: 18 operators were producing 70 tonnes of product each week. In 2008, Manumixx installed a second Matcon IBC Blender, allowing further expansion and growth. Within two years, the company had outgrown its existing facility and invested in building a new production facility. The original plant remained in operation so production could continue in parallel. The state-of-the-art new factory, which features a Lean Matcon Powder Handling System, meets the strictest food and hygiene standards. Full traceability is ensured by

electronic recording of all ingredients and process equipment at all times. Automated raw material batching is employed, reducing heavy labour tasks. With the new installation, production output has reached 450 tonnes/month, using only 35 personnel on a single shift. Manumixx says this throughput is achieved without compromising flexibility at any time during the manufacturing process. “Matcon has helped me grow my business with full confidence that I always supply a top quality mix to my customers,” said Manuel Peralta, general director of Manumixx. Matcon Pacific Pty Ltd Contact info and more items like this at wf.net.au/U963

System-wide automation development software ABB has launched an engineering development tool suite for industrial automation projects. Automation Builder provides an integrated development environment for control and motion systems based on PLCs, safety PLCs, robotics, motion control and related automation components. Combining all of the tools required for configuring, programming, debugging and maintaining automation projects from a common intuitive interface, Automation Builder addresses the largest single cost element of most of today’s industrial automation projects: software. Automation Builder builds on the company’s Control Builder Plus tool for programming PLCs. This provides PLC development resources in the form of the standards-compliant CoDeSys IEC 61131-3 development environment and the Panel Builder tool for creating HMIs. These are now complemented by tools for configuring and programming the latest generation of safety PLCs, and the RobotStudio tool for simulating and programming industrial robot applications, as well as Mint WorkBench and pre-built and tested libraries for controlling drives, and other devices connected via fieldbuses, networks or the web. The suite integrates all these capabilities into a single environment served by common data and intuitive user interface. This provides data consistency that eliminates the need to enter data multiple times. It also avoids the programming effort and issues associated with exchanging data between the controller and all of the various devices in the automation system. These devices include servomotor drives, robot arms, operator panels and I/O. Third-party devices can also be interfaced into the environment. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/U429

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Sep/Oct 2013

High-speed roll door High-speed roll doors are becoming significantly more essential in food processing areas, used to maintain a high level of atmospheric control and minimising contamination of product. DMF supplies the Efaflex STR High Speed Door, which it claims is the fastest in the world, with an option to open at 4 m/s.

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The doors are custom manufactured in Germany by Efaflex and can be made to suit openings of up to 6 x 7 m. The door panel is a polyester reinforced coloured PVC with extensive windbars that provide the door with high wind exposure capacity of about 140 km/h. The door rolls around a spiral design meaning the panel does not roll onto

Layer palletiser BEUMER has re-engineered its high-capacity layer palletiser, the BEUMER paletpac. In re-engineering the paletpac 2500, the company has exchanged the lifting frame for four chains with a counterweight, reducing the machine’s weight and minimising the energy required for the lifting movement. The pallet is now pulled up by the chains. Previously, a large hoist drive was needed for the system; the re-engineered model has a mall motor operating as a servo drive. According to the company, this results in further weight reduction, less maintenance and lower costs for the user. The frame of the palletiser head has been downsized, saving on material costs and providing better access to the machine. The external frame elements can be

itself, resulting in a very quiet action. This model includes the ACS (Active Crash System) feature, providing a fully automatic repair system if the door blade is impacted by a forklift. While the top speed means impact is unlikely, the ACS provides additional protection. Many options of activation and safety sensors are available to enhance the performance of this door. DMF International Pty Ltd Contact info and more items like this at wf.net.au/U548

Experts in product movement EZSplice™

Ladder Belt folded, meaning the whole palletiser head fits into one transport container. The palletiser head does not need to be dismounted, reducing transportation costs and shortening the assembly period. BEUMER engineers have modified the guides for the

Wirebelt is the leading manufacturer of stainless steel conveyor belts for product handling and processing. Manufacturing range includes Flat-Flex , Eye-Flex , Compact Grid™, Honeycomb and Spiral Woven Mesh. Wirebelt - for conveying, cooking, cooling, covering, drainage, heating and drying applications. ®

pallet side plate, introduced a lateral guide system, changed the drive performance and decreased the system width. Users can quickly and easily adapt the palletiser to different pallet sizes without the use of tools. The paletpac palletises bags up to a pack height of 2400 mm, in all technically possible packing patterns and on any commonly used pallet size, including intermediate sizes such as 1400 x 1200 mm. A multiprogram enables the user to set parameters easily and quickly. The paletpac can also be supplied with a bar-type turning device or with a newly developed twin-belt turning device to position the filled bags quickly, ensuring their dimensional stability.

Honeycomb Belt

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Sep/Oct 2013

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The paletpac can palletise paper, polyethylene and polypropylene bags at a rate of up to 2500 bags/h. BEUMER Group Australia Pty Ltd Contact info and more items like this at wf.net.au/U532

Beer is booming - 2 billion hectolitres to be sold worldwide in 2013

Growth in volumes is expected to continue to be a feature of the global beer market for many, many years to come, according to market researchers. The simple reason is that worldwide per-capita consumption is still below 30 L.

eer is continuing to boom with the world beer market set to exceed 2 billion hectolitres for the first time ever in 2013. The growth is not even all over the world, but even regions where the beer market is stagnating or shrinking new and interesting opportunities still abound. Canadean, for example, is predicting that between 2009 and 2015 the world beer market will have grown by 2.8% per year on average. For Asia, Canadean is forecasting an annual average increase of 5% for the same period. These British market researchers also predict an annual rise of 5% for the African beer market, 3% for South America and 5.5% for the Middle East. For Eastern Europe their forecast is a rise of only around 1.5%, and, for North America, even

lower, at only 0.5%. For Western Europe, Canadean is even predicting a small decline. As growth hotspots, they have identified Kazakhstan, Vietnam, Angola and India, some of which will see double-digit increases.

China soon to represent one quarter of the world beer market The market researchers at Euromonitor come to similar conclusions. In the period from 2011 to 2016 they are expecting the strongest expansion, with rates of around, or even higher than, 10% in India and Iran. The fastest growing volume markets, they predict, will be China and Brazil, both growing at around 5% per year. However, the markets in the US, Russia and Germany, they say, will probably shrink by around 0.5 to 1.5% per year.

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Sep/Oct 2013

This shows therefore that the consumer is basically

This strong growth in the Asian markets, says Canadean, means that in 2015 around 40% of the world’s beer output will be brewed in this region. For many years now the Asian market has been dominated by China, which Euromonitor sees as reaching 624 million hectolitres by the end of 2015. In other words: in just a few years’ time, China will be accounting for at least one quarter of the world beer market and it will then be at least twice as big as the number two, the US.

cub g/profile/leo © stock.xchn

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willing to spend more on beer.

USA demonstrates the potential of craft brewers For some time now the US has been demonstrating the power of specialist beers - the ‘craft brewers’ movement started out there and has been very popular. According to the Brewers Association, in 2012 this segment saw volumes increase by 15% and monetary value by 17%. In 2011, the rises were 13 and 15% respectively. In total, the craft brewer segment in the overall US beer market in 2012 accounted for 6.5% by volume and 10.2% in monetary value. This success story is even more notable when you consider the number of brewing facilities in the US: in the 1970s there were only 89 in the entire country, but now that figure is 2403 - with 2347 of them being brew pubs, microbreweries or regional craft breweries.

Germany: faint blossoming of interest in specialty beers In the stagnating or shrinking traditional beer markets, such as the US and Germany, there is, however, an interesting trend: the increase in craft beers and specialty beers. According to GfK ConsumerScan, beer demand in German households fell by 0.2% in 2012. The value of beer purchases, by contrast, rose by 0.4%. This shows therefore that the consumer is basically willing to spend more on beer, a theory supported by the development in the price classes for 0.5-litre returnable beer crates, according to statistics gathered by GfK. The only clear increase in a year-on-year comparison 2011/2012 was seen here in the €13 and over segment, from 13 to 16%. Admittedly, this is only a faint blossoming, the German market in 2012 having, in fact, trended downwards. According to the German Federal Statistical Office (Statistisches Bundesamt - Destatis), year-on-year beer sales fell by 1.8%, or 1.8 million hectolitres to 96.5 hectolitres of beer. There was no end to this trend in 2013, either: in the first quarter German beer sales dropped a further 4.3% as compared to the same period last year.

See it all at drinktec The world beer market - interesting for its increasing segmentation - will be covered in full at drinktec 2013, from micro to global brewers, and right across the spectrum from raw materials and process technology to packaging and marketing. 50

Sep/Oct 2013

The new Innovation Flow Lounge (IFL) in which attention focuses entirely on marketing, is looking at the subject of beer in its program for the first day of the show. IFL partner Krones is sending its expert Charles Schmidt to talk about ‘The power of social media’. And ‘With hops to the top’ is the title of a talk by Stephan J Barth, Managing Director of the Barth-Haas Group. The first day of the show in the drinktec forum will be dedicated to beer. ‘German beer - fit for the future? Risks and chances’ will be the question posed by Peter Hahn from the Deutscher Brauer-Bund. Small and medium-sized companies should make a note of the lecture by Jürgen Nordmann from Störtebeker Braumanufaktur, who will be speaking about ‘Strategy options for medium-sized breweries in a declining beer market’. On the second day of the show, the winners in the ‘European Beer Star’ competition, one of the world’s most prestigious beer awards, will be offered for tasting. And on the Sunday before drinktec opens, the World Beer Sommelier Championships will be held and the winner crowned in the exhibition halls in Munich. Also at drinktec 2013, there are two more hotspots for brewers from all over the world: The Brewers Meeting Point, held in Hall B1 in cooperation with the Bayerischer Brauerbund. One of the attractions here is the chance to take part in exclusive beer samplings. The other hotspot is the Craft Brewers Lounge in Hall A5. Here, European brewers can meet up with and talk to members of the US Brewers Association. All of which adds up to many good ‘beery’ reasons to visit drinktec 2013! At drinktec, manufacturers and suppliers from all over the world - global companies and SMEs alike - meet up with all sizes of producers and retailers of beverages and liquid food products. At this event, manufacturers present the latest technology for processing, filling, packaging and marketing all kinds of beverages and liquid food - raw materials and logistics solutions included. The themes of beverages marketing and packaging design round off the portfolio. drinktec 2013, which took place at the Messe München exhibition centre in Munich, from 16 to 20 September 2013, was expected to attract over 1400 exhibitors from over 70 countries and approximately 60,000 visitors from more than 170 countries.

www.foodprocessing.com.au

Make the unpredictable totally predictable.

Swagelok® Pressure Regulators are now an even better choice for all your pressure regulator needs. Why? Well, alongside our proven experience and expertise, our range now covers sizes from 1/8 to 4 in. and all your regulator needs – high-flow capability, two-stage, back-pressure and vaporizing models. With our regulators you get accuracy, sensitivity and pressure stability. In short– total predictability. Exactly what you would expect. Visit swagelok.com/pressure.

Non-toxic grease Safe for incidental food contact and NSF H1 registered, STELLA Clear 2 is available from Food Grade Oils. Clear 2 is a non-melting and non-toxic grease which is suitable for lubricating plan and rolling element bearings, plastic

PROCESSING

components and O rings.

Multihead combination weighers Multiweigh combination weighers, available from Perfect Packaging, The product’s resistance to moisture and salt water enable lubrication intervals to be extended, according to the company. The inclusion of PTFE provides good antiwear properties, which may prolong component life. It offers good resistance to vibrating conditions and is

are suitable for precise and fast weighing of products ranging in size from granulates to large and bulky products. They are suitable for almost all food products: dry, fresh or deep frozen, snacks, crisps, confectionery, fresh salad and vegetables, frozen products, seafood, pet foods, and technical and pharmaceutical products.

suitable for a wide temperature range.

The weighers provide full statistical data on the screen. The

Food Grade Oils Contact info and more items like this at wf.net.au/U938

data can be transmitted to a host computer using the floppy drive integrated in the display or by network communication. The multihead weighers have automatic control of product infeed; the product level on the central cone is controlled by a central load cell. Product infeed systems can be directly linked.

Small-diameter lockouts Master Lock has launched a range of safety padlocks, hasps and lockout cables designed to fit smaller-diameter

Perfect Packaging Contact info and more items like this at wf.net.au/U851

lockout points. Designed for lockout/tagout, the S31 safety padlock has a durable non-conductive Zenex lock body and a 4.76 mm marine-grade 316 stainless steel shackle. Available in nine colours, the lightweight safety padlock is easy to carry and comes with a weather-tough cover designed to keep out dust, dirt and grime. It also performs well in extreme conditions with a temperature rating range of -46 to +177°C and the ability to withstand harsh chemicals and corrosion. When work is being undertaken by more than one employee, it is vital that a lockout hasp is used. In response to industry needs, the company has developed the S430 and S431 hasps to fit smaller lockout points. The S430 is a compact, lightweight lockout hasp that has a 4 mm diameter steel shackle

waterproof power, signal and digital (USB or ethernet) connectors. With an easy-to-use, patent-pending push-pull latching mechanism, combined with a 30° twist lock, the 6000 series is claimed to connect up to 10 times faster than a traditional screw-thread mechanism. The series is designed to withstand harsh environments and meets IP66, IP68 and IP69K standards. constructions, the body mouldings and pin carriers

plastic body that closes like a book

have been specifically designed to create a robust

and accepts two lockout hasps. The

interface while avoiding damage during coupling. This

S431 is suitable for highly corrosive

is said to guarantee a correctly sealed connection,

environments as it is constructed

even where access is restricted.

from marine-grade 316 stainless steel. The S806 is a multipoint lockout solution that measures 4 x 1.8 mm. To use, simply feed the cable through the points to be locked out, then back through the lockout body, cinch

The adaptable connectors are suitable for a range of applications, from industrial automation to food processing. Walcom Pty Ltd

it tight and apply a safety padlock.

Contact info and more items like this at wf.net.au/U463

Mayo Hardware Australia Contact info and more items like this at wf.net.au/U477

Sep/Oct 2013

Bulgin has released the Buccaneer 6000 Series of

Available in fully interchangeable metal and plastic

to fit these applications. The S430 has a

Waterproof power, signal and digital connector series

www.foodprocessing.com.au

PROCESSING

Heat-resistant chocolate for hot summer days ©iStockphoto.com/dibrova

Chocolate in summer is always problematic - regular chocolate melts at 34°C and it is 38°C in the shade. The chocolate has melted in its packaging before it has even been unwrapped. But Canadian researchers may be coming to our rescue as researchers in the University of Guelph’s Department of Food Science are developing heat-resistant chocolate.

n hot climates, it’s especially difficult to keep chocolate from melting during transportation. “India is the big market that the chocolate companies are going after right now,” says Terri Stortz, a PhD student in food science working with Prof Alejandro Marangoni. “What we’re aiming for with heat-resistant chocolate is for it to hold its shape or resist deformation at 40°C,” says Stortz. “But the problem is that you still want the fat to melt at 34°C, because body temperature is 37°C. That’s why chocolate is so desirable - and that’s why people like it - because it melts in your mouth.” Increasing the melting point of the fat can result in chocolate with a waxy texture. To overcome this, researchers are developing a ‘secondary structure’ that would allow the fat to melt while keeping the chocolate together. “There aren’t any heat-resistant chocolates on the market right now,” says Stortz. The product being developed in the lab would probably cost slightly more than those currently on the market, she says, because of the additive (ethyl cellulose) that helps the chocolate keep its shape. A chemical process replaces some of the hydroxyl groups in cellulose with ethyl groups to make it 54

Sep/Oct 2013

oil soluble. Ethyl cellulose dissolves in oil at high temperatures; when it cools down, it creates a gel that behaves like solid fat. The ethyl cellulose interacts with the non-fat solids in chocolate, which include 50% sugar and 20% cocoa solids and milk proteins. The remaining 30% is fat. “The ethyl cellulose is sort of a glue between the solid particles and it creates this network within the chocolate that physically traps the fat,” says Stortz. Although the solids wouldn’t melt at body temperature, she adds, they would dissolve when they came into contact with saliva, because of their solubility in water. How does heat-resistant chocolate taste? “It tastes a little bit different,” she admits, but most consumers probably wouldn’t notice. Ethyl cellulose typically lacks flavour but it depends on how it’s manufactured. Chocolate can be modified in many ways, she adds, so the slight change in flavour can easily be addressed in the lab. As for baking applications, she doesn’t recommend using heat-resistant chocolate in recipes that require melted chocolate. “I wouldn’t make a fondue out of it.” Stortz received two grants from the Natural Sciences and Engineering Research Council of Canada.

www.foodprocessing.com.au

Britannia rules the public sewerage system

Switched mode power supply units with IP67 protection

The D15-76 monitor has enabled Britannia Food Ingredients to realise turbidity measurements down to 0.001 nephlometric turbidity units (NTU) and as high as 4000 NTU, eliminating the need for separate high and low ranges. Britannia Foods Ingredients has found the pH and turbidity monitors to have overcome challenges associated with sensor fouling and are reliable, accurate and low maintenance. “Both monitors have enabled us to comply with the stringent trade-effluent consent criteria outlined by Yorkshire Water, providing reliability and giving us peace of mind that our effluent will not negatively impact upon the environment or the sewerage system,” said Richard Stockdale, Operations Manager at Britannia Food Ingredients. “In addition to this, we have found the Analytical Technology instruments and controllers to be extremely easy to program and set up, with the whole implementation process taking less than two days.” Hydramet Pty Ltd Contact info and more items like this at wf.net.au/T347

Compact analog pressure sensor

For users requiring a 24 V power supply directly in the field, Turck has introduced the

imf efector’s PQ series pressure sensor with analog

PSU67 series of switched mode power supply

and switching output has been designed for efficient

units with IP67 protection.

compressed air control or filter monitoring. The sen-

A large amount of expensive cabling with large cross-sections is required if the field device and the control cabinet for

sor measures both relative and differential pressure. The sensor is suitable for condition-based

the plant are large distances apart. The use of power supply units with

maintenance, such as when a

IP67 protection is suitable for these instances, since they supply a 24 V

filter is exchanged or leakage is

power supply directly in the field without any voltage drop.

detected by pressure loss.

Due to their degree of protection to IP67, the PSU67 power supply units

The coated silicon measuring

can also be fitted directly to the machine without any protective measures.

cell is claimed to guarantee high

The power supply units offer a high level of failsafe performance, thanks

overload resistance and an ac-

to their no-load and short-circuit protection as well as passive air cool-

curacy of ± 0.5%. The coating

ing. The devices also automatically bridge voltage dips of up to 50 ms.

protects the measuring cell from

The devices’ efficiency ensures a good energy balance of up to 90%.

air humidity and condensate.

The AC/DC wide range input and an ambient temperature range from

The parameter setting can be

-25 to +60°C make the power supply units suitable for worldwide use.

carried out via two pushbuttons or

They feature a voltage output with a 4-pin 7/8″ connector. LEDs indicate

IO-Link interface. The compact sensor

the actual operating state to the user. Four variants are available: 2, 4 and 8 A variant, each with one output, and a variant with two 4 A outputs. The power supply units are compliant with the requirements of EN 60950-1 and the cULus and CE approval. Turck Australia Pty Ltd

PROCESSING

Formed in 1966, Britannia Food Ingredients produces a range of specialty fats for the chocolate, confectionery, biscuit and snack food industries. Like all manufacturing companies, Britannia Food Ingredients’ trade effluent that enters the public sewerage system must comply with strict regulation. The company’s trade effluent is handled by Yorkshire Water, which issues trade effluent consents relating to the rate and maximum volume of the discharge, the temperature of the discharge and where the discharge may be made. The conditions of a trade effluent consent are set for a number of reasons, including preventing the corrosion of sewer fabric, overloading of sewers and possible flooding of properties, blockage of sewers and hazardous situations involving employees conducting maintenance within the sewerage system. In order to comply with its trade effluent consent and ensure protection of human health, Britannia Food Ingredients selected Analytical Technology’s Q45P AutoClean pH monitors and D15-76 monitor with an Air Blast AutoClean system to indicate water quality and the presence of suspended solids in its wastewater stream.

offers an analog output and a switching output, both of which are configurable. ifm efector pty ltd Contact info and more items like this at wf.net.au/U401

Contact info and more items like this at wf.net.au/T626

www.foodprocessing.com.au

Sep/Oct 2013

PROCESSING

Upgrade improves throughput, accuracy and quality

Introducing Ishida equipment has paid off for throat lozenge manufacturer Ricola AG, reducing product breakage during packaging, increasing throughput and minimising giveaway. The company found it needed to move a line that packed 100, 250 and 400 g tins in its factory in Laufen, Switzerland, due to expansion of other activities in the factory. Ricola used the opportunity to upgrade the line, asking Ishida to develop a solution that would improve quality by reducing the level of product chipping and breakage. Original Ricola herb drops weigh 4.2 g each and contain a special blend of 14 herbal extracts, including marshmallow, peppermint, thyme and sage. Each lozenge is cut from a warm filament, leaving two ridged surfaces which, on cooling, present many brittle facets. While this method gives each lozenge its distinctive appearance, the pieces are easily damaged by collision with other lozenges or metal surfaces. On the new line, product arrives via a conveyor, which is equipped with a suction system to remove dust and debris. It then runs via an elevator to the top of the 12-head Ishida weigher. The multihead weigher is designed with short drop distances, while the discharge chute is divided into sections to minimise product swirling and reduce collisions. The weighed product passes via timing hoppers and chutes to a special filling station, where the tins arrive on a carousel to be filled two at a time. They then move on for lidding and overprinting with batch data. The new line packs 100 g tins at 140 packs/min, 250 g tins at 110 packs/ min and 400 g tins at 90 packs/min. Ricola says this represents an increase in throughput of 20% across all packing formats. At the same time, the accuracy of the weigher means product giveaway is very low: just 1.5 g (or less than one third of the weight of a single lozenge) for the 250 g tins, for example. The upgrade also addressed cleaning downtime. The new line complies with IP66 standards, enabling it to be conveniently hosed down rather than individual parts having to be removed for cleaning. A feature unique to Ishida products makes this possible: a positive pressure maintained in the body of the weigher renders it watertight. Ricola says it has experienced a sharp decrease in breakage debris and more ‘perfect’ lozenges per tin than ever before. Daniel Bhend, the company’s technical and engineering manager, says the investment in the new packing line has been “a success in every respect”.

Reduced temperature foam cleaning program Ecolab’s Advantis FC Cleaning Program is a high-foaming, chlorinated alkaline cleaner formulated for use with reduced-temperature water. It provides food and protein processing facilities with good cleaning performance against protein and fat soils on stainless steel processing equipment and plant environmental surfaces. Previous processes required sanitation water to be heated to temperatures as high as 62°C; Advantis FC effectively cleans protein and fat soils at temperatures as low as 40 to 43°C. The program may improve cleaning performance in plants that cannot achieve or maintain high water temperatures throughout the sanitation shift. According to the company, the program decreases water-heating costs and the refrigeration costs necessary to return production areas back to the appropriate temperatures. The company claims the product reduces the overall downtime for the sanitation shift and may save users up to one hour per day of cleaning time. The program may improve employee safety conditions by reducing poor visibility due to condensation and reducing the potential for scalding injuries.

Heat and Control Pty Ltd

Ecolab Pty Ltd

Contact info and more items like this at wf.net.au/U974

Contact info and more items like this at wf.net.au/U573

Sep/Oct 2013

www.foodprocessing.com.au

Sweet Only Wonderware MES software provides dependable consistent quality and safety without sacrificing flexibility. For more information, visit wonderware.com/MESQuality and get a free whitepaper called “Be ready for changing tastes, a new approach to plant software”.

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© Copyright 2012. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.

Australian food and drink market report Business Monitor International (BMI) has published the

PROCESSING

External mix spray nozzles

Australia Food & Drink Report, which analyses food, drink and mass grocery retail markets, and gives forecasts for market performance in 2013 and beyond.

Exair’s External Mix Spray Noz-

The report provides key sub-sector analysis and forecasts

zles atomise fluids in a range of

to end 2017 for food and drink by expenditure, sales, con-

spray patterns for a variety of

sumption, imports and exports, allowing food and beverage

uses. The nozzles are suitable

industry stakeholders to benchmark industry views and

for applications where a high

improve budgetary and business development planning.

volume of liquid is needed.

It offers evaluation of macroeconomic data, a detailed

They can be used on liquids

macroeconomic outlook and growth factors in Australia

with a viscosity up to 800 cP.

across nominal GDP growth, real GDP growth, population,

The nozzles are available in a round or flat pattern. They combine liquid and compressed air to create a coating of liquid that can be adjusted to meet the needs of different applications.

industrial production index and unemployment. The report also includes competitive landscape tables and company profiles including SWOTs, KPIs and activity,

With the company’s external mix atomising nozzles, the user can coat, cool, treat and paint a variety of products. Used with water, atomising nozzles

which may enable manufacturers to exploit competitive intelligence on competitors, partners and clients.

are an efficient way to evenly cool hot items in automated processes. Since

Also included are business environment ratings that

they are external mix, airflow and liquid flow can be controlled independently.

clearly compare the strengths and weaknesses of Australia

which provides the most precise liquid flow, according to Exair.

against its peers to enhance risk management.

The stainless steel construction of these nozzles adds to their durability and corrosion resistance. Internal mix and siphon fed atomising nozzles

Business Monitor International www.businessmonitor.com

are also available, as well as no-drip versions. All models are adjustable. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/U599

Stainless steel industrial keyboard Interworld Electronics has released the PM-102-SS NEMA 4X, IP66-specification, panel-mount stainless steel industrial keyboard from iKey. The keyboard has 101 stainless steel keys that include 12 function keys and a numeric keypad, a stainless steel bezel

Multiturn encoder

and integrated touchpad. The durable PM-102-SS is completely sealed and designed

The robust and compact RM9000 multiturn encoder

to meet NEMA 4X and IP66 specifications. It can operate in

from ifm efector is designed for use in mobile ap-

temperatures ranging from -20 to +60°C. The bezel measures

plications. The encorder converts 4096 revolutions

449.6 x 229.1 x 40 mm. Rear stud mounting bolts are provided

into one absolute position value.

for panel mounting.

The gear-free system uses the Wiegand effect to

Stainless steel is known for its longevity, corrosion resistance

keep the position values stored in case of a power

and ability to retain strength in extreme temperatures. It is also

failure without battery buffer and to pass the exact

low maintenance and easy to clean. These characteristics

position on to the controller without referencing. The

make stainless steel a suitable material for keyboards used

multiturn encoder can be easily connected to the CAN

in industrial and food-processing applications.

bus of the external electronics via M12 connector.

The keyboard is available with PS/2 or USB interface cables

The high protection rating of IP68/IP69K is claimed

and is compatible with all Windows operating systems.

to offer superior performance in harsh environments

Interworld Electronics and Computer Industries

and the EMC requirements to e1 type approval.

Contact info and more items like this at wf.net.au/U852

ifm efector pty ltd Contact info and more items like this at wf.net.au/U416

Sep/Oct 2013

www.foodprocessing.com.au

Wedeco Spektron-e Shining new light on Drinking Water Disinfection. New UV systems fully validated to ONORM, DVGW , or USEPA for up to 4 log inactivation of Cryptosporidium, bacteria, viruses for the food industry. Power cost can be as low as 0.4 cents per 1000 liters thanks to the new Wedeco Ecoray速 UV lamps.

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

PROCESSING

Faster pasta for supermarket chain

Roundy’s supermarkets is a well-known group of 160 retail stores and 88 pharmacies throughout Wisconsin, Minnesota and Illinois, with annual sales topping US$4 billion. Since 2007, Roundy’s has relied on a chain-driven, semicontinuous conveyor batch process system for cooking and cooling its pasta and potatoes for fresh soup and salad products. Unfortunately, these systems have many drawbacks. “With our potatoes, the wedges and slices did not cook well,” said Mario Jedwabnik, Vice President Manufactured Foods at Roundy’s. “They would stack up, and the steam penetration was insufficient to cook through the layers, so some potatoes were undercooked. Cooling them down was another problem. We could not get enough water on the potatoes to cool them evenly. “But pasta was a nightmare for us. Our conveyor baskets were 40 x 91 cm, and the pasta tended to compact into them like a paste during the cooking and cooling processes. There was not enough circulation of water through the baskets to keep the pasta separated.” Roundy’s was plagued with excessive downtime of around 30% due to problems like conveyor chain breaks and baskets becoming separated from the chain and jamming inside the cooking and cooling chambers. Whenever this happened, the unit needed to cool down and be taken apart, repaired, re-welded, cleaned and restarted. Changeover times between potato cuts or pasta varieties took about 60 minutes. Changeovers from pasta to potatoes, which required cleaning the system, took 2.5 hours. Roundy’s was processing 300 kg/h potatoes and 450 kg/h pasta, but this was not enough to keep up with demand. The company researched a number of systems that could handle its throughput needs. One was a new continuous rotary cooking and cooling design from Lyco Manufacturing. “We visited the Lyco plant in Columbus, Wisconsin,” said Jedwabnik. “We discussed options with their engineers

Sep/Oct 2013

and subsequently tested our potato and pasta products through Lyco’s cooking and cooling equipment at their on-site test lab. The speed of processing and the quality of the finished product impressed us.” In 2011, Roundy’s selected a Lyco Clean-Flow continuous-flow cooker and cooler system to process its potatoes and pasta. The Clean-Flow cooker was backed up by a CleanFlow cooler, capable of moving 907 kg/h of potatoes or pasta - a 300% and 100% increase respectively compared to the company’s existing machinery. The continuous-process cooker/ cooler uses an auger to control product retention time, while a water-injection system called Hydro-Flow agitates the product and holds it in suspension through an enclosed water-filled screen. The Roundy’s system uses two enclosed continuous Clean-Flow units - one for cooking and one for cooling. The machines have internal augers to control dwell time in a wedge wire basket. The auger flights do not drag the product through the cooker and cooler system; rather, product is carefully agitated while suspended in water as it advances through the auger and basket assembly. Damage to potatoes and fragile pasta products is less than 1%, Lyco says. The cooler runs at 10-15°C, which stops the potatoes or pasta from further cooking. This improves the product consistency and gives a better quality product than what Roundy’s had with its previous conveyor batch process system. Clean-up time was reduced from 2.5 hours to 45 minutes, as the auger is completely exposed for cleaning. By early 2012, Roundy’s experienced a dramatic increase in demand, exceeding capacity of its 12-month-old cooker/ cooler system. “We went back to Lyco’s engineering team to re-evaluate our needs,” Jedwabnik said. “We emerged with an upgraded Clean-Flow system capable of processing 1360 kg/h potatoes per hour and 1580 kg/h pasta, which is significantly more than our previous system.” In fact, the new system can process more than 400% more potatoes and more than 300% more pasta per hour than Roundy’s’ original conveyor batch system, with virtually zero product defect and near-zero downtime from malfunction. “Aside from the sizeable increase in throughput volume, the product coming out of the new Clean-Flow cooker/cooler is consistent,” Jedwabnik said. “We are very pleased with the system’s performance.” Lyco Manufacturing www.lycomfg.com

www.foodprocessing.com.au

Integrated safety solutions at your doorstep When it comes to safety, NHP combine expert people with an extensive range of products and services from leading global suppliers to deliver integrated, valueadd solutions. It’s all a part of our customer promise to be easy to do business with. In addition to these partnerships including Rockwell Automation and the Allen-Bradley® range, our IECEx certified Hazardous Area Workshop offers the ability to customise solutions to suit project specific application. Bringing together individual safety components, NHP has the knowledge to design integrated solutions that offer increased control across your operations.

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Calling upon our safety team which includes TUV certified experts, we can also offer a range of services and training opportunities to ensure you are up-to date with the ever evolving machine safety industry. For increased convenience, this same team can also provide onsite consultation and risk assessments for site specific applications. If you’re looking for an advantage when it comes to safety, the safe choice is NHP. For more information on our On Tour programs please visit nhp.com.au/Media/Events/On-Tour

EASY TO DO BUSINESS WITH

Web-based software application for foodservice operations FirstCarbon Solutions and Compass Group have launched the software

Scroll air compressors Depending on the size (2.2 to 22 kW), Hitachi scroll compres-

PROCESSING

sors have one to four heads.

tool being used to support Compass Group’s Carbon FOODprint toolkit. This web-based tool, powered by FirstCarbon Solutions, is designed to help lower environmental impact and operational costs.

Each compressor head consists of an oil-free compression

An easy-to-use toolkit, Carbon FOODprint allows chefs and man-

chamber with a scroll element generating compressed air. In

agers to create customised strategies to reduce their operations’

the event that one of the compressor heads is taken offline, the

carbon footprints by decreasing waste disposal and energy and

machine is able to continue operating with the remaining heads.

water use. Foodservice managers can make up to 185 strategic

According to the company, this design extends the scroll life.

choices across five key areas, including menu engineering, kitchen

Hitachi scroll compressors offer two modes of operation:

operations, kitchen services, site equipment and facilities.

standard pressure control, which is

Developed by FirstCarbon and hosted as part of its Sustainability

similar to conventional pressure switch,

Workbench platform, the web-based software application is an in-

and multidrive mode. Under pressure

tegral part of the Carbon FOODprint toolkit. This online technology

switch control (P-mode), the compres-

allows cafes to benchmark and measure the improvements made

sor stops operating when reaching the

throughout the cafe, which can be shared with clients for annual

maximum pressure and restarts when

reports, sustainability indexes and disclosure to public programs

the pressure drops to the specified

such as the Carbon Disclosure Project (CDP). As part of the design and collaboration, FirstCarbon collected

recovery pressure.

thousands of pieces of data on the production, packaging and

In multidrive mode, operation of

transport of individually purchased food items, serving materials

the compressor heads is modulated

and cleaning chemicals required to manage a foodservice operation

automatically, matching air supply to

“from cradle to customer.” The company coupled this information

the need of the compressed air. The delivery pressure is controlled by the quantity of the working heads, meaning that pressurising to the maximum pressure is not necessarily required and energy is saved. For example, a 15 kW unit, running at 50% capacity, will use 36% less energy compared to unload type. Scroll compressors can be installed flush on the back and

with site-specific operational data from individual cafes to provide up-to-date dashboards on the carbon, energy, water and wastes associated with all aspects of a foodservice operation (facilities, kitchen operations, kitchen services, and menu engineering). FirstCarbon Solutions www.firstcarbonsolutions.com

right-hand sides, saving space. They output little noise and vibration; according to the company, the scroll compressor is as loud as a person talking or whispering, depending on the size. The oil-free operation gives better air quality and means used oil disposal is not required. In selected models, the option of 1 MPa discharge pressure is available. Hurll Nu-Way Pty Ltd Contact info and more items like this at wf.net.au/U887

Food-grade lubricant starter kit Food Grade Oils is offering a STELLA Food Grade Lubricant Starter Kit. Each kit includes: WD Spray, which displaces water, penetrates, lubricates and is anti-corrosive; Spray Grease, a grease with a wide temperature range; Chain Spray, a waterproof chain and rail lubricant; and Anti-seize, which prevents bolts seizing and extends equipment life. All products are NSF H1 registered and safe for incidental contact with food. Food Grade Oils Contact info and more items like this at wf.net.au/V029

Sep/Oct 2013

www.foodprocessing.com.au

HAPPY MACHINES FOR SAFER FOOD

Improving Efficiency, Performance and Quality â&#x20AC;&#x201C; Safer Food with CASSIDA food grade lubricants The CASSIDA portfolio covers a full range of food grade lubricants including speciality oils and greases. Our products fulfil the highest safety and quality standards and are registered by NSF International and certified according to ISO, Halal and Kosher standards. The performance of CASSIDA lubricants, coupled with FUCHSâ&#x20AC;&#x2DC; expert knowledge and service support, allows plant efficiency to be increased, maintenance costs to be reduced and the level of food safety to be improved. Get to know the CASSIDA food grade lubricants for Happy Machines at fuchs.com.au or Free Call Australia 1800 1800 13.

©iStockphoto.com/Ben6

Flame pasteurising sizzles A breakout solution for pathogen control increases safety and productivity of onions and other vegetables Flame pasteurisation - the flash roasting of vegetables over an open flame system - is now bringing breakout cooking efficiencies while reducing yield loss for processors who prepare onions and vegetables. Moreover, the effects of pasteurisation are providing important new levels of food safety, which has been a growing issue in this food category.

“T

here has been a lot of concern in recent years about produce safety when it comes to field-grown vegetables,” says Dr Peter Muriana, a food microbiologist at Oklahoma State University (OSU) in Stillwater, Oklahoma. “But the presence of these pathogens on vegetables and produce is not surprising; it’s really not news because many of the pathogens that cause outbreaks, such as Salmonella and Listeria, are enteric pathogens which can colonise in the intestinal tracts of domestic or wild animals, birds, amphibians and reptiles, and are readily shed in their faeces in the fields where the vegetables grow, or find their way into water retention ponds used for irrigation. So, the exposure of plant life to these pathogens is quite common and not an unexpected occurrence.” Dr Muriana was recently involved in a project to test for surface pasteurisation of whole onions to eliminate potential pathogen contamination on post-harvest onions. “Onions are a highly popular ingredient in many processed foods and therefore deserve thorough consideration when it comes to food safety,” said Adam Cowherd, Sales Manager of food processing equipment manufacturer Unitherm Food Systems (Bristow, Oklahoma). Because the potential for pathogen contamination of onions and other vegetables occurs on the outer surfaces, the OSU study concentrated on the flame pasteurisation of onion skins via 64

Sep/Oct 2013

Unitherm’s Flame Grill, a small-footprint system that individually quick flames (IQF) products such as vegetables and proteins. The OSU study concluded that, using the flame grill, nearly a 5-log reduction of indigenous bacterial contamination was obtained, as well as a 4-log reduction of yeast and mould (below level of detection after processing), and a 6-log reduction of inoculated Listeria innocua. Use of the flame grill for pasteurisation also minimises yield loss of onions and other vegetables. Cowherd says that field tests showed that conventional mechanical peeling of whole onions resulted in an average of about 30% loss of the onion, whereas those processed on the flame grill lost an average of only 3%. “The flame process burns off only the paper-like layers on the surface of the onions,” he explained, “which makes the removal of only the skin portion quite easy compared with the traditional mechanical peeling method, which causes quite a bit of yield loss and does not totally eliminate the potential for pathogen cross-contamination.” Flame grilling is also highly useful in the pasteurisation and peeling of other vegetables, such as capsicums. Cowherd says that, in many instances, yields are significantly improved and energy efficiencies are increased over mechanical methods. Reactive Engineering Pty Ltd Contact info and more items like this at wf.net.au/T988

www.foodprocessing.com.au

Turning wastewater into green energy

PROCESSING

Sugar cane, the world’s largest crop, is grown in more than 90 countries with a worldwide harvest of more than1.6 billion tonnes annually. Historically, the crop has not been deemed suitable for biogas production because the large quantities of water used in its processing are too weak in their organic carbon concentration to yield profitable amounts of methane. However, Global Water Engineering, which is represented in Australasia by CST Wastewater Solutions, says the industry has progressively reduced the amount of water it uses, increasing its waste stream concentrations to levels where it can successfully be used for biogas. Another bonus is that less effluent pollution is produced, through using the latest anaerobic technologies. “Use of less water can produce major environmental benefits in the cane industry, where the size of a processing plant bears little relation to the huge amount of wastewater it has traditionally produced,” said GWE President and CEO Jean Pierre Ombregt. “We are now getting towards the stage where, instead of having a series of huge anaerobic and aerobic lagoons impacting the environment, we can treat the effluent in contained anaerobic reactors where biogas is extracted and influent wastewater is cleaned of most of its impurities without release to the environment.” GWE has installed more than 300 anaerobic wastewater plants globally. In some installations, the biogas is used to generate green energy for sale to the local grid or to other factories or plants consuming fossil fuels. Using biogas in this way can ensure payback of plant costs in as little as one to two years. The United Farmer and Industry cane sugar mill at Khon Kaen in Thailand is one of the latest mills to use GWE Anaerobic technology. The plant has a capacity of 3500 m3 a day of wastewater, containing 22,750 kg per day COD (chemical oxygen demand) of natural origin that can be broken down into biogas by anaerobic bacteria. The process employed at United Farmer and Industry comprises influent screen, equalisation, pH control, anaerobic treatment, biogas flare, two-stage biogas sweetening (Bio-Sulfurix followed by activated carbon filtration). At the plant, biogas production is building to 9000 Nm 3 a day (75% CH4), which will be used as fuel in several factory steam boilers. Wastewater effluent levels have also improved, with a minimum of 85% removal of COD being achieved, to a maximum 975 mg/L COD, produced from influent with 6500 mg/L, or 3250 mg/L BOD (biochemical oxygen demand).

Sep/Oct 2013

GWE’s ANUBIX B medium-to-high loading rate UASB (upflow anaerobic sludge bed) reactor employed at the plant is of a type used for most low-to-medium strength mainly soluble carbohydrate containing effluents. By cane industry standards, the effluent COD reduction achieved at United Farmer and Industry is outstanding. In other food and beverage industry applications, the technology has attained COD removal efficiencies of up to 99%. “In addition to substantial environmental benefit from cleaner water being treated in reactor tanks rather than lagoons, the United Farmers Plant achieves a supply of green energy that delivers energy savings virtually in perpetuity,” Ombregt said. Anaerobic reactors like those used at United Farmer and Industry reduce the need for huge lagoons - and their associated odour, land use and environmental issues. This technology is applicable to any factory or process with one or more digestible solid waste streams. Such plants - including breweries, fruit, food waste, agro industries and energy crops such as corn and cane used for ethanol - can easily use this technology to generate energy. It opens the door to environmental and production efficiency gains globally, GWE says. As a result of their efficiency, anaerobic digestion facilities have been recognised by the United Nations Development program as one of the most useful decentralised sources of energy supply, as they are less capital intensive than large power plants. They can also benefit local communities by providing local energy supplies and eliminating the need for large - and often smelly and environmentally dubious - settling lagoons. CST Wastewater Solutions Contact info and more items like this at wf.net.au/U560

www.foodprocessing.com.au

Epoxy coating system

High-pressure piston pneumatic regulators range

Fernco Australia Pty Ltd

Rotork Australia

Contact info and more items like this at wf.net.au/U936

Rotork Fairchild, available through Rotork Australia, has increased the capacity of its compact leak-free pneumatic regulators for instrument and industrial control applications with the introduction of the HPP range. A companion to the HPD diaphragm-style range of regulators, the HPP (high-pressure piston) range incorporates a piston design to manage supply pressures up to 413 bar (6000 psi) at temperatures up to 260Â°C and deliver output pressures between 69 bar (1000 psi) and 207 bar (3000 psi). The HPP high-pressure performance complements that of the HPD, which will manage supply pressures up to 413 bar (6000 psi) and accurately regulate output pressures down to 1.66 bar (25 psi). Constructed with 316 stainless steel bodies, the HPP and HPD ranges have patent-pending improved valve seat sealing that eliminates the risk of media leakage often associated with conventional high-pressure regulators. Both ranges are available with 6 mm (Âźâ&#x20AC;ł) ports in either 2- or 4-port configurations and in multiple output pressure ranges. Standard knobs can be replaced with tamper-proof caps for high-temperature and/or non-adjustment applications. Rotork Fairchild regulators can be mounted at the ports, the bottom surface or in panel-mounted configurations. Contact info and more items like this at wf.net.au/V041

www.foodprocessing.com.au

Sep/Oct 2013

PROCESSING

The Ultracoat epoxy coating system from Fernco Environmental provides repair, rehabilitation and protection of grease traps, settlement tanks, manholes and all other trade effluent chambers. Due to the chemical composition of the trade effluent, chambers traditionally built with concrete and brick will become corroded over time. Effluent may then leach out into the ground, and groundwater can infiltrate into the drainage network. As a result, the structure may become unstable, maintenance can become more expensive and the facility may experience downtime. Furthermore, environmental issues may become legal issues. The Ultracoat epoxy spray applied coating system is highly chemical resistant (pH 2-14). According to the company, the system can extend the life of structures by up to 50 years. Containing no VOCs (volatile organic compounds), Ultracoat is suitable for application in corroded chambers and settlement tanks that are located underground or in confined spaces. According to Fernco, Ultracoat is only used by licensed applicators who have completed its training scheme.

PROCESSING

Ishida checkweighers key to 20% throughput increase As part of a target to increase production throughput by 20%, one of the UK’s largest frozen vegetable processors and packers has installed five Ishida multihead weighers. Pinguin Foods UK, part of the Belgium-based PinguinLutosa group, installed an advanced 24-head CCW-R multihead weigher with three 1 L hoppers for mixed vegetables and four 5 L hopper 14-head models for single varieties, which include carrots, peas, sweet corn, beans, broccoli and cauliflower. A combination of the Ishida weighers and new colour sorters, which check for and reject substandard vegetables, overall weighing accuracies are now running at under 0.7% deviation from the target weight, compared with 1.8% prior to the weighers being installed. At the company’s Kings Lynn facility, the weighers are handling pack sizes of between 125 g and 2.5 kg, including mixed vegetables of two, three and four varieties on the 24head mix weigher. The weighers are also used for special pack requirements; for example, one weigher in ‘double dump’ format can pack 10 kg boxes. Pinguin says this has effectively doubled speed and greatly improved accuracy over the previous method. While Pinguin initially selected the Ishida weighers for their speed, their accuracy, reliability and flexibility have been equally beneficial to production. “We have had no problems with the weighers since their installation,” said Packing Hall Manager Steve Walton. “Another major advantage is their flexibility; we can easily switch product from line to line depending on requirements - something that was not possible with our previous volumetric and older multihead models.” The weighers’ ease of changeover is key to their flexibility. Product specifications including target weight are pre-programmed into the easy-to-use remote control unit for changeover at the touch of a button. The waterproof construction and easily removed change parts also mean clean down can be carried out quickly and efficiently. The weighers are in operation 24 hours a day, five days a week, with additional shifts during busy seasons such as preChristmas. Typical speeds are around 75 packs/min for a 1 kg pack - well within the weighers’ capability of 90 packs/min. “We are continuing to work on further developing the performance of the lines,” said Paul Spurrell, Pinguin’s

Sep/Oct 2013

Chief Engineer. “Our focus is not just on speed but on delivering consistency and ensuring that the weighers are fully integrated so that they work as efficiently as possible with the existing equipment.” The weighers are working so efficiently, in fact, that Pinguin has needed to install new checkweighers, also from Ishida. “Our old checkweighers simply couldn’t cope with the higher line speeds,” Walton said. Installation of the Ishida equipment “went like clockwork”, Spurrell said. “It was literally a question of plug in and play. The weighers are very easy to operate. “In the few months that they have been installed we have already achieved a 15% improvement in throughput so we are well on the way to reaching our 20% target.” While Pinguin has now installed a range of Ishida equipment, the company began by installing just one Ishida model. Impressed by its effectiveness, Pinguin then installed the weighers over four more lines. Now the company is planning to convert its final line to include Ishida equipment. “We are a forward-looking company and constantly challenging ourselves to deliver the highest standards to our customers,” said Pinguin Foods UK Managing Director Nigel Terry. “This means we are committed to continual investment in the best equipment that will help us deliver on these promises. Ishida weighers are a key part of this.” Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U500

www.foodprocessing.com.au

Air humidifier The JetSpray humidifier from JS Humidifiers is designed for use in abattoir chill down areas to reduce carcass moisture loss after slaughter. When a carcass enters the chill store, the cold dry air can strip moisture from its exposed surfaces, reducing moisture by 2.5%. By maintaining a high humidity in the chill store with a JetSpray humidifier during the initial cooling, moisture loss from the carcass is inhibited and can be reduced to less than 1%, the company claims.

PROCESSING

The humidifier consists of rows of precision-engineered nozzles that combine compressed air and water to produce a spray that has a droplet size of 7.5 microns. The nozzle line is mounted directly in front of the evaporator coils of the refrigeration system and introduces moisture to the airstream as it enters the chill store. The fine spray ensures the moisture is absorbed by the atmosphere, preventing wetting inside the room. The flow of compressed air also reportedly avoids the possibility of drips. Tiny needles inside the nozzles act as a self-cleaning mechanism and prevent blockages, reducing maintenance. The humidifierâ&#x20AC;&#x2122;s hygienic design makes it suitable for use in food processing facilities. A reverse osmosis water filter removes all minerals from the supply water before it is treated with ultraviolet sterilisation to kill any remaining microorganisms. In addition, the system regularly runs purge and flush cycles to ensure water cannot stagnate in the humidifier. Aireven Pty Ltd Contact info and more items like this at wf.net.au/U343

www.foodprocessing.com.au

Sep/Oct 2013

Leaders stays in front with new packaging line

PROCESSING

Auckland-based frozen convenience foods manufacturer Leader Products has experienced continuous strong growth in its packed range of IQF (individually quick frozen) products. Finding that its existing weigher and bagger couldn’t keep up with the increased demand, Leader contacted John Redai from Reactive Engineering for a solution.

Jetting tank washer Available from Tecpro Australia, the Typhoon Jetting Tank Washer with rotating cleaning head is suitable for large vessels, including food and beverage storage tanks, transport containers and chemical reactors. The tank washer produces four high-powered jets that give complete coverage in a seven-minute wash cycle. Even at high flow rates, the geared movement maintains an optimum jet peripheral velocity that increases impingement and chemical dwell times to maximise cleaning effectiveness. According to the company, the machine’s efficient wash cycle reduces downtime and saves on water and effluent costs. Constructed of only 48 parts, which can be dismantled and reassembled in minutes, the machine is supplied with a basic repair kit of 10 parts. The external design and selfcleaning backwash nozzles reduce wear and tear and improve hygiene

Based on the expansion of production capacity and the company’s future plans, Reactive proposed a new set-up for the packaging line: changing the current multihead weigher for a Multiweigh 14-head weigher and replacing the existing bagger with GKS Packaging’s FLOW FL350 bag maker. The machines were installed in October 2012 and the line was optimised and set up for all of the company’s products, which are packed in transparent and pre-printed films. With the FLOW bag maker, Leader is now able to pack at speeds of 50-60 bags/min in LDPE films - three to four times the capacity of the old line. The key factor in choosing the FLOW, besides its capacity and robust build, is the washdown capability of the machine. FLOW has a clean design and IP67 rating throughout the machine, significantly reducing cleaning time. According to Leader, the packaging area is now no longer a cause of concern, allowing the company to focus completely on optimising and expanding the processing side of the factory.

by ensuring product cannot settle

Reactive Engineering Pty Ltd

Contact info and more items like this at wf.net.au/U691

Contact info and more items like this at wf.net.au/U834

Sep/Oct 2013

www.foodprocessing.com.au

on the cleaning head. Carbon PTFE bearings improve performance and reduce contamination risks associated with wear and tear of traditional ball bearings. Weighing 3.1 kg, the compact tank washer has a 1″ BSP connection and requires a minimum manhole/flange opening of 110 mm for unit insertion. At a pressure of 10 Bar and a flow rate of 225 L/ min, the washer has a cleaning radius of 9 m and a wetting radius of 17 m. It is suitable for working temperatures up to 95°C and ambient temperatures of up to 140°C. A suitable replacement for large spray balls, the Typhoon is suited to use in the food and beverage, brewing, pharmaceutical, chemical, coatings and transport industries. Tecpro Australia

On-machine seasoning system tna has launched the intelli-flav OMS 5 for on-machine seasoning (OMS) applications. The system offers consistent coverage and flavour for both wet and dry seasoning. Fully integrated with both oil spray and flavour injection systems, the OMS is claimed to provide total control of adhesion and fast flavour changes for snack lines. The responsive variable mass seasoning system with dynamic vibratory weigher

PROCESSING

directly controls oil spray and powder flow into the drum. This enables an accurate, proportional amount of seasoning to be evenly applied to the product for improved coverage and flavour dispersion. Mounted to the edge of the drum, the scarfplate better directs the product into the spraying and flavouring area,

Sanitary ram valve

providing high-quality seasoning performance. Addition-

Spray Nozzle Engineering, exclusive technical supplier of

ally, the scalloped infeed conveyor allows more product

Strahman Valves and Washdown Equipment, has launched

to enter the seasoning drum while also helping to control

what it says is the first sanitary ram valve to be compliant

product direction for greater accuracy and reduced waste.

with ASME-BPE-2002 standards.

With a modular, simple design, the tna intelli-flav

OMS

The valve is self-pigging, preventing foreign matter from

5 is fully enclosed for increased hygiene and ease of

collecting in the recess cavities of the valve interior. It

cleaning. A pivoting drum improves accessibility for

is suitable for food and beverage applications including

hard-to-reach areas.

hydrogenated oils, margarines, flavouring and food addi-

TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/U303

tives, and anywhere highly sanitary conditions are required. Custom valves are available on request. Spray Nozzle Engineering Contact info and more items like this at wf.net.au/U885

www.foodprocessing.com.au

Sep/Oct 2013

Donâ&#x20AC;&#x2122;t let your business go to the rats

Food manufacturers need to be vigilant of rodent infestations to prevent reputation backlash and physical damage to their businesses. ÂŠs

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odent infestations can quickly get out of control, within a period of a year a single pair of mating rodents can result in a rodent population of 400700. One female rodent is capable of giving birth to between five to 10 offspring more than four times a year and those offspring are ready to reproduce just three months after birth. So if you notice evidence of a rodent you need to act quickly or better still, you need to have preventative measures in place so there is no chance of an infestation. From summer 2012/13 to autumn 2013, Rentokil saw a spike of 18% in its call-out rate and the company is expecting to see further increases. So businesses should definitely start preparing for potential rodent infestations and have adequate rodent control programs in place. As with most businesses, in the food industry, reputation is everything, but by taking preventative measures when it comes to rodent control, businesses can counter any potential damage to their reputation. A positive reputation that has taken several years to build can be destroyed in several seconds and the emergence of social media is exacerbating this problem. Just one customer complaint can spiral into major customer backlash and significant financial consequences for your business. 72

Sep/Oct 2013

More about rats in large buildings The most common pest rodent species in Australia are the black rat, brown rat (Norway rat) and house mouse, all of which are widespread throughout Australiaâ&#x20AC;&#x2122;s highest populated areas. Rodents are nocturnal and build their nests in wall cavities, under floors, in roof voids and close to areas where they can scavenge for food and water.They can all carry diseases by leaving infected urine or faeces in places where people can come in contact such as food preparation and storage areas and rubbish tips. The effect of rodents can consequently be more serious for businesses serving or selling food and businesses with large storage areas, where rodents can find areas with food, shelter and nesting sites. Research from Rentokil indicates that mice can change behaviour in large buildings.Typically, the home range of a mouse is 5 m; however, Rentokil has observed that when there is lack of females in these environments male mice are forced to hunt up to 1 km to find mating partners. Large buildings work as closed ecosystems with adequate food, shelter and warmth; they enable mice to set up temporary residences throughout. For large buildings, this means there is an increased risk of mice infestation that is harder to treat and control.

www.foodprocessing.com.au

Potential harm • Rodents are known to spread infections such as Salmonella, Weil’s disease, E.coli, Tuberculosis and Hantavirus. • Damage to stock and buildings. • Contamination of foodstuffs and goods.

Business consequences • Alarm - Immediate loss of customer and employee trust, which will affect the bottom line. • Damage - To goods, foodstuffs and your health and hygiene reputation. • Cost - Can be considerable; temporary closure may be necessary, which means loss of business and the costs of replacing damaged stock. • Legal - Failure to comply with legislation

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when there is lack of females in these environments male mice are forced to hunt up to 1 km to find mating partners.

Danger signs • Droppings - Rodents leave small, dark droppings particularly along walls or in enclosed areas. Rat droppings are sausage shaped, approximately 1-2 cm long and mouse droppings are thin, spindle shaped and approximately 5 mm long. • Distinctive smell - If you detect an ammonia-like smell that is particularly strong in more enclosed areas, the chances are it may be due to rodents. • Damaged stock and damage to fabric of premises. • Nesting material - Rodents build nests with shredded material such as newspaper, cardboard and fabrics. • Damage - Rodents have teeth that grow continuously and will gnaw on wood, plastic, cables and other hard materials, which can be a fire hazard. • Smears - Grease marks from the body of the rodents as they repeatedly brush up against objects.

Preventive measures • Hygiene and housekeeping should be a key focus with thorough, regular cleaning taking place frequently to avoiding infestation. • Crates and boxes should be stacked 70 cm away from the wall to ensure you can check what’s behind them. • Set up a contractual relationship with your pest controller, rather than hiring them on a reactive basis to ensure there is no risk of recurring infestations. • Staff need to be educated on the risks of infestation and act responsibly. • If you do spot a rodent on your premises it is essential to seek professional advice immediately. • If you own a property that is standing empty for any period of time, make sure you inspect it regularly to look for any signs of rodent activity. • Seal up holes in the building to keep rodents out. • Ensure all pipe-work is in good working order. • Look after your drains, clean them regularly to avoid infestations and unblock gutters.

Steps to take • Arrange immediate removal with rodenticides handled by qualified technicians. • Get rodent proofing and design advice. • Schedule regular rodent control visits to prevent further outbreaks. Rentokil offers a comprehensive survey process that includes a review of the site to identify areas of risk, consideration of all control procedures including attention to sanitation and hygiene, trapping, proofing of entry points and the use of baiting procedures. In high-risk industries like food processing and pharmaceutical, the appraisal goes one step further with a scientific approach completed by a field biologist. Rentokil Initial Pty Ltd www.rentokilpestcontrol.com.au

www.foodprocessing.com.au

Sep/Oct 2013

Flexible hose for liquid transfer The Liquiflex flexible hose for liquid transfer is manufactured from food-grade PVC and has high resistance to both internal and external pressures. It is suitable for use in the food, beverage, pharmaceutical, chemical and water treatment industries as it can withstand temperatures

PROCESSING

between 0 and 60°C.

Polycarbonate LED light fitting

The hose is crush-resistant and can be used for the

Available from GMP Lighting, the DALSP-X is a fully sealed,

delivery and suction of liquids including beer, milk, fruit

polycarbonate, non-corrosive, lightweight LED light fitting.

juice, wine, spirits and a range of other liquid products.

It is IP65 rated, surface mounted and energy efficient.

The Liquiflex consists of a smooth, soft, transparent

According to the company, the light fitting offers 80,000

PVC wall combined with rigid antishock PVC-reinforced

hours of maintenance-free life, giving ROI within 3 years.

helix rings, which gives it strength, structural integrity

The fitting can be used in laboratories and cleanrooms

and a high degree of flexibility even at low temperatures.

as well as food processing areas. Its fully sealed construc-

Available in diameters from 20 to 150 mm, Liquiflex is

tion makes the fitting suitable for use in the food industry

phthalate-free and conforms to EU and FDA regulations.

as it can withstand wash-down, corrosive atmospheres

It has a bed radius of 90 to 680 mm and a maximum

and freezers down to minus 40°C.

working pressure of 10 bar.

It is also dimmable for comfort and energy saving

Being constructed of heavy-duty PVC, the hose is also

and can be used with a BMS. The company offers every

resistant to a number of harsh and hazardous chemicals

project, regardless of size, a free lighting simulation to

such as ammonium sulfate, ammonia, aluminium sulfate,

ensure every room has the desired amount of lighting.

calcium chloride, citric acid, ferric chloride, glycerine,

GMP Lighting

phosphoric acid, sodium hypochlorite, sulfuric acid and

Contact info and more items like this at wf.net.au/U854

zinc chloride. Eximo Contact info and more items like this at wf.net.au/U763

HEALTH AND SAFETY FLOORING

Do you need flooring for your Food Facility?

S LIP RES I STANT • U LTR A CLE AN • IMPERVIOU S

1800 ROXSET 1800 769 738 www.roxset.com.au

Sep/Oct 2013

Food Factories, Meat Processing Facilities, Bakeries, Hotels, Nursing Homes, Hospitals, Restaurants, Retail Outlets, Seafood and all other Safety Surfaces.

www.foodprocessing.com.au

NORD drives Little Creatures Geelong Brewery PROCESSING

Little Creatures Brewing’s new Geelong site is nearing completion, with brewing expected to begin in mid-2013. Housed in a heritage-listed former carpet factory, the site will be more than just a brewery: the company plans to host brewery tours including beer tasting and functions. Within the 20,000-litre brewhouse, the large lauter tun (mash separator) is central to the beer-making process. The machine separates the liquids from the solids in the mash to produce the wort. A new model from NORD Drivesystems’ Industrial Gear Unit (IGU) series was selected as the main gearbox drive for the lauter tun. The model SK9307EA WK120 drive is rated to 65,500 Nm torque. The whole assembly, comprising the NORD IGU and two smaller NORD geared motors, weighs 1600 kg in total. The lauter tun machine consists of a large stainless steel tank with internal rotating rakes that separate the malt solids from the water solution and also move vertically inside the tank. This process involves a sophisticated arrangement involving a NORD SK9032.1EAFH132MP/4TF F IG Helical bevel geared motor with an encoder and the mechanical adjuster mechanism which passes vertically through the hollow bore of the NORD IGU gearbox. The nominal output speed of the IGU is 4.7 rpm. “This new brewery represents a major investment for Little Creatures Brewing, and will become the hub of our beer manufacturing and distribution for Eastern states of Australia and for export,” said Tom Champion, Little Creatures Geelong Brewery Manager. “We are on schedule for the commencement of brewing and bottling of Little Creatures beer from mid-2013. This new brewery will ensure that our product reaches our customers in the fastest time frame possible.”

Economical & Scalable...

Pilz has a wide variety of cost effective & flexible safety solutions for your packaging machinery. Looking for a reliable Partner for the automation of your packaging line? We offer you a comprehensive portfolio of solutions ranging from the small with only a handful of sensors using our new PDP technology all the way though to the most complex of systems utilising our PSS4000 safe automation platform. Talk to us today about your packaging safety requirements!

NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/U492

safety@pilz.com.au

www.foodprocessing.com.au

www.pilz.com.au

Sep/Oct 2013

03 9544 6300

Electric contact grill The Crown L-Series Taylor Electric Contact Grill provides two-sided cooking quickly, easily and safely at the touch of a button. The Taylor Model Crown #L820 incorporates two separately controlled cooking zones, with three heaters per zone and two upper platens. Programmable controls provide accurate time, temperature and gap settings. The upper platens close automatically to the preset gap setting with the touch of a button. Side-to-side release material protects the entire upper platen cooking surface. An external USB port allows user access to upload new menu and promotional items.

PROCESSING

JL Lennard Pty Ltd Contact info and more items like this at wf.net.au/U670

Suction air drying system The Kronen SDS 5000 suction dry system has been designed to give salads, fruits and vegetables a longer shelf life by ensuring low final moisture and low product damage. The suction-air-dry system is claimed to deliver the final products not only drier, but in optimal condition. The system is suitable for baby leaf, fresh cut fruit, chopped lettuce and vegetables such as sugar snap peas, cauliflower and broccoli florets. A food-grade mesh belt with a beating unit on the infeed section of the suction-blow unit helps to gently dewater the product before the main drying section. Along the length of the mesh belt, there are a number of desdry the product as it passes through the system. The product is

Hydraulics safety program

softly dried in 2 x 6 steps of blowing and 2 x 6 steps of sucking.

Unsafe hydraulic systems can be a financial drain, and

Above the main transport belt, a second mesh belt has been

worse, put employees at risk. Gates Australiaâ&#x20AC;&#x2122;s preventive

installed to ensure the product is held in the correct area for

maintenance training materials and seminars make it easier

drying and prevent product from being blown out of the system.

to identify component weaknesses before failure.

ignated blowing and suction systems working together to carefully

A range of recipes can be controlled from the central panel, ensuring a suitable setting is used for each product. The machine can process 250-300 kg/h baby leaves, 400-550 kg/h iceberg lettuce and 600-800 kg/h hard vegetables.

Preventive maintenance is especially important with hydraulic products. The high pressures and temperatures associated with hydraulics make maintenance critical to mitigate the risk of injury and downtime. Proper hydraulic preventive maintenance is important to

Reactive Engineering Pty Ltd Contact info and more items like this at wf.net.au/U176

anyone who operates hydraulically powered equipment. Improperly maintained equipment can lead to premature hose failures and blowouts, resulting in equipment downtime, possible equipment damage or personal injury. Gates has developed an in-depth hydraulic preventive

Control & Power Switches

maintenance training program called Safe Hydraulics that can help users properly maintain and service equipment

Extensive Range of

for safe operation.

Stainless Steel & Insulated Enclosures

Gatesâ&#x20AC;&#x2122; Safe Hydraulics Program ensures the same consistent safe hydraulic message is delivered to all participants, providing what is claimed to be the most thorough hydraulic preventive maintenance short course into the marketplace. The half-day seminar includes information on safe hydraulic

www.krausnaimer.com.au

practices, including safety, health, environmental procedures

Adelaide Sydney Melbourne Brisbane Tel: (02) 9797 7333 Tel: (03) 9720 9777 Tel: (07) 3252 8344 Tel: (08) 8371 1443 Fax: (02) 9797 0092 Fax: (03) 9720 9766 Fax: (07) 3252 1497 Fax: (08) 8371 0901

and fluid injections protocol as well as safety tips and hy-

Linked with an Australian Wide Distribution Network

Contact info and more items like this at wf.net.au/U052

Sep/Oct 2013

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draulic cleanliness advice. Gates Australia Pty Ltd

Processing strawberries - gently product and keeping the product intact. “Chopped fruit and vegetables, which are aseptically packed in a convenient, readyto-use form, have become very popular for commercial use,” said Carlos Cobian, General Manager, HRS Process Technology. “The reason for this lies in their high added value compared to canned products and their ease of use for transformation companies that use them for commercial production of convenience foods. “The success of our technology for fruit diced aseptic plants is based on our corrugated double tube heat exchangers, piston pump and our aseptic filler. Combining them makes it possible to process the fruit pulp and puree, minimising the undesirable thermal effects and gets a reliable, hygienic and well-controlled filling process.”

PROCESSING

Industrial treatment of products with particulates, such as whole or diced fruits, can be challenging for food processors as the product itself can be easily damaged. An aseptic fruit processing plant in Oxnard, California, that produces sliced and diced strawberry in syrup used HRS Process Technology’s heat exchanger and pump solutions to guarantee zero damage to the particulate while maintaining product integrity and shape. The system, which includes a DTA-series heat exchanger and a BP8 and BP10 pump, processes 4 tonnes/h of aseptic sliced and diced strawberry in syrup. Designed to overcome many challenges associated with traditional pumps, HRS’s BP-series reciprocating positivedisplacement pump is a hydraulically operated pump that delivers high flow rates and high pressure drop. The pump’s hygienic design makes it suitable for food processing applications, especially for particulate and low shear rate products. Featuring large dimple corrugated tubes, HRS’s DTA-series heat exchangers are suitable for other food applications. The movement of the product generated by the corrugated tubes ensures the gentle agitation of the product through the tube and guarantees the thermal process without degrading the

GEA Process Engineering (NZ) Ltd Contact info and more items like this at wf.net.au/U698

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CMY

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Sep/Oct 2013

Improving flavour and shelf life

PROCESSING

To achieve the needed food safety and cooking efficiencies, many meat and poultry items such as hams, turkeys and chickens are today cooked in a pouch or bag and then chilled. However, when processors need to add colour, texture or flavourful seasonings to these items, additional post-processing is required. The question is, what is the best way to attain those desired effects and also maintain extended shelf life? The answer for many processors is a technology that can roast, flavour, sear and colour meat and poultry while providing the needed surface pasteurisation to extend shelf life. ‘Tunnel of fire’ pasteurising and flash roasting systems take the cooked and chilled product from the chiller and place it on a belt that moves through an enclosed flame that colours, sears and surface-pasteurises the product so it is ready for immediate packaging. Because of the speed of the process - 30 to 60 seconds complete surface pasteurising and searing is achieved, yield loss is minimal and a long shelf life is ensured. Flame tunnels such as Unitherm Food Systems’ Tunnel of Fire also include a dispensing unit that sprays browning and flavouring agents like liquid smoke or other seasonings onto products as they enter the tunnel. This allows the colour, texture and flavour of products to be easily and consistently controlled. Using this flash-roasting and pasteurising process, finished products maintain their cool core temperatures and can be immediately packaged for distribution. This eliminates food safety problems that can occur when products are cooled in the open air prior to packaging, which exposes them to cross-contamination that can limit shelf life to a few days rather than weeks. Comercializadora Andina SA (Comansa) of Santiago, Chile, produces a line of foods sold to supermarkets, including chicken, beef and other meats, plus a ready meal line. One of the company’s primary products is roasted chicken, which is sold to supermarkets at a rate of about 80,000 units per month. Eduardo Carvajal, Comansa Operations Manager, says that providing these chickens in a rotisserie style and an assortment of seasonings has enhanced sales and offers other benefits. “We cook the chicken in bags in a steam tank for about three hours, then chill it in the same unit,” he explained. “Afterwards we put the chicken through the Unitherm Tunnel of Fire to keep the surface pasteurising, get the colour and develop the seasonings. This is all done in just 30 to 35 seconds.” Carvajal says that using the flame tunnel provides benefits besides the assurance that each chicken is exposed to the air for only seconds before it is surface pasteurised and put in retain bags immediately afterwards. “The colouring process of the flame tunnel is very important because our customers prefer that finish rather than a plain white colour,” Carvajal said. “Also, the same equipment enables us to provide a variety of seasonings, including spicy, barbecue, butter and sweet flavours.” One of the most important benefits of the flame pasteurising process is the extended product shelf life. While many roasted chickens have a typical shelf life of about three days, Carvajal’s is considerably longer. “After we ship the chicken, we are certain of a shelf life of 42 days,” Carvajal said, “and that is an important reflection of our high standards.” Luka Meats (Luka Vleeswarenfabriek NV), Vilvoorde, Belgium, produces a variety of cooked hams, including smoked, roasted and extra lean hams as well as Strasbourg meat loaves. Until recently, the hams and Strasbourg loaves were pasteurised, browned and seared by hand, using a handheld torch, but handling 1200 hams and 300-400 loafs per week proved too timeconsuming. “We used to spend an average of two hours a day finishing these products by hand,” said Thomas Leemans, Luka Meats founder and owner. Recently, Luka Meats automated its pasteurising process with a Unitherm Tunnel of Fire flash roasting system. “This new equipment makes quite a difference in productivity,” Leemans said. “We now save approximately 60% of the time it used to require to brand our products by hand, as well as considerable labour.” Unitherm Food Systems Inc Contact info and more items like this at wf.net.au/U041

Sep/Oct 2013

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HMI software FactoryTalk View Site Edition (SE) and Machine Edition (ME) 7.0 applications offer more efficient alarm management, simplified installation, improved user experience and integrated data sharing in a wide range of production environments. FactoryTalk View SE 7.0 software supports a larger number of HMI clients and servers in a single system, increasing the size of systems that can support the FactoryTalk View SE alarming subsystem, FactoryTalk Alarms and Events.

PROCESSING

The FactoryTalk Alarms and Events alarming subsystem has been enhanced to align with ISAâ&#x20AC;&#x2122;s Alarming Standard 18.2, and will now support the shelving state. The subsystem now also allows users to configure remote-alarming commands on display faceplates, saving crucial time when an operator needs to react to device alarm situations. A network-scoped option for FactoryTalk View SE Station software allows a single-computer HMI to better integrate with products such as FactoryTalk Historian SE and ME software. Using the networked FactoryTalk View SE Station software, users will be able to browse to a FactoryTalk Historian SE server, select tags and view the historical information for those tags directly on the operator workstation. Better device connectivity and diagnostics are available for Allen-Bradley PanelView Plus 6 operator terminal applications with FactoryTalk View ME 7.0 software. PanelView Plus 6 operator stations can now connect directly to, and display data from, non-controller devices, such as smart overload relays or power monitors, saving controller memory. Rockwell Automation Australia Contact info and more items like this at wf.net.au/U513

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Sep/Oct 2013

pH/mV transmitter and conductivity/resistivity transmitter Sensorex’s TX2000 pH/mV Transmitter and CX2000 Conductivity/Resistivity Transmitter monitor changes in process fluids for more accurate control in a wide range of water, chemical, electronics, food production, environmental and wastewater processing applications.

PROCESSING

Both transmitters include Multi-Cal calibration with automatic buffer recognition, two assignable isolated analog (4-20 mA) current outputs, two alarm/control relays with an additional wash feature and a universal 100-240 VAC power supply. CE certified, the compact NEMA 4X/IP65 enclosures can be wall mounted, installed in a panel or pipe/handrail mounted. The TX2000 has a pH measurement range of -2.00 to 16.00

Colour sensor for food, packaging and pharmaceuticals

pH and an oxidation reduction potential (ORP) measurement

The Wenglor colour sensor for food, packaging and pharmaceuticals

range of -1999 to 1999 mV. The CX2000 has a conductivity

provides colour recognition even with changes in distance and is ca-

measurement range of 0.000 µS/cm to 200.0 mS/cm and a

pable of evaluating up to three colours simultaneously. A small spot

resistivity measurement range of 0.00 to 20.00 MΩ cm. Both

and large working range are made possible due to single-lens optics.

are compatible with a number of probes and sensors to fit

All sensor settings can be selected by means of Teach-In, as well as via the RS232 interface. Values generated by the sensor can be

most application requirements. An optional RS model offers additional features including

read out via the interface or digital switching outputs.

data display charts and trend graphics, a real-time clock with

The colour sensor is equipped with two digital inputs, three switch-

logbook function and user-defined, five-point calibration with

ing outputs and an RS232 port for reading out RGB, XYZ and HSL

displayed calibration curve. The RS models are also equipped

colour values.

with one analog output and serial RS485 interface for Modbus

The intensity of the emitted light can be increased in order to detect

RTU or ASCII communications, easily interfacing to existing

dark objects. With a spot diameter of 3 mm and a working range of 30

plant SCADA or DCS control systems.

to 40 mm, complex detection tasks can be implemented in a simple,

Both units have a large backlit display with easy-to-navigate

uncomplicated fashion.

text and graphic illustrations. A password protection option

The sensor can detect self-luminous and dark objects, and the com-

prevents unauthorised tampering. With a temperature span of

pany claims that even extremely fine colour nuances can be recognised.

-30 to 130°C, the transmitters are claimed to ensure accuracy

The graphic user display allows for easy, intuitive use with multilingual menu prompting in English, French, German and Italian. Additional

even in challenging process environments.

password protection offers security against unauthorised access.

Envirosensors Pty Ltd Contact info and more items like this at wf.net.au/U949

The sensor works in temperatures ranging from -25 to +60°C. Treotham Automation Pty Ltd Contact info and more items like this at wf.net.au/U469

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Sep/Oct 2013

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k.xchn

g/waw

PROCESSING

Frankenburger vs farmed meat: which would you choose?

Our current food system allows us the luxury of ignorance, to some extent, when it comes to the source of our meat. The perfectly sanitised, blood-free meat products that come neatly packaged from the supermarket seem terribly far removed from the animals from which they came, and allow us to distance ourselves from the animal’s death - and life - so that we can dine with a relatively clear conscience.

ut the uncomfortable truth is that, as the human race has grown and with it our appetite for meat, production methods for meat animals have become less and less humane. Huge feed lots, sow stalls and tiny cages have become the standard for industrialised meat production throughout the world. With more and more awareness about meat production methods - such as increased labelling of poultry as free-range or otherwise - it’s becoming harder to ignore the fact that your dinner may have been raised under conditions that would put you off your meal. Worldwide vegetarianism, while an admirable stand against factory farming, simply isn’t a realistic option - and may not be the answer to the environmental issues caused by factory farming. Similarly, sourcing ethically produced meat is prohibitively expensive for all but a small proportion of the population. But there is another possible solution: cultured meat - meat produced in a laboratory from animal stem cells. The world’s first cultured meat hamburger was recently cooked - and consumed - in London, developed by Professor Mark Post of Maastricht University and cooked by Chef Richard McGeown. It was tasted by two intrepid volunteers: Chicago author Josh Schonwald and Austrian food researcher Hanni Rützler. Professor Post believes that cultured meat could solve the looming food crisis and simultaneously combat climate change. “What we are trying today is important because I hope it will show cultured beef has the answers to major problems that the world faces,” Professor Post said.

To produce the meat, muscle cells taken from a cow are cultured in a laboratory by placing them in a nutrient solution which creates muscle tissue. The tissue is grown by placing the cells in a ring around a hub of gel. The muscle cells grow into small strands of meat. To create one 140 g burger requires 20,000 of these strands of meat. The burger was made of cultured beef with the usual burger ingredients, such as salt, egg powder and breadcrumbs. To give the meat colour, red beetroot juice and saffron were added. The burger reportedly cost more than €250,000 to produce, but, as the culturedbeef.net website says, “high costs today are a small price to pay for the potential future benefits of cultured beef to all of humankind”. Not only will cultured meat reduce the carbon emissions associated with factory farming, it could also free up valuable land for producing other types of food to feed our rapidly increasing population. University of Oxford research suggests that producing cultured meat could use up to 99% less space than current farming methods. While cultured meat might seem to be the cure to all our food ills, encouraging consumers to eschew traditionally raised meat in favour of that created in a lab could be challenging. If, however, traditionally produced meat becomes as expensive as some are predicting, buying meat that came from a lab rather than the farm could become the more palatable option. What do you think? Could the ‘Frankenburger’ be the solution to the looming food crisis? Or will consumers just not be able to stomach the thought of meat grown in a petri dish?

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Sep/Oct 2013

Miniature pressure sensor The Futek Miniature Pressure Sensor PFT510 is a general pressure

No bull: biogas recovery to reduce carbon bill

solution that is suitable for a range of applications. Designed with a flat, flush-mount diaphragm, the PFT510 model is claimed

PROCESSING

to avoid clogging at the installation port. With a capacity range of 15 to 700 bar, this 20 mm sensor solution uses strain gauge technology, is suitable for OEM integration and is compatible with Futek’s entire line of instrumentation. Combining the PT510 with Futek’s USB solutions gives users the ability to create a system to monitor up to 16 channels side by side. According to the company, by using the linearisation feature within Sensit Test and Measurement Software, users can expect an improved overall performance and accuracy of the This platform may also be utilised by quality inspectors/auditing teams to log data and perform further analysis. M101x1 and 3/8-24 thread options are available. Metromatics Pty Ltd Contact info and more items like this at wf.net.au/U920

system by point-to-point linearisation.

JBS Australia, the country’s largest producer of meat products, has engaged Wiley to project manage the $8.7 million upgrade of its wastewater treatment system. The upgrade will involve the design, construction and installation of new pre-treatment equipment and covered anaerobic lagoon technology. According to Wiley, the technology will start reducing JBS’s carbon tax bill as soon as the lagoons are covered. A new 20 megalitre anaerobic pond will be built, and a biomethane gas recovery system will be attached to the new and existing ponds. The biomethane gas will be used to fuel the existing gas-fired boiler. A red waste stream dissolved air flotation system replacement will be implemented, as will a system for tallow recovery. In addition, the existing trade-waste system will be modified. Wiley and JBS’s 2010 collaboration on a revolutionary saltwater hide processing plant was awarded the Master Builders Association Brisbane Award for Innovation in Environmental Management. “We are proud to work with JBS, supporting their ongoing commitment to environmental innovation,” said Wiley’s Managing Director, Tom Wiley. “Every project like this is a step towards a better future.” Currently in the construction phase, the project is expected to be completed in March 2014. Wiley & Co Pty Ltd Contact info and more items like this at wf.net.au/U925

Sep/Oct 2013

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Batter-coated French fry system Heat and Control’s batter applicator and multizone fryer system can process more than 16,000 kg/h of batter-coated French fries. The batter applicator applies a clear coating that gives fries a crisp texture and long service life. Submersion in a pool of premixed batter and passage through two batter curtains ensures uniform coverage. The applicator’s batter tank and drip pan are chilled to maintain batter consistency and reduce cleaning requirements. The outside-return conveyor belt can be raised clear of the pan to simplify cleaning, and the entire applicator system slides aside for sanitation, or when uncoated product is run. Each of the fryer’s two independent stages has three oil temperature zones for precise temperature control and rapid fines removal. Oil inlets and outlets are designed to deliver uniform side-to-side oil-

PROCESSING

to-product velocity and Delta-T. The outside-return conveyor belt reduces oil volume in the fryer. Unitised construction provides a stable pan structure that resists thermal deformity. Oil filters, pumps, the steam heat exchanger, clean-in-place components and piping are pre-assembled on a compact fryer support module to reduce installation time and maintenance costs. The complete system and all batter-mixing, coating, cooking and cleaning functions are controlled from one PLC touch screen. Oil mist eliminators and heat recovery systems are available to remove oil mist and utilise otherwise wasted heat from fryer stack emissions. Heat and Control Pty Ltd Contact info and more items like this at wf.net.au/U760

Need inductive sensing that goes the extra distance? The OsiSense™ XS9 Fully Enclosed 316L Stainless Steel Proximity Sensors were designed with harsh conditions and challenging sensing distances in mind. Standard features include: • up to 3 x standard sensing distance • IP68 & IP69K degree of protection • factor 1 sensing for ferrous and non-ferrous metals • ECOLAB® compliant for high temp and chemical cleaning. The XS9 housing comes with a 0.4mm thick front face, making them highly resistant to mechanical shock and vibration. These sensors are ideal for the food and beverage, marine and mobile application markets.

Simply easy!™ Discover more

Sensors

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Sep/Oct 2013

Putting the bite in the bubble in the soft drink Soft drinks have a distinctive ‘bite’ that consumers enjoy as part of their thirst-quenching experience. It has long been assumed that the bubbles of CO2 are responsible for this bite but new research from the Monell Centre has found that bubbles are not necessary for ‘bite’.

he bubbles do enhance the carbonation bite through the light feel of the bubbles picked up by our sense of touch but it is acid, not bubbles, that is responsible for the distinctive bite feature of carbonated beverages. Soft beverages are produced when carbon dioxide is dissolved in a liquid, typically under high pressure. Carbon dioxide is added to beverages through production processes or it can occur naturally in certain spring waters or in fermented beverages like beer. When the consumer opens the bottle or can, pressure is reduced and some of the carbon dioxide is released from the solution in the form of bubbles. After a sip, enzymes in the mouth convert the remaining free carbon dioxide into carbonic acid. The acid then activates sensory nerve endings, which signal the mild irritation that we refer to as ‘bite’. In the study, published in the public access journal PLOS ONE, the Monell researchers examined the role that bubbles play in carbonation bite. In the first experiment, they took advantage of the fact that bubbles cannot form when atmospheric pressure is raised above a certain level. Twelve healthy adults were comfortably seated in a hyperbaric chamber and asked to rate the bite intensity of several concentrations of carbonated water. The ratings were collected once while under normal atmospheric pressure (with bubbles) and a second time at higher pressure (no bubbles), equivalent to diving to a depth of 10 m in sea water. There was no difference in the bite reported in the two conditions, even though bubbles are physically unable to form at the higher pressure. “Because the subjects experienced the same bite when bubbles weren’t present, the findings clearly told us that 84

Sep/Oct 2013

carbonation bite is an acidic chemical sensation rather than a purely physical, tactile one,” said study author Bruce Byant, PhD, a sensory biologist at Monell. Although bubbles aren’t necessary for bite, they still could be contributing to the overall sensation of carbonation. Thus, a second experiment was designed to address this possibility. In this experiment, 11 adults rated the intensity of bite in a laboratory setting. The ratings were made for carbonated water under normal conditions and again when additional air bubbles were added to the liquid. The researchers were surprised to find that air bubbles enhanced the bite of the carbonated bubbles, presumably by stimulating the sense of touch. “We thought the touch of the bubbles would suppress the painful aspects of carbonation, much as itching a mosquito bite or rubbing a sore muscle does,” said Bryant. Together, the studies reveal that carbon dioxide bubbles are not directly responsible for the bite of carbonation. However, by stimulating the sense of touch inside the mouth, bubbles do enhance the bite sensation beyond the chemical irritation caused by carbonic acid. “Pain from some cancers also depends on acid formation in tissue,” noted study lead author Paul M Wise, PhD, a sensory psychologist at Monell. “Because the bite from carbonation can be considered to be a mild type of pain, the fact that pain intensity can be enhanced via the sense of touch may have implications for understanding these types of cancer pain.” Future experiments will continue to explore the interactions between chemical and mechanical stimuli. Also contributing to the research, which was funded by Anheuser Busch InBev, were Madeline Wolf of Monell and Stephen R Thom from the University of Pennsylvania.

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Vegetarian red colourant range LycoRed has developed a range of vegetarian red colourants as part of its Tomat-O-Red line of tomato lycopene colour for various food and beverage applications. The formulations are claimed to provide a deeper red lycopene colour with blue background, similar to shades from carmine. This makes them a natural solution for food manufacturers wanting to replace the insect-derived cochineal extract in their formulations. The Tomat-O-Red lycopene colourant formulations are available in liquid forms, and are free from any allergenic components, as listed in the EU’s Directive 2007/68/EC and those identified in the USA’s Food Allergen Labelling and Consumer Protection Act of 2 August, 2004. The formulations have a high stability across a wide range of pH levels, light conditions, high temperatures and also in the presence of vitamin C.

INGREDIENTS

LycoRed www.lycored.com

Milk protein fractions for baby formula Built around Arla Foods Ingredients’ Lacprodan portfolio of protein ingredients, Staging is an improved approach to infant formula designed to reflect the fact that the composition of breast milk changes significantly during lactation. At present, formula-fed babies’ diets do not take account of this, and they are usually given a ‘static’ diet during their first six months. However, Arla Foods Ingredients has identified that the protein content of breast milk is dynamic and changes constantly during this period. The company has developed blends of specialised milk protein fractions that will help manufacturers create formulas that mimic the changing nutritional profile of milk more closely during this time in a baby’s development. At the centre of the Staging concept is a range of Lacprodan milk protein fractions which can be blended in varying proportions to create staged infant formulas that mimic the nutritional profile of breast milk more closely. Extracted from high-quality whey proteins, Lacprodan ingredients are claimed to provide a suitable amino acid profile to meet the needs of developing infants. This means formula manufacturers can reduce the overall quantity of protein in their products to levels closer to those found in breast milk, but still provide all the nutrients formulafed infants need to develop healthily and grow at a similar rate to breast-fed infants. Arla Foods Ingredients www.arlafoodsingredients.com

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Sep/Oct 2013

INGREDIENTS

Pectinase 872L keeps fruit firm Many food processors or manufacturers experience the problem of soft fruit and vegetables breaking down or becoming damaged during processing. Biocatalysts Ltd, an enzyme specialist based in South Wales, took up the challenge when approached by a customer to increase the firmness of strawberry pieces in its yoghurt following the failed tests of an alternative enzyme manufacturer. Biocatalysts carried out various trials and finally came up with the enzyme Pectinase 872L, which works by catalysing the hydrolysis of the methyl ester bonds in pectin, releasing free carboxyl groups. These free carboxyl groups are then cross-linked with divalent ions such as calcium to form a network of pectin. This essentially means that very soluble pectin is converted into less soluble pectin, which in turn is more likely to stay in fruit tissue during transformation processes. This ensures the strawberries maintain their structure and form within the yoghurt. The company says Pectinase 872L is different to other fruit firming products as it has fewer problematic side activities causing unwanted characteristics. This liquid enzyme can be used not only for strawberries but for any soft fruit or vegetable that is being processed to produce fruit preparations, jams, yoghurts, sauces and so on. The dosage of Pectinase 872L will depend on the type of fruit or vegetables that requires processing and also the process conditions. For this particular enzyme, the optimum pH range is between 4 and 5 and the optimum temperature range is 30 to 50Â°C. Biocatalysts says an improvement in shape, texture and firmness will improve the quality of the final food product; and extended freshness of the produce over time will save money. After all, no manufacturer or processor enjoys spending money to ship fresh produce over long distances only to have it deteriorate quickly from a short shelf life. Biocatalysts Ltd

Fruit pieces, flakes and pastes Taura Natural Ingredients has available a range of premium-quality fruit ingredients, made using its ultra rapid concentration (URC) technology. URC is a process of concentrating the taste, texture and nutrients of fruit into pieces, flakes and pastes for use in applications such as chocolate, breakfast cereals, baked goods, confectionery and snack bars. Three key formats are available. URC Fruit Pieces are a value-added alternative to fresh, sugar-infused or dried fruit, developed for use in a wide range of bakery, confectionery and snack applications. URC Fruit Flakes allow manufacturers to add the taste, colour and nutrients of fruit to cereals, snack and bakery products. URC Fruit Pastes are suitable for use in dry bakery applications, including biscuits, cookies, wafers, baked bars and cereal pillows. Also available is the URC BakeFruit range, which comprises six varieties of fruit pieces. Six flavours are available: Gold Kiwifruit, Apricot, Orange, Blueberry, Strawberry and Honey. The range is Halal and Kosher certified and vegetarian. The range has a high fruit content, bake stability and low water activity. The products are free flowing, create no mess during preparation and can be stored for up to 18 months, with no refrigeration required. According to the company, BakeFruit pieces wonâ&#x20AC;&#x2122;t burn or bleed during baking. In high-moisture applications such as bread and cakes, they absorb moisture to become spots of soft fruit. In low moisture applications, the low water activity ensures they retain their soft texture without spoiling the base product. The URC range is free from preservatives, artificial colours and flavours. Taura Natural Ingredients Ltd Contact info and more items like this at wf.net.au/U514

www.biocatalysts.com

Szechuan pepper extract Kalsec has increased its portfolio of peppers with the addition of Szechuan pepper extract. Szechuan (or Sichuan) peppers have a citrus and herbal aroma that is different from black, white or chilli peppers. Its active ingredient, sanshools, delivers a tingling, numbing sensation in the mouth. The Szechuan plant belongs to the citrus family and is not botanically related to the black pepper or chilli pepper. Szechuan peppers are commonly used in Asian cuisine. Kalsec says the Szechuan pepper extract has an ability to enhance other flavours and so has potential beyond traditional flavouring. Columbit Australia Contact info and more items like this at wf.net.au/S127

Sep/Oct 2013

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Microencapsulated beadlet line of natural carotenoids and vitamins LycoRed has introduced a line of microencapsulated and sustainable natural carotenoid and vitamin beadlets. This highly stable, vegetarian, sustainable beadlet line, manufactured in the United States via an advanced process, will complement LycoRed’s core encapsulation technologies of applied gelatin, alginate and spray-dried coating systems.

INGREDIENTS

Beverage and supplement manufacturers face obstacles when using tablet-grade carotenoids since these lipid-soluble compounds are highly unstable and oxidise very easily. LycoRed says its beadlets are stable, which protects the carotenoids and vitamins from oxidation. The beadlets also are formulated in such a way as to not allow leakage following direct compression - a common problem associated with substandard coating systems. The starch beadlets are designed for use in dry-blend beverages as the coating is water soluble. The starch beadlets are initially available for the carotenoids lycopene, beta-carotene and lutein, and also for vitamin D and vitamin A-acetate. The beadlets are easy to use both for dry-blend beverage mixes and effervescent tablets, as well as hard shell capsules. LycoRed natural carotenoids and vitamin beadlets have several certifications, including NSF, kosher by OU and halal by IFANCA. They are certified vegetarian and vegan. LycoRed www.lycored.com

H184532 Titratable Acidity Mini Titrator for Fruit Juice Analysis

• All-in-One Fruit Juice Titrator, pH meter, and Magnetic Stirrer • Piston Driven Pump with Dynamic Dosing • CAL CHECK™ • Log-on-Demand • Graphic Mode/Exportable Data via USB Port • Automatic Stirrer Speed Control • GLP Feature • Easy to use interface • On-screen titration curve • Supplied with electrode and temperature probe

Tel: 03 9769 0666 Fax: 03 9769 0699 Email: sales@hannainst.com.au

www.hannainst.com.au

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Sep/Oct 2013

Bindaree Beef beats the carbon tax

When Tony Windsor supported the introduction of the carbon tax scheme, Bindaree Beef was the only company in his New England

A.B.N. 22 152 305 336 www.westwick-farrow.com.au

electorate that was to be affected. Now, with the help of a government grant of nearly $23 million and at an overall cost of $46 million,

Head Office Cnr. Fox Valley Road & Kiogle Street, (Locked Bag 1289) Wahroonga NSW 2076 Ph: +61 2 9487 2700 Fax: +61 2 9489 1265

the family-owned company is slashing its carbon emissions and

Chief Editor: Janette Woodhouse wnift@westwick-farrrow.com.au

operating costs and eliminating its carbon tax liability.

Publisher: Geoff Hird Art Director/Production Manager: Julie Wright Art/Production: Tanya Scarselletti, Jeanette Teuma, Colleen Sam Packaging Section Editor: Alice Richard Assistant Editor: Alice Richard Circulation Manager: Sue Lavery circulation@westwick-farrow.com.au Copy Control: Mitchie Mullins copy@westwick-farrow.com.au Advertising Sales National Sales Manager - Nicola Fender-Fox Ph: 0414 703 780 nfender-fox@westwick-farrow.com.au NSW, QLD - Kerrie Robinson Ph: 0400 886 311 krobinson@westwick-farrow.com.au VIC, SA, WA - Sandra Romanin Ph: 0414 558 464 sromanin@westwick-farrow.com.au NZ - Gemma Burr Ph: 0800 44 2529 Fax: +61 2 9489 1265 gburr@westwick-farrow.com.au USA - Huson International Media East Coast Ph: +1 212 268 3344 West Coast Ph: +1 408 879 6666 ralph.lockwood@husonmedia.com

n 2011-12, Bindaree’s total taxable carbon emissions were listed at 28,345 tonnes - which is above the government’s 25,000-tonne direct carbon tax threshold. The company could have made some cheap changes and just snuck in under the threshold, but instead the owners, the McDonald family, spent two years and up to $2 million researching and developing a much more significant approach that will reduce the company’s carbon emissions by a staggering 95.58%. An on-site pilot plant has established that the proposed system is viable and now Bindaree is installing a more energy-efficient rendering plant and directing all of its organic waste through a digester. The company will cut its electricity consumption by up to 50% by using the biogas from the digester to generate clean energy. This will allow Bindaree to replace a coal-fired boiler and reduce its coal consumption by 7200 tonnes each year. The abattoir currently processes around 1100 head per day and these changes will reduce the utility cost of processing each head of cattle by more than one third. At the same time, carbon emissions will be cut by 95.58% and the company will not be liable to pay any carbon tax. The digester will also produce high-quality recycled water for irrigation and organic fertiliser for sale. It is anticipated that the project will deliver annual operating cost savings of $2.44 million to the business and projected income from fertiliser sales of $1.8 million. As an added benefit, the fertiliser sales will create 10 new jobs. 88

Sep/Oct 2013

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

Compare these Blowoffs

Facts about Blowers

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

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

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

Drilled Pipe

Blower Air Knife

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

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

Flat Air Nozzles

EXAIR Super Air Knife

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

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

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

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

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

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

Blowoff Comparison

$954 *Based on national average electricity cost of 8.3 cents per kWh. Annual cost reflects 40 hours per week, 52 weeks per year.

$2,671