food engineering, september 2007

September 2007

www.foodengineeringmag.com

ALSO THIS MONTH■ Raising the Bar on Sanitary Design■ Year of Living Sustainably ■ Bacteriophages: Food Safety’s Newest Weapon? ■ Tech Update: MES Software

ALSO THIS MONTH■ Raising the Bar on Sanitary Design■ Year of Living Sustainably ■ Bacteriophages: Food Safety’s Newest Weapon? ■ Tech Update: MES Software

April 6-9, 2008Sheraton Sand Key

Clearwater Beach, FL

Savethe

Date

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See Food Master, p. 158-159

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Demaco helped to create co-extrusion technology for manufacturing snack foods, pizza rolls, egg rolls, fi lled doughs, and other fi lled products.

New for 2007 — Demaco Systems announces its partnership with Spiral Technologies. Demaco provides the latest in spiral freezer technology and improvements including reduced maintenance, ease of retrofi t for any space, improved conveying confi gurations.

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3www.foodengineeringmag.com Food Engineering September 2007

FF eaea turtur eses Contentswww.foodengineeringmag.com

September 2007

52 COVER STORYGlobalization: Where in the World is Your Supply Chain?Globalization offers opportunities and risks for US food manufacturers striving to optimize their supply chains.

73 Packaging Trends Survey:The Year of Living Sustainably The sustainable packaging bandwagon is gathering momentum,and most food and beverage companies are on board.

85 A Higher Sanitary BarHygiene demands are ratcheting up in facility and equipment design.

103 Tech Update: MES for the Little GuyProcessors with fewer than 100 employees get a boost from MES.

119 Tech Update: Non-thermal ProcessingPut the heat on some cool techniques to kill nasty “bugs.”

127 Seven Ways New Media Will Transform Your BusinessEmbrace new technology tools by managing how and when you receive information.

8 Editor’s Note

10 Calendar of Events

13 Manufacturing News Is China ready for prime time?

15 Food Packaging Special section on materials and containers

21 Technology Sourcebook Focus on Lubricants and Ovens & Dryers

131 Field Reports Larger roasters help processor meet product demand.

133 PROCESS EXPO & PACK EXPO Show preview

160 Classified Advertising

167 Engineering R&D Are bacteriophages food safety’s newestweapon?

86

110

DD eparepar tmentmen tsts

58

15


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FOOD ENGINEERING (ISSN 0193-323X) is published 12 times annually,monthly,by BNP Media II,L.L.C., 2401 W. Big Beaver Rd., Suite 700,Troy, MI 48084-3333.Telephone: (248) 362-3700, Fax:(248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate forsubscriptions to nonqualified individuals in the U.S.A.: $79.00 USD.Annual rate for subscriptionsto nonqualified individuals in Canada:$105.00 USD (includes GST & postage);all other countries:$119.00 (airmail) payable in U.S. funds. Periodicals Postage Paid at Troy, MI and at additionalmailing offices. POSTMASTER: Send address changes to: FOOD ENGINEERING, P.O. Box 2146,Skokie, IL 60076.

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EDITORIALJoyce Fassl Editor in Chief

[email protected], 610-436-4220 ext. 8519

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Wayne Labs Senior Technical [email protected], 215-345-4548

Morgan Smith New Products [email protected]

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8 Food Engineering www.foodengineeringmag.com September 2007

Joyce Fassl Editor in Chiefe-mail: [email protected]

EDITOR’S NOTE

Food Engineering Editorial Advisory BoardDavid WatsonVice President, EngineeringPepperidge Farm Inc.

Greg LissoVP Engineering & Environmental AffairsPilgrim’s Pride

Karl Linck Vice President, EngineeringSargento Foods

Scott ButlerVice President Operations Services Del Monte Foods

Steve KunkleSr. Director, Engineering Planning, Execution & DevelopmentKraft Foods

Peter MigchelsDirector of Engineering, Fresh BakeriesMaple Leaf Foods

Tom WoltersGroup Manager EngineeringFrito-Lay NA, Convenience Foods (PepsiCo)

Sam CaseyDirector of EngineeringH.J. Heinz

Kevin MellorDirector, Process TechnologyConAgra Foods

I guess that’s why they call it work

Food safety, sustainability, plant safety, outsourcing, trade secrets, lack of quali-fied workers. Sound familiar? If you work in the average North American foodor beverage manufacturing plant, chances are you face these challenges each

month and maybe even each day.In order to remain competitive, today’s food engineers have to foster global part-

nerships, cut energy usage, conserve water and get products to market at lightningspeed. And while you are at it, don’t forget to build some rainbow pallets and assem-ble a few meal kits.

It’s no surprise that recent studies say Americans are growing increasingly unhappywith their jobs. A Conference Board report published earlier this year says the declinein job satisfaction has occurred over a period of two decades, with no sign of a signif-icant reversal in attitudes anytime soon.

The breadth of dissatisfaction is somewhat unsettling, says the report, since it carriesover from what attracts employees to a job to what keeps them motivated and produc-tive on the job. Although a certain amount of dissatisfaction with any job is normal,there are things employers can do to improve morale such as an increased focus onlife-work balance.

I find it somewhat ironic that I am writing this column as the Labor Day holidayapproaches. By the time you read this, the holiday weekend will be a distant memory,and you will be back in the office contending with piles of emails, phone calls andpressing projects.

Each week, Food Engineering receives calls from processors looking for help on pur-chasing everything from software to mixing equipment. While we might not alwayshave the perfect answer to your unique challenge, we can certainly help steer you in theright direction. Sometimes it’s just nice to know someone is out there to relieve yourstress in the quest for continuous improvement. Let us know if we can help. ◆


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OCTOBER 20077-10 International Baking Industry Expo 2007, Orlando, FL; The American Bakers Association and The Baking Industry Suppliers Association; www.bakingexpo.org.

11-14 NAMP’s 65th Annual Convention, North American Meat Processors Association; Tucson, AZ; 703-758-1900; [email protected].

13-17 National Frozen & Refrigerated Foods Convention, San Antonio, TX; The National Frozen & Refrigerated Foods Association; 717-657-8601; [email protected].

15-17 PACK EXPO and PROCESS EXPO Las Vegas 2007, Las Vegas, NV; Packaging Machinery Manufacturers Institute and Food Processing Suppliers Association; www.packexpo.com. and www.processfood.com.

24-27 Worldwide Food Expo 2007, Chicago, IL; International Dairy Foods Association and American Meat Institute; 703-645-9302; www.worldwidefood.com.

NOVEMBER 200728-30 PET Strategies, Ponte Vedra Beach, FL; Packaging Strategies; 610-935-2183; [email protected]; www.packstrat.com.

JANUARY 2008 13-16 Northwest Food Manufacturing and Packaging Expo, Portland, OR; Northwest Food Processors Association; 503-327-2200; www.nwfpa.org.

23-25 International Poultry Expo, Atlanta, GA; US Poultry & Egg Association; 770-493-9401; www.internationalpoultryexposition.com.

29-31 Package Design, St. Petersburg, FL; Packaging Strategies; 610-935-2183; [email protected]; www.packstrat.com.

29-31 West Pack, Anaheim, CA; 310-445-4200; www.canontradeshows.com.

FEBRUARY 20084-7 ARC Forum, Orlando, FL; ARC Advisory Group; 781-471-1000; www.arcweb.com.

MARCH 20081-4 Snaxpo, San Antonio, TX; Snack Food Association; 703-836-4500, www.sfa.org.

12-14 Summit Meeting of the Packaging Industry: Packaging Strategies 2008, Weston, FL; Packaging Strategies; 610-935-2183; www.packstrat.com

CALENDAR

Food Engineering www.foodengineeringmag.com September 2007


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MANUFACTURING NEWS

China’s food safety is improving,but is still imperfect, says LuHuisheng, deputy director of the

Chinese State Food and Drug Adminis-tration (SFDA). He said that China hasbeen experiencing a “high-risk period”when other countries’ efforts had alreadybeen intensified in combating foodborneillness outbreaks. Since 2006, the Chinesegovernment has invested $12.43 millionin food safety risk research.

But whether or not it can get its food safety act together for international trade in the foresee-able future, China is aware it will be on the world stage next year as it hosts the 2008 SummerOlympics.Beijing Olympics organizers have unveiled high-tech plans to maintain food safety asthey serve meals to the equivalent of a small city, according to the China Daily.

“Our country and the Beijing municipal government are taking the food safety issue veryseriously, especially for the Olympics,”said Wang Wei, executive vice president of the organizingcommittee. Food delivered to athletes will be closely monitored throughout production, pro-cessing and transport. State-of-the-art technologies such as global positioning satellites will beused to help track food during production and distribution phases.

Other measures include staying vigilant on food safety and enhancing data collection,improving the market entry system for food suppliers and strengthening food safety monitor-ing and supervisory systems.All food entering the Olympic Village will carry a logistics code toenable tracking. The Chinese General Administration of Quality Supervision, Inspection andQuarantine also introduced similar measures to ensure food products for both athletes and thegeneral public will be safe to consume.

Meanwhile, China and the US will work together to strengthen food and drug safety.According to Yan Jiangying, SFDA spokeswoman,“The two sides will increasetechnical exchanges through seminars and training programs, and boostexchange activities between their working staffs.”

Creative Food Products Inc. openeda 27,000-sq.-ft. snack food processingfacility in Bryant, AR, on May 22, 2007.The $2 million facility initially employs20, but at full production is expected torequire 200 employees. The facility willmanufacture a new product calledLeanne’s popcorn chips.

Crown Holdings announced that itsBrazilian subsidiary, Crown EmbalagensS.A., plans to build a $48 million bever-age plant in northeast Brazil. The newfacility is expected to be operational inthe fourth quarter of 2008 and will havean initial capacity of 700 million cans.

DSM has opened a new 10 million europrocess flavors plant in Xinghuo, China.Located near Shanghai, the fully func-tional facility will double the compa-ny’s production capability in flavorsused in culinary and savory productssuch as soups, snacks and ready meals.

YamCo LLC. will open a food manufac-turing facility to process and packagesweet potatoes in Snow Hill, NC, invest-ing $6 million during the next threeyears. The company accounts for about40% of the country’s annual sweetpotato production.

PLANT OPENINGS& EXPANSIONS

China: Ready for prime time?

Farm Bill under fireAfter months of movement through Con-gress in relative obscurity, the Farm Bill isigniting controversy. Everyone, it seems, isfinding something in it not to like. Forstarters, the House version of the bill contin-ues a number of agricultural subsidies for USproducers. Cal Dooley, president and CEO ofthe Grocery Manufacturers Association, saysthe bill will become a “missed opportunity”ifit fails to take a hard look at these long-exist-ing subsidies, many of them established inthe Great Depression. After the House Agri-culture Committee approved the bill in lateJuly, Dooley characterized the measure as a

failure, at least whenit comes to reform.

“The bill approved by theHouse Agriculture Committeewould actually increase food and commodityprice distortions, does nothing to reducefarm subsidies and has the potential to actu-ally increase government payments towealthy farmers,”Dooley said.

Domestic food producers and manufac-turers are also displeased with an aid provi-sion contained in one version of the bill.Instead of purchasing domestically pro-duced food products and shipping the aidto countries in need,the US would purchasefood products in the country, or region,where the recipients live.

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MANUFACTURING

The Boston Beer Company has signed a purchase and saleagreement with Diageo North America to acquire a brewerylocated 60 miles outside of Philadelphia, PA, for $55 million. The purchaseis expected to take place in late spring 2008. It is expected that the Pennsylvaniabrewery will initially increase Boston Beer’s capacity by approximately 1.6 mil-lion barrels annually.

KHS named Michael Brancato as president of KHS USA Inc.,overseeing the operations in the US and Canada.Brancato waspreviously director of sales for the KHS beverage division.

FDA, which is responsible for overseeing about 80% of theUS food supply, has suspended plans to close seven of its

13 labs around the country. Andrew von Eschenbach said plans to keep thefacilities open was viewed by some lawmakers as essential to protecting thefood supply from tainted products.

PPM Technologies, a newly formed corporation, has signed an agreement withFMC Technologies to acquire Allen Systems and PPM, suppliers of global foodprocessing and packaging technologies. Wright Capital Global Equities will fundthe PPM Technologies business.

GE Fanuc Automation has entered into an agree-ment with Pepperl + Fuchs North America to

provide interface components for industrial automationsystems including Profibus and digital fieldbus communications.

The Food Packaging Division of the Instituteof Food Technology (IFT) awarded the Riester-Davis Award to Tom Powers (left), director ofmarketing and R&D at Multisorb Technologies.Powers received the award for innovative contri-butions over 35 years to the field of food packag-ing technology. His expertise includes moisture

management technologies and oxygen scavengers.

Larry Pereira has joined SensorLogic as vice president of marketing. Pereirawill remain actively involved in the development of wireless standards for indus-trial sensors, including the ISA100 initiative.

David R. Underwood has been named president, Cown Food Packag-ing, North America. He previously served as president, Crown AerosolPackaging USA.

INDUSTRY & PEOPLE

BRANCATO

NEWS

Ph: 616-399-2220 • Fx: 616-399-7365 • 12838 Stainless Drive • Holland, MI 49424www.nbe-inc.com • email: [email protected]

Bulk Bag Discharger With Integrated Bag Conditioning Technology

• Unquestionably the most efficient and effective way to discharge severely hardened materials like salts and seasonings from Bulk Bags.• Conditions and Discharges in one step instead of two, increasing productivity 30% or more over the use of stand alone Bulk Bag Conditioners and Unloaders.• Deblocking Rams fully extend into the center of the bag while material discharges, eliminating large lumps that can drop and block the discharge spout.• Spout Lump Deblocker breaks apart lumps that can get caught in the discharge spout to ensure an uninterrupted flow of material from the bag.• Crumbler lump breaker further reduces material to conveyable particle sizes.

RIESTER-DAVIS AWARD


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Clearer, toughervacuum bags

S P E C I A L S E C T I O N

Vacuum bags with high oxygen-barrier propertiesare fresh-meat workhorses, and the newest genera-tion of B 2000 bags from Sealed Air Corp.’s Cryovac

Food Packaging division overcomes the aesthetic shortcom-ings of older bags.

The bags debuted at the beginning of the year, with cheese,smoked meats and pork products leading the conversion. New

resins and improved extrusion processes enabled Cryovac engi-neers to improve the optical properties of the bags. Retailers want

bags that look great in the meat locker, and that was becoming a big-ger challenge with the growth in “moisture enhanced products,”

according to Walker Stockley, Cryovac’s marketing director of freshred meat.

A recent meat case study by Cryovac found that up to 45% of thepork now in stores has sodium phosphate, water or both added to the

original cut. Sealing those products has required more opaque films toprevent leakers. The B 2000 allows packers to add their marinade and

keep it, too.Percent of diffused light is one metric used by film suppliers to measure

clarity. The new films have only 4.1% haze, down from 6.9% in the last-gen-eration film. Clarity and greater shrink give products a glossy look, and nom-

inal shrink went from about 77% to 89%, Stockley says, resulting in “smallercorners and ears.”

The new familyof fi lms is also

tougher.In field tests,impact resistance of

the new bags has beenmeasured at 243 new-

tons, up from 198.“There’s a noticeable

improvement in gloss,clarity and sealability, and

food companies can getthe better performance on

exist ing vacuum equip-ment,” says Stockley.

For more information:Walker Stockley,

Cryovac Food Packaging,864-433-2000

■ Kevin Higgins, Senior Editor

Enhanced clarity and a tighter fit are among theimprovements in Cryovac’s B 2000 series vacuum barrier bag.

Source: Cryovac Food Packaging Systems.

Controlled atmosphere packaging (CAP) for fresh-cut fruits and veg-etables typically has required lasers to produce micro-perforatedfilms, driving up costs. A mechanical process from the German

firm Multivac is changing the cost equation for processors in Europe.Known as FreshSAFE, the microscopic perforations can be pro-

duced in line on a packaging machine’s upper web or before thefilm arrives at the plant. Either way, packagers benefit fromlower film costs.

Multivac researchers have worked with food scientists at theUniversity of Gent and University of California-Davis to deter-mine the optimum exchange ratios for oxygen,carbon dioxideand nitrogen for a variety of produce, both cut and whole.Companies in five European countries are using FreshSAFEto extend shelf life without preservatives or gas.

The Greenery, a major fruit company in the Nether-lands, had used clamshells to pack up to 1,000 tons ofstrawberries a week. Using a Multivac T-350 tray-sealer with a micro-perforator, the company wasable to extend shelf life to nine days from six whenstrawberries are stored at 12˚C (54˚F). Similarly,France’s Mandar uses an R-530 thermoformerto automatically load freshly cut mango cubesfrom above the molds, then seals the packwith previously micro-perforated film onthe machine’s upper web. The finishedpackage is stackable.

For more information:Jerry Hirsh, Multivac Inc.,816-801-3974,[email protected]

Precision perforationsaid CAP films

Micro-perforations in the

upper film extend shelflife without preservatives orgas in packages of fresh-cut

mango from Mandar in France.Source: Multivac SeppHaggenmuller GmbH.


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Engineering an easier-to-scoop icecream container requires a lot ofwork—by dairies, packaging

companies and material suppliers. Just ask thefolks at Wells’ Dairy Inc.A leading private-label ice cream supplier, Le

Mars, IA-based Wells’ decided in 2005 that its BlueBunny brand could benefit from a more innovative

package than the cylindrical paperboard container thatcontinues to serve Wells’ private-label products. Dreyer’s

Grand Ice Cream was having great success with the bite-sizedDibs novelty items in a small plastic tub, and Wells’ marketers

thought a polypropylene 56-oz.container could bring excitementto its ice cream business, too. They were right: Blue Bunny sales

spiked 12.5% in 2006, according to IRI retail scan data, making it oneof the fastest growing brands in the country.“It’s really going gang-

busters in the Northeast, with grocers broadening the assortment of BlueBunny products in their freez-

ers,”reports Lesley Bartholomew,Wells’ communications manager.To execute the change,Wells’ spoke

with several injection molders beforeselecting Omaha-based Airlite Plastics

Co. Tooling and robotics systems had to bebuilt to execute an in-mold labeling process

which fuses a preprinted label to thepolypropylene during injection molding. The

five-color label is offset printed in Belgium by Ver-staete and “enables us to have cutting edge graphics

that help the product stand out on the shelf,” adds Bartholomew.The container also has a tamper-evident lid that snaps into a depres-

sion in the lip and a tapered profile that makes scooping easier andeliminates what Wells’ marketers term “knucklemuck.”A key supplier to Airlite is Basell North America Inc., Elkton, MD. Coin-

cidentally,Basell also supplies the resins used to make the Dibs container.How-ever, the Blue Bunny container is bigger and heavier,so a more impact-resistant resin

was needed. Basell’s EP390S copolymer fit the bill.“Theoretically, dropping it 3 ft. onto a con-crete floor at -40ºF will not crack or break it,”according to Dave McKeeman,Basell’s marketing manager,rigid pack-

aging.“It can withstand microwave temperatures, and Wells’ is encouraging reuse of the container with a ‘dishwashersafe’ statement on the container.”Instituting the changeover in Le Mars was a big commitment.“We had to change the fillers, the lidders and adjust all the

downstream material-handling equipment,”says Bartholomew.A two-week scheduled shutdown at one of Wells’plants pro-vided the necessary window.

For more information: Dave McKeeman, Basell, 410-996-1314, [email protected]

Containeris a winner

Bold lithographyand a superhero tie-in

resulted in a quicksellout of Delacre cookies at Carrefour supermarketsthroughout France this summer, prompting plansfor another limited edition container in Belgium

in October when the Spiderman 3 DVD isreleased in Europe.

“We wanted to offer our target audience—fami-lies with children—a fun, delicious and reusable keepsake

to remind them of their favorite superhero,” says Annabelle Millet,a spokesman for United Biscuit. “We’re thrilled with the success.”

United Biscuit worked with Crown Holdings to create thecross-promotional tins showing Spiderman in variousaction poses. The tins, timed for the movie’s release inFrance and Belgium, contained a six pack of premiumDelichoc Belgium chocolate cookies. Mini BN Chocoand Mini BN strawberry cookies will be in theOctober tins.

“Quality printing of the vivid color graph-ics was an essential element to the successof the design,” notes Liz Goodwin, mar-keting manager with Philadelphia-based Crown.For more information:Liz Goodwin,Crown Specialty Packaging USA,410-273-1885, ext.234, [email protected]

Spidermantin clickswithFrench

Wells’Dairy credits a switch to

an injection-moldedpolypropylene container with asnap-in, tamper-evident tab for

helping drive a 12.5% gain in BlueBunny ice cream sales last year.

Source: Basell NorthAmerica Inc.

High-quality printing

and a reusable tinhelped Spiderman move

lots of cookies in France thissummer. Source: Crown

Holdings.


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Create the perfect floor with Eco-ProTekt and 135 years of flooring experiencefrom Tennant Company. Eco-ProTekt offers:

STABILITY – under extreme thermal variations, from -330º F to +240º F.

––––

RESISTANCE – to bacterial growth.

––––

PROTECTION – against harsh conditions thanks to superior durability andchemical resistance.

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PEACE OF MIND – backed by unwavering service and support from TennantCompany’s professionally certified, locally based independent installers.

BEFORE AFTER

TENNANT COATINGS: For First Impressions That Last™

Call 800.228.4943 today to schedule a free floor-care survey,or visit www.tennantco.com/food-beverage.

Eco-ProTekt™ Floor Coating:Superior stability, proven protection.IDEAL FOR FOOD AND BEVERAGE PROCESSING PLANTS.


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Gentleman Jackis best in glass

The best-in-class container made of glass in2007 is Brown-Forman’s Gentleman JackRare Tennessee Whiskey, according to the

Glass Packaging Institute (GPI).High margins and image-selling enable distillers

like Brown-Forman to raise the container aestheticsbar, particularly for premium brands. The twice-charcoal mellowed variety of Jack Danielswhiskey was due for a package update after 19

years, and Owens-Illinois Inc. obliged with asloped-shoulder bottle with an embossed signa-ture and brushed silver foil label. The Lynch-burg, TN, distillery started filling the new bottles

in January.For manufacturers with more limited budgets,

applied ceramic labeling (ACL) was a more popularchoice. Vitro Packaging Inc., Plano, TX, used ACL silkscreening technolo-gy on two of its five GPI award-winning designs.Vitro captured almosthalf of GPI’s 11 awards.

ACL’s heyday ended with the passing of the returnable bottle,which needed a painted label to withstand multiple trips throughwashing and filling cycles. Its future was threatened when Califor-nia banned the lead-based inks that give the labels vibrant color.Vitro resolved the issue with precious metals, an eco-friendly solutionthat restored ACL’s stock with organic food companies. One of them, Frütz-zo Organic Pomegranate Acai juice, was GPI’s winner in the organic bever-age category.

UV curing technology also comes into play with the alternative inks,explains Doug Hesche, Vitro’s vice president-sales & marketing. Thelabels are baked onto the bottle in a lehr at temperatures between500˚ and 600˚F.

Sustainability is another draw for glass, and that’s a big-ger draw than vibrant colors for organic-products mar-keters. Depending on the color and availability ofrecycled glass, as much as 90% of a glass contain-er’s content can come from recycled bottles,Hesche says. Recycled glass also allows theovens to run cooler, lowering the process’scarbon footprint.

For more information:Doug Hesche,Vitro Packaging,469-443-1123,[email protected]

Carbonneutral

and refreshing

Distilledspirits set the

aesthetic standard for glassbottles (left), but sustainability

is emerging as the material’s keypackaging attribute (right).Source: Glass Packaging

Institute.

Thecraggy outline of

a glacier is captured inthe well-traveled bottles

of Icelandic Glacial water. Source: Icelandic

Glacial Inc.

Getting on the shelf with an attractive container may no longerbe enough to sell premium bottled water: Discriminating con-sumers want energy offsets, too.

Icelandic Glacial Inc. elbowed its way onto the overcrowded shelves at WholeFoods, Super Target and other stores a year ago with a PET bottle blow-molded to

resemble a glacier formation. The bottles are designed and produced in the UK by Lon-don-based Design, Bridge and Bath-based Zenith, then shipped to Iceland for filling and

international shipment.Thousands of miles of diesel-powered transport contradicts the goal of sustainability, however,

so Icelandic Glacial secured the first carbon-neutral certification for bottled water from the Carbon-Neutral Co., London.

“There’s been some criticism recently about shipping bottled water long distances,” notes Patrick Racz, aLondon entrepreneur and 20-year veteran of the purified water business. When the product’s unique selling

proposition is purity, greenhouse gas is unwelcome baggage. Hydroelectric and geothermal power used in his prod-uct’s production is enough to offset the CO2 emissions generated in distribution, Racz says, and that enables Icelandic

Glacial to claim,“We don’t have a negative impact on the environment.”


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People.It takes great people to build a great company.

Baldor, Dodge and Reliance are fortunate to

have so many great people who have earned

a reputation of being the best in the industry in

product marketing, design and manufacturing.

Now we have brought these three great

companies together. Combined, our company

is over 8,000 employees strong, committed to a

common goal of “producing the highest quality

products for our valued customers.”

Our experienced people in manufacturing

facilities and sales offices around the world

will carry forward a combined 300-year

heritage, writing the next chapter in the book of

manufacturing excellence, product innovation

and customer service.

www.baldor.com

Bringing the Best Together

©2007 Baldor Electric Company See Food Master, p. IFC15


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TECHNOLOGY SOURCEBOOKFocus on Lubricants, Ovens and Dryers

Heavy-duty checkweigherDesigned for use with products up to 500 lbs., theThompson 4693 heavy-duty checkweigher can weighbagged products, boxes, cartons and pails at angles up to+/-12°. A pop-up reject mechanism provides quick rejec-tion of off-spec items, while the checkweigher’s internallycontrolled pacing conveyor ensures properly spaced pack-ages across the scale. A variety of weigh station conveyorsthat run at speeds up to 220 ft./min. is available.Thompson Scale Company; 713-932-9071;www.thompsonscale.com

Wraparound labeling systemDesigned for hazardous environments, Quadrel’s labelingsystem applies wraparound labels to glass and cylindricalcontainers measuring from 1 to 4 liters or can be modifiedto apply front/back labels. The system, which includes aconveyor, labeling head, head support, wrap station andrails, is completely constructed of corrosion-resistant 316stainless steel.Quadrel Labeling Systems; 800-321-8509;www.quadrel.com

Heavy-duty greaseIntended for use in harsh production environments andmachinery requiring frequent re-applications of grease,Shell FM grease HD 2 provides oxidation and mechanicalstability, washout resistance to hot/cold water and corro-sion prevention. It can be used as a lubricant, anti-rust filmor release agent. Neutral in taste, smell and color, the greaseis registered by NSF (Class H1).Shell Lubricants; www.shell.com/us/lubricants

Biodegradable hydraulic fluidDerived from vegetable seeds, Cosmolubric FG-46hydraulic fluid is biodegradable, meets USDA H1 lubricantrequirements for incidental food contact and doesn’trequire treatment as a hazardous waste. The oil maintainsa low total acid number, high viscosity index and highflash/fire points. It is appropriate for equipment used in themanufacture of snack foods, baked goods, meat, poultry,soft drinks, seafood and fruit.Houghton International Inc.; 610-666-4095;www.houghtonintl.com

Miniature batch mixerMunson’s MX-5-SS miniature rotary batch mixer blendsingredients in ratios to one part per million in less thanthree minutes. With a 10-cu. ft. drum capacity and 500-lb.,5-cu. ft. batch capacity, the mixer blends batches that com-prise 5-100% of the rated capacity. The rotating drum hasmixing flights that tumble, turn and fold material. Therotating vessel and internal flights lift and direct an entirebatch through a plug gate valve for complete evacuation.Munson Machinery Company, Inc.; 800-944-6644;www.munsonmachinerycom

Scale integratorThe Siemens Milltronics BW500 belt scale integrator hasNTEP certification of conformance for weighing and measur-ing devices. Intended for use on fast-moving belts, short idlerspacing and light or uneven belt loading, the BW500/MMIsystem weighs two-thirds less than other belt systems. Acrane is not required to transfer the BW500/MMI scale pack-age to the installation point.Siemens Energy & Automation; 215-646-7400, x2592;www.usa.siemens.com

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PlateCheckPlateCheck

Eastern10129 Piper LaneBristow, VA 20136703.257.1660800.825.8820FAX 703.330.7940

Western9109 SE 64th AvePortland, OR 97206503.774.7342800.715.8820FAX 503.774.2550

AGCENGINEERING

New UnitsOver 40 modelsto choose from

Hydraulic Frames2X Faster!

PlatesandUpgrades

Field LeakChecksthe only all-inclusiveleak check service

GasketsandRegasketingAll Makesand Models

Building the BestServicing the Rest™


TECHNOLOGY SOURCEBOOK

Synthetic lubricantAvailable in ISO 150 and 220, Shell Lubricant’s Cassida fluid GLE is odorless, tastelessand nontoxic. A full-synthetic lubricant, the fluid emulsifies water in gear reducers,aiding in the reduction of deposit and sludge formation. Suitable for facilities wherevegetarian and nut-free food are produced, the lubricant does not contain any nat-ural products from animals, nuts or GMOs and is Kosher- and Halal-certified.Shell Lubricants; www.shell.com/us/lubricants

High-performance vacuumsSuitable for continuous-duty applica-tions, Nilfisk’s CFM 08 series vacuumscollect and retain contaminants suchas dust, bacteria and food scraps. Thevacuums’ filtration system has HEPAand optional ULPA filters that trap upto 99.999% of ultra-fine particles toprevent cross-contamination. Themodular vacuums can be customizedbased on the type of materials beingcollected.Nilfisk-Advance America, Inc.;610-232-5469;www.pa.nilfisk-advance.com

Pressure gaugesAshcroft’s ASME grade 2A 1200 seriespressure gauges can be used for a vari-ety of processes. Type 1259 is intendedfor basic applications. The type 1279Duragauge is suitable for use in thepresence of harsh pressure media, firehazard or extreme cycle volumes. Thetype 1279 Duragauge plus pressuregauge dampens pointer flutter withoutliquid fill in rigorous installations withpulsation and vibration.Ashcroft Inc.; 800-328-8258;www.ashcroft.com

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See Us at the Process Expo at Booth 6812

Fluorinated greaseCompatible with most rubbers and plastics, Molykote HP-300 fully fluorinatedgrease withstands low and high temperatures, corrosion, solvents, liquefied natu-ral gases and high vacuums. The grease is NSF-H1 approved for applicationsinvolving incidental food contact, has a temperature range of -65˚ to 250˚C andresists oxidation.Dow Corning; 202-478-3548; www.molykote.com

Bottle testingAgr’s testing package for aluminumbottles includes a high-precisionautomated dimensional gauge formeasuring the unique attributes ofbottles; a pressure tester for buckleand bottom roll-out tests; dual-pur-pose tester for fill point volume meas-urement and top-load tests; and thick-ness gauge for material distributionmeasurement. Each instrument canbe purchased individually. Most of theinstruments can be used to test alu-minum beverage cans as well as alu-minum bottles.Agr International, Inc.;724-482-2163 ▼

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When consumers open the bottle, they’re expecting fresh-picked flavor. Thanks to the Evergreen Unibloc bottling machines, with advanced AVE® filling technologies, that’s exactly what they’ll get.

From rinse to seal, HEPAfiltration and auto sanitizationin the fill section create aclean room environment to protect all the goodness and flavor consumers are looking for. Whether you bottle in PET, HDPE or glass, then seal it with a snap, screw or foil lid, the BFC machines offer extremely efficient fills at speeds up to 84,000 bph.*

To learn more about the high-speed gravity or electronic fill Unibloc bottling systems and the local 24/7 after-sale service that comes with it, talk to the shelf life people at Evergreen.

Any fresher and it would

still be on the tree.

* 500ml water© 2007 Evergreen Packaging. All rights reserved.AVE is a registered trademark of AVE Industries S.P.A.

EVERGREENPACKAGING EQUIPMENT2400 Sixth Street SWCedar Rapids, IA 52404 USAT 319-399-3200F 319-399-3543E [email protected]

Booth S-5484

Booth S-4500


Hydraulic motorsWhite Drive Products’ low-speed, high-torque WG serieshydraulic motors have continuous flow rates up to 57 LPM (15GPM), torque to 548 Nm (4850 lb.-in.) and pressures up to 138bar (2,000 PSI). Available with 12 displacements from 41cc andrevolution to 404cc, the motors come with six shaft options,five mounting options and various porting options.White Drive Products; 270-885-1110;www.whitedriveproducts.com/wg.html

High-dispersion air classifiersThe Netzsch-Condux CFS HD-S line of high-dispersion,ultra-fine air classifiers separate particles of any hardness inthe range of 1 to 50 mm. The classifiers disperse materialclose to its wheel to prevent re-agglomeration, while thespiral design housing guides coarse fraction to its own out-let. Fines are carried with the classifying air through thewheel to a separation cyclone or baghouse.Netzsch Fine Particle Technology, LLC; 484-879-2020;www.netzsch.com

Laser-marking solutionApplied to the substrate in coatable or ink form by a papermanufacturer or converter, non-pigmented Ciba’sPergamark laser-marking solution yields stable, high-con-trast black images. With all non-toxic additives and no inkat the point of printing, Pergamark allows variable data tobe printed on demand with a low-power CO2 laser in thefinal stage of the packaging process. All components ofPergamark are in line with food contact regulations.Ciba Specialty Chemicals; www.cibasc.com

Motor driveThe Leeson SM2 series Flux Vector drive, with a powerrange up to 25 hp, is designed for operation with vectorduty-rated induction motors in packaging machinery, foodprocessing machinery, materials handling/conveying sys-tems and HVAC systems. Suitable for demanding applica-tions, the drive includes four modes of operation, as well ashigh starting torque, autotuning, advanced low-speed con-trol and dynamic speed regulation.Leeson Electric; 262-387-5410

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SPRINTDIVERSACUT

™

NEW HIGH PERFORMANCE SMALL DICER

THE SAME RUGGED MACHINE AS THE DIVERSACUT 2110® DICER IN A MORE COMPACT SIZE.

The DiversaCut Sprint™ Dicer, byUrschel Laboratories, is the new highperformance dicer designed to uniformlydice, strip cut, and slice a wide varietyof vegetables, fruits, and meats.

Efficiency and flexibility are key traits of the Sprint. The compact machine size combined with the ease ofswitching over from one cut size or typeto another deliver infinite productionpossibilities.

Maximum product input size is approxi-mately 6.5" (165.1 mm) in any dimension.

The Sprint produces a myriad of flat orcrinkle slices, strip cuts, and dices ranging from 1/8" up to 1" (1.6 mm up to 25.4 mm).

Contact your local Urschel representativefor more information or to schedule a complimentary test cut of your product.

Urschel Laboratories, Inc. PO Box 2200, 2503 Calumet Avenue, Valparaiso, IN 46384-2200 U.S.A Phone: (219) 464-4811 • Fax: (219) 462-3879 • Email: [email protected] www.urschel.com® Urschel and DiversaCut 2110 are registered trademarks of Urschel Laboratories, Inc. ™ Sprint is a trademark pending of Urschel Laboratories, Inc.See Food Master, p. 173-179


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Industrial hubA standalone device that can be used as a Level 2 hub in standard Ethernet or real-timeindustrial Ethernet Powerlink networks, the AC808 hub automatically recommends correcttransfer speeds and configures the respective channels to them. With the hub, pin assign-ments can be crossed for the first channel using a switch, enabling the use of the same typeof cable for connections between hubs and between the hub and network station.B&R Industrial Automation Corp.; 770-772-0400; www.br-automotion.com

Interlocked receptacleRated NEMA 4X, Appleton’s ASR non-metallic interlocked receptacle isdesigned for use in adverse locations,such as damp or wet environmentswhere a service outlet is required forelectrical equipment. Compact insize, the receptacle has an inter-locked switch to prevent accidentalplug removal, bottom-mountedinternal hinges, enclosed disconnectswitch and self-cleaning contacts,movable mounting feet and internalmounting tubes.Appleton; 800-621-1506;www.appletonelec.com

Specialty pouchesAvailable in sizes from single-serve tosuper-size, CMS’s Flavorseal pouchescome unprinted or custom-printedand in flat or gusseted stand-up styles.The pouches are available with hang-ing punch holes and tear notches orreclosable zippers for specific shelf liferequirements. Small, medium or largeproduction runs for finished productsare available.Carroll Manufacturing and Sales;866-769-1500;www.carrollmfg.com

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Sanitary Grade Forged for Strengthand Durability

Food • Dairy • Beverages • Wine • And More

30271 Tomas Street • Rancho Santa Margarita, CA 92688 • Tel. 949/589-3978 • Fax 949/589-3979

Email: [email protected] • Website: www.ciprianicorp.com

Replenishment systemDesigned for less-than-full case picking, FKI’s automated replenishment systemuses mini-load cranes to provide continuous, demand-based replenishment.Dynamic slotting logic in the system minimizes the number of flow lanes requiredto service orders. The system maintains a balance of static locations and dynamiclocations that can be reassigned.FKI Logistex; 314-993-4700; www.fkilogistex.com

Tubidity analyzerDesigned for potable water plants,Emerson’s model 1056 turbidity ana-lyzer is available with a universal AC-driven or 24 VDC power supply andprogrammable power alarms that aretriggered when set thresholds arereached or process events occur. Theanalyzer offers a choice of measure-ments: turbidity, pH/ORP/ISE, conduc-tivity, oxygen, chlorine, ozone andother combinations.Emerson Process Management;512-832-3162; www.emerson.com

Metal detectorDesigned primarily for dried foodmanufacturers, Lock’s MET 30+ 3f/hffully automated triple frequencymetal detector can be used to inspectpoly-film and metallized packagedproducts. The metal detector’s auto-matic product set-up facility has set-tings for up to 100 products, while theautomatic frequency selection featurechooses the optimum frequency foreach product or packaging, includinga high frequency at 875 Khz.Lock Inspection Systems, Inc.;978-343-3716;www.lockinspection.com

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Industrial computer enclosuresPC Enclosures, Inc.’s WS-1721 and WS-2015 industrial computer enclosures offer protection fromdust, water, heat and oil. All cables and filtered air enter through the bottom of the enclosures tokeep harmful elements out. Compact in size, the enclosures house any LCD monitor and a small-to medium-size computer tower.PC Enclosures, Inc.; 866-646-4383; www.pcenclosures.net

Inspection sensorsCognex’s Checker 200 series sensorsoffer variable working distance andinspection capability rates faster than6,000 parts/min. The sensors over-come varying part positions on theline and deliver precisely timedpass/fail results. Intended for food, bev-erage and consumer product packageinspection, the sensors have IP67 hous-ing and quick disconnect cables.Cognex Corporation;877-264-6391; www.cognex.com

Sanitary conveyorUSDA-certified, Dorner ’s AquaPruf7600 ultimate series conveyor isdesigned for use in environmentswith high-pressure sanitary require-ments, such as ready-to-eat foods,raw protein or dairy production. Theconveyor comes with a positive-driv-en solid urethane belt that has nobacteria-harboring hinges or pinsand resists stretching in humid con-ditions. The conveyor meets NSF andAMI design specifications.Dorner Manufacturing;800-397-8664; www.dorner.com

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Basket strainerEaton’s model 72 basket strainer protects piping system components by removingdamage-causing material from the liquid process flow. Large in size, the strainerbasket is available in stainless steel, brass or a number of alloys and has openingsfrom 40 microns to 0.5 in. in size. A free straining area helps to reduce the initialpressure drop across the strainer. The basket strainer is rated to 200 psi at 100˚F.Eaton Filtration LLC; 908-787-1000; www.filtration.eaton.com

Lubricant plus antimicrobialFully compliant with FDA and EPArequirements, Petro-Canada’s PurityFG NSF H1 industrial-strength foodlubricant with Microl is manufacturedfrom 99.9% pure base oils. Microlmeets all necessary food safety andregulatory requirements and is thefirst EPA-registered antimicrobialfood-grade lubricant additive. PurityFG with Microl is available as a grease,hydraulic or gear fluid.Petro-Canada; 800-268-5850;www.petro-canada.com

Tamper-evident closureOwens-Illinois’ EasySeal HT compres-sion-molded 70 mm tamper-evidentwide-mouth closure works on glass orPET containers. Eliminating the needfor a separate PVC shrink band or foilliner, the closure’s barrier and non-bar-rier liners are FDA-compliant and non-PVC-based.Owens-Illinois Closure & SpecialtyProducts; www.o-i.com

Temperature control unitSterling’s 2010 temperature controlunit features a simplified internal castor non-ferrous circuit, as well as ahigh-efficiency pump for higher flowrates at lower pressure. Equipped witha NEMA 4X stainless steel enclosureand wash-down motors, the unit hasan operating leaving water tempera-ture range of 32˚F to 250˚F.Sterling; 262-641-8610;www.sterlco.com

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Single planetary mixerEquipped with a custom helical mixingblade, Ross’s single planetary mixer isused to mix high-viscosity paste materi-als. It comes with a mix can with a dishedbottom and 6-in. flush discharge valve; anair/oil hydraulic lift to raise and lower theagitator; and NEMA 4 panel purged forCI1 Div 1 hazardous areas.Charles Ross & Son Company;800-243-ROSS

Air impingement systemUsing high-velocity air jets that impingeair through the product bed onto a non-perforated conveyor, Aeroglide’s Aero-Flow system creates a gentle fluidizingaction as the product bed is dried.Designed for a variety of food products,the system handles a wide range of par-ticle sizes and densities.Aeroglide; 919-851-2000;www.aeroglide.com

Controller and drivesA fully integrated control solution, theFesto SMLC multi-axis controller provideshardware and software building blocksengineered to plug together easily. FestoSEC-SDD drives simplify servo systemtuning by making loop adjustmentsbased on motor and load inertia madevia the drives’ configuration tool.Festo Corporation; 800-99-FESTO;www.festo.com/usa

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HOW FINE IS FINE?In 2006, CESCO Magnetics introduced a new generation of extra powerful magnetic chutes, ducts, grates, and line traps to remove ferrous and stainless trash metal fines that evade detection by state-of-the art metal detectors and Xray inspection equipment.

In 2007, CESCO awarded Iowa State University a grant to measure just how “fine” those metal fines includingferrous, and 316, 304, or 430 stainless steel shear could be – the answer as shown in the photo taken by ascanning electron microscope is 0.001102 inches.

Replacing a five-year or older magnetic separator could increase your separating and holding power by as much as 300% - and all CESCO magnetic separators carry a LIFETIME GUARANTEE againstmanufacturing defects.

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How important can the right lubricant be to your company’s bottom line? More than you might think. Because lubricants typically make up only 1% of a company’s total operating costs, many lubrication programs do not receive the attention they deserve. However, the surprising truth is that the lubricants a company chooses can have a significant impact on high-visibility and high-value line items such as energy, labor and equipment costs.

Price versus costIdentifying the true cost of your lubricant program is the first step in optimizing your plan to positively impact your bottom line. When analyzing your current lubrication program consider how much lubricant you’re using, how often you relubricate and how much time that relubrication takes. If you already have a handle on these numbers, you’re well ahead of the game. If you don’t, take some time to establish a baseline so that when considering alternative products you can conduct an “apples to apples” comparison. By tracking these variables, you will come to realize that the true cost of your program includes much more than the price per kilo or price per liter of your lubricants.

Now that you have a firm grasp on the true cost of your company’s lubrication program, the next step is to evaluate where savings are possible. Let’s take a more in-depth look at the factors involved.

Increased productivity is the name of the gameFacilities are constantly pushed to increase productivity while reducing maintenance and operating expenses. Any time your equipment is idle, you’re losing productivity. While some maintenance, including lubrication, can be completed while your line is in operation, some has to be conducted during downtime. This is not a huge inconvenience if you have regularly scheduled downtime that coincides with your relubrication schedule. However, if you have to bring a machine down once a shift specifically to relubricate, that’s money taken away from the bottom line every shift. What if you were using a lubricant that extended that relubrication interval to once a month?

Consider, for example, a manufacturing facility in the food and beverage industry running nine lines, with a total operating time of 8,000 hours per year. Their current bearing lubricant requires re-lubing once a week. By using a specialty synthetic lubricant, their relubrication interval could be extended to once a month. This not only saves time but also reduces consumption.

Reducing maintenance costs and operating expensesIf your plant is like most, there is probably a “wish” list of maintenance projects just waiting for the man-power and time to get them done. While even the best lubricant can’t create time, an optimized lubrication program can help free-up resources to accomplish those tasks. If your lubrication specialist is able to extend relubrication intervals through the use of synthetic, newer-generation products, you can do more with the same staff and with the same time. In our case study, the facility had the potential of reallocating almost 1,500 man-hours annually. Just imagine what could be accomplished in that time!

Used-lubricant disposal is also a variable in calculating the costs of your lubrication program. Extended lubrication intervals impact these figures. If you’re using less lubricant, you’re disposing of less lubricant — another savings

Cutting Your Costs by Not Cutting Corners

To learn more about the specialized world of Klüber lubricants, visit our web site at www.kluberna.com/cba.

We lubricate your world.

Lubrication is our World

to the bottom line. And don’t forget your spare parts inventory. Proper lubrication can help your machinery and its components last longer, which means less money spent on repairs or rebuilds. Your equipment is a major investment and should be maintained accordingly.

Another factor many companies fail to consider is how much energy a company can save by utilizing highly efficient gear oils. The right lubricant can reduce the coefficient of friction, resulting in less power loss. In other words, the right lubricant equals less required energy, leaving you with a lower energy bill at the end of the month. All of which serves your bottom line.

Lubricants on your line affect your bottom lineIn order to avoid the pitfalls of purchasing lubricants based solely on price, evaluate your current program and then request a comparative cost benefit analysis from your potential supplier. Simple calculations can reveal significant savings that aren’t always evident in the initial cost of a lubricant. If you’d like to see how a lubricant that costs twice as much as its competition can actually SAVE money, please see the chart below. The numbers tell the story.

If you’d like to run the numbers for your plant, please contact Klüber Lubrication at 800.447.2238; an application engineer would be happy to visit your plant to conduct a complimentary cost benefit analysis and recommend ways to optimize your program.

Lubricants for Conveyor Bearings Competitive Grease

Klüber Grease

Cost per Kilogram $8.63 $17.78

Cost to Re-lubricate Bearing (assumes 3g per re-lube) $0.026 $0.053

Re-lubes per Year 52 13

Annual Lubrication Cost (re-lubes per year x cost to re-lube) $1.35 $0.69

Annual Labor Cost (1/60th of an hour x $30/hr labor cost x re-lubes per year) $26.00 $6.50

Total Annual Cost per Bearing $27.35 $7.19

$0.69

$6.50

$17.78

$0.053

13

Lubricants for Conveyor Gearboxes Competitive Oil

Klüber Oil

Cost per Liter $7.01 $14.56

Cost to Re-lubricate Gearbox* (assumes .5 liters per re-lube) $3.51 $7.28

Re-lube Intervals (years) 2 4

Annual Lubrication Cost (cost to re-lube ÷ re-lube intervals) $1.76 $1.82

Annual Labor Cost (.5 hours x $30/hr labor cost ÷ re-lube intervals) $7.50 $3.75

Total Annual Cost per Gearbox $9.26 $5.57

*Assumes a change from PAO to PAG oil

$14.56

$7.28

4

$1.82

$3.75

If Applied Over the Entire Plant…An average plant has 2,196 Bearings (244 bearings per line x 9 lines) and 540 gearboxes

Competitor Product

Klüber Product

Bearing Lubrication (annual lube cost x 2,196 bearings) $2,964.60 $1,515.24

Gearbox Lubrication (annual lube cost x 540 gearboxes) $950.40 $982.80

Bearing Re-lube Labor (annual labor cost x 2,196 bearings) $57,096.00 $14,274.00

Gearbox Re-lube Labor (annual labor cost x 540 gearboxes) $4,050.00 $2,025.00

Total Annual Costs for Entire Plant $65,061.00 $18,797.04

Total Savings in Lubrication and Labor Costs $46,263.96

$1,515.24

$982.80

$14,274.00

$2,025.00

See Food Master, p. IFC16

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800-421-1266Call for FREE Brochure 14716 South Broadway • Gardena, California 90248

Tel: (310) 532-1555 • Fax: (310) 324-3030Internet: www.marsair.com • Email: [email protected]

®

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InteriorSpaceSeparations

CustomerEntrances

LoadingDocks

Clean Room

Walk-in Cooler

Walk-in FreezerPerfect for:• Food Processing Plants• Commercial Kitchens• Cold Storage Facilities• Warehouses• Bakeries• Breweries• Cafeterias• Supermarkets• Restaurants• Fast Food Restaurants

Mars® Air Curtains improvesanitation levels and stabilize your environment by helping you to control flying insects, dirt andpollutants, climate and energy.

AIR CURTAINSFor the Food Service Industry

AIR CURTAINSFor the Food Service Industry

SecurityKiosks

Oven technologyIntended for rapid, high-volume cooking,Heat and Control’s AirForce impingementoven provides independent adjustmentof cooking conditions on both sides ofproduct, while the company’s compactsingle- and twin-drum spiral ovens deliv-er cooking atmosphere circulation in aneven 360˚ pattern around the spiral con-veyor. Heat and Control’s MPO convec-tion oven provides rapid heat transfer forprocessing meats, pizza topping, sausage,poultry and seafood.Heat and Control, Inc.; 510-259-0500;www.heatandcontrol.com

Slide conveyorSuitable for a variety of material handlingapplications, Eriez’s E-Z Slide conveyormoves food products with a smooth, slid-ing action. The conveyor may be floor-mounted on a pedestal or suspendedoverhead, and the single-drive unit canbe located at either end or under the tray.The slide features self-cleaning actionand long conveyor lengths.Eriez Magnetics; 800-300-3743;www.eriez.com

Linear actuatorsWinco metric linear actuators featurechrome-plated, precision steel guidetubes, a gun metal follower and plasticend caps. Also available in stainless steel,the tubes come in a variety of diametersand travel lengths from 65 to 315 mm. Theactuators are available with a right- or left-hand thread with one or two shaft ends.J.W. Winco; 800-877-8351;www.jwwinco.com


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Silverson’s high shear In-Line mixers outperform conventional mixers, cutting processing times by up to 90%! And every one of our mixers will emulsify, homogenize, solubilize, suspend, disperse disintegrate solids in times superior to any machine on the market while improving your product quality, consistency and process efficiency.

Silverson High Shear In-Line Mixers will:

• Eliminate agglomerates and fish eyes

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AZO is your Quality Choice!

4445 Malone Road Memphis, TN 38118 901.794.9480 [email protected] www.azo.com

When you need to receive, store, convey,

feed, weigh, control and track your ingredients. . .


Plane bearing insertsIntended for extreme heat applications,MRC high-temperature plane bearinginserts can be integrated into any MRCMarathon bearing housing style to resisttemperatures up to 500˚F. The insertsinclude 316 stainless steel inner rings, 304stainless steel outer rings and a high-per-formance polymer sleeve. Shaft diame-ters measure from 3⁄4 in. to 1-15/16 in. Theplane bearing inserts are USDA-approvedfor direct or incidental food contact inmeat, poultry or dairy applications.MRC Bearing Services; 716-661-2727;www.mrcbearingservices.com

Vat washerA specialty washing and sanitizing sys-tem for 400-lb. and 600-lb. stainless steelvats, the Douglas vat washer lifts andinverts containers into the wash/rinsechamber and returns them to the floorafter cleaning. Smaller in size than earliermodels, the washer cleans up to 20 con-tainers per hour.Douglas Machines Corp.;800-331-6870; www.dougmac.com

Mini-pitch beltThe Intralox series 1000 flat top belt issuitable for applications requiring tighttransfers and high belt strength. Withreduced chordal action and transferdead plate gap, the belt allows smoothtransfer over 0.75-in. nosebars. The beltis available in polypropylene, polyethyl-ene or acetate.Intralox, L.L.C.; 800-535-8848;www.intralox.com


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World Headquarters • 17477 Hurley Street • City of Industry, CA 91744-5106800.423.4585 tel • 626.435.0180 fax • email: [email protected] • www.claytonindustries.com

Here’s proof that a well-designed product becomes popularquickly. Available in 25 to 200 BHP models, they are used toefficiently produce steam by major industries around the globe.

Here’s why:Unique vertical design and counterflow technology deliveroutstanding performance... amazing energy efficiency...space-saving size... unsurpassed safety... and modularity thatmakes installation a snap.

SigmaFire steam generators come up to full pressure rapidly,maintain pressure when demand fluctuates, expedite routinemaintenance, and eliminate the steam explosion hazardassociated with conventional boilers.

Backed by 24/7 service and chemicals,they’re hot performers that are cool to thetouch, gentle on operating budgets, andup to any demands you place on them.

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Dryer, cooler, roasterBNW’s Belt-o-matic cus-tom-built horizontal con-veyor dryer, cooler androaster top air chamberproduces an even air-flow across the productbed without air-adjust-ing baffles or balancingfans, while its bottomair chamber produces ahigh airflow for dryingat the wet end of theproduct flow. With thedryer, airflow doesn’t

need balancing for changes in product thickness, resident time, size, capacity orother factors; only air volume, which is controlled with a frequency drive, needsadjusting.BNW Industries; www.belt-o-matic.com

ClarificationIn Food Engineering’s August issue, an article entitled "Don Your Battle Clothes"referred to Cintas Sanis UltraClean. This Cintas cleaning service is not used withor related to the Cintas uniform services described in the article.

Raleigh, NC USA +1 919 851 2000Philadelphia, PA USA +1 215 464 6070

England +44 1780 767 007China +86-21-5132-1880

Malaysia +60 3 6411 9999

Visit www.aeroglide.com/food

CaptureThe Power

PERFECTING THERMAL PROCESSING WORLDWIDEConveyor Driers & Roasters, Fluid Bed Driers & Toasters,

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www.foodengineeringmag.com Food Engineering September 2007

Decanting centrifugePennwalt’s Super-D-Canter solid-bowl decanting centrifuge provides the con-tinuous separation of liquids and solids from incoming feed slurry. Equippedwith an advanced polymer injection system and high abrasion points fitted withreplaceable parts, the centrifuge requires only one drive motor. Typical applica-tions include: lactose/food product dewatering, meat rendering, separating fry-ing oils from solids and waste sludge dewatering.Pennwalt Limited; 856-241-9970; www.mpegroupusa.com

Drying systemThe Paxton Products PowerDry system eliminates potential contamination fromoils and scale in a compressed air supply. Generating high-velocity airflows toremove debris and moisture, the system has a washdown-capable design suit-ed for food, beverage and packaging operations. A high-performance centrifu-gal blower develops maximum airflow and pressure from a 3-hp motor.Paxton Products; 800-441-7475; www.paxtonproducts.com

Spiral ovenFMC’s GCO-II spiraloven offers threedistinct cookingprocesses: steamand condensationto lock moistureinto product; heat-ed air and super-heated steam toquickly cook prod-uct; and heated airat high velocities toadd additional sur-face color develop-ment. The re-engineered drive system in the GCO-II oven has an expected life-time of three years before requiring a re-build.FMC FoodTech; 419-626-0304; www.fmcfoodtech.com

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Servomotor couplingsZero-Max’s composite disc couplingshandle high-torque loads while provid-ing zero backlash in servomotor-drivenpackaging systems. Suitable for applica-tions that require both high reverse loadsand high speeds, the couplings have hightorsional stiffness and high dynamic loadcapacity that allow packaging machinesto run faster while maintaining accuracy.They are available in sizes for most servo-motor packaging applications.Zero-Max; 800-533-1731;www.zero-max.com

Latex-free glovesA powder-free alternative to natural rub-ber latex, Sempermed SemperGuardGripSafe nitrile gloves have 4.0 mils in thetextured fingertips for tactile sensitivityand a firm grip on objects. Intended forgeneral purpose, the gloves are packed in200-count, standard-size boxes.Sempermed USA; 800-897-7599;www.sempermedusa.com

Dust collector cartridgesAvailable to fit most leading brands ofdust collectors that use cylindrical car-tridges, Farr’s HemiPleat retrofit cartridgesoffer high moisture resistance and a filtra-tion efficiency of 99.99% on particles assmall as 0.5 microns. Made of a silicone-treated polyester/cellulose blend, the car-tridges are pleated for greater airflow.Flame-retardant and carbon-impregnat-ed cartridges are also available.Farr Air Pollution Control;800-479-6801; www.farrapc.com


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Micro driveAvailable in cabinet sizes as small as 2.75”x 6” x 6”, Danfoss VLT micro drives provideout-of-the-box, plug-and-play control ofAC motors up to 3 hp. An automatic ener-gy optimizer reduces the drive’s energyconsumption, while an automatic motoradaptation feature leverages the motor’sfull operating potential. The drive has a“flying start” feature and an electronicthermal relay.Danfoss Drives; 800-432-6367;www.namc.danfoss.com

Sealed container dischargerUsing an Allen-Bradley PLC located in aNEMA 4X box, the NBE Lift and Seal contain-er discharger’s hydraulic linkage system pro-vides a controlled 180˚ rotation for dis-charging container contents into receivinghoppers, while an interlocked safety cagewith hinged doors protects the operator.The discharger withstands harsh plant envi-ronments and is intended for applicationswhere sanitary design is required.NBE Inc.; 616-399-2220;www.nbe-inc.com

Printer applicatorLabel-Aire’s 3138-N dual-action tampprinter applicator provides automatic set-up with multiple programmable levelpages, rate compensation and user-con-figurable I/O connectivity. Made of stain-less steel and anodized aluminum, theapplicator is corrosion-resistant and com-patible with any OEM printer.Label-Aire, Inc.; 714-441-0700;www.label-aire.com


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We’re already belt experts with 60 years in the business and

more than 60 patents, including the invention of lotension

spirals. And now, we’ve hired the industry’s spiral freezer service experts.

Introducing…Ashworth Factory Service

Experience counts. So we staffed our Northfield,

Minnesota office with the industry’s most respected

service experts to bring you more than 90 years of

combined spiral experience. Time is money.So we’re on call 24/7 to install new belts, add extra

tiers, rebuild or even relocate complete spiral systems.

Your job is complicated enough. So we take

care of everything. One responsible party, one call away.

ENGINEERING | MATERIALS | SUPERVISION | LABOR

158 North Water Street | Unit 7 | Northfield, MN 55057

www.ashworth.com/fs

©Ashworth Bros., Inc. 2007

Contact Bryan Hobbs or Barb Loftness at Ashworth’s new Northfield office

1.866.204.1414 or [email protected].

Turbine flow meterThe Blancett Model 1100 turbine flow meter maintains measurement accuracy and mechani-cal integrity in corrosive and abrasive fluids found in many industrial applications. With arugged 316 stainless steel housing and rotor support assemblies, CD4MCU stainless steel rotor,abrasive-resistant tungsten carbide rotor shaft, and journal bearings, the meter offers repeat-able flow measurement in ranges from 0.6 to 5,000 (20 to 171,000 BPD). It installs on pipe sizesfrom 0.5-10 in.Blancett; 262-639-6770; www.blancett.com

Combination scaleDesigned for larger products weigh-ing up to 6.5 lbs., the CombiScale CS-10 big bucket combination scaleweighs product and then chooses thebest combination of buckets toachieve a predetermined weight. The10-head large capacity scale reducesproduct variations and operates atspeeds of up to 75 bags/min. Stainlesssteel construction and tool-less disas-sembly reduce product build-up, con-tamination and changeover time.Wash down and dimpled stainlesssteel constructions are also available.CombiScale; 847-806-0606;www.combiscale.com

Photoelectric sensorsAvailable with a 350mm range forbackground suppressions or 3mrange for clear object detection,Pepperl + Fuchs MLV41 series photo-electric sensors have built-in cross-talk protection and high-visibility,dual-position LEDs to indicate sensorstatus. The sensor features an IP167-rated housing with a protective topcoating and can be use in low tem-peratures to -40˚.Pepperl+Fuchs; 330-486-0001;www.am.pepperl-fuchs.com

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PAUL MUELLER COMPANYP.O. Box 828 • Springfield, MO 65801-0828Phone: (417) 831-3000 • 1-800-MUELLER E-mail: [email protected] • www.muel.com

©2007 Paul Mueller Company 385-5

For over sixty-five years, Paul Mueller Company has earneddistinction for delivering outstanding equipment and uniquesolutions to the process industries.

Your production plant is an integrated system that requires abroad range of disciplines to optimize. Mueller® has thetechnical expertise, innovative engineering, and manufacturingresources to implement a process system specific to your needs.

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How do premium products get the edge?

Grundfos pumps.

Consumers expect only the best. To deliver, you

need pumps of the same premium grade as the

products being manufactured. Robust, innovative

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Booster compressorsKaeser booster compressors provide pressures to 650 psig and flow to 685 cfmfad to boost existing plant pressure and eliminate the need for separate high-pressure systems. Standard N high-pressure compressors come with a TEFCmotor and starter, plus aluminum cylinder heads and finned copper coolingpipes for aftercooling. Booster extra-pressure compressors include precision-manufactured, two- or three-cylinder pumps with 100% duty cycle and a forcedlubrication system with continuous, full filtration.Kaeser Compressor; 800-777-7873; www.kaeser.com

Electrode sensorsMettler Toledo InLab high-performance pH electrode sensors provide fast pH,ORP, conductivity and dissolved oxygen measurements. Highly precise and reli-able, the glass sensors are low maintenance and appropriate for a range of appli-cations. The InLab viscous sensors are intended for pH measurements in highlyviscous samples or samples that tend to carry over.Mettler Toledo; 614-438-4505; www.mt.com/electrodes

Linear ball bearingsAvailable in compact andstandard metric versions,SKF’s pre-lubricated sealedlinear ball bearings are fit-ted with an inner lip seal toretain the lubricant and anexternal lip that wipes theshaft surface as the bear-ings move to prevent con-tamination. Special greasesare available to satisfya p p l i c a t i o n - s p e c i f i crequirements. Shaft diameters range from 3 mm to 80 mm, with basic diameterload ratings from 60N to 37500N.SKF Linear Motions & Precision Technologies; 800-541-3624;www.linearmotion.skf.com

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For tight turns, turn to KVP.

See the new Spiral Pro PR620-TTR at:

800-445-7898 • www.kvp-inc.com

Booth S3032 Booth 2556 Booth S-5057

Introducing Spiral Pro PR620-TTR,industry’s all plastictightest turning radius—1:1.0

Our Spiral National ApplicationProgram team makes every joba SNAP — from installation aidto ongoing support

• Based on KVP’s popularfield-proven Spiral ProPR620-SPS

• Easy metal belt retrofit—just change out drive sprockets and rollers

• One-piece rod for easyinstallation and maintenanceon belts 50”wide and under

• Belt widths from 20” to 44”in 0.5” increments; largerwidths available with slightlyreduced turn radius

• Superior strength — 1,200lbs/ft straight runs; 570 lbsradial turns

Silicone greaseNSF-rated H1 and comprised of FDA-accepted ingredients, Haynes siliconegrease is designed to prevent the sticking of valves and O-rings duringhigh-temperature and freezing applications. Made of silicone fluid plusadditives, the grease is non-toxic and can be used in high-vacuum or pres-sure systems to seal synthetic rubber and plastic parts. The grease is inertand resists many chemicals.Haynes Manufacturing Company; 800-992-2166; www.haynesmfg.com

Polypropylene copolymerBasell’s metallocene-based metocenepolypropylene Clyrell EM248Ucopolymer for clear, injection-molded,thin-wall applications does notrequire vis-breaking or peroxides, andcan be used in food applications thatrequire low organoleptic properties.With a melt flow rate of 70 g/10 min.,the copolymer resists distortion andwarpage and retains stiffness in hot-fill applications. It can also be used inin-mold labeling and off-set printingapplications.Basell; www.basell.com

Liquid removal/surfacedecontaminationDesigned for use with fresh-cut orprocessed foods, Reyco’s DynaVac sys-tem removes water and other liquidswhile simultaneously decontaminat-ing food product and conveyor sur-faces of mold and bacterial/viral con-taminants through the use of high-output ultraviolet-C (UVC) energy.Approved by the USDA and FDA forsurface decontamination, the UVCtechnology destroys multiple types ofbacteria, does not require irradiationlabeling and does not alter the look ortaste of most food products.Reyco Systems Inc.; 208-888-2449;www.reycosys.com

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An ITW Company

Hygienic flow meterThe Promass S hygienic Coriolis flow meter provides a signalfor mass flow, volume flow, density and temperature, andcalculates temperature-dependent density variables ofconcentration. A single-tube device, the meter per-forms in high-value clean liquids, heavy solids-ladenslurries and precision-density applications. With acurved tube design, the flow meter providesflow accuracy of 0.1o.r., performs over a largetemperature operating range and recoversafter in situ cleaning processes to itsspecified measuring performance.Endress + Hauser; 888-ENDRESS;www.us.endress.com

Dairy nanofiltrationKoch Fluid Systems TFC-SR nanofiltra-tion elements can be used for a vari-ety of selective rejection dairyapplications, including de-ashingand the separation of carbohy-drates and proteins. Utilizinga polyamide thin-film com-posite membrane, thespiral wound elementsare suitable for wheypre-concentration,salt whey diafil-

tration and lactose demineralization.Koch Membrane Systems, Inc.;888-677-5624; www.kochmembrane.com

EMX UV sensorThe EMX UVX-300-GC luminescence sensorwith calibration capacity detects the pres-ence or absence of critical componentson assembly lines, such as O-ring seals,adhesives, labels, paint and lubricants,as well as transparent objects. Thecalibration function allows simul-taneous calibration of all sen-sors in a central location priorto their being distributedwhere needed.EMX Industries Inc.;800-426-9912;www.emxinc.com

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Dual-input analyzerThe Emerson Rosemount analytical model 1056 multiparameter, intelligent ana-lyzer offers single- or dual-sensor input with an unrestricted choice of dual meas-urements. The analyzer continuously monitors for problematic conditions, dis-plays fault and warning messages, provides information about each conditionand guides troubleshooting through help screens.Emerson Process Management; www.emerson.com

Bird repellerWith sound waves that move fromspeaker to speaker, the Bird-XBroadband Pro bird repeller forcesbirds to leave manufacturing andwaste facilities, rooftops, parking lotsand towers, yet is harmless to animalsand the environment. The repeller tar-gets birds with a combination of foursound types and includes three visualscares to frighten birds. One unit cov-ers up to 10,000 sq. ft.Bird-X, Inc.; 800-662-5021;www.bird-x.com

Wet-vacuum sample collectionMicrobial-Vac’s wet-vacuum collectionsystem utilizes liquid and air-assistedmicrobial detachment and captureprinciples to collect samples, typicallyfrom 1 to 2 sq. ft. of surface area persample in 100 to 150ml of liquid.Reducing materials needed for sam-pling, lab processing and detection, thesystem can be used to collectpathogens from rinds, carpets, meatcarcasses and other common surfaces.Microbial-Vac Systems, Inc.; 801-523-3962; www.m-vac.com

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www.apv.com

To fi nd out more, contact us:

T: 800-554-5290 F: 888-278-5329

E: [email protected]

Source code: 0907FE

APV —APV — Made To WorkMade To Work Better…Together.

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Ystral–Leaders inMixing/Dispersing and Powder WettingTechnologies

P.O. Box 780 • Hainesport, NJ 08036 USA

Ystral Conti-TDS and Dispermix powderinduction and dispersing systems combinenumerous processing functions in a singlepiece of equipment designed to improveproduct quality and lower production cost.

“Conti-TDS”� Dust-free powder induction

directly from bags, big bags,and containers

� Immediate powder wetting and effective dispersion with no agglomeration

� Adapts to existing systems, installs outside the vessel and can be installed with multiple vessels

� Induction rates up to 800 lb/min and shear speed up to 100 ft/sec with sheer gradient up to 50,000 sec-1

� Patented, clean-in-place system is ideal for food,cosmetics, pharmaceuticals, etc.

“Dispermix”� Mixing and dispersing in a

single operation

� Jet stream principle with 100% homogeneous mixing

� Simultaneous dispersion – no baffles required

� Extremely short processing times and high rationalization potential

� Fast de-agglomeration with no additional disperser required

� Patented, clean-in-place system installs from top, side or bottom

For more info or a FREE test using your products, call 609/914-0521, FAX: 609/914-0318, E-mail: [email protected] or visit online at:

www.PowderTechUSA.com

Powder

Dispersion

Liquid


High-power motorRockwell’s HPK series motor extends the normal powerrange of a traditional servo motor solution. The motor isequipped with single- or multi-turn, high-resolutionabsolute feedback that eliminates homing routines,improves velocity regulation and expands the system’s iner-tia matching capability. Suitable for applications requiringhigh-power capacities, the motor offers positioning, accel-eration and productivity capabilities.Rockwell Automation; 800-223-5354, ext. 2001;www.ab.com/motion/servo/hpkseries.html

Continuous motion fillerAvailable with two or eight pistons, Hinds-Bock’s high-speed, continuous motion filling system has a servo-drivendiving and traveling bridge that moves spouts in time withcontainers that are captured with a timing screw. The filleris intended for use with dressings, condiments, salads,soups, dips and other flowable products.Hinds-Bock Corporation; 877-292-5715;www.hinds-bock.com

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Servo drivesCopley’s Accelnet state-of-the-art open standard Ether CAT-compatible servodrives provide centralized control of multi-axis automation and enhance theperformance of distributed motion control systems. The AEP-90-18 and AEP-90-36 drive brushless or brush motors and run on 20-90V DC power. Operatingmodes include torque, velocity, trajectory tracking, point-to-point and homing.Copley Controls Corporation; 781-828-8090; www.copleycontrols.com

Palletizing softwareA PC-based off-line engineering and programming tool, KUKA’s PalletTechsoftware version 3.5 features capabilities for robotic operations including aug-mented gripper support and multiple orientation pick-up. A suite of applica-tion development and run-time tools, PalletTech enables out-of-the-boximplementation and can work off-line and dynamically reposition itself duringpallet builds.KUKA Robotics Corporation; 866-873-5852; www.kukarobotics.com

Energy compressorsDesigned for energy efficiency, Sullair S-energy compressors combine an air-enddesign with integrated inlet valve and low package pressure drop, as well as anoptimal cooling system with a low-noise centrifugal cooling fan. Ranging from15 to 60 hp, the compressors are available in standard or encapsulated air-endmodels, with capacities of 43.7-267 acfm and pressures from 100-175 psig.Sullair Corporation; 219-861-5089

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r

The only time you make a profi t is uptime.

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Processors worldwide depend on reliable Key

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vision…to convey product with gentle vibratory

motion…and to avoid downtime with true

innovation in automated solutions.

Find us at 509-529-2161 or the www.key.net –

we design performance you can rely on.

© Key Technology 2007

Optyx® 3000

sorter with

Raptor/FluoRaptor™

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DESIGNED f o r r e l i a b i l i t y

NEW



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W e’ve all heard the world is flattening and glob-alization is the next big business driver. Whatdoes that mean to food manufacturers and, in

particular, to their supply chains? Will globalization bethe new road to manufacturing efficiency?

Not so long ago, food industry leaders believed global-ization would not significantly impact US manufacturersbecause: We are the largest market; we grow most of theraw materials; transportation costs are too high to shipfood long distances; food is fragile and must be deliveredto the consumer quickly; and too many unknown hazardsexist within foreign manufacturing sectors.

Globalization has moved to the forefront with theemphasis on food manufacturers’ supply chains andhow they are being impacted today and in the future.The consensus of those interviewed for this article is thatthe impact on food manufacturing is significant,but it isbeing applied differently based on the nature of a com-pany’s business. However, that impact will continue togrow and must be understood to facilitate good busi-ness decisions.

According to Jim Hurley, president and CFO of Veg-etable Juices, Inc.,“Globalization is the process by whichthe economies of the world’s nations are becoming moreclosely integrated, particularly through trade, technology

and financial flows across borders.” It is reducing the oldartificial boundaries and opening up free trade betweennations at a rapid pace.

From the field to the shelf As food manufacturers look for more efficiency, many arechoosing to offshore raw material sourcing,as well as foodmanufacturing, to suppliers in other parts of the world.Clearly, international companies have manufacturedproducts for their local markets and regions in local facto-ries for decades. Now, they have the opportunity to pro-duce products for transport to the US market for US foodmanufacturers. Several strategies are being employed.

Dr. Angel Cabrera, president of the highly regardedThunderbird’s Garvin School of International Manage-ment, states that “Capital will flow to where it can beused best—is a basic principle in globalization today.First, a country has to create a competitive differencewhich will provide an advantage to manufacture prod-ucts in that locale. These advantages have traditionallybeen less expensive labor—but now may be less expen-sive or better raw materials, more creative sources ofproductivity, or even government incentives.” Thencompanies will invest the necessary capital to takeadvantage of this opportunity, he says.

Jim Getchell, Contributing Editor


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Not without risksA lthough there are many opportunities for US food manufacturers to offshore parts of their

supply chains, there are also risks to be managed. Possibly the most significant risk isguaranteeing food safety. The recent pet food recall in North America is a good example of this.How do processors monitor and control a supply chain stretching around the globe?

Companies must have expanded traceability and tracking capabilities not only to ensurefood safety but also to deal with counterfeiting of products and packages. Today’s low-costsource may not be tomorrow’s low-cost location.

Volatile dynamics are constantly changing the market and business environments.Social and environmental compliance must be managed to protect the corporation’s reputa-

tion and image, now including your global “carbon footprint.”Here are a few examples of risks to be managed in a global supply chain:1. How long can a supply chain be and still manage “out of product” events due to inaccurate forecasting?2. Political volatility in a country equals potential supply chain volatility.3. How do you secure the transport of your products between producing locations and intended destination?4. Do you understand the different cultures and values and how their behavior impacts your business relationships?5. How do you ensure your product and ingredient quality requirements are met each and every time?6. How do you manage concerns with product shelf life and fragile product damage?

Outsourcing shift The US food manufacturing industry has continued to out-source a portion of product manufacturing over the pastyears. Typically, major companies contract from 20 to 35% oftheir total production, whereas smaller companies may actu-ally contract all production to avoid capital investment andtake advantage of a contract manufacturer’s expertise. Keyadvantages of outsourcing include new product introductionsthat would otherwise require capital and space internally; thefinal production of foods in their “twilight” phase (where thedemand is on a continuous decline); and the use of existingcapacity in a selected contract manufacturer. Contract manu-facturing is not new to food companies, but where the con-tract manufacturing lands is shifting.

“More work and value in the supply chain can be doneglobally” says John Church, vice president of supply chainoperations for General Mills,“but the question is at what costand quality?” A number of US food companies believe thatforeign companies have great plants and technology, goodworkers and an evolving management talent base.

One strategy is to infuse capital into local partnerships orextended supplier relationships. The result is the manufacture ofhigher value ingredients, more intermediate or “base” productsthat will be shipped to the US plants for finishing and final prod-ucts manufacturing for shipment to the US distribution system.

Lower labor costs have been the incentive in the past. Buttypically, labor is only 15 to 25% of the total manufacturingcost. Over time, labor costs tend to equalize, and lowest costlabor shifts to another part of the world.Labor cost is only oneconsideration for off-shoring manufacturing.

Retailers are taking a different approach by outsourcingprivate label or store brand products manufacturing to for-eign plants with the goal of getting a desired price point on theshelf. In this case, the retailer typically has no capital risk andcan control production quantities based on actual demand,not just initial forecasts.

According to Diane Wolf,vice president of global engineeringfor Kraft Foods,“A number of foreign manufacturers are con-tinuing to ‘move up the value chain’by producing more complexproducts and enhancing the value of ingredients. Examples arecoffee bean producers moving to freeze-dried coffee for export,high-quality fruit concentrates and total custom spice blending.The objective is earning a bigger share of the profits throughthis value creation.” Clearly some ingredient suppliers are nowleveraging their traditional advantage in new ways.

Does this mean US food manufacturing will become obso-lete in the future? Most likely not, but there will likely be aperiod of correction as US companies find ways to exploit theopportunities of globalization. This global view will forcecontinuous improvement everywhere. Outsourcing is viewedas a source of productivity in some sectors. Automation willcontinue to drive costs down everywhere, especially with suf-ficient capital investment in the capital-intensive food manu-facturing business. However, it is likely that externalmanufacturers will play a larger role in manufacturing processand capability.

As companies increase investments with overseas manufac-turers and suppliers, several strategies should be considered tobetter manage the risk. The global marketplace is rapidlychanging and highly volatile. Investments can be made incre-


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© 2

007

Orki

n, In

c. When it comes to pest control for food processing, Orkin wrote the book. We talked with industry professionals about their needs and surpassed them. The result is a program for great inspections that anyone can follow. Simply call 1-800-ORKIN-NOW or visit Orkincommercial.com and find out what Gold Medal Protection can do for you.


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mentally to create only the needed new manu-facturing capability, without building new fixedcosts. New joint ventures or partnerships willspread the risk to your partner—an additionalincentive for success for both parties.“Projectsand investments need to be made more flexibleto reduce risk and increase the potentialreturns,” says Hurley. “The greater the uncer-tainty, the greater the value of flexibility.”

Raw material sourcingRaw material pricing continues to be a signifi-cant issue for food manufacturers. The recent food-versus-fuel debate is a great example of the global impact toingredient pricing. Ethanol production is projected to con-sume 30% of the corn crop by the year 2010,up from 14% last

year, according to the USDA. Farmers are shifting to plantingcorn, with more acres planted this year than at any time sinceWorld War II. However, the resulting impact is less soy beansand wheat being planted, increasing those and related com-

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Ethanol production is projected to consume 30% ofthe corn crop by the year 2010. However, theresulting impact is less soy beans and wheat beingplanted, increasing those and related commoditiesprices. Source: USDA Economic Research Service.


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modities prices. Next year the European Union has stipulatedthat 6% of all diesel fuel produced in Europe must bebiodiesel—up from a level of 2% today. In the US, Californiawants all gasoline to include 10% ethanol starting in 2009,and the US Senate passed energy legislation calling forincreased use of ethanol in the future. The demand for cornand other grains can also be impacted by other global eventssuch as a possible drought in China or elsewhere that couldsend more US corn overseas.

Recently, Mexico was forced to put a price cap on tortillasat $0.35/pound to control the impact of corn price increas-es. A similar impact can be seen in Brazil, where competi-tion is underway for sugar cane for either cane-ethanol orfor sugar production.

Food companies are looking at the impact of diversifiedgrowing regions and the diversification of foreign currenciesfor advantage in the raw material supply. Global seasonal dif-

ferences can mean fresher ingredients throughout the year,and can manage the risk of crop failures due to droughts andshifting climatic changes. However, the extension to regionalagriculture also can increase the complexity of managingfuture supply chains.

Another future driver could be the availability of land fororganic farming. Much of the current farm land in the USwould require significant time and effort to be certified


Trade agreements have created new opportunities for the movementof ingredients and food products around the world. The eliminationor lowering of traditional barriers has significantly impacted theoverall economic analysis of sourcing decisions.


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organic. However, land in South America and Africa could befuture sources for organic crops as their demand continues togrow globally.

The scenario may be that foreign companies will increas-ingly supply the US with raw materials, or US food manufac-turing facilities may locate closer raw material sources. Futuresourcing decisions may well be based on raw material qualityand costs—not just labor.

Distribution and transportationThe continued rise of multi-national companies has resultedin more efficient transportation systems. New and expandedfreight lanes are now available. The size of the Panama Canalwill be doubled in the near future. Houston, one of the pri-mary ports of entry for Wal-Mart imports, is also expanding.The result is transportation cost, in itself, will not be a barrierto off-shoring food manufacturing. However, transportationcosts remain dynamic and will most likely continue to risebecause of increased demand and rising energy costs.

Free trade agreements and preference programs (such asNAFTA,MERCOSUR,the European Union,WTO,Codex,etc.)

have created new opportunities for the advantageous move-ment of ingredients and food products around the world. Theelimination or lowering of these traditional barriers has signifi-cantly impacted the overall economic analysis of sourcing deci-sions. These agreements must be understood and integratedinto US food manufacturers’ sourcing strategies.

Opportunity knocksThere are many opportunities for food manufacturerswho effectively manage global supply chains. As new sup-ply chain capabilities emerge, companies are taking acloser look at what they must make internally and whatthey can outsource.

There may be an opportunity for fresher products in themarket. For example, building a cheese plant in the MiddleEast, but shipping the raw material (milk) from Australia.

Will a future concentration of capital create new knowl-edge and capabilities centers in new regions,such as the phar-maceutical industry’s concentration in Puerto Rico?

There is an opportunity to ship intermediate or finishedproducts directly to the US plants for final processing/pack-


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aging close to the market. This may create “buffers” of supplyin the supply chain.

Speed and agility will be key, and foreign plants may offerincreased capabilities to source more complicated consumer-demanded products, such as assembled meal kits.

Sourcing value-added products in global locations allowsfor a focus on internal capabilities, protecting and enhancingcore products and developing next generation products.

Alternative sourcing locations may allow for early produc-tion of products that have not yet been proven in the primarymarketplace,with minimal financial risks.The resulting knowl-edge and experience can then be scaled up for major produc-tion once the product is proven.

Global organizations can provide other sources of knowl-edge or best practices. For example, one major food compa-ny has seen continuous improvement best practices fromoperations in Turkey.

The need for infrastructureGlobal supply chain management requires significant infra-structure. Certainly information systems are a key example.

They must provide consistency and standards for not onlyproduction, but for product quality. They must focus on bet-ter forecasts due to the longer delivery lead times and addressthe seasonality of sales to an even larger degree. Decisionsmust be made as to where to ship the product. Advancedscheduling techniques are critical to an integrated supplychain. Lot tracking and traceability capabilities become evenmore complicated, but are critical to ensuring food safety aswell as the reputation of the corporation.

PLM (Product Lifecycle Management) systems must becurrent and used across the global supply chain. With chang-ing formulations and processing requirements for productsbeing made across multiple geographies, a comprehensivePLM system is a necessity for the new expanded supply chain.

“Technology is essential to overcoming the barriers andachieving the benefits of globalization,” says Rory Granos, direc-tor of industry and product marketing for Infor. “Many compa-nies just got ERP implemented and now must understand theymust be demand-driven to compete in a global environment.”

IT systems are available for all size companies, not just For-tune 100 firms. However, some modules are not found in just

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one supplier. Granos cites the example that plant schedulingand production planning modules are not currently availablefrom SAP. But they must be integrated with all elements ofthis new extended supply chain—whether they are “owned”by the food company or contracted to raw material suppliersand external manufacturers for actual production. Hebelieves the keys to success are “quality, compliance and sus-tainability”as companies go more global.

A new perspective“We are seeing the unfolding of unintended consequences forthe food industry’s shift, as we choose new partners andsources of supply,”says Hurley.“For the true paradigm shift tooccur we must have effective regulations, the technology tosupport the extended business and an advantage that sup-ports the general market need—all three elements are essen-tial.”Leading food companies have already started,and otherswill follow once they determine their new business strategyand how to manage it.

A number of strategies are underway to improve overallsupply chain costs for US food manufacturers. Some compa-

nies are just putting their toe in the water to check the tem-perature. Others are taking best practices from internationalbusinesses and reconfiguring where they source their rawmaterials and where they choose to actually manufacturetheir products for the US market. There is not one answer ordirection for the food and beverage industry—and thereprobably never will be. Each company must address its ownbusiness requirements.

Without question, today’s world is flatter. Savvy manufac-turers are rethinking how the supply chain will work. Thereare risks to be managed and new relationships and strategiesto be developed. However, it is important to remember thatany advantage is only temporary in nature. For a company tostay competitive, it must continuously learn and adapt to thenext opportunity. ◆

Jim Getchell has more than 30 years of food industry experi-ence.Formerly vice president of engineering at General Mills,hehas held executive positions with Nabisco Brands and TheFoxboro Company. He now consults, speaks and writes onindustry-related topics on a part-time basis.

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S2 Food Engineering www.foodengineeringmag.com September 2007

W hat kind of company areyou? Are you driven byprofits or by principles—

specifically, by my principles? Do yourecycle, reuse, reapply? Do you con-serve, preserve and reserve? What isyour carbon footprint, your qualityindex, your environmental scorecard?Can I trust you?

Increasingly, say industry experts,today’s consumers—more informedand educated than ever before, and,thanks to the Internet, flexing vastlygreater power of choice—want toknow more about a food or beverageproduct than simply what meets theeye. They want to know how the prod-uct was processed and the environmen-tal impact of the processing. This, inturn, has pushed major retailers suchas Wal-Mart to demand more environ-mental responsibility from their foodand beverage suppliers. In short, wherequality once meant consistency, theword now encompasses a wide-rang-ing definition, beginning with sustain-ability. Ultimately, that’s good newsfor processors: Enter the age of thesustainable food plant.

“Forty years ago, consumers assumedthe companies knew best, that theywould never put an unsafe product onthe supermarket shelves,” says JimHauge, environmental and safety man-ager at Kettle Foods, a snack-chip man-ufacturer. “That began to change wheningredient and nutrition informationbegan to appear on product labels. Nowthere’s a much greater awareness of notjust the health effects of foods, but of thewhole food system in general.”

“Manufacturing has gone from beingrelatively unimportant to being veryimportant,” comments John Blanchard,a principal analyst focusing on food andother packaged-goods industries forARC Advisory Group. “Innovation isstill important, but now responsivenessto the market is critical. That meansresponding to new customer interest in

not just the quality of the product, butthe quality of the processing,” he says.

Sustainability at a food processingplant means, in part, managing process-ing resources, including energy, water,fuel, chemicals and other non-renewableinputs, in such a way to reduce, con-serve, reuse and/or recycle thoseresources to reduce a plant’s environ-mental “footprint.” Sustainability alsobrings in economic and even socialcomponents into what has been called a“holistic” approach toward process-ing—in short, aiming toward a goalwhere all the resources used by an oper-ation, whether they be natural, monetaryor human, are utilized to create, inessence, a zero-use system, one in whichevery resource is fully replenished.

“More and more companies are put-ting measurables on sustainability,” saysScott Normandeau, a partner with SolidWaste Solutions, an Evanston, IL-basedconsultancy focused on helping proces-sors find dollars in waste products. “It’sstill in its infancy, but it’s key to estab-

lishing benchmark performance to buildfrom. Overall, what we’re seeing is thatsustainability can be both market-drivenand profit-driven.”

Many companies already have pro-grams in place to conserve resources toreduce costs— it’s just good businessnot to waste money, of course. The word“sustainability” defines the approach ina new way: By shrinking the resourcefootprints while at the same t imebecoming a corporate good citizen inthe community, a processor improvescompliance with regulations and has apositive long-term societal impact intheir local communities as well as in thelarger global community.

Blanchard points out that many fac-tors drive growing environmentalawareness among food and beverageshoppers, which connects to a growinginterest in the environmental sensitivityand sustainability of the processing. Keyamong these is the marketing opportu-nities offered by the Internet, whichaffords small, niche-type companies

The US government supports sustainability through methods developed by theDepartment of Energy to evaluate steam-generating systems for efficiencies andimprovements. Source: Nalco.


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the same marketing possibilities asmajor corporations. “Specialty manu-facturers can reach those consumersjust as quickly and efficiently, andthey can do it with who they are andwhat they stand for, not just with asteady stream of new products,”Blanchard said.

“‘Green’ is a nice badge for a com-pany to wear when we walk in,” saysPeter Meehan, co-founder and CEO ofNewman’s Own Organic, which part-ners with a variety of processors to co-pack Newman’s Own Organic brandsnacks, cookies, oils, vinegar and petfoods. “I think we have a brand that’smeaningful in the trade, and we are avery loyal partner. The companies wework with want us to take a lead in sus-tainability—they want to be associatedwith that.”

Mary Kay Kaufmann, division pres-ident with Nalco, a supplier of water-treatment and process-improvementsystems, points out that food industrysuppliers are feeling the shift towardenvironmental responsibility as well:“Our food industry customers increas-ingly have assigned senior levelaccountability to improving corporatesustainability based on measurableobjectives for conformance, economic

impact and social accountability. Theyrecognize that sustainable practiceslead to greater efficiency, a positivebottom line impact and enhancedbrand image and value.”

Efficiency and responsibilityIt’s not just progressive, socially awareniche players who are benefiting fromthe focus on sustainability. Majorprocessors also understand the cost-savings sustainable processing canmean. But whether large or small,processors agree that a full sustainabil-ity program involves closely managingdozens, and perhaps hundreds or eventhousands, of details that collectivelyshrink resource footprints and add sub-stantively to the bottom line.

“There are very few home runs outthere in terms of immediate big energysavings or sustainability savings,”comments Dave Watson, vice presi-dent of engineering at PepperidgeFarm, the snack and cookie manufac-turer. “It’s the hundreds of smalldetails that will add up to the big sav-ings. What we stress at our company isa teamwork approach in managingthese details.” Pepperidge Farm’sdirector of environmental programs,Tom Rieth, heads a monthly confer-

The solar-panel array at Kettle Foods’ headquarters plant in Salem, OR, is one of thelargest in the Pacific Northwest. Source: Kettle Foods.


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ence call that includes management ofthe company’s eight plants to discussupdates in energy savings, fuel andwater usage, and other resource issues.

Rieth and Watson say that the compa-ny goal is to flat-line total delivered costof product from year to year. Rieth isdeveloping a sustainability scorecard for

company-wide use that “tracks wherewe are in terms of resources—water,gas, and our overall carbon footprint.”He notes that gathering and managingthe scores is challenging, because theeight Pepperidge Farm plants are locat-ed in seven states, and the carbon foot-print varies from region to region.

Moreover, state regulations factor in: Inthe company’s recently built plant inBloomfield, CT, which received FoodEngineering’s Food Plant of the Yearaward in 2004, 10% of the plant’spower is supplied by a large fuel cell—but Connecticut, which is home to mostof the US fuel-cell industry, offersincentives for fuel-cell use.

Heinz North America is another com-pany establishing baseline data as part ofwhat it calls its Utility OptimizationProcess (UOP). “We have been captur-ing utility and production data for five-plus years in a global data warehouse,”comments Don Fonner, utility servicesmanager. “What we’re doing now, how-ever, is incorporating metering and mon-itoring systems to capture real-time data.This allows us to find anomalies asthey’re happening rather than relying onhistorical data and then going back to tryto figure out the problem.” The UOPprogram focuses on electric power, natu-ral gas and water use, with projectedsavings benefits for fiscal 2007 of 19.5million kilowatt hours of electricity, 54billion BTUs of natural gas and 30 mil-lion gallons of water. “The across-board-goal is to reduce energy andnatural-resource use,” says Fonner. “Ittakes time and it takes dollars, but I’mvery pleased with our progress so far.”

John Stiers, director of environmentalaffairs at Anheuser-Busch (A-B), under-scores the practical reality for processors.

“We’ve found that things like energyefficiency and environmentally sensitiveprocessing and sustainability can co-exist with ROI. You can do the rightthing for the environment and the share-holders at the same time,” he says.

Cindy Baerman, general manager ofJohnsonDiversey’s Food & BeverageGroup, agrees. “JohnsonDiversey hasbeen a pioneer in environmental stew-ardship as recognized in not only ourproducts but our leadership in LEEDcertification of our facilities. Around theglobe, our food and beverage customers

Five years ago, the number of LEED-certified buildings in the US was just under 40. Today889 buildings, including food and beverage manufacturing plants, offices, technical centers,laboratories and other types of construction have earned LEED certification, the ultimate inbuilding enviro-cred.

Another 6,800 projects are in the LEED pipeline, combining for more than 1 billionsquare feet of potential LEED-approved space. To date there are LEED-certified or LEED-pending construction projects in all 50 states and in 24 countries.

The Leadership in Energy and Environmental Design certification is sponsored by the USGreen Building Council (www.usgbc.org), founded in 1993 to encourage environmentallysensitive and sustainable building construction. JohnsonDiversey joined USGBC in 2003and anticipates LEED-certification of its recently opened distribution center in Wisconsin inthe coming months. The 550,000-square-foot center, which features water usage at a rate30 percent below state requirements and energy use at 40 percent below, and substantialuse of recycled materials in construction, complements JohnsonDiversey’s headquartersoffice building, built in 1997, which was one of the first four buildings certified under theLEED for Existing Buildings program in 2004.

In short, LEED is a common standard of measurement for what constitutes a “green”building. It’s kind of a green nutrition label, listing and measuring the kinds of materialsused in construction, water and energy efficiency, and the building’s indoor environment—air quality and lighting, for example.

The organization offers on-site workshops as well as online training in sustainable-con-struction and LEED principles. USGBC’s annual Greenbuild conference and exposition will beheld at McCormick Place West in Chicago, IL, from Nov. 7 through 9.

Several bottled-water plants owned by Nestle are LEED-certified, as are some wineries,including pinot-noir specialist Stoller Vineyards in Oregon. Anheuser-Busch’s new technol-ogy center in St. Louis is also LEED-certified. Gold-level certification is pending for KettleFoods’ new snack-chip factory in Beloit, WI. If awarded, it will be the first Gold LEED foodmanufacturing plant in the US. Pilgrim’s Pride is building a new R&D center at its head-quarters in Pittsburg, Texas, with the aim of gaining Silver-level LEED certification.

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expect us to use our knowledge andproducts to deliver environmentallyresponsible cleaning and sanitationsolutions,” she says. “Customersunderstand that environmental stew-ardship has a direct correlation to theirprofits and productivity, as well as theexpected social responsibility.”

Stiers has seen a steady progressionfrom a compliance-only approach tointegration of progressive technologiesto sustainability. “At our company, weare guided by a basic philosophy:Brewing, packaging and shipping thehighest quality products in the mostefficient and responsible manner. Thatmeans we have got to continuallyfigure out ways to reduce our use ofnatural resources.”

Water, water—it’s not everywhereA mega-volume processor l ikeAnheuser-Busch approaches sustain-able processing from many stand-points . Beer brewing consumesenormous quantities of water, a dwin-dling natural resource, especially in

the western US, where the companyoperates two huge breweries.

“We looked very closely at everyplace we use water throughout ourbreweries. Once we understood boththe needs and limits of those uses, wewent to the equipment parameters tofigure out how we could use the mini-mum amount of water,” Stiers says.

The brewer created three fundamen-tal ideas to guide not just water use, butuse of all natural resources, includingenergy: one, all uses of the resourcemust be as efficient as possible; two, theresource will be recycled whenever pos-sible; and three, where in-plant recy-cling is not possible (or sanitary), theresource will be used in outside-the-brewery applications, such as irrigation.For water alone, A-B targets a goal ofreducing overall use by 20% in 20 yearson a brewery-by-brewery basis.

“There are two sides to water,”adds Scott Butler, vice president ofoperations services at Del MonteFoods. “One is acquiring it, the otheris using it. For a processor like us,with several operations in the West,

Counterflow water systems allow incoming fruit to be washed with outgoing water.Processors should ask themselves one very important question: “Do I really need allof this water?” Source: Nalco.


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where water is a major environmentali s sue and fundamenta l na tu ra lresource, both of those are critical. Thekey driver, of course, is managingcosts. The cost of discharging waterinto the public system has gone up con-siderably, so bringing that down to thelowest cost possible has helped driveour overall approach to water use andto shrinking our water footprint.” DelMonte, he points out, owns large tractsof farmland, and has become adept atrecycling process water used at itsplants into irrigation water for crops.

Pilgrim’s Pride, the Pittsburg, Texas-based poultry processor, is anothermajor water user —necessarily so,because federal meat-inspection regula-tions require large amounts of water tobe used for plant sanitation and birdcleaning. Recycling has been the answerfor the company. In fact, half of its 50processing operations recycle water; intotal, Pilgrim’s recycles 4.1 million gal-lons of water every day. The poultryprocessor has installed large-volumewater recycling systems from AmericanWater Purification Inc. at five of its oper-ations. (AWPI’s first commercial water-

recycling system was installed in 1997at a Gold Kist plant.)

“We’ve been working very hard andfor a long time on recycling,” commentsGreg Lisso, the company’s vice presi-dent for engineering and environmentalaffairs. “For us, there’s really no silverbullet for reducing water use, since fed-eral regulations require us to use xamount of water in our operations. Butrecycling brings us a double benefit:one, we don’t have to buy as much waterand we don’t have to treat as muchwater.” USDA regulations permit recy-cled water to be used in “like use” appli-cat ions and, af ter t reatment , forsanitation in meat and poultry plants.

A full sustainability program goesbeyond water. “I think breweries havealways had a kind of recycling mentali-ty,” says Anheuser-Busch’s Stiers,“going back to 100 years ago whenspent grain was sold as livestock feed.”Pepperidge Farm and Del Monte alsorecycle edible waste into livestock feed.

Anheuser-Busch is also the world’slargest operator of an anaerobic digest-ing system, which turns wastewaterinto biogas. In fact, approximately

15% of A-B’s natural gas needs are ful-filled by the biogas. A chemical-man-agement program likewise focuses onfinding efficiencies and alternativeswherever possible: particularly safe,biodegradable yet effective products.

Details, detailsBesides improving management of non-renewable resources to reduce footprints,processing plants are finding new ways tozero in on those all-important details.Company inspections of PepperidgeFarm’s operations led to the surprisingdiscovery that the plants leaked com-pressed air like sieves—in fact, someplants were losing as much as 20% oftheir power-sucking compressed air pro-duction. Patching up the “micro leaks,” asDave Watson and Tom Rieth call them,saved immediate dollars. The companyalso cut boiler pressure in half. Now thecompany is exploring “different cogener-ation options” for heat recover and reuse,says Rieth. Like many food processors,Pepperidge Farm recycles all fiberboardand cardboard; it also has switched to dis-tributing fresh products such as breads inreturnable, reusable plastic containers. Toreduce in-plant water use, all appropriateequipment is sanitized with a dry, ratherthan wet, wash.

“We’re centralizing our sustainabilitymetrics,” says Scott Butler. “Most of ourdata was decentralized to the pointwhere it was very difficult to say whatour company’s overall environmentalfootprint is. But that’s changing. We’redeveloping a baseline, then goals forcontinuous improvement.” In that effort,Del Monte has created a pilot programwith Enablon, a French company thatoffers a software package to collectresource-usage information. “The Euro-peans are pretty far ahead of us on mostof this stuff, frankly,” points out Butler,who adds that Del Monte also belongs to

Asset protection is one component ofimproving sustainability. Source: Nalco.


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the Global Reporting Initiative, aninternational network of thousands ofbusiness, civic, labor, and professionalinstitutions that have united to create asustainability reporting framework.

Heinz North America has changedlighting to energy-efficient bulbs on alight-by-light basis; it has also opti-mized boilers and steam generators,upgraded air compressors, upgradedrefrigeration controls and installed co-generation units for heat efficiency.“We assess, we calculate and wereview internally on a daily/monthlybasis,” says Fonner. “This has got tobecome a day-to-day, shift-to-shiftthought process for everyone involved.Awareness and responsibility are key.”

The gold standardWind is just one resource filling thesai ls of sustainabi l i ty a t Ket t leFoods—but wind fills those sails liter-ally. At i ts headquarters plant inSalem, OR, and i ts new LEED-designed operation in Beloit, WI, (seesidebar on page S4) Kettle buys wind-generated energy to create a 100% car-bon offset. According to Jim Hauge,the offset means that approximately250,000 pounds of CO2 pollution areprevented each year at Beloit alone.

“Our guiding philosophy is to findall opportunities to reduce and offsetenvironmental impacts. There are somany benefits to this approach—long-term economic benefits, cer-tainly, but moral and social benefitsas well,” says Hauge.

The “right thing to do” at Kettle hasbeen the guiding principle at the newBeloit operation, which has pendinggold-level Leadership in Energy andEnvironmental Design certificationfrom the US Green Building Council.If the gold level is achieved (the com-pany will find out in September, saysHauge), Kettle will be the first non-beverage food processing plant in theUS with gold LEED certification.

The result is a tribute to sustainablefood processing. Three-quarters of theconstruction waste was recycled forother uses or otherwise salvaged.Twenty percent of the building materi-als, including steel and brick, had beenpreviously used. Forty percent weresourced locally. The roof is made ofreflective materials to keep the build-ing cool. The plant’s gas and electricalequipment feature variable-speeddrives so the equipment never runsfaster than required. Inside the plant,water is filtered and reused for wash-

Anheuser-Busch’s Bio Energy Recovery System converts wastewater into enoughnatural gas to supply 15% of the brewer’s total natural gas needs. Source:Anheuser-Busch.


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ing potatoes, saving 1.6 mil-lion gallons a year. Excessprocess water is used to flushrestroom toilets, saving anoth-er 120,000 gallons per year.

Brass ringsStill, there’s more to be done.Hauge calls recycled chippackaging “the brass ring” forthe snack industry, and Kettleis working with its packagingsuppliers on new laminatesthat are amenable to recyclingor reuse. “We’re trying to doour part to push the industry,”he says. “Our foremost con-sideration for packaging has to be theintegrity of the product. For us, thatmeans the packaging has to be imperme-able to light and oxygen. Recyclablepackaging is an extremely challengingtechnological problem. There’s a market-ing aspect to it, too, because packaging is

our greatest vehicle for informing ourcustomers about who we are.”

Supplier commitment to sustainabilityis key, and not just for packaging.

“We’ve oriented our global R&Dpipeline to support the industry’s com-mitment to sustainability with new

Nalco innovations like water-conserving system controlequipment, cleaning systemsto reduce energy waste andsafer, high-actives polymers,”says Nalco’s Mary Kay Kauf-mann. “Another example isthe water efficiency programoffered by the JohnsonDi-versey Nalco Alliance.”

“Once we measure wateruse, water costs and energycosts associated with produc-tion, facilities have the metricsneeded to make decisions onsustainability projects” accord-ing to Pat Anderson, managerof the Aquacheck water effi-ciency program for the John-sonDiversey Nalco Alliance.

Both Kaufmann and Ander-son agreed that the focus onthese new types of program andtechnology platforms shouldproduce sustainable ROI totheir food industry customers.

At Solid Waste Solutions,“we try to get processors tolook at waste, at all the thingsthey throw away, not as a lia-bility but as a potential revenuesource. If they manage wasteas an asset and resource,there’s profit there,” says ScottNormandeau. “I tell our clientsto look at the perception thepublic has of them. That’s theirreputation, and if they careabout public perception, thentheir reputation has value. Ifthey manage their waste in away their local communitiesfind compatible, that adds

value. If they’re doing it better than theircompetitors, that brings value.”

Lydia Kuyawa-Dow of SWS says theheart of any successful sustainabilityprogram is buy-in from the corporatelevel. “It really comes down to whetheror not corporate wants to make a com-mitment and whether they’re going towalk the talk. You need leaders.”

As more food and beverage manufac-turers make sustainability a priority, theywill not only experience increased pro-cessing efficiency and energy savings,but will enjoy the satisfaction of know-ing they did the right thing. ◆

For more information:John Blanchard, ARC AdvisoryGroup, 781-471-1169,[email protected] Glass, Nalco Company, 630-848-3344,[email protected] Ed Binot, The JohnsonDiverseyNalco Alliance, 630-848-3344, [email protected] Michael Hanschke, JohnsonDiversey, 513-956-2581,[email protected] Normandeau, Solid Waste Solutions Corp., 207-423-2928, [email protected]

Modern filtration equipment allows process water to be recycled.Sophisticated water pretreatment is a key to achieving energy costcontrol. Source: Nalco.

Anheuser-Busch partners with other major breweriesto share best practices for efficient and sustainableprocessing. Source: Anheuser-Busch.


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Kevin T. Higgins, Senior Editor

Passing fad or serious sea change, the sustainablepackaging bandwagon is gathering momentum, andmost food and beverage companies are on board.

S ustainability may be a frustratingly vague andhard to define term, but it’s getting harder to findanyone in corporate America who is against it.

Not only is sustainability joining mom and applepie on our favorite-things list, formal plans of actionare being put into place by packaging engineers andother food company profes-sionals. Three-fifths of FoodEngineering readers polled inthis year’s Packaging TrendsSu r ve y i nd i c ate d a for m a ls u s t a i n a b i l i t y p l a n w a s i nplace at their companies. Dri-ven partly by the sustainablepackaging initiative launchedlast year by Wal-Mart, 59%indicated they had adopted aplan. Efforts to reduce wastes t re a m s a n d e n e r g y u s a gew e r e t h e m o s t f r e q u e nt l ycited actions taken, followedby ef for ts to reduce t rans-

portation costs and cut back on both primary andsecondary packaging.

Reuse of secondary packaging was the sixth most-common sustainable practice, though only 13% of com-panies were reusing materials, far less than those usingother tactics. Use of more sustainable packaging materi-


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als, in-store stockingand other actions alsowere mentioned.

Food professionalsare on the lookout formaterials, technologiesand techniques that canaid the sustainabilityc au s e . In a n op e n -ended quest ion re -garding notewor thychanges implementedby their firms in the lastyear, respondents citedthe use of more recy-clable packaging andpalm fiber trays thatare fully compostableand biodegradable.

On the other hand,there is room for considerableimprovement, as packaging profession-als point out. Asked where their com-

pany’s packaging programs fall short,one reader noted,“Waste reduction onfilm/plastics.” Another wrote, “Envi-

ronmental impact—make it a considerationon future projects.” Athird criticized his com-pany by simply writing,“reduce waste.”

The sustainabi l it ybandwagon may becrowded, but it remainsa back-burner priority.Asked to rate the impor-tance of 10 factors whendeveloping new packag-ing, respondents rankedsource reduction deadlast. Food safet y andcost topped the list, with86% and 76% of read-ers, respectively, ratingthem very important. By

contrast, only 19% indicated sourcereduction was very important, lessthan half the proportion that rated the

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ninth ranked fac tor,product differentiation,as very important. Onein 10 said source reduc-tion is not important,double the ratio of anyother factor.

Sustainability steps—specifically recycling,material recovery andsource reduction—did-n’t fare much better inanother question. Askedto rate 24 packagingissues and their impacton business operations inthe next two years, foodprofessionals ranked sus-tainabilit y 14th, justbehind club-storedemands. Though a mediocre rating,it’s consistent: Five years ago, environ-mental concerns such as recycling,

material recovery and source reductionranked 13th out of 17 factors in the2002 Packaging Trends Survey.

The case for ’botsPackaging sustainabilityefforts may not be gen-erating much enthusi-asm, but the same can’tbe said of robot ics.Robotic machines werethe most f requentlyment ioned develop-ment in an open-endedquest ion regardingnoteworthy packagingtechnology. Robots alsocropped up in responsesto packaging-line wishlists, with some com-menting on the technol-ogy’s potential to loweroperating costs.

Palletizing continuesto be the most frequent packagingfunction for articulated arm robots,with two-thirds of respondents saying



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their companies make use of roboticpalletizers, up from 64% last year. Casepacking and carton forming are otherstrong applications.

Robotic depalletizing is being doneat 17% of readers’ plants, triple the ratefrom a year ago. Vision systems andadvanced controls that can deal withthe variability of incoming pallets ofraw materials and supplies are aidingthis rapid growth. The technology alsois demonstrating its diversity. Only 5%of 2006’s respondents said they wereusing robots in applications outside ofthe four listed; this year, 12% citedother applications, including in-linepallet wrapping, filling, pallet storageand retrieval, product placement oncooling conveyors and unit packing.

Performance and dependability rat-ings of robotics remain very strong,with 82% rating performance excel-lent or ver y good and 68% giving

dependability similar scores. Mainte-nance remains an issue, with 48% giv-ing robotics a fair rating on this metricand 8% suggesting the technology is

poor. As with any new technology, theskills needed to keep robots up andrunning may be lacking in-house. Ifmaintenance personnel are unable to

YOU CARE FOR THE CONTENT.WE CARE FOR THE FILLING ANDPACKAGING.

Variety is the recipe for success. The process of producing, filling, and packaging yogurt is a law unto itself that involves meeting a wide variety of demands with a single, ideal solution. KHS offers highly efficient, all-inclusive concepts and systems, ranging from pasteurizing through filling to packing, that not only the dairy industry will savor.

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troubleshoot and repair a system, many packaging profes-sionals will defer robotic installations, rather than jeopard-ize line operations.

RFID, on the other hand, is a technology mired in indif-ference. It slipped to 20th on a list of 24 issues that will havean impact on business operations in the next two years,down two notches from a year ago and approximately thesame as RFID’s rating in 2003, before the Wal-Mart RFIDmandate surfaced. A quarter of respondents predictedRFID would have little or no impact.

Product shelf life and consumer convenience, on theother hand, are growing in business-impact importance,with readers ranking them behind only product safetyand cost of materials. Faster packaging line speedsslipped to No. 8, immediately behind tracking and trac-ing requirements.

The need for greater flexibility and line automation is thefocus of several reader comments. “Line equipment is 20years old. We need to upgrade equipment to improvethroughput,” one reader gripes. “Need to invest in newpackaging equipment,” another writes. Overall, 45% planto install new packaging lines this year, virtually the sameas last year. Corporate financing is getting harder to find,however, with only 37% reporting an increase in capitalexpenditures, down from 50% in 2006. Capital cutbacksare being felt by 36%, the same as last year.

Outsourcing is on the rise, with one in five saying proj-ects will go to copackers this year. Time-to-market focus isdriving much of the packaging outsourcing: 32% say theirfirms are using contract packagers to decrease time-to-market for new products. Only 16% deployed that strategyfour years ago.

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Modification of existing equip-ment remains the most popularspeed-to-market tactic, with almosttwo thirds of companies using thisapproach. Automation of operationsis almost as popular, and its growthis notable: Three in five are automat-ing, up from two in five in 2003.

Inflation has had an impact on totalexpenditures for automation, new linesand sophisticated equipment, but foodcompanies also are more committed toinvesting in packaging improvement.

More than a third—34%—of respon-dents indicated their companies willspend $1 million or more this year onpackaging equipment, compared to19% in that spending bracket five yearsago.A greater proportion fell into everyequipment budget range above$100,000 than in years past, while thesmall-ticket brackets are shrinking.

Food safety and machine safetyrate as the most important of 20 fac-tors when selecting new machinery,but s t icker pr ice is decl ining in

importance, slipping from the thirdconsideration in 2003 to tenth. Rawspeed doesn’t mean what it used to,either: It ranked 12th among packag-ing professional’s criteria, down fournotches in five years.

Compliance with government reg-ulations, on the other hand, rosefrom fifth to the third most impor-tant criterion. It is followed by aller-gen/contamination issues, reflectingthe greater importance of sanitarydesign in the industry. ◆

F ood professionals from a wide variety of production facilities partic-ipated in the 22nd annual Food Packaging Trends Survey. Question-naires were mailed in April to a sample of Food Engineering readers

involved in buying or specifying packaging machinery and materials.Usable surveys were returned by 110 readers.

Engineers and operations/production managers are the largest respon-dent groups, each accounting for 29%. General administrators/managersare 15% of the sample, with purchasing professionals composing 11%.

Other job functions include quality control, R&D, maintenance and packag-ing. A majority are involved in dairy production or meat, poultry andseafood processing (28% each). Beverages, bakery products, cereals andother grain-based products, coffee/tea/spices, confectionery products,frozen foods and canned foods are other major product categories. Facilitystaffing is almost identical to last year’s survey, with 59% working at plantswith 250 or more employees and 29% at plants with 100-249 workers. Theremaining 12% are at locations with fewer than 100 employees.

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F rom the machines to process food and beverageto the floors they rest on, the sky’s the limit whenit comes to sanitary design in today’s plants.

Cleanable walls, food-contact surfaces and equip-ment are essential if food and beverage processors areto meet threshold requirements for food safety. Dairyremains the gold standard in food, and meat and poul-try processors are making tremendous strides in raisinghygiene levels. But virtually every segment of the indus-try is focused on improving sanitary conditions. “Theold way of thinking in bakery was, ‘We’ll kill it in theoven,’ but today you have to have solid food-safety stan-dards,” notes Jon Anderson, director of the BISSC bak-er y equipment desig n cer t i f icat ion prog ramadministrated by AIB International, Manhattan, KS.Customers are setting minimum sanitation require-ments, and how far manufacturers exceed those is botha value judgment and a business decision. Some plantsare going far beyond the basics.

Take Smithfield Foods Inc.’s year-old ready-to-eatfacility in Kinston, NC. Separation of raw and cookedoperations has become standard in meat and poultry,where Listeria and other pathogen concerns are

approaching zero-tolerance. The design/engineeringteam at Smithfield used raw/cooked separation as astarting point and went from there.

The Kinston design team went well beyond sepa-rate lockers, washrooms, parking lots and employeecleaning rooms (ECRs) in implementing state-of-the art sanitary process and facility design. Mainte-nance pers onnel have their ow n ECR , and a l lmaintenance equipment passes through a sanitizingstation before entering either the raw or cooked side.Separate water and drainage systems serve the raw,ready-to-eat and slicing rooms. Additionally, sepa-rate plumbing and HEPA air filtration serve each ofthe five slicing rooms.

“With separate slicing halls and air-handling sys-tems, it’s possible to stagger sanitation and keep pro-duction going 24/7 and give the plant extra flexibility,”observes corporate engineer Paul Kafer. “That level ofseparation is extreme, and it’s not for everyone, but wewere able to make a business case for it in this plant.”

The Kinston facility’s sanitary design grew from twosources: Robert Urell, Smithfield’s now-retired seniorvice president of engineering, and project manager



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David Dixon. Now in the Chicagooffice of The Facility Group, Dixon waschairing a task force of the AmericanMeat Institute (AMI) to pinpoint bestpractices in facility sanitary design.

“We looked at what the state-of-the-art was and at the AMI principles, butthe talent is in knowing how far to go ineach room in the facility, and Bob Urelldid an excellent job in setting thosepriorities,” recalls Dixon.“The goal wasto create a best-in-class slicing facility,and I think we achieved it.”

Elements of art, science and eco-nomics are at play in sanitary design offo o d pro cessing faci l it ies andmachines. Pressure from manufactur-ers and their customers are drivingimprovements in the technology, andthe payback calculations are becomingmore sophisticated, with chemicalcosts, wastewater treatment, labor andproduction downtime helping bolster

Work surfaces that are cleanable to a microbiological level are fundamental to good sanitary design,according to the American Meat Institute. Hygienic considerations helped shape the design andlayout of Meadowbrook Farms’ Rantoul, IL, facility, which opened in 2004.

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the ROI argument for superior designs.The art is the Goldilocks solution:What option is neither too little nor toomuch but just right?

Pick a standardThe AMI facility-design principles—distinct hygienic zones, room tempera-ture and humidity control, a buildingenvelope that facilitates sanitary condi-tions, etc.—were devised with meat andpoultry operations in mind and comple-ment sanitary principles for equipment.

Whether a plant produces cooked meator candy, there is no shortage of sanitarystandards to consider. The granddaddy ofthem all is 3-A, the dairy certificationprogram that traces its roots to the Roar-ing ‘20s. The modern program was estab-lished in 1944, and it was upgraded in2002 with a third-party audit program toimprove the consistency and credibility of3-A certification.BISSC,which was estab-

Todd Jorgensen assembles a Dorner 7600 series conveyor, designed for high-pressure washdownwith caustic chemicals. The units are engineered for meat and poultry environments, but thecompany also wants to satisfy dairy 3-A sanitary requirements. Source: Dorner Manufacturing Inc.

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Then.

lished in 1949 by bakery engineers,equip-ment vendors and regulators, added athird-party verification option a few yearsago, though only a handful of audits have

been performed, according to Anderson.But end-users and suppliers clearly wantvalidated design improvements: 3-A cer-tification is being extended to replace-

ment parts to address OEM frustrationsthat their machineries’ hygienic perform-ance is being compromised by inferiorcomponents sold in the aftermarket.

Seeking common sanitary ground Sanitary design isn’t an interest for Joe Stout; it’s a passion.

Stout, director-global sanitation for Northfield, IL-based KraftFoods Inc., chaired the design task force that developed the AmericanMeat Institute’s 10 principles of sanitary equipment design. Unveiledin 2003, the principles were an attempt to elevate sanitation abovecompetitive considerations and make it part of an industry-wide foodsafety focus.

In the wake of deadly Listeria incidents involving ready-to-eatmeats, the task force began meeting in 2001 to identify common ele-ments in the sanitary standards already in place at major firms such asHormel, ConAgra and Kraft’s Oscar Mayer division. “The goal was toput together standards to make sure suppliers have the right focus on

sanitation and food safety,” recalls Stout. “Their expertise is inmechanical design and materials and typically not cleaning or micro-biological sanitation.We want equipment that is not only visibly cleanbut can be validated as microbiologically clean.”

While many of the principles apply to food production other thanmeat and poultry, each manufacturing segment must have equip-ment designed for its specific needs. “Allergens pose a potential food-safety risk in bakeries, so you want to make sure equipment in thatenvironment is cleanable to an allergen level,” he points out.WhetherNSF 14159, 3-A, BISSC, EHEDG or another standard is most appropriatedepends on the product being produced. “We refer to it as outcome-based approaches,” says Stout.


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Now.

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cans that is still recognized worldwide as the industry standard. The new Angelus 5K Can Seamer represents a century of perfecting this process into the new standard of durability and reliability.

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Angelus: 95 Years of Seaming Excellence. For more information, call323-583-2171, Fax 323-587-5607or visit www.angelusmachine.com

Cleanability is the essence of 3-A,notes Lou Beaudette, a director of the3-A Sanitary Standards Inc. board andpresident of Admix Inc., Manchester,

NH. The board has made stainless steelthe material of choice for most certi-fied equipment. “Some plastic compo-nents, notably for gaskets and O rings,

are permissible, but 95% of the fabrica-tion is stainless steel,” Beaudette says.

Though 3-A may be considered best-in-class, for many processes, it’s overkill,

10 Commandments of Sanitary DesignTrained personnel, cleanable materials and repeatable resultsare components of food safety, but sanitary equipment designalso is a critical element. Food processors and equipment fabri-cators devised 10 guiding principles of design for the AmericanMeat Institute:

1. Cleanable to a microbiological level

2. Compatible material construction

3. Accessible for inspection, maintenance and

cleaning

4. No liquid- or product-collection areas

5. Hermetically sealed hollow areas

6. No niches

7. Sanitary operational performance

8. Hygienic design of maintenance enclosures

9. Hygienically compatible with other systems

10. Validated cleaning and sanitizing protocols.


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points out Joe Stout, corporate director ofsanitation for Kraft Foods Inc., North-field, IL.“All the standards are good,” saysStout.“But 3-A is over and above what weneed in a dry processing environment.”Ina bakery,316 stainless steel is unnecessarybut may be the required material of con-struction in a dairy application.

Dairies embrace the 3-A standard,though adding more rigor, allows thoseprocessors to avoid the standards mazethat exists in other segments of the indus-try.“Right now there are too many differ-ent standards,” Beaudette believes.“There’s a need to unify them.”When theUSDA dropped its approved-equipmentprogram in the 1990s, Underwriter’sLaboratories, NSF and other standardsorganizations rushed to fill the void.Add in company-specif ic hyg ienerequirements such as Kraft Foods’ 107sanitary standard and similar specifica-tions from other major processors, and

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If there is one thing over 50 years of industry experience have taught us, it’s that products whichmay have worked in the past may not be sufficient to provide adequate lubrication in the future.At JAX, we are relentless in our quest to provide you with the most innovative and individualizedlubricant solutions to extend the life of your machinery, reduce downtime and increase production.Just as your needs are ever-changing, so is our line of industrial lubricants – because after all,there is no such thing as a cookie-cutter solution.

IfI h i hi f i d i h h i ’ h d hhi hhhIf there is one thing over 50 years of industry experience have taught us, it’s that products whichmay ha ked in th ot be sufficient to ovide ade te lubricati in h fmay have worked in the past may not be sufficient to provide adequate lubrication in the future.At JAX lentless in our vid i h he t inno ive and indi id li d At JAX, we are relentless in our quest to provide you with the most innovative and individualizedlubl i l i d h lif f hi d d i d i d ilubricant solutions to extend the life of your machinery, reduce downtime and increase production.Jus eds -ch i o i line of i d ial l b ib – b af llllJust as your needs are ever-changing, so is our line of industrial lubricants – because after all,ththe i h hihi kiki l iithere is no such thing as a cookie-cutter solution.


No tension is needed to convey primal cuts on a flat belt in this New Zealand beef plant because thebelt turns on sprockets. The flat design also reduces weight and eliminates vertical surfaces comparedto modular belts, enhancing sanitary performance. Source: Mol Industries Inc.


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Come visit us at the Process Expo in Las Vegas, Booth #S-6652

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it’s what’s insidethat matters most...

From five gallon process vessels to 500,000 gallonfield-fabricated tanks, the sizes and shapes of DCImanufactured stainless steel tanks and components are asvaried as our customers’ needs. Proudly serving the food,dairy, beverage and OEM industries, DCI has remainedtrue to our commitment to quality since 1955 throughour design and fabrication services—we know it’s what’sinside that matters most.

DCI’s Dynamixer Processor!Performs three separate process functions all in the sametank—mix dry or semisolids into liquid, chop/chip solids,heat and/or cool the mixed batch.

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the f ine points of sanitar y desig nbecome murkier. The resurrection of anaccepted meat, poultry and dairy equip-ment list from USDA’s Agricultural Mar-keting Service further compounds theconfusion. Borrowing elements of theNSF and 3-A programs, the AMS pro-g ram imposes technical rev iew ofequipment’s sanitary features but has sofar failed to attract much attention.“I’mnot sure suppliers recognize what USDAis doing,” suggests Beaudette, whosefirm is the only mixer manufacturer toseek and receive AMS acceptance.

Conveying systems are one categorywhere the program has achieved sometraction with vendors. In designing itshigh-pressure-washdown conveyorsfor meat and poultr y, engineers atDorner Manufacturing Corp. had theAMI principles and the AMS standardsin mind. But the ultimate goal is 3-Acertification, according to John Kuhnz,

food marketing manager. “Some peo-ple say 3-A standards go too far, but therequirements were developed by verypassionate people who have helped theindustry by creating the highest level ofsanitary design anyone has seen.”

Hartland, WI-based Dorner beganfabricating food-grade conveyors afterinterviewing managers at more than100 food companies in 2001 to learnabout operating conditions and sanita-tion requirements in different types ofprocessing plants. Elimination of areasthat could harbor food and waste was abaseline need, and the earliest designssatisfied the sanitary demands of dry-material plants. To deal with 1,500 psiwashdown pressures and caustic clean-ers used in meat and poultry, tougherneeds had to be met, such as eliminat-ing bolts and fasteners and enclosingdrives to house bearings and preventgrease from being blasted out. The

value of economical cleaning alsobecame a bigger consideration.

“The open design of our 7600 seriessaves 80% of the water needed to wash itdown,”says Kuhnz. It also slashes sanita-tion time: One meat processor validateda 10-minute savings for sanitizing a 40-ft. conveyor. Some processors specifyhow quickly cleaning, sanitizing andchangeover must occur in purchaseorders,“and if the equipment can’t meetthe time limit in performance testing atstart-up, the vendor has to take it back,”according to Dwight Nickerson, aprocess engineer in the Indianapolisoffice of CH2M Hill.

The eight-hour sanitation shutdownis becoming a relic of the 20th century,adds Kraft’s Stout.“We don’t have foodplants to clean them; we have foodplants to make products,” he says.“Effective cleaning has to be done in afast changeover environment.”

Barrels. Buckets. Belts.Scale Parts. Bins. Totes.Any washer, for any need. All push-buttoneasy to operate! This means saying goodbye to the time-consuming and costly routine of handwashing – freeingyour employees for more productive and profitable tasks.

Call 800-331-6870 today for pricing,literature and specifications on a model suited to your particular needs – or visitwww.dougmac.com foradditional details.

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AMERICAN CONVEYOR | www.amerconveyor.com | telephone 718-386-0480 or fax 718-456-1233

You can call yourself anything you want,

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dairies, processors, and co-packers from

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These same dairy customers have come

to rely on us to seamlessly integrate a wide

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Cleaning time may be reduced by out-fitting conveyors with flat belts, main-tains Barry Whitman, vice president ofMol Industries, Grand Rapids, MI. Molmakes solid, extruded thermoplasticbelts that overcome the slippage andfraying issue of fabric-ply rubber belts ofyears past. The sanitary belts, which arepowered by sprockets and don’t requiretension, are an alternative to modularbelts made of interlocking plastic hingesand metal pins. Elimination of verticalplanes means there is 40% less surface toclean, and the belt doesn’t need to beremoved and soaked in an antimicrobialbath. The belts also weigh less than halfas much as a modular plastic unit, whichmeans less bracing is needed on the con-veyor frame, reducing both harboragepoints and cleaning time.

“No matter what anyone says, hingesin modular belts harbor bacteria,”insists Whitman. “Meat and poultry

have issues with bug counts, despiteheavy water usage and labor costs toremove and soak belts.”

E nd - u s e rs d r ive s om e de s i g nimprovements. The welded freezerenclosure had its genesis in a dairy inthe early 1990s that fretted about thebacteria medium created by saturatedinsulation, recalls Ingmar Pahlsson,s pi r a l f re e z e r m a n a ge r at F MCFoodTech’s Helsingborg, Sweden,center. “The customers were ready tomake an investment in enclosuresthat did not depend on caulking,” hesays . “Sudden ly there was a newindustry standard.”

Clean-in-place designs and greateruse of foam cleaning are current trendsimpacting machine design, Pahlssonreflects. High-pressure washdown inan open environment requires toomuch water and can be counterpro-ductive: Bacteria not killed on contact

get atomized and later settle in already-cleaned areas. “Putting your contami-nants into a mist is never a good idea,”agrees CH2M Hill’s Nickerson. Phar-maceutical plants never use high pres-sure, he adds, and their electricalcontrols appreciate it.

Localized CIP options in equipmentare exploding. A vacuum packagingmachine from Multivac Inc. makes itsNorth American debut at October’sWorldwide Food Expo in Chicago.“Sometimes you have to take the humanout of the equation” if sanitation is toimprove, observes Don Smith, Multi-vac’s chief technical officer.

Stainless-steel drives, gear reducersand motors are becoming standards inmeat and poultry plants, but these poseadditional design challenges.Heat trans-fer is inhibited, resulting in motors thatrun hotter and require beefed-up com-ponents. A hot motor in a refrigerated


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LET SHAMBAUGH & SON SOLVE YOUR FOOD MANUFACTURING PUZZLE“The Premier Design-Builder of FOUR U.S. Food Plants of the Year”

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room also means more condensation,points out John Malinowski, productmanager-AC & DC motors at BaldorElectric Co., Fort Smith, AR. Gasketsand seals that keep water out while let-ting condensate out are a must.

AMI’s equipment design initiativehelped make hygienic design a priorityfor Kansas City-based Multivac’s Ger-man engineers.“Sanitary design is a big,big deal for them now,” Smith says, andnewer models incorporate open designsthat feature lighter, stronger materials ofconstruction that lower overall costs.

Better box designOpen design also is a consideration inplant layout. Joe Bove, a vice presidentwith Jacksonville, FL-based Stellar, says ithelped shape the AMI’s 11 facility designprinciples.“Respect the clearances aroundthe equipment and try to minimize thesticks and bricks,”Bove summarizes.

When it comes to sanitation, facilitydesign “remains an art form,” he adds,but the task force attempted to quantifyas much as possible with an audit form(posted at www.meatami.com) that QA,production and sanitation managerscan use to assess their plants.

The devil truly is in the engineeringdetails of facility design. Bove and Nick-erson mention seal-tight gaskets aroundwall-penetrating pipes and smooth,cleanable finishes on walls and othersurfaces.“I wish there were a few piecesof low-hanging fruit, but it’s a game ofdetails,”says Nickerson.

Food engineers at A/E firms arealmost unanimous in touting the sani-tary benefits of epoxy flooring. Somefavor it over dairy brick, which can har-bor microbes in the grout.Poor concretepreparation and application of thedressing resulted in poor performanceby epoxy and resinous flooring in years

past, but today’s technology is muchimproved and may come with a five-year warranty.“We’ve had great successwith both dairy brick and toppings,”saysBove. “Any contractor can buy epoxyflooring materials,” cautions Nickerson,“so you really have to do your researchon the installer you’re using.”

Floor caulk with silver ion for antimi-crobial protection is another sanitaryupgrade that is beginning to be used infood plants, adds Bove.

Ron Frattare, vice president-facilitiesdevelopment at The Austin Co. in Cleve-land, reports good results with epoxyflooring in general and polyurethane inpar t icular for cold env ironmentsbecause of their ability to handle thethermal shock of steam cleaning. Butmoisture is the enemy of resins, and thatcan compromise long-term perform-ance.“The issue with epoxy is the rec-ommendation that you put a vapor


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seepexInc.511 Speedway DriveEnon, Ohio 45323(937) 864-7150Fax (937) [email protected]

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barrier under the concrete,” he pointsout.“That’s not always possible with anexisting concrete slab.”

Frattare served as project manager onthe Tanimura & Antle fresh-cut saladplant in Plymouth, IN (“Heads roll inIndiana,” Food Engineering, October2003). Subsequently sold and shuttered,the facility serves as a useful gauge wheresanitation standards were and wherethey are headed.

The building formerly served Procter& Gamble, which produced Sunny Djuice drinks in Plymouth before sellingthe brand. Walls with cavities that couldharbor insects and rodents had to betaken out, roof repairs and window anddoor recaulking and replacement to ren-der the plant water- and weather-tighthad to be under taken, and otherupgrades were required to bring it up toearly 21st century sanitary standards. Ifit returned to food production today,

sanitary expectations would requireeven more work.

The same is true of the SmithfieldKinston plant, allows The FacilityGroup’s Dixon. “In the last two years,chemical sanitizers have improved, bet-ter packaging machines have becomeavailable,and other changes would allowus to build a more sanitary plant,” hesays, “and the possibilities five yearsfrom now will be even better.”

Sanitation, after all, is a continuousimprovement challenge. “The designstoday are so superior to the norm 25years ago, and they will continue toimprove,” Kraft’s Stout says. “Newerdesigns incorporate features I neverthought possible. I’m excited aboutwhere the industry is going.” ◆

For more information:Lou Beaudette, Admix Inc.,603-627-2340, [email protected]

Ron Frattare, The Austin Co.,440-544-2660,[email protected] Malinowski, Baldor Electric,479-459-5905,[email protected] Nickerson, CH2M Hill,317-331-4568,[email protected] Kuhnz, Dorner ManufacturingCorp., 262-369-1332,[email protected] Dixon, The Facility Group,312-846-4910Ingmar Pahlsson, FMC FoodTech,011-46 42 490-4353,[email protected] Whitman, Mol Industries,616-453-2484Don Smith, Multivac Inc.,816-891-0555Joe Bove, Stellar Group, 904-899-9370,[email protected]


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Still entering your production data on clip-boards? Still hoarding away chart recorder output in shoeboxes? Still transferring your

data into Microsoft Excel spreadsheets? Want to “upgrade” your manual system? Behold, the auditor stands at your door and knocks. Will you be ready?

The real worldI received a phone call from a processor a few months ago, and had it not ended by the caller saying, “Whoops, the auditors are here; I gotta go,” I might not have given it a second thought. Seems he, like other manufacturers, is still managing his pro-cesses the old-fashioned way: clipboards, spreadsheets, charts, paper and pen. When the auditor shows up, he scrambles to find needed records. The caller (from a small company that employs 100 people) and I spent 30 minutes discussing software options to automate the process, keep track of batches and track and trace.

Unfortunately, the first complaint that many small processors have is “Software is just too expensive,” and the second, “It willcause people to have to relearn their jobs.” While the first issue may be true and a hard pill to swallow, the second complaintabout relearning jobs may be the most important. Manufacturing execution system (MES) software, sometimes known as “shop floor” software offers modular products and solutions without a plethora of expensive tools that will never be used. In many cases, software developers who write prod-ucts specifically geared to the food and beverage industry will understand a processor’s needs and its ability to pay for software. And in some cases, the use of this software will transform people and the way they do their jobs—which is good!

Marsan Foods (Scarborough, ON) employs 100 people in two facilities and provides frozen prepared entrees, soups and sauces to national brands, store brands and club stores as well as restaurants and hospitals.

Faced with significant growth, Marsan built a new plant in 2000 and installed high-speed produc-tion lines. Although one line is capable of produc-ing 125 meals per minute (60,000 meals per shift), Kristoffer Soderlind, director of operations, says the company could run just 30,000 to 36,000 meals on a good day. He expected better numbers, and he needed to know why he wasn’t getting them. Old methods of logging shift and manufacturing data on clipboards weren’t getting the job done.

“You need information to be able to solve your problems. Using clipboards is just wasting your

TECH UPDATEWAYNE LABS, SENIOR TECHNICAL EDITOR

Processors with fewer than 100 employees get a boost from MES—just like the big guys!

MES for the little guy

MES software should give operators the tools to do their job, not complicate matters with overly complex screens and confusing information. Source: CDC Software.


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time,” Soderlind says. He needed to get hold of downtime, machine yield and weights. On a suggestion from an equipment supplier, he and the company’s president looked at CDC Software’s CDC Factory.

Marsan’s president visited two up-and-running applications in England and thought the system would pro-vide value to his company. Soderlind was looking for a solution that used

good manufacturing practices, but he didn’t have the time to program software or learn the complex nuances of different manufacturing theories, and he wanted something plant floor operators could understand.

The solution worked. On the one large line, he has seen overall equip-ment effectiveness (OEE) increase from 65 to 74%, and he reports fig-ures of close to 80% in the last three

months. The software shows what’s causing downtime and allows staff to find new ways to fix problems. In fact, by adding an extra sauce pump in a line and cleaning a sauce hopper for each SKU, he was able to reduce downtime due to product change-overs from 50 minutes to 30 minutes

“Before [using MES], we always said that continuous improvement is impor-tant for us, but it was primarily at the

TECH UPDATE

Building MESfrom ExcelUK-based Ryvita, located in Poole, Dorset, is part of the ABF Group and has been making crsipbread since 1925. It recently began a total qual-ity management (TQM) and best practices program to improve system effi ciencies, monitor downtime, track products and react dynamically to changes in the business. Silchester Control Systems (SI) was hired to revamp Ryvita’s mostly manual system into a competitive tool with the latest MES and ERP systems. Weeks were spent in scoping out the project, interviewing users/operators, capturing requirements and writing a user requirements specifi cation.

Since most of the equipment in use was Schneider, Silchester imple-mented a Schneider OPC server, Citect SCADA, Citect Ampla (MES), Mi-crosoft SQL and Reporting Services. Ryvita operators originally entered data into a 40 MB Excel spreadsheet fi le, which contained thousands of separate calculations taken from hundreds of manual entries. All the data in the Excel fi le was recreated from SCADA data and manual entries within the SCADA system. Manual data entry used to take many hours per week; now entries are only a few short minutes per shift. The accuracy is

unquestioned, and the repeatability is perfect. Trends are now based on actual machine data instead of personal interpretation.

A 90% reduction in manual entries has been achieved. Reports are available over the network in Internet Explorer, and slice/dice reporting of shift/product/line/machine/day data can be achieved using both Citect Ampla Analyst and Microsoft SQL Server Business Intelligence Reporting Studio. Tabular, Pareto, trend, pie charts and reports are customized in clearly understandable dashboards and linkable to Microsoft Dynamics NAV (ERP) data. The technology and data transport of the production management system is hidden to end-users who only need straight-forward real-time information to use their own skills and experience to make business decisions in a timely manner.

“This is a major step forward in terms of information accessibility for the site,” Mark Chesworth, supply chain director for Ryvita, reports. “It allows live data to be used by the teams in the factory to drive and improve business performance without time being wasted trying to collate vast quantities of information. It also enables the teams to assume real-time responsibility for driving their KPIs and to witness the results of their efforts. We believe this evolution will prove to be truly empowering for our production staff.”

The Ryvita control room includes several PC-based windows into its operation, including MES and ERP functionality. Tools include Schneider I/O system, Citect SCADA and Ampla (MES) software plus Microsoft Dynamics NAV (ERP) software. Source: Silchester Controls.

Dashboards at Ryvita give operators key performance indicators at a quick glance and allow them make the appropriate actions based on the information they see. Source: Silchester Controls.


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management level,” Soderlind states. “Now when the operators on the shop floor can be part of this, there is more accountability, and they enjoy coming to work.” And, yes, MES has justified its cost a couple or more times over.

MES ill-definedThe foregoing example shows how MES can benefit processors. But one of the problems hindering its wide-spread acceptance is that MES has not been clearly defined, although it would seem MES should at least be capable of downtime monitoring, batch records, track-and-trace, quality,

Chocolate Potpourr i , a small specialty company with 20 employees, uses SYSPRO ERP software to gain the efficiencies of an integrated, real-time database. In the past, the processor had several non-connected databases and applications and no quick way to make important decisions. Source: SYSPRO.

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OEE and SPC—to name a few. Over the years, ERP software, traditionally steeped in accounting functionality, has been extending its functionality toward the plant floor, providing some or all of these capabilities.

Meanwhile, process control software has added many of these functions, working its way up the enterprise hier-archy. MES software was supposed to be the missing link between enterprise and process control system. Should it inherit ERP functionality? Should it perform data acquisition and PID control? What modules should it have? In many cases, MES has had too much complexity and in other cases, not enough to be useful.

Trying to categorize what MES is and where it fits in may be part of the problem. According to Terry McCor-riston, director, CSB-System Interna-tional, “I think the small guys make

a huge mistake by thinking in cat-egories like MES, ERP, SCM, SCADA, etc. Historically these multiple sys-tems loosely connected to each other have never worked, not for the small guys and very limited for the big guys. What [the small guys] need to focus on are the business processes and how to collect or record the data once, for all areas to use.”

In the food industry, Microsoft Excel may be the logical next step from paper records. Claus Abildgren, Won-derware marketing program manager, laughingly defines MES as “Microsoft Excel Spreadsheets.” According to Sie-mens Energy and Automation’s US MES Marketing Director, Maryanne Steidinger, “The two products we see that are used for tracking and tracing of lots are typically Excel or Access. We laugh and say that Microsoft is our biggest competitor.”

“In all honesty,” she adds, “proces-sors have to start somewhere, and depending on a processor’s size, a paper-based system will work fine for a number of years.” But when sales really take off, output and growth will be more than paper systems and Excel can handle.

Another problem for its acceptance has been the way MES is sold. Because it occupies the “middle” space between ERP and process control, many MES suppliers have duplicated much of ERP and process control functionality with-out really providing users what they need on the shop floor. It’s no wonder that this shovel-ware attitude is not the right approach. “The last thing you want to do with a mom-and-pop company is to sell them 25 modules they won’t need,” says Martin Michael, Advanced Automation’s VP busi-ness solutions. Food processors know

TECH UPDATE


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Today’s MES software can locate recurring problems and calculate OEE. It’s important to have the hardware and communications architecture in place so MES can collect data automatically and find problems in real time. Source: Schneider Automation.

they need to improve their business; that’s why they start with Excel. “In my opinion,” says Michael, “if you’re using Excel and its power, you are to some degree getting MES. The thing you don’t get with Excel is organized data—it’s often fragmented.”

But many MES products are just as fragmented. According to Mark Sutcliffe, general manager for CDC Factory, the reason MES hasn’t taken off is because it’s still a scrambled, piecemeal sector with lots of design and build solutions, which are more programming-like, rather than busi-ness solutions. “I think that’s because it’s been built out from engineering

TECH UPDATE


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and controls and not from the organi-zational and results perspective of the business,” Sutcliffe says.

ERP can also deliver MESMES-like tools, however, are not mutu-ally exclusive to ERP systems. “Batch processing, lot tracking and traceability, downtime monitoring, etc. are all cov-ered in a quality ERP program,” says Rebecca Gill, vice president, Technology Group International. ERP packages, says Gill, will have readily available the vast majority of food-based manufacturing requirements if the processor is looking at a package geared toward small- to medium-size businesses (SMBs). These include production planning and fore-casting, scheduling, recording and full lot control capabilities. What will dif-ferentiate these ERP products is the soft-ware vendor’s knowledge of the food and beverage industry. Gill asks, “Do they

understand batches and scalable formu-las, ingredients, substitutions, etc.?”

An example of ERP vendors offering MES-like functionality comes from Lawson’s QuickStep product, which now offers asset management. Accord-ing to Rob Wiersma, director of indus-try strategy, food and beverage, “ERP functionality today includes capabili-ties such as inventory management, traceability and asset management.” He adds, “With QuickStep, we can get a smaller but growing company up and running in a shorter period of time with standard business processes already defined for the food industry.” Wiersma says his company can help processors focus on planning, analysis and inventory management.

ERP vendors that focus on small- to medium-size food processors tend to develop industry-specific modules. Rene Inzana, SYSPRO product marketing

manager, lists some of them: goods in transit, lot traceability, finite schedul-ing, landed cost tracking, quality data collection (warns of out-of-tolerance conditions), engineering change control, material variability and dynamic formu-la adjustment, inventory management (multiple units of measure and variable or catch weights), low-cost manufac-turing (keeps finished goods inventory at a minimum), shop clock (monitors employees’ time, attendance, time spent on jobs and operations), customer ser-vice management, trade promotion and deduction management system.

Getting startedAdvanced Automation’s Michael says that while it would be possible to take the processor’s existing spreadsheets and make a custom MES product, it may not be the most cost-effective option. This is when it’s a good idea

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to enlist the help of an independent system integrator (SI) to assist in a “make or buy” decision on software. The SI can help define the processor’s business objectives and priorities and map a strategy for the next several years. Michael provides some basic tips for small processors just getting started:

■ Create a plan for MES and follow the plan. Do the dis-covery process early and thoroughly so software functionality can be easily incremented or scaled up without having to start from scratch in two years.

■ Map the process with all points inside the process, state changes, ingredients and touch points that address track and trace, production and quality.

■ Be aware of regulatory requirements, recall issues and food safety. Keep in mind that track and trace is an extension of quality.

■ Evaluate the package options, but don’t get distracted by advanced functionality of complex MES products if you don’t need it.

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MES software allows operations and functional managers to get an overall view of the plant. MES functionality has always included traditional shop floor functions (e.g., scheduling, asset management and product tracking), but many ERP systems duplicate these modules. Today, MES software often duplicates some plant floor functionality such as SPC and trending.

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■ A SQL server with a data collection system is often a good place to start for small manufacturers, but a historian may be a better solution if you need to monitor trends.

Unfortunately many processors are still suffering the “islands of auto-

mation” syndrome and need some basic architecture, says Schneider Electric Food Processing Develop-ment Manager, Rusty Steele. In many cases, automation providers and SIs can do this. He recommends a three-step process:

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1. Make sure there is a control layer (at least sensors, e.g., tempera-ture, weigh scales, pH, etc.) for the collection of data and a network to support it.

2. Add a repository layer. A SCADA system and or data server to connect to MES and ERP systems through ODBC or through OPC servers (a slightly higher investment).

3. Implement MES modules neces-sary to the operation of the plant: e.g., SPC, OEE, monitoring KPIs, down-time monitoring, etc. Don’t implement modules that will have no benefit.

Arming with informationWonderware’s Abildgren points out the value of information SMBs will find with monitoring the data. Once a processor gets started with automatic data collection, it realizes the value of a report is increasing the understanding of the process. In addition, the report can compare current results of the process with results that are two weeks old, providing valuable troubleshoot-ing information. This, he believes, is where purchased software may be able to better grow with a processor’s needs because a custom-built system may require more frequent attention from a programmer.

Sutcliffe says that it’s not only man-agement that needs access to the infor-mation. “People on the shop floor should be counted as assets.” He adds that operators should have action-able information; they shouldn’t have to crunch numbers or rely on paper records. When operators can make intelligent choices, they can be part of the change process.

Therefore, says Abildgren, give opera-tors the information they need to set up a machine for the next batch based on the information collected from the last time the same recipe was run. It might be a Pareto chart of the most frequent reason codes for machine stops. A cen-tral definition for the sequence of opera-tions should be available for setting up the machine, and setpoints and data



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should be downloaded to the machine. Abildgren calls this part of operational discipline, and this discipline should be taken away from supervisors and given directly to the operators.

Can I afford it?Fortunately, most vendors offering MES capabilities realize there are simply many more SMBs than there are Fortune 500 companies, and they have tailored their pricing structures to make sure an SMB can get started with MES, which can pro-vide both automated production and performance systems.

Some vendors now offer pricing based on number of trans-actions processed (the smaller the company, the fewer the transactions). Another pricing method includes base cost of packaged software plus the actual modules used, which allows the user to pay for exactly what is needed and no more. Anoth-er method is based on dollar volume of sales, which works on a percentage of sales with different sliding factors.

Yet another method, which Gill’s company makes available in addition to its regular packages, is the ASP model (appli-cation service provider), sometimes known as subscription. This is a completely Web-based solution, where the server, application(s) and user data reside at a third-party site. This subscription-based system is the least expensive to use, but hasn’t caught on. Microsoft has tried this with Office with very limited success. Most users want their data on site because they know it’s secure, and should there be a connec-tivity problem, their data will still be accessible.

Whatever product you choose, it’s time to put away the clip-boards, put digital outputs in the chart recorders and graduate from “MES” (Microsoft Excel Spreadsheets) to software sys-tems that can improve your business. ◆For more information: Claus Abildgren, Wonderware, [email protected], 949-727-3200Rebecca Gill, Technology Group International, [email protected], 800-837-0028Rene Inzana, SYSPRO, rene.inzana@ us.syspro.com, 714-437-1000Terry McCorriston, CSB-System International, [email protected], 519-579-7272, ext. 203Mark Sutcliffe, CDC Software, [email protected], 786-235-0682Martin Michael, Advanced Automation, mmichael@ advancedautomation.com, 610-458-8700, ext. 257Rusty Steele, Schneider Electric, [email protected], 317-306-5564Maryanne Steidinger, Siemens, maryanne.steidinger@ siemens.com, 215-646-7400, ext. 2210Cevn Vibert, Silchester Control Systems Ltd., [email protected], +44 (0) 1420 561902Rob Wiersma, Lawson, [email protected], 905-592-1473

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Non-thermal processing techniques kill “bugs” quite effectively if they’re used correctly. But techniques like irradiation,

pulsed electric field (PEF), high-pressure process-ing or pasteurization (HPP) and ozone are mostly unknown to consumers, and not always better understood by some processors.

Irradiating irradiationThe biggest problem with irradiation is the off-and-on-again nature of it. As Aaron Brody, PhD, president/CEO of Packaging/Brody Inc. (a consultancy in food packaging technology), says, “Radiation has been around since 1949 and has been up, down, around and around.” The FDA authorized radiation pasteurization for meats, and the US Army spent a lot of time perfecting it in the 1960s. NASA applied as much as 44 kGy min. radiation to sterilize frozen meats while the FDA recommended about one-tenth the levels for pathogen control. Consumers found over-irradiated, sterilized products didn’t taste good. But if applied properly, irradiation for pasteurization can be viable and doesn’t cause significant flavor issues.

Unfortunately, the story doesn’t end so simply. One manufacturer, CFC Logistics, had planned a large meat irradiating plant near Quakertown, PA. Bad press in the local papers and just about every-where else helped put an end to it as many Penn-sylvanians were convinced another “Three-Mile Island” would be imminent. But more worrisome to consumers, as Brody points out, is that once the term, “irradiation” goes on the label, consumers are reluctant to buy the product inside—even if the meat is guaranteed free of nasty bugs.

Information from Idaho State University sug-gests irradiation doesn’t “sterilize” the food com-pletely, killing all microorganisms; therefore, best practices still should be followed when handling and cooking irradiated food. While irradiation doesn’t cause food to become radioactive, it does cause some chemical changes in the food in the same way cooking does. While complaints have been leveled that the resultant chemicals pro-duced by irradiation are carcinogenic, lately many

TECH UPDATEWAYNE LABS, SENIOR TECHNICAL EDITOR

Put the heat on some of these cool techniques to kill nasty bugs!

Non-thermal processinggoes in for the kill

Ozone is often created by a high-voltage corona. Here, ozone is created by plasma block technology combined with PLC control and touch screen interface operating the corona discharge above 20,000 hertz. Source: Guardian Manufacturing Inc.


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cooked foods (especially starch-es) have been under scrutiny for acrylamide, a known carcinogen.

With all the bad press, it wasn’t surprising to find several vendors that were in the past involved in food irradiation have non-functioning Web pages or phone numbers. Some of those still in business said that food was no longer part of their services or a very small part of it.

PEF pulsing alongPulsed electric field (PEF) tech-nology has been through FDA approvals and was employed in 2005 at Genesis Juice in Eugene, OR. The processor wanted to preserve its organic commit-ment to customers and decided not to use thermal pasteuriza-tion, which would destroy most of its vitamin content and the healthful enzymes in raw juice. FDA officials put Genesis in con-tact with Ohio State University, which was developing PEF technology and licensed it to Diversified Technologies Inc. (Bedford, MA).

PEF, says Mike Kempkes, Diversified Technologies VP of marketing, works well with juices, but could also be used for beer and wine. Yogurts and salad dressings have also been processed successfully with PEF in the lab. The requirement is that the media must be pumpable—liquid or slurry. Kempkes points out that while PEF is good at killing bacteria, it doesn’t kill spores. But spore formers don’t normally grow in acidified foods, which tend to be the products applicable to PEF.

According to Howard Zhang , research leader at ARS’s Eastern Regional Research Center (EERC) and previously on the Food Science faculty at Ohio State, PEF offers a 5-log reduc-tion of most pathogens and is consid-ered a pasteurized process, so product must be refrigerated. The advantage of PEF, he says, is to avoid the loss of flavor from normal thermal pasteurization.

PEF applies a strong electric field on a flowing fluid for a very short time. Above a critical field strength of about 15 kV/cm, vegetative cells are killed. Fields up to 35 kV/cm are practical today and can destroy bacteria, fungi and other microbes. Kempkes notes that since PEF can break down cell walls, another use for it may be the extraction of juice from plant mate-rials such as sugar beets or grapes. Diversified Technologies, which pro-vides the electronics for the system, has found PEF also works well in wastewater treatment. In either food or wastewater applications, volume is limited by piping size. The larger the piping, the bigger the electronics must be to sustain the output, which is not unlike a pulsed radar system. In the juice application, 10 microsecond pulses are applied in up to eight suc-cessive chambers as the juice passes by. With the short pulse duration, there is no heating effect.

But is PEF ready for primetime? “Yes, it is,” says Kempkes. This is a technolo-gy looking for users. But it’s not cheap.

Figure about $1 million to get started, about the cost of high-pressure systems. While more than the cost of standard ther-mal pasteurization equipment, this system offers the advantage of continuous processing rather than batching.

As an epilog to the PEF story, in June, Toby’s Family Foods (Springfield, OR) acquired Genes i s Ju ice w i th an eye toward increasing the prod-uct lines that Genesis carried. Sheldon Rubin, Toby’s Family Foods’ vice president, said its goals included keeping organic customers in mind by offer-ing non-thermal pasteurization and expanding the variety of Genesis beverages even further. Toby’s Family Foods is also an organic supplier and has been using high-pressure processing techniques with a great deal of success. In expanding Genesis

product offerings to include carrot juice, smoothies and other similar drinks, Toby’s found PEF couldn’t handle foaming beverages in a pre-dictable way. Therefore, it has decided to process Genesis beverages using high-pressure pasteurization, and customers can soon expect to see their favorite label back on the shelf.

Squeezing germsHigh-pressure literally squeezes bac-teria to death while keeping intact food quality, taste and texture. With a typical HPP system, food products are packaged in a pouch or plastic bottle, then placed into a high-pressure ves-sel usually filled with water. The sys-tem is pressurized upwards of 80,000 psi or more for two to five minutes. Unfortunately, while HPP systems do a good job of killing microorganisms, they, too, are not as effective in killing spores; therefore, they can’t be used to process shelf-stable, low-acid foods. While HPP systems don’t affect the appearance of foods containing liq-

TECH UPDATE

Pulses are conducted through an electrode to a collar surrounding the tube through which the juice is flowing. Positive and negative pulse pairs of 1-10µs duration are applied to the juice in the gaps, destroying pathogens and harmful enzymes. Source: Diversified Technologies Inc.


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uids, the pressure in these systems can crush foods with air pockets such as marshmallows or strawberries. Purdue has found for certain poultry prod-ucts, it has been able to obtain a 2- to 6-log Listeria reduction, improve shelf life to 60 days and improve or extend fresh flavor.

According to Zhang, the price of HPP may be a deterrent for all but large manufacturers. He estimates the cost at about five to 10 cents per pound. Glenn Hewson, Avure Tech-nologies vice president of global mar-keting, says prices for an HPP system start around $650,000 and go up to $2 million or more. Because these systems work on a batch format, throughput can be an issue, although Hewson says that the larger systems are capable of processing more than 5,000 pounds of food per hour with a three-minute hold time.

Like PEF technology, what sells the higher cost of a non-thermal technology is the taste and appear-ance of the processed food, and most of all, the “clean label” that goes on the package. “As the world’s largest producer of high-pressure processed foods, we depend on our

HPP systems to create the unique, clean-label products that our cus-tomers demand,” says Steve Parnell, president of Fresher ized Foods. Parnell sees this technology as pro-viding processors with space-effi-cient, higher-throughput systems to take advantage of the growing demand for fresher, natural and organic foods. Another company that has signed on to HPP is Por-tugal’s Frubaca Coopertiva, which uses HPP to produce all its natu-ral fruit juices. Technical Director Jorge Periquito finds that a 5,000-lbs./hour unit will be sufficient to fill its production demands.

Hewson says it’s the clean label (“all natural—no preservatives”) that allows Hormel to introduce a new line of meats called Hormel’s Natural Choice. The line includes deli meats, carved chicken breast, dinner ham, bacon and Canadian bacon, and they’re all subjected to the 87,000 psi treatment. Hewson says when a processor consid-

ers removing what are perceived to be bad chemicals from a product, it can increase the cost customers are will-ing to pay, even though removing the chemicals saves a processor about two cents per pound. Today, the cost of HPP is about three cents per pound, a one-cent gain in cost. When cus-tomers see lunch meat contains only six ingredients (which are natural) instead of 12 (six of which are chemi-cals), they will pay a premium of 25 to 50% more. In addition, while an advertised shelf life of 60 days is twice the conventional 30 days, actual shelf life can extend to 90 days.

Gassing germsOzone was first used in the production of drinking water in the early 1900s in France and has been more generally used in Europe where it was found to be stronger than chlorine and much more effective over a wider variety of microorganisms. Ozone kills micro-organisms through oxidation of their cell membranes, and most food-borne pathogens can be destroyed with ozone. Early uses in food processing include extending the shelf life of shellfish by five days through rinsing with ozon-

The life cycle of a bacteriophage that “eats” Listeria bacteria is shown above. At the end of the cycle, there is no longer a viable Listeria bacterium. Source: EBI Food Safety.

TECH UPDATE


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ated water; using gaseous ozone to extend the shelf life of meats and eggs; and applying ozonated water to apples and other fruits to kill bacteria.

In 2001, the FDA (21 CFR Part 173) approved the use of ozone in gaseous and aqueous phases as an antimicrobial agent for the treatment, storage and processing of foods. Ozone has multiple uses in food safety. Guardian Manu-facturing Inc. is a controls and automation system integrator with experience in using ozone. According to Jim Baker, Guard-ian Manufacturing Inc. national accounts manager, ozone is a good match for direct contact of all meat, poultry, fruit and vegetables, plus bot-tled water. For clean-up operations, ozone can be applied to all surfaces in the food processing environment, used in CIP systems and applied in many applications during the produc-tion operation.

John McClain of McClain Ozone services 2,000 wineries in California as well as Coca-Cola and Coors. But he’s also working with producers of mush-rooms, bean sprouts, fish and produce that use ozone at one or more phases of the process. While ozone can kill bac-teria 3,000 times faster than chlorine, it doesn’t leave the toxic byproducts related to chlorination. Ozone is also 51% more effective on bacterial walls than chlorine and can control and remove films that build up on process-ing equipment.

Proper application of ozone can knock down Salmonella by 6 log (99.9999%), Escherichia coli by 5 log (99.999%) and Lysteria by 4 log (99.99%). Some researchers, however, have found 0.5% ozonated water may

only have an effect of 1.3 to 2.5 log when used on beef tissue. According to Mark Taggatz, president and owner of Ozone Safe Food, proper application levels vary according to temperature, water composition and food prod-uct composition. Proper application depends on careful engineering and planning to determine prescribed dos-age, contact time and application, so there isn’t a one-size-fits-all approach. A basic rule of thumb is that for water-based contact, a level of 1.0 ppm will be sufficient for many applications, and for water-based clean-up, a level of 2.0 ppm should be sufficient.

Eat my bacteria!Listeria monocytogenes (Lm) wreaked havoc in turkey luncheon meat about five years ago as the FDA traced the bacteria to a Wampler plant in Franco-nia, PA. Seven deaths in the northeast-ern US were attributed to the bacteria, plus dozens of people were sickened. Lm bacteria also contaminate cheese and ready-to-eat foods such as hot dogs, sausages and other deli-style foods, and they thrive and multiply in the refrigerator. A year ago, the FDA

first approved the use of bacterio-phages as a food additive to kill Lm bacteria, and this ruling has had sup-pliers worldwide scrambling to get their products approved.

According to the FDA, bacterio-phages (phages) are viruses that infect only bacteria and do not infect mammalian or plant cells. (See relat-ed story on page 167 in this issue.) In fact, phages are nature’s own device to control bacteria. Phages are ubiquitous in the environment, and humans are routinely exposed to them at high levels through food and water without adverse effect. Phages are very specific. They infect and destroy only the targeted host organism, as a result of which, the final product does not contain any viable Listeria.

Bacteriophages, according to Mark Offerhaus, CEO of EBI Food Safety (Netherlands), provide a safe, non-chemical solution to ridding RTE foods of Lm. EBI’s product, LISTEX, already in use in Europe, was approved “GRAS” (generally recognized as safe) by the FDA the first week of July for use in all food products in the US. As

TECH UPDATE

This chart shows the suppression of Listeria growth in smeared Muenster cheeses. Blue bars indicate cheese treated with bacteriophage; red bars indicate untreated cheese. Source: NIZO Research.


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Join us for the Plant of Year Award Celebration at:

April 6-9, 2008

Sheraton Sand Key Resort • Clearwater Beach, FL

For more information see page 117.

Food Engineering’s 26th Annual Plant of the Year Award In food and beverage manufacturing, the impossible becomes possible everyday. For more than a quarter ofa century, Food Engineering’s Plant of the Year Award has commemorated the most impressive plant andoperations accomplishments in the food industry. This prestigious award is presented to one outstandingfacility in North America that features world-class operations in processing, packaging and automation.

Submission Deadline is December 3, 2007Enter your plant’s accomplishments in Food Engineering’s Plant of the Year Award competition today. ContactJoyce Fassl, Editor-in-Chief, for entry forms and more information ([email protected]) or call 610-436-4220ext. 8519. Visit www.foodengineeringmag.com and click on the Plant of the Year Entry Form.

Presented by

Recent Plantof the YearWinners

T. Marzetti Co.

Dreyer’s Grand Ice Cream

Bell & Evans

Pepperidge Farm

American Italian Pasta Co.


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confirmed by the USDA/Food Safety Inspection Service (FSIS), LISTEX has no adverse effect on organoleptic prop-erties (color, odor and taste). A culture of bacteriophages, such as LISTEX, can be diluted in a solution and applied to the food surface by dipping, spray-

ing or showering. The best point of application is generally the closest to the point of expected contamination. Bacteriophages can function in tem-peratures from 1 to 35°C (34 to 95°F), survive in saturated NaCl solutions, are not affected by atmosphere, work

TECH UPDATE

in solutions with a pH range of 5.5 to 9.5 (7.7 is optimum) and are inac-tivated by temperatures in excess of 50˚C (122˚F) and pHs below 3.

It’s important to remember that, as in any other food safety manage-ment program, phages should not be used as a curative treatment without regard to good manufacturing prac-tices (GMP) and a HACCP program. If applied properly, phages can cut bacteria count by up to six or seven orders of magnitude. ◆

For more information: Mike Kempkes, Diversified Technologies Inc., 781-275-9444, ext. 211, [email protected] Hewson, Avure Technologies, 253-981-6239, [email protected] Baker, Guardian International, 321-508-3392, [email protected] McClain, McClain Ozone, 707-254-0576, [email protected] Taggatz, Ozone Safe Food, 760-329-4304, [email protected] Offerhaus, EBI Food Safety, +31 (0)654-913-176, [email protected]

The “treated by ir radiation” logo goes on all food that is exposed to radiation. Source: FDA.


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Food Engineering can help. As part of a customer-focused media company, we are committed to delivering informa-tion in ways that will make your job eas-ier and more efficient. You can embrace new technology tools by strategically managing how and when you receive information. Here are seven ways new media can transform the way you man-age your business:

Go Online for Training and Certification Online training has come of age and keeps getting better.

Early attempts at Webcasts and Webi-nars were clunky, strained affairs. Fuzzy

images and lost connections were the norm. Today, high-speed connections, in-house projection, enhanced software, improved two-way communication and experienced providers make Web-based training an engaging experience.

Got a question? Most Webinars allow you to submit questions and answer them during a Q&A period.

Want a video clip or additional infor-mation about the Webinar? Providers often include video links, which can be entertaining, and related Web sites so you can dig deeper.

Need proof of participation to qual-ify for CEUs? You might need to take a short quiz, but many Webinars provide

a link allowing you to print a course completion certificate.

Visit www.foodengineeringmag.com to view upcoming as well as archived Webinars.

Takeaway: Challenge your staff to use Webcasts instead of costly travel, and you’ll improve training.

Use Online Community to Obtain Real-Time, Real-Life AnswersPerhaps you’ve avoided plac-

es like You Tube, bulletin boards and blogs. Aren’t those for newbies, techies or people without lives? In some cases, that’s true. But for a growing number of people, online community is now an essential source of business success.

A huge benefit of online community is free access to people like you who have already tackled your challenges. Whether you’re fixing a broken part, launching an initiative or revolu-tionizing your company, someone is waiting to tell you how he or she suc-ceeded at that task or, equally valu-able, which pitfalls to avoid. Many sites also offer videos that show you how to do it.

Another aspect of community is the ability to build your reputation. Com-munity participants don’t want a sales pitch, but they respect you for providing useful information and solving prob-lems. Respect translates into trust, and trust translates into opportunities for your company.

Takeaway: Find trustworthy bulletin boards, blogs and communal spaces that focus on your industry. You’ll benefit by engaging with sharp-minded, impas-sioned participants.

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Find Information with Lightning SpeedSearch Engine Optimization (SEO) is a geeky way of saying

“fast answers.” If you’re even a bit Web savvy, you’ve Googled something. But Google can be overwhelming when you pull up 101,234 results.

A better option is vertical search—using the search functions of indus-try-specific Web sites. Niched sites are more targeted and eliminate fluff. Some, like www.foodengineeringmag.com and the other sites owned by its parent company BNP Media, license Google technology for speed but limit the search to a highly defined universe of data, making your search vastly more efficient.

Takeaway: Visit the top Web sites in your field, and bookmark those providing the best search results. You’ll save a ton of time.

Locate Products Quickly with Online DirectoriesFinding products poses a problem when you need

specific items to complete a proj-ect. Online directories are a great solution. Most allow you to enter a company name, product catego-ry or a brand and then provide a defined list.

While you may love print directo-ries, online versions make good sense because they can be updated daily and include links to supplier Web sites, spec sheets and even product videos. Food Engineering’s Web site currently contains an online directory for sourcing Replacements Parts as well as Food Master.com, an online database containing more than 4,000 product categories listing equipment, suppliers and services to the food and beverage market.

Takeaway: Keep your print directo-ries handy, and visit their online ver-sions for updated and comprehensive information.

Read Breaking NewsWhether you’re a leader in your company or headed up the ladder, staying informed

has never been easier. Some Web sites are updated daily,

while others languish for weeks. Limit your visits to sites that are updated fre-quently and offer professional coverage.

Electronic newsletters offer a big advantage because they come to you. E-newsletters have proliferated, so focus on those that provide truly use-ful industry information.

RSS feeds are a way to assure you are alerted whenever certain news breaks on the Web. RSS requires you to sign up for a reader and select the topics

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you want. Those articles are col-lected until you access them.

Takeaway: Avoid news over-load. Focus on Web sites, e-news and RSS feeds that best meet your needs, and unsub-scribe to the rest.

Study In-depthContent for Personal Development and Strategic Planning

While the Web is fantastic for immediacy, it is equally strong in pro-viding content that will help you obtain comprehensive knowledge, perspective and leadership skills.

Archived articles stored on industry Web sites allow concentrated study of a topic or in-depth analysis of an expert’s opinions.

White papers allow you to read thoughtful analysis on new products

and procedures, often complete with statistics and projections.

Syndicated research can help you maintain a high level of expertise on a topic or industry, and provides insight for strategic planning.

Takeaway: Search Web sites for meaty data and expertise. If required, regis-ter to gain access to highly valuable information that others may miss.

Conduct Business OnlineE-commerce is more t h a n a b u z z w o r d .

Many companies now require online purchase orders, appli-cations, designs, specifications, bids, change-orders, credit checks and payments. A recent

survey conducted among subscribers to BNP Media publications showed that while most had company Web sites, only 30% allowed customers to place orders online.

Takeaway: Embrace this trend by becoming e-commerce savvy. Promote your company as Web-friendly, making sure your Web site is customer-driven, and you will be rewarded. ◆

SIMPLIFYYour Equipment

Sourcing

www.FoodMaster.com

JUST WHAT YOU NEEDNo need to work with an incomplete vendor list or wade through thousands of consumer listings online. Food Masteris the most comprehensive reference source for Plant Operations, Engineering, Packaging and Maintenance professionals.

OVER 4,500 COMPANY LISTINGSPlus over 3700 products in Food Master’s hardbound print issue or searchable online version – includes hundreds of technical catalog pages, an alpha company section and an equipment product index.

ROBUST ONLINE SEARCHEver-expanding, FoodMaster.com includes a new more-robust keyword search powered by Google to search by equipment or company. Review a company’s info and products, view technical catalog data or use live web and email links.

The NEW 2007 Food Master -- Available October 17.Order your copy at FoodMaster.com.

Webinars provide information and t ra in ing wi th no need to leave the office.

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FIELD REPORTS

Following major growth resulting from joint venturesand acquisitions, Dairy Crest, a large, UK-basedchilled dairy foods company, needed to centralize its

distribution to handle its 50-million case annual throughput.With a goal set for next-day delivery, the processor needed toshorten its lead times, some of which were 10 days. Buildinga central distribution center( D C ) c ap able of h a nd l i nghigher volumes, higher-palletm a ke - up complex it y a ndshorter lead times seemed tobe the only solution.

“We have over ten produc-tion facilities in the UK andfour factories in France, whichprovide us with product on adaily basis,” says Andrew Wat-son, Dairy Crest distributiondirector. “Following the con-solidation, all product comes toone DC in Nuneaton, about100 miles northwest of Lon-don. Our clients typically orderabout mid-day, and we picktheir orders through the night and deliver from midnightonwards. It’s a 24-hour, 364-day operation.”

“When we first started looking at building a central DC,”says Watson, “we had to consider increasing existing productsales and continued brand acquisitions. Since the DC opened,we have acquired four companies and/or brands. We current-ly dispatch 250,000 cases daily on roughly 2,500 pallets andmaintain and store over 12,000 pallets of finished goods.”

Dairy Crest selected Dematic Corp. (formerly SiemensLogistics & Assembly Systems) to design and implementthe central DC in a brand-new 240,000-plus-sq.-ft. build-ing. A new warehouse management system (WMS) wasalso planned.

The heart of the pallet transport system, Dematic’s DSB sin-gle track monorail, has 28 suspended pallet carriers (eachapproximately 150 m long) and is fed by conventional palletconveyors. The monorail connects storage, picking and ship-ping areas, all of which are confined to a closed environment

maintained at 35.6˚F. There aref ive l i f ts for mov ing pal letsbetween levels. The inboundproduct-laden pallets go intostorage and then are later taken tothe picking area.

The finished goods store offers12,000 pallet storage locationsspread across five aisles, each ofwhich is served by a double-pallethandling storage and retrievalcrane. Typically, goods remainhere for no more than a few daysb efore b eing t r ansfer red bymonorail to the picking hall,where radio data terminals assistthe picking process. From the

picking hall, completed order-specific pallets are taken to theshipping area where they are automatically shrink-wrappedand labeled before being transferred to the dispatch area.

Incoming product is tracked with pallet labels, and eachpallet is immediately scanned as it is received and associatedwith a prior electronic purchase order. The WMS integrateswith sales order processing, creating a seamless path from thecustomer through to the dispatch of picked goods.

“By moving our stock control next to our transport, we cannow run efficient transport out of the distribution center,”saysWatson.“We have moved the distribution point close to someof our factories, and all of our stock is now in one building andon one system.”

Order fulfillment is up to 99.9 % and stock turnarounddecreased from 24 hours to 14 minutes. Dairy Crest now regu-larly dispatches products within six hours of receipt.◆For more information: John Clark, Dematic, 616-913-7287,[email protected]

Products on the moove

The Dairy Crest distribution center handles 50 million cases ofproduct annually with a 99.9% fulfillment rate. Source: Dematic.

Dairy consolidates itsdistribution configurationto deliver products faster.


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FIELD REPORTS

Nuts! And lots of them. While the Warrell Corpora-tion in Camp Hill, PA, makes some hard candies,nut-based confectionaries are its specialty. The

company has its own retail brands, Katherine Beecher andPennsylvania Dutch Candies, but concentrates on contractmanufacturing. In 2006, Warrell produced more than 500individual new-product development sample shipments tocustomers and processed more than 25 million lbs. of candy.

When the company moved to its current 200,000-sq.-ft.location to start up one of the largest panning operations inthe US, it was time to stop buying roasted nuts from suppliers.

“When we moved here, we expanded our panning, which isour number one sales operation,”says Rich Warrell, marketingmanager. “Then we put in the continuous brittle line, so ourvolume went from 100,000 lbs. a year to 600,000 lbs. per year.Now we’re roasting 2.75 million pounds per year.” At fullcapacity, the company has a throughput of up 11 millionpounds per year.

Warrell management decided to go with Compak 2000 and2500 gas-fired dry roasters from Wolverine Proctor instead ofoil-based or other types of roasters. In addition to the healthbenefits of roasting without oil, there are production benefits.The biggest is timing, says Ron Stadnicki, operations manag-er. “An oil-roasted nut needs time for the oil to incorporateitself before going into the panning process. You can’t attemptto take a fresh oil-roasted nut and get it under chocolate—plus you have bloom issues. Therefore, there is a 24-hour min-imum waiting period before you can apply the chocolate.”

By using dry roasters, the nuts are cooled to an ambient tem-perature and coated with chocolate in less than 30 minutes.

There are other benefits to dry roasting. Stadnicki says oilroasters are much more difficult to clean, and the liquid wastecan pose environmental problems. When it comes to healthissues, Stadnicki says it’s much easier to calculate fat contentsbecause the only fat is the naturally occurring oil in the nut,and not the added roasting oils. Not using oils also makes iteasy to label products as “all natural” and helps minimizeallergen problems.

The Compak 2000 roaster is dedicated to peanuts full time,helping to minimize peanut allergens issues. The other roast-er, the Compak 2500, processes cashews, pistachios, walnutsand just about any other tree nut imaginable. Stadnicki saysboth roasters are now operating continuously on two shifts.

“These machines require very little maintenance,” Stadnickisaid.“It’s a very simple process with very few moving parts.” ◆

For more information:Paul E. Smith, 215-443-5200,[email protected]

How sweet it is!

Wolverine Proctor Compak Model 2500 roaster is fed cashews fromtotes (top right) and nuts emerge on the other end (inset).

Larger roasters helpprocessor meetincrease in productdemand.


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25,000ATTENDEES

1,900EXHIB ITORS

1000sOF PROCESSING & PACKAGING INNOVATIONS

3DAYS

1PLACE TO SEE

THE ENTIRE SUPPLY CHAIN FOR

THE FOOD & BEVERAGE INDUSTRY

To learn more and to register visit fpsa.org/processexpo

Register now and attend the one show this year with solutions for all your processing and packaging challenges. This year will boast the industry’s latest innovations spanning the entire processing and supply chain:

Containers Material Handling Converting MachineryIngredients & Flavors Processing Machinery And MoreServices Packaging Machinery

YOUNEED TO BE

HEREOCT. 15 - 17, 2007Las Vegas Convention Center

Las Vegas, Nevada, USA

SPONSORED BY: SPONSORED BY:

To learn more and to register visit fpsa.org/processexpo


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O rganizers of PROCESS EXPO and PACKEXPO are doing their best to make sure whathappens next month in Vegas does not stay in

Vegas. In fact, suppliers of processing and packagingequipment, ingredients and services to the food andbeverage industries are betting buyers will take thetechnologies on display back to their plants and head-quarters.

Close to 400 PROCESS EXPO exhibitors willdemonstrate state-of-the-art equipment in the fruit andvegetable, beverage, food safety and sanitation, confec-tionery, bakery, prepared foods, pharmaceutical, canmaking, meat, dairy and snack food industries.Visitorsare expected to kick the tires and make purchasingdecisions on the latest offerings in food processingequipment, air and liquid handling, engineering/archi-tectural design services, cooling/freezing, ingredientsand instrumentation/controls.

PACK EXPO will focus on developments in packagingmachinery, converting machinery, materials, containers andcomponents. More than 1,200 exhibitors will focus on tech-nologies in the packaging development process. With 25%of the exhibitors offering containers and materials, PACKEXPO aims to help brand owners find solutions thatincrease sales and grow brand loyalty. PACK EXPO alsoplaces a strong emphasis on helping packagers learn how tocommercialize concepts and achieve required output.

In addition to walking the show floor, visitors will have theopportunity to attend educational seminars. FPSA, sponsorof PROCESS EXPO, has integrated its educational sessionswith PACK EXPO and will be offering six seminars, two eachmorning during all three days of the show. FPSA’s seminarsare targeted to processing professionals and will include top-ics on food safety, food formulation, processing technologiesand sanitation design. The Conference at PACK EXPO willfeature sustainability as well as other many other packagingtopics. A complete list of all seminars can be found on theWeb sites listed at the bottom of this page.

Co-located eventsConverting & Packaging Printing (CPP) EXPO will be co-located with PACK EXPO and PROCESS EXPO. The CPPexhibit showcases the latest in printing, coating, slitting andother state-of-the-art finishing processes.

Also co-located, the International Bottled WaterAssociation’s (IBWA) 2007 Convention and Tabletop TradeShow provides educational seminars on technologies,processes, marketing/sales techniques and industry trends.IBWA will take place at the Las Vegas Hilton, which is direct-ly connected to the Las Vegas Convention Center. ◆

Dates: October 15, 16, 17, 2007Exhibit Hours: 9:00 a.m. to 4:00 p.m.Location: Las Vegas Convention Center, 3150 Paradise RoadPROCESS EXPO Exhibitors: 400PACK EXPO Exhibitors: 1,200Show Sponsors: Food Processing Suppliers Association andPackaging Machinery Manufacturers InstituteFor More Information: www.processfood.com or www.packexpo.com

PROCESS EXPO & PACK EXPOat a Glance

Close to 25,000 visitors are expected in Las Vegas next month forPROCESS EXPO and PACK EXPO. Source: FPSA.


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2007 | IBIE, PROCESS EXPO and PACK EXPO Las Vegas Show Previews

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Contact:Contact us today at 888.258.2789 or www.abprocess.com.

DESIGNYou design the process, we’ll design the system! Our process system design-

ers and automation engineers will work with you to define your unique

process needs and blend them with 35 years of process experience to

provide a cost effective solution with a quick turnaround time.

BUILDNothing leaves our facility without thorough inspection and rigorous test-

ing. Our process modules are pre-assembled in our certified ASME facilities.

Additionally, each system is fully tested and inspected in our new state-of-

the-art test center, making it “ready to run” immediately after it has been

installed. The overall result is a modular system that costs significantly less

and reduces downtime.

INSTALLInstallation is where a process system all comes together and at A&B

Process Systems, it comes together with precision. Our flexible project

scheduling expert project management allows us to execute even the

most complex projects within a short time frame while still providing a

high quality product. Complimented with our broad range of installation

services including the installation of sanitary and high purity process

piping and equipment in addition to field erection, equipment rigging &

millwright services, your process system will be up and running quickly

and efficiently.

Admix, Inc.

Contact:Admix, Inc.234 Abby RoadManchester, NH 03103Phone: (603) 627-2340 or (800) 466-2369Fax: (603) 627-2019email: [email protected]: www.admix.com

At Admix, we design high performance mixing systems for sanitary processing and wetting out powders into liquids. Our mixing expertise combined with our understanding of commonly used ingredients allows us to offer solutions to improve production capabilities with more effective mixing, reduced horse-power and optimized capital costs. We strive to provide our customers with a payback of one year or less by use of new technology that will outperform their current equipment.

Whether you are processing salad dress-ings, sugar slurries, fruit fillings, poultry marinades, beverage emulsions, tomato products, cereal coatings, ice cream mix, cheese products or other food applications,

Admix will customize a solution that’s right for you.

Products, formulas and ingredients become more complex year after year. Partnering with Admix pro-vides complete access to our expertise and our 2,000

square foot test kitchen and pilot plant. That means new products will move from development to full production faster and more cost efficiently.

Admix specializes in sanitary high speed dispersers, high shear emulsifiers, inline emulsifiers and wet mills, sanitary static mixers and blenders, low speed stainless batch mixers and vacuum conveying and powder delivery mix stations. Our mixers, dispersers and emulsifiers comply with the newest and toughest hygienic and safety standards, including 3-A TPV, USDA-Dairy, USDA-AMS and AG-Canada and are available in corrosion-free stainless steel configurations, including the motor and drive frame, from 1/2 HP lab models through 100 HP production sizes.


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IBIE, PROCESS EXPO and PACK EXPO Las Vegas Show Previews | 2007


Contact:Allpax Products LLC a Division of Pro Mach13510 Seymour Myers Blvd.Covington, LA 70433Phone: 985-893-9277sales@allpax.comwww.allpax.comwww.retorts.comwww.promachinc.com

“If it’s in the retort room, WE’VE DONE IT!” - BOOTH # 6266

With solutions ranging from fully automated robotic retort lines to small research and development autoclaves, Allpax has produced quality results for customers in the food, nutraceutical, and pharmaceutical industries for the past 20 years. Now a member of the Pro Mach (www.promachinc.com) family, Allpax has a deeper and broader solution set than ever before!

Allpax customers are repeat customers because we build strong relationships through great machinery, on time delivery, and professional support by the men and women who built your equipment. Allpax can not only build all of the comprising modules of the retort room, but can also integrate them and test them together before they ship to the installation site for a true FAT. Know of anyone else who can do that? We sure don’t!

The Retort Room is our Playground• Thermal Process Services• R&D Retorts and Autoclaves• Production Retorts of All Sizes and Styles• Container Consolidation — Pouches — Glass — Plastic Cups and Bowls — Trays — Cans — And More!• Conveying Systems with Product Sterility Tracking• Retort and Autoclave Loading Systems• Retort Control Systems

Allpax Products LLC

Contact:APV Invensys100 South CP Avenue, Lake Mills, Wis., 53551P: (920) 648-8311, (800) 554-5290 F: (920) 648-1441E: [email protected] W: www.apv.com

The people behind the brandIn this world, experience matters. Companies in markets such as food and beverage, power, oil and gas, depend on suppliers on whom they can rely. There is no room for error in environments where downtime can lead to financial losses. This is why, across the world, APV teams provide an end-to-end approach, from developing deep understanding of the customer ’s business, through to designing solutions that meet these specific requirements and ensuring that the end result meets the exact purpose, not just at the time of installation, but for many years to come.Projects carried out by APV are wide-ranging, from assisting customers to enter new business areas, to simply helping them to reduce operating costs and improve processing speeds. What makes all this possible is the quality of the people behind the APV brand. Not only do they have the experience, but they are also instilled with an attitude of embracing challenges and never walking away from a problem. Since 1910, APV people have led the way, developing and bringing to market many of the technologies that are today ’s process industry standards. APV has been sharing that expertise with customers for almost a hundred years and intends to carry on doing so for many years to come.

What we offerAPV is a global supplier of high quality process engineering solutions and automa-tion to the dairy, food, beverage, and healthcare industries. From engineered components to a complete, fully automated process plant, APV focuses on adding value to its customers’ business performance and profitability. APV’s range of manufactured products includes: heat exchangers (plate, tubular, scrape surface and steam infusion), Gaulin/Rannie homogenizers, pumps and valves for hygienic appli-cations. APV also offers a complete range of process technologies including: UHT/ESL systems, aseptic systems, membrane filtration systems, plate evaporators, butter packers/churns and batching/blending systems. And, in addition to these technolo-gies, APV offers a wide range of genuine aftermarket parts as well as lifetime maintenance services to keep your equipment up and running at peak performance and maximum operating efficiencies.

APV Invensys


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Contact:Ashworth Bros., Inc.450 Armour DaleWinchester, VA 22601Phone: 540.662.3494 or 800.682.4594Fax: 540.662.3150 or 800.532.1730E-mail: [email protected]: www.ashworth.com

After 61 years, Ashworth continues to revolutionize the food processing industry with its new line of hybrid belting, The Advantage series. Designed for lotension spiral and turn-curve applications, The Advantage combines the benefits of plastic with the strength of stainless steel rods. The stainless steel rods provide unparalleled beam

strength while the plastic mod-ules offer the greatest open area which increases air flow and facilitates significantly reduced dwell times. Our unique module design makes sanitation quick and easy. More capacity, faster speeds, and easier sanitation result in greater profits for your processing plant.

Our newest all-metal belt, the Omni-Pro™ is our strongest belt ever – 400 lbs. of load capacity! The strength comes from our patent pending link design that incor-porates a rod-to-link “zero-tension” weld along with a protrusion leg that ensures a smooth contact between the belt and drum.

Our straight running belts, includ-ing CB5 Baking Bands and tight-transfer Cleatrac belts continue to be proven performers in the industry. Along with our broad product range, Ashworth also offers a full range of engineer-ing services, including system refurbishment, trouble shooting and belt installation. Ashworth

maintains a strong global presence with manufacturing plants in the USA and Europe along with sales teams around the globe.

See us at the IBIE show – Booth #5000

Ashworth Bros., Inc.

Contact:Bob MoorePresidentAZO Incorporated 4445 Malone RoadMemphis TN 38118901.794.9480 901.794.9934 [email protected]://www.azo.com/usIBIE Booth # 1423

AZO Incorporated, Booth 1423, will be exhibiting the AZO Componenter® which has redefined ingre-dient automation. With its extreme accuracy and configuration flexibility, the AZO Componenter®

has become the world standard for the precise automatic metering, weighing and feeding of minor and micro ingredients.

The AZO Componenter® provides clear advan-tages to your process including: a separate scale for each ingredient providing accurate metering, weighing and discharge; a flexible system for all types of containers including bags, drums, big bags, portable bins and silos; and precise automated weighing and fast batch times with simultaneous weigh-ing. The closed system provides dust-free operation and it is constructed with easy to clean stainless steel. The flexible AZO Componenter® can be designed to meet the needs of your process

AZO will also exhibit the Dosibox® and Dositainer® which are portable containers with integral screw feeders for use in automating minor ingredients. Additionally, AZO will exhibit superior mixing technology with the Amixon AM 400 Conical Mixer as well as AZO cyclone screening technology for safety screening and delumping of flour and a variety of other products.

AZO and Bachelor Controls have partnered to provide a new MES solution suite for batching, called

BatchEngineTM, as “the bridge to a plant-wide integrated solution.” BatchEngineTM features a SQL database foundation, automatic batch scheduling, drill-down screens for detail, bar coding / lot tracking options, and reporting. BatchEngineTM provides our customers with “top floor to plant floor” total system integration.

AZO Incorporated


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Baldor Electric Company

Baldor Electric Company designs, manufactures, and markets a broad line of energy-efficient electric motors, adjustable-speed drives, linear motors, motion control prod-ucts and generators. We have more than 6,500 different stock products available for immediate delivery. Our custom products are available in two weeks or less - the shortest lead times in the industry. Baldor products are manufactured at 16 locations - 15 in the U.S.A. and one in England.

We support our worldwide sales offices and warehouses from our home office in Fort Smith, Arkansas. Baldor products are available 24 hours a day, every day of the year. We have sales offices and warehouses throughout North America and international affiliates in Europe, Latin America, the Pacific Rim, and Australia. Products are sold in more than 60 countries to distributors and original equipment manufacturers.

Baldor leads the industry in delivering information to our customers through our award-winning CD-ROM and web site, as well as numerous printed catalogs. We also offer many different training classes for distributors and customers to help them learn our products and competitive advantages. Over 10,000 students have benefitted from this training.

We also have an ongoing commitment to employee education. Baldor employs nearly 3,800 employees worldwide and believes that well-trained employees make a better product. We also believe that better products translate into better value for our customers and shareholders. We have been selected by Training Magazine as one of the top 100 training companies in America.

Many years ago, Baldor carefully defined "Value" in terms meaningful to our customers. Value is defined in terms of Quality and Service (both as perceived by the customer) in relation to Cost and Time. The result is a value "formula" which guides our thinking and directs our work every day.

Contact:For more information about Baldor, contact us at 1-800-828-4920 or visit our web site at www.baldor.com

Contact:Patrick Chisholm / Email: [email protected] F. McLaughlin / Email: [email protected] Trinity Road, Suite 303, Raleigh, NC 27607Phone: 919. 781. 0054 / Fax: 919. 859. 9011www.bekbuildinggroup.comBooth #2544

BE&K Building Group, a subsidiary of BE&K, Inc., is a diversified construction services company with project capability in a number of market sectors, with specific focus on Food and Beverage. Our firm has a rich history and solid track record when it comes to construction excellence for the Food and Beverage sector. During the past decade we have put in place more than $1 billion of food and beverage projects encompassing

over 5 million square feet.

ServicesProgram Management, Project Management, Preconstruction, Design-Build, Construction Management and General Contracting

Specialized ExpertiseBE&K Building Group has an impressive portfolio of projects for food and beverage companies that vary in size and scope. We understand the highly specialized requirements for constructing food and beverage plants. For example, we understand Sanitary Facility Design principles, cGMP, USDA and FDA regulations, and HACCP.

We have the experience and resources to respond to a wide range of facility needs, including:Processing Facilities, Pilot Plants / Test Kitchens, Distribution and Storage Facilities, Low Temperature, Food Service, R&D Facilities, Laboratories, Offices, and Commissaries

AwardsFour Food Engineering magazineFood Plant of the Year winners: • Bell & Evans (2005)

Fredericksburg, PA • Pepperidge Farm (2004)

Bloomfield, CT • Future Beef Operations (2002)

Arkansas City, KS • Tyson Foods (1997)

Henderson, KY

Representative Food and Beverage Clients:Boar’s Head, Campbell Soup Company, Excel, Hershey Chocolate USA, Mayfield Dairy Farms, Pepperidge Farm, Perdue Farms, Sara Lee, SYSCO Corporation, Tyson Foods

BE&K Building Group

April 2004

ALSO THIS MONTHReal-Time Performance Management

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Supply Chain Payoffs with RFID■

Tech Update: Advanced Inspection Systems Go Mainstream

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Tech Update: Advanced Inspection SystemsGo Mainstream



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Bosch Rexroth Corporation

Contact:Bosch Rexroth Pneumatics1953 Mercer RoadLexington, KY 40511-1021 Telephone (859) 259-3852Fax (859) 281-3491www.boschrexroth-us.comWeb Code US0397See us at the PACK EXPO Las Vegas Booth #S-5032

Wash-down applications are some of the most demanding on pneumatic components. Rexroth has developed specific hygienically designed valves and cylinders to with-stand high-pressure wash-down, including the Clean Line, Series CL03 valves and the Series ICS pneumatic cylinders.

The Clean Line, Series CL03 valve system has an IP69K protection class rating for high-pressure wash-down up to 1450 psi. The unique design eliminates the need for a protective cabinet, and provides improved system performance from mounting valves closer to the actuators. With a high flow of up to 0.85Cv, the valves can perform a very wide variety of

tasks. Choose from multi-pin connection or use serial communication options for major protocols which allow the use of Rexroth advanced diagnostic capabilities.

The Rexroth ICS (ISO Clean Stainless) air cylinders are available in 304 stainless steel for demanding wash-down applications, and 316 stainless for extremely demanding wash-down applications. The new Series ICS pneumatic cylinders are hygienically designed, with smooth sur-faces and no cavities/dead spaces for easy cleanup, and are inherently corrosion resistant. Direct contact with food is not an issue, as the ICS is lubricated with food grade grease (NSF H1). The ICS cylinders meet ISO 6431 standards, and have threaded end caps for increased life expectancy and easy repair. An on-line configurator allows designing of a custom cylinder with a CAD drawing.

Contact:Boston Gear14 Hayward StreetQuincy, MA 02171Phone: 888-999-9860Fax: 617-479-6238Email: [email protected]

700 SeriesSpeed Reducers with PosiVent® OptionIntroducing the new enhance-ment to the Boston Gear 700 Series family of worm gear speed reducers.

The Boston Gear PosiVent® option is available in all current 700 series styles and configurations. Thisspecially-designed internal pressure equalization system allows the gearbox to oper-ate in all environments without the use of conventional pressure vents. The unique design comes complete with Mobil SHC 634 lubrication pre-filled for all mounting positions. Unlike competitive versions, our unique single seam design allows for easy installation and extended life. This means longer trouble-free operation with virtu-ally no maintenance.

The PosiVent option is ideal for material handling, food processing, medical and pharmaceutical applications.

Features • Factory filled with synthetic lubrication for universal mounting • Lubed for life, no oil changes are required • Ideal for dusty environments, wasdown applications and extreme temperatures • USDA approved washdown finishes available in Bost-Kleen™ and Stainless Bost

Kleen™ • All units are available for same day shipment via Boston Gear’s industry leading

Reducer Express program.

Boston Gear


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Contact:BREDDO LikwifierDivision of Caravan Ingredients1230 Taney St.North Kansas City, MO 64116800-669-4092 – phone816-561-7778 – faxwww.breddo.comcontact: Don Wolfe, ext. 1162Located in IBIE Show booth #4500

BREDDO Likwifier

The Breddo Likwifier is designed to dissolve solids or semisolids where time, temperature and complete hydration are important. Originally developed to dissolve natural gums and synthetic thickeners used in the manufacture of frozen desserts, the Likwifier dissolves and disperses virtually any food product. The unit will put into solution, not just suspension, products that can be dissolved by agitation.

The benefits of the Breddo Likwifier include dissolving soluble products in less than 5 minutes, complete hydration, total product liquefaction, elimination of solid “burn-on” in the vat, elimination of waste at strainers and tank bottoms and the complete dispersement of insoluble particles in water or non-aqueous media.

The following products can be processed by the Breddo Likwifier at high concentra-tions and in a few minutes: stabilizing gums, emulsifiers, flours, cocoas, yeast, powdered eggs, starches, condiments, caseinates, juice concentrates, food purees, whey solids, frozen products and cheese slurries. Breddo Likwifiers are being used in the food industries to manufacture ice cream mixes, candies, reconstituted products, canned condiments, sauces, salad dressing, fillings, instant breakfast, and many other similar items.

One of the most overused claims in business is “we do it all.” The reason that phrase is discounted is that it is usually a vague, soft expression; but if there is substance behind the message, it can positively affect your project.

Burns & McDonnell is the ONLY firm with extensive food processing experience that can also solve your

wastewater issues, permit your facility, power your plant, supply your water …with sustainable solutions.

We are an engineering and construc-tion firm that knows the food process-ing industry inside out and also has the full-service capabilities to bring all elements of your project together: site selection, permitting, environmental remediation, water supply, wastewater, process design and integration, utilities/facilities, co-generation, construction, start-up, and operator training.

Our Reputation is Built on Predictable OutcomesFor more than 50 years, Burns & McDonnell has worked with processing industry clients to apply a full-service range of creative technology, engineering and construction techniques. Our strong process capabilities have helped develop “first-of-a-kind” processes in concert with our clients.

Predictable Execution through Integrated Engineer-Procure-Construct (EPC)EPC project delivery from Burns & McDonnell establishes a team of client, designer, con-struction and quality control staff. This team works from conceptual design through post-construction to ensure efficient progress, quality and predictable outcomes. Your project will be designed and constructed in accordance with your contract documents, project schedule, quality and project budget. This level of integration provides substantial benefits and pre-dictable results.

Contact:Mark SwansonBurns & McDonnell9400 Ward ParkwayKansas City, MO 64114816-822-3812, FAX: [email protected]

Burns & McDonnell


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Charles Ross & Son Company

Contact:Charles Ross & Son Company710 Old Willets PathHauppauge, NY 11788631/234-0691 fax800/243-ROSS (7677) toll free631/234-0500 overseas phoneE-mail: [email protected]

Ross Ribbon Blenders in Stock,Priced up to 30% less.Charles Ross & Son Company, theworld’s largest manufacturer of Ribbon Blenders, now maintains alarge selection of Ribbon Blenders instock for immediate delivery. All arepriced up to 30% below most majorcompetitors. Sizes normally in stock include 1, 5, 10, 18, 25, 36, 52, 62.5, 80,100 and 120 cu.ft. working capacity.

The complete line of Ross Ribbon Blenders ranges from .5 to 515 cu.ft. workingcapacity. Standard designs accommodate materials with a bulk density up to 60pounds per cu.ft.. Each sanitary blender is constructed in type 316 stainless steel,and both exterior and interior surfaces are polished. Ross Ribbon Blendersinclude a compact right angle drive system and a manually operated valve located in the bottom center of the trough.

Ross High Shear MixersEquipped for High Speed Powder InductionThe Ross SLIM (Solid/Liquid Injection Manifold) system accelerates the process of wetting outhard-to-disperse solids and virtually eliminates the clogging that has plagued eductor-based alternatives.

Available in either an in-line or batchconfiguration, the mixer draws solidsand liquids into the mix chamber and subjects the mixture to intense mechanicaland hydraulic shear. Even solids such as Carbopol, fumed silica and gums are dispersed instantly, and agglomerates are prevented from forming.

See us at the PROCESS EXPO Show Booth #S-6425

F o r o v e r 9 0 y e a r s , Chester-Jensen has produced stainless steel heat exchange and f ood p ro ce s s i ng products for the food, dairy, meat, beverage and allied industries. Displayed this year at the 2007 Process Expo will be Instant Water Chiller and recently modified Cooker-Cooler.

The model 70N2.5 Cooker-Cooler designed to cook, cool and superblend in the same vessel. Built to the same rugged specifications as its larger capacity

units, but at a 25-gallon nominal capacity, is perfectly sized for smaller volume producers like laboratory and products development applications. The unique dual agitation configuration, along with heat exchange jacket on the entire cone bottom, provides the operator with the capability to effectively combine and blend ingredients and, in doing so, process the most uniform finished product possible. Sizes available to 1000 gal.

The Chester-Jensen “Short Gas Flow” Chiller is designed to provide a sanitary means to instantly, continuously and safely chill water, brine, glycols and other homogeneous fluids to within 1 degree F of their freezing points. Evaporator plates are ASME certified for operation at 200 PSIG at 200 degree F. Units operate equally well on all standard refrigerants.

Visit the website and learn more about how Chester-Jensen can let its experience work for you.

Chester-Jensen

Contact:Chester-Jensen Co. Inc.Fifth & Tilghman Sts., P.O. Box 908Chester, PA 19016-0908800/685-3750 or 610/876-6276 phone610/876-0485 faxEmail: [email protected] Expo Booth #S-6530


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Contact:Clayton Industries, Inc.17477 Hurley Street • City of Industry, CA 91744800.423.4585 • Fax 626.435.0180e-mail: [email protected]: www.claytonindustries.com

Considering a New Steam Boiler?Look for These 10 Important FeaturesVisit us at Process Expo: Booth S6101

1. Is rapid start-up always important? Almost always. Whether you use steam for processing, heating or cleaning, fast startup is an asset. Clayton steam generators go from cold to full steam production in approximately 10 minutes.

2. Is size important? Absolutely. Compact design in steam generators saves valuable in-plant floor space, and reduces installation and maintenance time.Clatyon generators are available in sizes from 20 to 700 BHP with design pres-sures up to 2,600 PSI.

3. What about fuel consumption? For significant energy cost reduction you obviously want peak fuel efficiency. Adaptability also can be important. Clay-ton steam generators burn natural gas, fuel oil, or a combination.

4. Should you focus on steam qual-ity? Consistently delivered high-quality steam improves the quality of your operation. Clayton’s fixed vane separators yield the driest saturated steam available, typically less than 0.5% at all loads.

5. What should you look for in ser-vice? Factory-direct chemicals, sales and services are a benefit. So are branch offices that can react quickly to your needs.

6. What should your safety objectives be? There can be no compromise. A Clayton steam generator design puts safety foremost and eliminates the possibil-ity of steam explosions.

7. Should you ask about packaged systems? Sure. Sometimes a packaged system is the ideal solution to your steam generation needs. Clayton offers com-plete skidded systems, pre-wired and pre-plumbed.

8. How important is single-source service? It’s convenient and time-saving to have steam generators in a range of sizes, supplementary equipment and feedwater chemicals from the same supplier.

9. What about emission control? Very important. Clayton features state-of-the-art low NOx–low CO burners as well as flue-gas recirculation systems.

10. Can waste heat be put to work? Could and should. Make sure all gas above 390˚F can be recovered and converted into steam or hot water.

Clayton Industries, Inc.

Clayton steam generators employ exclu-sive counterflow circulation technology. Spiral spring-coil construction delivers rapid startups without thermal stress.

Contact:CPM Wolverine Proctor251 Gibraltar RoadHorsham, PA 19044Tel: 215.443.5200Fax: 215.443.5206Contact: Paul SmithEmail: [email protected]

CPM has reunified Wolverine Proctor’s U.K. and U.S. operations. CPMWolverine Proctor customers now benefit from unsurpassed global product support and sales coverage.

CPM Wolverine Proctor offers a complete line of energy efficient equipment to processors of vegetables, fruits, snack foods, nuts, ready-to-eat-breakfast foods and more, including conveyor dryers, roasters, toasters, fluidized bed dryers and coolers, impingement ovens (jet-tube or parajet nozzle design), cereal flaking roll mills, and shredding and forming systems.

CPM Wolverine Proctor Equipment Highlights:

Multi-Stage and Multiple Conveyor Dryers are designed for maximum capacity using minimum floor space. Unique air circulation patterns, multiple air direction reversals, and multiple temperature and humidity control zones, produce the most uniformly dried products possible.

Compak Dryers and Roasters are designed for the smaller producer of nuts and snacks. Simple to operate and maintain, these machines are robustly built for years of life and have become standard equipment for the nut processing industry.

JETZONE Fluid Bed Dryer/Puffer/Toaster is a unique jet-tube fluidization dryer that offers the best solution for manufacturers of most flaked, pelletized, granulated, extruded and coarse powdered products.

The CPM Wolverine Proctor Tech Center offers both continuous and batch testing. Engineers and process technologists are available to test and evaluate of a wide range of products and materials.

With over a century of experience and expertise in Customer Service, CPM Wolverine Proctor offers parts and service for what it sells and for other drying equipment brands as well.

See us at the IBIE show – Booth #6522

CPM Wolverine Proctor


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Demaco Systems is primarily known as the only US manufacturer of food processing equipment for the production of pasta includ-ing extruders, dryers, sheeters, and accesso-ries. However, Demaco Systems has extensive experience in design and manufacturing of co-extrusion systems for snacks, stuffed pasta and dough products, as well as other custom co-extrusion products.

New products to be shown at this years Process Expo include new spiral freezer technology for simplified operation and mainte-nance. Reduced maintenance costs and the flexible design capabilities provide for our spiral freezers to be custom fit to any size room. New installations or retro-fit to existing facilities.

Meal assembly lines can handle a range of packaging materials including PET, foil, clamshells, bowls, and film or lid sealers. Capacities include processing speeds of 25 containers up to 300 containers per minute, either intermittent or continuous motion, up to six lanes wide.

Standard features include continuous improvement diagnostics and reporting, quick-release change parts, infeed extension for add-on fillers, automatic tray trans-fer at the discharge. Optional features include remote monitoring, automatic tray denesters, inline depositors for sauces or fillings, net-weigh scales for portioning, in-line load-cells and reject stations, and servo controls.

Demaco Systems meal lines and freezing systems are designed to meet producers needs in the manufacture of complex foods including ready-made meals, salads, snacks, lasagna, pasta, stuffed products, pies, pizza, and much more.

Be sure to stop by our booth S-6313 at the Process Expo 2007 in Las Vegas, and see our new offerings and best of breed solutions.

Demaco Systems

Contact:Joe Gervasi – Business DevelopmentDemaco Systems1141 E. Main Street Unit 104East Dundee IL 60118P: 847-836-9033F: [email protected] #S-6313

DCI, Inc., an employee owned company, has been a leader in the design, manufacturing and servicing of stainless steel/other alloy equipment since 1955.

The sizes and shapes of DCI manufactured equipment are as varied as the customers we serve. From 5 gallon process vessels to 500,000 gallon field-fabricated tanks, DCI tanks process, blend, store, heat, cool, mix and ferment the most trusted products and brands in the market. As a custom fabricator, we proudly serve the food, dairy andbeverage industries with:• Tanks/Vessels (silo tanks, processors, starter tanks,

whey crystallizers, round horizontal tanks, mix/blend tanks,

• Dynamixer & Dynamixer Processor tanks, and DCI Site-Fab field-fabricated tanks).

• Mixers/Agitators• Manways, Heads, Components• Replacement Parts• Field Service/Repair

The DCI Dynamixer is designed to mix dry solids, semi-solids or liquids into a slurry or liquid product. This high speed mixer/blender may also be used to blend, disperse, reconstitute, dissolve, re-hydrate, prebreak or rerun soluble solids, soluble pastes and liquids quickly, efficiently and completely. Insoluble products are dispersed into liquids to make suspensions and slurries with greater stability and homogeneity. Models are available in a variety of shapes, sizes and motor horsepower to fit a broad range of applications.

DCI’s Dynamixer Processor combines all the features of Dynamixer high speed mixer with the benefits of a cone bottom processing tank. It can perform three separate process functions all in the same tank. Mixing dry or semi-solids into a liquid, chopping and chipping solids, and heating and/or cooling the mixed batch.

DCI, Inc.

Contact:DCI, Inc. – Corporate Headquarters600 North 54 Avenue (56303)P.O. Box 1227 (56302-1227)St. Cloud, MN – USAPhone: (320) 252-8200Fax: (320) [email protected] in Booth #S-6652


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Contact:Douglas Machines Corp.2101 Calumet StreetClearwater, FL 33765Phone: 800-331-6870 or 727-461-3477Fax: 727-449-0029Email: [email protected] Expo Booth 6563 • IBIE Booth 1754

Douglas Machines Corp. offers

a full line of automated washing

and sanitizing equipment

for all containers commonly

used in the food processing and

distribution industries. Batch

and continuous cleaning

designs are available for several

hundred to several thousand

containers per hour. Pictured

are some of their most recent

product introductions; a Rack

Washer for detachable weigh

scale parts, a Vat/Bin Washer

for bulk ingredient bins, and

a Tunnel Washer for Totes and Lids.

Other models are available for

barrels, pans, trays, moulds, vats.....

versus barrels, pans, trays, moulds,

totes, screens, smoke

sticks, racks and buckets. Call

800-331-6870, or visit

www.dougmac.com to get additional

information on a model

suited to your specific needs.

Douglas Machines Corp. Endress+Hauser

Contact:[email protected]+Hauser, Inc2350 Endress PlaceGreenwood, IN 46143888-ENDRESSwww.us.endress.com/foodinfoProcess Expo Booth 6733

ONE PARTNER FOR ALL YOUR NEEDS

Endress+Hauser is a full line supplier of innovative, sanitary measurement solutions for the food and beverage industry. Dedicated to high performance, we manufacture instrumentation designed to meet the stringent requirements of the food industry for safety and reliability. Whether your application requires level, flow, pressure, temperature or analysis measurement, we offer the process connections, materials, special finishes, flow tubes, seals, diaphragms and surfaces required for optimal safety and process integration.

Endress+Hauser applies decades of application know-how to help our customers increase up-time and production repeatability, while minimizing product loss. We work closely with organizations around the world, like 3-A, FDA and EHEDG to ensure Endress+Hauser instruments meet the standard in sanitary design and clean ability for instrumentation.


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Advantage ERIEZEriez features a complete line of metal detection and magnetic separation equip-ment, screeners, and vibratory feeders and conveyors. Eriez’ products have applications across all process industries as well as the metalworking, aggregate and recycling markets.

Detectors and Inspection• Metal detection equipment• Liquid, dry and packaged goods

Magnetic Separators• High performance Rare Earth• Electromagnetic filtration systems• Sanitary easy-to-clean systems

Vibratory Feeders & Conveyors• Complete line for all food applications• Accurate, uniform product flow• Sytems include hoppers, controls, screeners, etc.

Xpress Delivery• 60 stock items ready-to-ship• Feeders available in 5 days• Sizes for most applications

Technical SupportHome to the industry’s largest magnetic, vibratory and metal detection test labora-tory, Eriez’ Tech Center has more than 100 pieces of specialized test equipment to analyze products and raw materials.

Worldwide Sales & SupportRecognized as a world authority in advanced technology for magnetic, vibratory and inspection applications, Eriez serves the worldwide food and food processing industry with nine international manufacturing facilities located on five continents.

Visit Eriez at Pack Expo Booth 3632.

Eriez

Contact:Keith Jones1-888-300-ERIEZ (3743)[email protected]

Evergreen Packaging to Highlight Equipment Capabilitiesand Carton Options in Booth S-4500

CEDAR RAPIDS, IA, USA – Ever-green Packaging will feature one of its industry-leading gable top packaging machines for refrigerated dairy, juice and liquid food products. The N-8ESL model which forms, fills and seals paper gable top cartons, is available for pasteurized or ESL (Extended Shelf Life) applications. This machine fills Eco-Pak® cartons from 4 to 10 oz. (125-250ml) at speeds up to 340 cartons per minute (20,400 cph).

Evergreen’s BFCG-32/16 bottle filler for dairy, juice, water and other still beverages also will be demonstrated in the booth. This small footprint rotary machine fills 8 to 32 ounce bottles at speeds up to 400 bottles per minute with an integrated screw capper. Demountable fill nozzles, electronic product level control, and dual product tank spray balls add to the flexibility and versatility of your production needs. ESL options include auto saniti-

zation, HEPA, and full CIP capabilities. A starwheel transfer system satisfies produc-tion versatility requirements for various bottle styles.

In addition to equipment demonstrations, the booth will showcase a comprehensive collection of packaging options for fresh and aseptic products.Made from sustainable materi-als, cartons can be custom-designed to meet your product needs and maximize shelf appeal. Your finished product will be both visually appealing and user friendly with the SPOUT-PAK® opening.

Worldwide Food Expo will be the first time Evergreen Packaging Inc. will be co-located with sister company, SIG Combibloc, a leading manufacturer of aseptic carton packaging for long-life foods such as juice, milk, soups and sauces, and recently acquired Blue Ridge Paper Products, an innovative producer of gable top packaging for liquid and dry products.

For more information, contact Evergreen Packaging Equipment at 319-399-3306 or fax 319-399-3543. Visit the web site at www.evergreenpackaging.com.

Evergreen Packaging Equipment


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Contact:Tony Pitrone2233 Lake Park Dr.Smyrna, GA 30080Phone: 770-437-2616Fax: 770-437-2601URL: www.facilitygroup.comE-mail: [email protected]

Across all segments of the food industry – including meat & poultry, grains, confections, dairy and produce, The Facility Group has extensive experience and specialized expertise in master planning, designing, engineering and constructing highly-efficient processing plants and distribution centers that bring these products to market. With twelve offices in the U.S. and Europe, The Facility Group employs more than 450 professionals who collectively have completed more than 30 million square feet and $1.5 billion in projects for the food and beverage industry.

From site selection to planning, design engineering and construction – there is just one source. The Facility Group Advantage:Staff Know-How• Former food & beverage industry leaders on staff • Industry recognized process planners • Hundreds of food processing & manufacturing facility projects, ranging in size

from 10,000sf - 500,000sf • Over 30 million square feet and $1.5 billion in distribution and processing facilities

for the food industry.

Experience• Liquid process, beverage & bottling • Frozen and fresh prepared foods • Dairies • Bakeries • Red meat and poultry • Confectionery and snack foods

Geographic Reach• Projects throughout the continental U.S. and Europe • Twelve strategic office locations: Atlanta, Chicago, Los Angeles, Sacramento,

Orlando, Baton Rouge, Oklahoma City, Kansas City, Raleigh, Seattle, Amsterdam, Dusseldorf

Total Quality Management Approach• Seamless planning, design and construction approach under one roof • Project design and layout customized to client operations, procedures, merchandis-

ing practices, & growth projections • Ongoing technical training to stay apprised of state-of-the-art solutions and regula-

tory requirements

The Facility Group FMC FoodTech

FMC FoodTech is a leading supplier of integrated food processing solutions. From single machines to complete processing lines, we enhance value and capture quality, nutrition and taste in food products. As a local presence on six continents, we can quickly provide customers and partners in the food processing industry with know how, service and support that ensures their profitable enterprise.

For your Filling, Can Seaming and Sterilization solutions, it’s all at FMC FoodTech, including our latest technology introductions TwinTec® the two-in-one filling and seaming machine and our complete range of newly developed closers, SeamTec™ designed to enhance your competitive edge. Our SuperAgi™ multi-process sterilizer technology is capable of spray, partial and full immersion processing methods.

The Frigoscandia Equipment GYRoCOMPACT® M10 Tight Curve (M10 TC) Spiral Freezer has an outer width the same as the GYRoCOMPACT 76, but with a 40” belt width and nearly 50 percent greater capacity. Incorporating all of the benefits that make the M-series product line the industry leader in freezing, the M10 TC boasts superior hygiene, flexibility, reliability and performance.

Ask about our new GYRoCOMPACT Steamer for in-pack pasteurization of pasta and vegetables.

• Process Technology & Training Centers• Aftermarket Parts & Service• Process Authority• Controls and Modeling

Contact:FMC FoodTechFor filling, can seaming, sterilization equipmentand process controlsMadera, CA – Phone: 800.835.3230Email: [email protected] portioning, coating, frying, filtration,cooking, freezing equipment and process controlsSandusky, OH - Phone: 800.447.2630Email: [email protected] Booth #815Process Expo Booth #S-6305

SeamTec™ Can Closer

GYRoCOMPACT® M10TC


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Contact:Fristam Pumps USA 2410 Parview RoadMiddleton, WI 53562Phone: 608-831-5001 - Fax: 608-831-8467Email: [email protected] Expo/Process Expo Booth #6111Worldwide Food Expo Booth #S6942

Fristam Pumps Fristam Pumps is a leading international manufacturer of high performance stain-less steel centrifugal and positive displacement pumps, blenders and mixers.

Powder MixersFristam’s Powder Mixer blends dry and wet ingredients into a fluid stream. This efficient mixing method pulls a consistent amount of vacuum and maintains performance even as product viscosity increases. Benefits include

consistent batch-to-batch repeatability, reduced blend times, ease of use, and customizable options.

Shear BlendersFor inline mixing the FS eliminates unblended product and prevents the for-mation of lumps and masses in mixture for consistent and repeatable results. CIP-able, no teardown is needed for cleaning.

Heavy-Duty Positive Displacement PumpsFristam’s FKL Series PD pumps reduce maintenance and downtime. Able to operate at 300 PSI and handle viscosities to one million cps, FKL pumps handle your biggest challenges.

Standard-Duty Positive Displacement PumpsThe bi-wing rotor design of our FL II series pumps reduces product damage concerns through low pulsa-tion and gentle handling.

Centrifugal PumpsOur centrifugal pumps serve as industry benchmarks for quiet, efficient, low maintenance operations. They include:• Standard-duty FPR series pumps for viscosities to 2,000 cps. Built with a

front pull-out seal for easy maintenance.• Heavy-duty FP series pumps for viscosities to 1,200 cps.• High pressure FM, FPH and FPHP series pumps for discharge pressures to

1,250 PSI.

Liquid Ring PumpsFor CIP return and other foamy or aerated products, Fristam’s FZX series pumps reduce waste by completely removing product from process equipment.

Fortress Technology Inc.Fortress Technology Inc. has become a world leader in the design, manufacture, and sales of metal detec-tor systems in less than a decade. In fact, thousands of Fortress systems have been installed and are operating in more than 45 countries.

Fortress’ goal is to provide its customers with everything they would expect in the most advanced metal detectors and a few things they didn’t expect. User-friendly, versatile Phantom metal detector systems with powerful digital signal processing provide faster, more accurate detection of ferrous and non-ferrous metals including

stainless steel in food processing and packaging operations. Metal detectors are available in a range of unique models and configura-tions for a variety of industrial applications.

Today’s Phantom metal detec-tors are exceptionally rugged

with a certified IP69K rating on Stainless Steel units. Fortress also offers a complete “all-in-one” integrated Conveyor solution that optimizes the overall system performance. The option of CONTACT Data Logging software with Wireless connectivity enables communi-cation with a PC to make your metal detector a Critical Control Point in HACCP programs.

Fortress Technology’s reputation is one of working closely with its customers from start through finish—from design and manufacture to delivery and installa-tion of the most effective customized solutions.

Pack Expo booth C-2500 • IBIE booth #1138 • WWFE booth S-3443

IContact:Fortress Technology Inc.51 Grand Marshall DriveScarborough, Ontario M1B 5N6 CanadaPhone: (888) 220-8737e-mail: [email protected] site: www.fortresstechnology.com


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Contact:Paxton ProductsITW Air Management10125 Carver RoadCincinnati, OH 45242800/441-7475 513/891-7474 phone513/891-4092 faxE-mail: [email protected] Expo Booth C-1416

Paxton Products

High Performance Air Knife Drying SystemsFor Processing and Packaging Applications

Paxton Products, by ITWAir Management, special-izes in Air Knife Dry-ing/Blow-Off Systems fora host of food and bever-age applications. Majorprocessors throughoutthe world rely on Paxtonto meet their cutting-

edge quality control standards and ever-changing production demands. Paxtoncustom designs each system to the blow-off cleaning or drying requirement andprovides a 100% Performance Guarantee. At the heart of every air knife systemis the high performance Paxton blower. Compact in design, these centrifugal blow-ers deliver clean, dry, oil-free air. Top-grade components, precision alignment,and proprietary dynamic balancing, ensures quieter operation, lower mainte-nance and long service life. Every Paxton blower undergoes full performance test-ing before it’s shipped, accompanied by a best in class, 3-year warranty program.

■ Saves up to 80% of energy cost vs. traditional systems■ Options include stainless steel air knives and in-line HEPA filtration■ Cleans and dries for pre-and post filling, labeling, and packaging operations ■ No water-related problems with ink-jet coding; eliminates water spots and

residue■ Thorough drying under tabs, caps, container bottoms and other problem

areas■ Ideal for cleaning and drying food molds, trays, crates and conveyors■ Fully adjustable for process-flexibility and production changes

Contact Paxton application engineers for information and assistance, or get anonline “Quick-Quote” at www.paxtonproducts.com

JaxJAX introduces its revolutionary new line of Halo-Guard™ FG greases, including Halo-Guard™ FG-PM.

Ideal greases for difficult, highly-loaded, greased gear and bearing applications, JAX Halo-Guard FG is manufactured with an advanced, proprietary calcium sulfonate complex thickener that provides exceptional mechanical stability, high load-carrying ability

and remarkable rust and corrosion control. This technology has been combined with a new high-viscosity, partial synthetic food grade base fluid for optimum performance on heavy loaded applications.

JAX Halo-Guard FG greases are ideal for applications such as gear sets and bearings, and all food or beverage equipment subject to water and corrosive washdown. As one of the most water-resistant food-grade greases available on the market with water washout results of 3.5 percent weight loss, JAX Halo-Guard FG greases also provide excellent compatibility with other greases. It also has outstanding corrosion control, as well as excellent antiwear and E.P. performance helping simplify grease inventory and provide the ulti-mate in food-grade grease performance.

JAX Halo-Guard FG greases incorporate JAX’s new, proprietary antimicrobial additive technology, Micronox®, to provide enhanced antimicrobial protection for the lubricant.

JAX Halo-GuardFG-PM is a “Heavy Duty” food-grade grease which can extend food-grade integrity to shop and plant equipment including pellet mills, fork trucks, conveyors, material handling equipment, presses, grain presses and packaging machines. Aside from its superior water washout and chemical resistance, JAX Halo-Guard FG-PM easily passed the standard Corrosion Preventative Properties Test with remarkable rust and corrosion resistance. With JAX Halo-Guard FG-PM grease, companies can also extend the life of lubricated parts, reduce grease incompatibility concerns and eliminate specialty high-temperature greases.

Contact:JAX/USAW134 N5373 Campbell DriveMenomonee Falls, WI 53051262-781-8850 Phone / 262-781-3906 Faxwww.JAX.com


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Contact:Key Technology, Inc.150 Avery StreetWalla Walla, WA 99362 USATel: 509 529 2161Fax: 509 527 1331Email: [email protected]: www.key.net

Visit us at Process Expo / Pack Expo Booth #S-6516

As a leading manufacturer of process automation systems for the food process-ing industry, Key Technology is built on the principles of innovation, reliability, and superior customer service.

Key develops next-generation solutions that produce competitive advantages for customers. Key helps improve product quality, optimize yield, reduce operating costs through labor reduction, and improve process control to enhance plant efficiencies.

The company’s products integrate electro-optical inspection and sorting systems, specialized conveying systems, and processing equipment to serve the unique needs of food processors around the world. Products and services include:• New – Optyx® sorters with FluoRaptor™ fluorescence-sensing laser technology

detect and remove defects, extraneous vegetable matter, and foreign material based on differing levels of chlorophyll as well as color, shape and size. Using the most powerful laser in the food industry in combination with Key’s proprietary color cameras, FluoRaptor achieves superior product quality.

• Inspection/Defect Removal Systems – Tegra® high-volume optical sorter, Optyx® compact optical sorter, Raptor Laser Technology to identify and remove foreign material, and ADR® for potato strips.

• Specialized Conveying Systems – Iso-Flo® vibratory conveyors, Impulse™ elec-tromagnetic conveyors, Spiral-Flo™ elevators, and pumping systems.

• Grading systems – Iso-Flo and Farmco equipment for sizing, grading, and separating.

• Preparation Systems – air cooling, air cleaning, washing, and feeding.

• Fresh-cut food processing equipment – washers, dry-ers and integrated lines.

• Services – application test-ing, custom engineering, installation and start-up, training, and customizable service packages for main-tenance and repairs.

Key Technology

Contact:Klüber Lubrication North America L.P.Kimberly Eldridge32 Industrial Drive; Londonderry, NH 03053(603) [email protected] us at PROCESS EXPO Booth #6509

Klüber has KLASSProgram Provides Customers with Lubricant Support

Klüber Lubrication, a worldwide manufacturer of specialty lubricants, offers a unique lubrication service for its customers called Klüber Lubrication Asset Support Service (KLASS). KLASS enables customers to manage and maintain an effective lubrication program, resulting in significant improvements to business performance.

KLASS is an integrated program that provides lubricants, service and support from one source – Klüber Lubrication. KLASS can help deliver measurable energy savings, increase plant efficiencies, reduce operating costs and support existing continuous improvement initiatives. The program is customized to the needs of the customer and is designed around 6 key elements:

• Comprehensive range of H1 food-grade lubricants for increased product safety• On-site lubrication and energy audits to determine lubricant consolidation and energy saving opportunities • Label management system designed to identify all lube points and reduce the risk of lubricant contamination • Lubricant and component analysis to ensure optimized lubrication service procedures• Lubrication training workshops, presented on-site, for management and main-tenance personnel• Routine on-site visits to review program and update as necessary

KLASS helps Klüber’s customers in the food and beverage industry maximize their overall equipment effectiveness. Benefits for the customers who take advantage of KLASS include reduced downtime, extended re-lube intervals, reduced energy expenditure and increased all-around efficiency.

For more information about the KLASS program from Klüber, visit the company’s Web site at www.kluberfood.com or call 1.800.447.2238.

Klüber Lubrication


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Contact:Booth #: 6329www.leeson.comPhilippe de Gail, Director of MarketingLEESON Electric2100 Washington StreetGrafton, WI 53024262-377-8810 Phone262-377-6116 [email protected]

LEESON Electric offers more than 7000 stock motors, gearmotors, gear reducers and drives solutions with 35 stock warehouses worldwide to provide availability and fast delivery to the demanding needs of the food and beverage industries. New in 2007, LEESON will be introducing a New line of Stainless Steel motors, a great addition to our line of Washdown Packaged Solutions.

LEESON’s stock motors include both AC and DC designs from sub-fractional hp through hundreds of hp for general-purpose use and specific duty applications. All popular enclosures and configurations are available along with some not-so-easy to find items. Standard at no extra cost on all stock NEMA three phase motors (1HP and larger) is LEESON’s Inverter Rated Insulation System (IRIS) which provides an extra margin of protection from inverter-induced voltage spikes.

LEESON’s gearing product array includes both fractional and integral hp gear reducers. The new LeCentric in-line reducer offers bolt-in interchangeability with leading brands, and the popular IRONMAN worm gear line, in both solid and hollow output shaft designs, has proven itself as a versatile workhorse.

We also offer our Bravo line of Aluminum Gear Reducers, which offers a vent-free and oil-free alternative for machine designers.

Adjustable Speed Drives – Speedmaster drives are a perfect fit with many types of the LEESON and Lincoln three-phase motors. Our Micro Series line of inverters is available through 60 HP at 230 Volts and through 150 HP at 460 Volts.

LEESON Electric

Contact:KVP825 Morgantown RoadReading, PA 19607-9533 (610) 373-1400Fax: (610) 373-7448www.kvp-inc.com [email protected]

KVP Introduces Spiral Pro PR620-TTR,Industry’s Tightest Turn Radius Conveyor Belt

IBIE Booth 2556 • Pack Expo Booth S-5057

A new, 2” pitch small radius spiral conveyor belt from KVP also happens to offer the all-plastic tightest turn radius in the industry — 1:1.0. Designated Spiral Pro PR620-TTR (for Tight Turn Radius), it is ideal as a replacement for metal belting on small footprint conveying systems. It is an enhanced version of KVP’s popular, field-proven Spiral Pro PR620-SPS spiral belt.

The new belt is simple to retrofit, requiring only a change out of drive sprockets and rollers. For ease of installation and maintenance, its design uses a one-piece 0.25” rod for belts 50” wide and under and KVP’s patented radius plugs (avail-able in five sizes). Rods are assembled from the outside edge and lock right into a PR620-SPS outside edge module. The new belt comes standard as Acetal, although other plastics are available, and can convey a wide range of foods and products, including baking and freezing applications. Belt widths are from 20” to 44” in 0.5” increments. Larger widths are available with slightly reduced turn radius.

The new belt can handle 1,200 lbs/ft in straight runs and 570 lbs in radial turns. It has an excellent open area for airflow. It is available for immediate shipment. KVP’s SNAP (Spiral National Application Program) team will be on hand at IBIE and Pack Expo to answer Spiral Pro PR620-TTR questions.

In addition to plastic conveyor belting, KVP makes a full line of competitively-priced plastic and steel conveying chains including flat-top, snap-on, case conveyor, multi-flex and plastic roller chain styles. KVP is a member of the Habasit Group.

KVP


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Contact:Mr. Jim Girard, VP General ManagerLubriplate Lubricants Company129 Lockwood StreetNewark, NJ 07105Phone 1-800-733-4755www.lubriplate.comPROCESS EXPO Booth S-6720

Lubriplate SFGO Ultra Series brings advanced synthetic technology to food machinery lubrication.

Lubriplate SFGO Ultra Synthetic Food Machinery Grade Fluid Lubricantscan help you consolidate, simplify and reduce your lubricant inventory.

These high-performance, NSF H-1 Registered, Polyalphaolefin (PAO) based synthetic fluid lubricants have been designed to meet the demands of wide variety of applica-tions thus reducing the need to inventory a myriad of application specific lubricants. Lubriplate SFGO Ultra Series lubricants are recommended for air compressors, hydraulic systems, bearings, gearboxes, pumps and chains. Available in 13 ISO viscosity grades.

Lubriplate Lubricants Company Meyer Industries, Inc.

Contact:Jim LassiterMeyer Industries, Inc.3528 Fredericksburg Rd.San Antonio, TX 78201(210) 736-1811(210) [email protected]

From single machines to complex integrated systems, Meyer Industries has a solution

to meet your requirements. Our family of integrated companies provides a single source for bulk material han-

dling & food processing equipment. Meyer Industries offers a full resource

for virtually all your handling & process-ing needs. Our wide range of material

handling equipment includes belt & vibratory conveyors, bucket elevators, hoppers, feed-ers, bulk box filling & unloading equipment, storage & distribution systems, and much more. Our top-of-the-line food processing equipment includes mix-blend systems, blanchers, hydrochillers, washers, dryers,

trim & inspection equipment, and much more. Efficient designs, rugged construction, & premium components have made Meyer synonymous with quality, productivity and value.

See us at Process Expo Booth S-6330


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Contact:Paul Mueller CompanyP.O. Box 828Springfield, Missouri 65801-0828Phone: 1-800-MUELLER1-800-683-5537(417) 831-3000Fax: (417) 575-9669www.muel.comE-mail: [email protected]

Paul Hume, National Sales Manager - Processing Systems and EquipmentTom Fulshaw, Regional Sales Manager - Refrigeration Products

Process Expo Booth No. 6423

Paul Mueller Company is your full service provider. Since our inception in 1940, we have evolved from a small-scale fabricator into a global process solution provider. Today, Mueller® is a certified ISO 9001: 2000 company with nearly one million square feet of manufacturing space under roof. Our products are used in over 100 countries in a wide variety of applications. We offer a full range of tanks/vessels from shop fabricated alloy vessels up through 20' in diameter to field fabricated vessels up through 2,000,000 gallons, but we do more than tanks — we provide process solutions. We offer integrated systems, modular fabrication, field construc-tion, plant maintenance/repair, and complete turnkey project execution.

We know that building a quality product starts from the ground up. Our sole purpose is to improve profit performance for our customers through our products and service offerings. Mueller has been built by focusing our extensive resources, process expe-rience, and craftsmanship on solving the processing needs of our customers. Mueller has the technical expertise, innovative engineering, and manufacturing resources to implement a process system specific to your needs.

Paul Mueller Company

Contact:Petro-Canada LubricantsColleen Flanagan 2310 Lakeshore Road WestMississauga, Ontario, Canada, L5J [email protected]: (905) 804-3631Fax: (905) 804-3619Booth # S-6168

Petro-Canada blends and packages more than 350 different lubricants, specialty fluids and greases that are exported to more than 60 countries on six continents. The company specializes in offering customers products and services proven to increase productivity and lower operating costs, lubrication consolidation, technical leadership and training.

PURITY* FG Food Grade LubricantsPetro-Canada is the world’s largest producer of pharmaceutical grade white oil

used in a variety of food processing industries. They offer a complete line of indus-trial lubricants suitable for ancillary use in food processing plants.

Petro-Canada’s food grade lubricant product line – PURITY FG – fits perfectly into a HACCP and GMP plan and provides industrial strength lubricant protection in processing operations.

On March 6, 2007 Petro-Canada announced the launch of a new product line called PURITY FG with MICROL*†. This industrial strength food grade lubricant now contains MICROL - the first and only antimicrobial preservative currently registered by the U.S. Environmental Protection Agency (EPA) for use in food grade lubricants.

PURITY FG with MICROL is available as a grease, hydraulic or gear fluid and is the only food grade lubricant on the market that is fully compliant with both the U.S. Food and Drug Administration (FDA) and EPA regulatory requirements. The product line has also been registered by NSF International, as the first NSF H 1 lubricant with an EPA registered antimicrobial preservative.

Petro-Canada was recently awarded an International Stevie Award (Best New Product or Service) for PURITY FG with MICROL.

Petro-Canada Lubricants


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seepex, Inc.

Sanitary pumps authorized by 3A standard 02-10BCSO our CIPable sanitary pumps with a new, patented universal joint also carry the latest 3A PD pump standard 02-10. This new standard requires third party verifica-tion to ensure compliance with the standards. seepex also offers equal wall stator designs, which last longer on CIP service and can generate twice the pressure of conventional “cylindrical tube” stators. It features molded-to-size stators, so neither gaskets nor “O” rings are needed, and the mechanical seal is directly in the suction line fluid flow to ensure full clean-in-place. The joint allows complete drive train disassembly without compromising component life or cleanability.

Chopper pumps The BTM, open hopper, pump which can chop or cut fruits, vegetable or fibrous materials and simultaneously pump them. New is the patented secondary cutter, a recommended option for juice producers who want a finer grind on fruit or vegetables before the pressing or extraction operations. The combination replaces hammer mills and conveyors for a more compact, cleaner, and sterile operation. The BTM is equipped with an auger-type coupling rod in the open hopper. Knives are fixed to the rotating auger and the stationary extension tube. Pump hoppers can be constructed in special lengths to fit other process equipment.

Sanitary metering pumpsOur MDC pump features a CIP able, easy-to-disassemble construction. The unit will deliver flows form 2 cc/min to 4 GPM and pressures to 350psi. A variety of variable speed drives and controls are available. Accuracy can be designed to less than 1% variation across the entire flow rate range.

Contact:seepex, Inc.511 Speedway DriveEnon OH [email protected] See us at PROCESS EXPO Booth S-6208

SEW-Eurodrive, Inc.

Contact:Mr. Chris Wood Food Industry Account ManagerSEW-Eurodrive, Inc. Phone: (804) 740-2269E-mail: [email protected] : www.seweurodrive.com

Creating food and beverages that taste good, are attractive to look at and safe for consumers to eat or drink is a complex process that requires precision and a team of experts from many different disciplines. SEW-EURODRIVE has been on that team for many decades, designing high-performance drive solutions for food processors that help improve hygiene and safety.

As one of the world leaders in power transmission and motion control, SEW-EURODRIVE offers a wide range of innovative products and systems that are easy to clean, prevent the build-up or distribution of contaminants and improve the traceability of materials that might come into contact with food.

Like our Food Industry Option Package (IOP), a drive system built specifically for the harsh environments common in the food processing industry. Stainless steel hardware, encapsulated structures and the use of food grade oil and compliant seals, cables and other components provide rugged reliability and long operating life.

This unique drive package features TorqLOC®, SEW’s patented keyless hollow shaft mounting system, which makes it easy to remove the shaft, even after years in use. There’s no need to supply a key or turn the shaft to exacting tolerances. Its interchangeable, tapered bushings fit a variety of standard shaft sizes without additional machining.

Engineering excellence and customer responsiveness distinguish SEW-EURODRIVE. U.S. operations include a state-of-the-art manufacturing center, five regional assembly plants, more than 60 technical sales offices and hundreds of distributors and support specialists, which enable SEW-EURODRIVE to provide local manufacturing, service and support, coast-to-coast and around the world.


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Siemens Energy & Automation

Contact:Siemens Energy & Automation3333 Old Milton ParkwayAlpharetta GA, 300091-800-964-4114, ref code: [email protected] S-5232

Siemens Energy & Automation offers innovative solutions for a wide range of industries. Our Food & Beverage Industry Suite is a unique and precisely coordinated range of products and systems, hardware and software, services and process know-how with which you can successfully meet the challenges faced by your industry. We not only provide you with comprehensive support during and beyond the whole life cycle of your plant, we also help you with our considerable pool of know-how and matching resources in order to solve all your problems quickly and reliably.

It is up to you to decide what we can do for your success – an all-round solution, a partial solution or, simply, an individual package. But one thing is clear; our Industry Suite facilitates and accelerates development of specific plant solutions and it also makes your task simpler and more flexible when you have to expand your equipment.

Siemens Energy & Automation, Inc. is one of Siemens’ operating companies in the U.S. Headquartered in the Atlanta suburb of Alpharetta, Ga., Siemens Energy & Automation manufactures and markets one of the world’s broadest ranges of electrical and electronic products, systems and services to industrial and construction market customers. Its technologies range from circuit protection and energy management systems to process control, industrial software and totally integrated automation solutions. The company also has expertise in systems integration, technical services and turnkey industrial systems.

Silverson Machines, Inc.For more than 60 years, Silverson has specialized in the manufacture of top quality high shear mixers for the food processing industry. Silverson has become the industry leader in the development of high shear mixing solutions and innovations through its professionalism and dedication to customer service.

Customers in more than 150 countries are a testament to Silverson’s market advantage. Whether it’s a mixer from

Silverson’s stock range or a custom-designed unit, time after time, companies specify Silverson mixers as “standard” equipment for their manufacturing process.

Silverson high shear mixers are extremely efficient, offering both speed and versatility—and are capable of reducing mixing times by up to 90 percent when compared to conven-tional agitators or stirrers. The action of any Silverson mixer can be modified with the use of rapidly interchangeable workheads that enable any mixer to:• Blend• Emulsify • Homogenize• Solubilize• Suspend• Disperse • Disintegrate

Flashblend powder/liquid mixing systemsDispersing powders into liquids and getting a consistent, homogenous product each time is one of the most difficult of all mixing applications. To satisfy this need Silverson has developed the Flashblend, a high shear system for rapid incorporation of a wide range of powders, including problematic gums and thickeners.

The Flashblend is designed to incorporate powders on a continuous and semi-continuous basis at rates of up to 30,000 lbs/hour. The system can handle a wide range of viscosities, from low viscosity products through to viscous gels. The Flashblend is suitable for large scale pro-duction and possesses many advantages including agglomerate-free product, repeatability, speed, minimum aeration, improved vessel hygiene and liquid/liquid mixing.

Contact:Silverson Machines, Inc.355 Chestnut St.East Longmeadow, MA 01028Email: [email protected]: 413.525.4825 Fax: 413.525.5804Web: www.silverson.com


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Contact:SalesSlipNOT® Metal Safety Flooring2545 Beaufait St.Detroit, MI 48207Ph. 313-923-0400, 800-SLIPNOTFx. 313-923-4555Website: www.slipnot.comEmail: [email protected] Owned: WBENC Certified Company

SlipNOT® NSF registered, slip resistant stainless steel flooring products are used by food and beverage facilities to increase productivity and worker safety while reducing injury and liability. SlipNOT® products are very versatile and can be used as floor plates, grating, ladder rungs, stair treads, drains covers and mezzanines among other uses. SlipNOT® non-slip products exceed all standards set by ADA, OSHA, ASTM and ANSI.

SlipNOT® products are grit free. The surface will not flake off like fiberglass products and will not contaminate the machinery or end product. SlipNOT® products have a file hard surface that is over 55 on the Rockwell “C” scale and have a bond strength of over 4000 psi.

SlipNOT® stainless steel products are used by companies such as: Campbell Soup, Nestle, Cargill, Tyson, Tropicana, Pillsbury, Kraft, and Sara Lee among many other food processors to keep workers safe and on their feet.

SlipNOT® non-slip flooring products provide a long lasting maintenance free alternative to slippery diamond plate and fiberglass products, while withstanding the caustic enzyme environments that are found in many food processing plants.SlipNOT® non-slip products clean easily by standard methods such as power washing and brushing.

SlipNOT® slip resistant products are available in stock sizes or can be manufac-tured and fabricated to detailed print specifications. Also SlipNOT® products are easy to fabricate. They can be sheared, welded, flame cut, torch cut, laser or water-

jet cut, plasma cut, counter-sunk, drilled and punched for complete versatility both in the shop and field.

SlipNOT® stainless steel slip resistant products are the safest answer to dangerous situations in the wet and slippery environment of food processing plants.

Visit us at the Process Expo, booth 6812

SlipNOT®

Contact:Dave Polvino, VP, Sales1806 Garner Station BlvdRaleigh, NC 27603Tel (919) 661-1911Fax (919) [email protected]

Our PROCESS EXPO exhibit at show Booth S-6446 will feature the following products:

STOCK America will feature our SSA Sterilization Systems division product line, including innovative retort and container handling solutions for foods packaged in flexible and rigid contain-ers. Our ABRS (automated batch retort systems) offerings combine the largest capacity multi mode retorts available with flexible, proven container handling solutions and systems for high sustainable throughput and safety.

Our designs include static, rotary and vari-ous oscillating retorts that have a proven track record on a global basis.

The new SSA Technology Center in Raleigh, NC provides the perfect opportunity for customer testing and validation of all our retort systems.

SSA, with the combined resources of STOCK immersion and SURDRY spray retort experts, offer design, build, valida-tion and compliance services to the food and pharmaceutical industry.

Stock America


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Tennant Company: Your Cleaning and Coatings Solutions Provider

From cleaning technologies and floor coatings to award-winning service, Tennant Company is a leading provider of integrated flooring solutions for the food and beverage industry. Specifically, Tennant Company has recently introduced a number of floor coatings and cleaning technologies that are ideal for the food and beverage industry and that support the Company’s commitment to environmental stewardship and sustainability.

The Tennant® Eco-ProTekt™ line of floor coatings, part of the Company’s Eco-Ad-vantage® coatings system, are seamless so as not to promote bacterial growth, resis-tant to chemicals, and formulated to withstand temperature variations from -330º F to +240º F, making them ideal for food and beverage processing facilities. The four coatings comprising the Eco-ProTekt line also offer superior slip resistance with a .60 coefficient of friction. Eco-CWO™, the newest addition to Tennant’s Eco-ProTekt line of coatings, is specifically designed to reduce odors and food borne illnesses caused by bacterial growth. Additional Eco-ProTekt coatings include Eco-CTO™, Eco-CFO™, and Eco-CVO™.

All Tennant Eco-Advantage coatings are virtually odor free, use reduced solvents, and contain a maximum VOC level of 250 g/L, all of which promotes improved indoor air quality by reducing evaporation and airborne contamination.

Tennant Company’s FaST® (Foam-activated scrubbing technology), available on a number of cleaning machines, including the Tennant 5700 Walk-Behind Automatic Scrubber and the T15 Battery-Powered Industrial Scrubber, uses 70 percent less water and 90 percent less chemical than conventional scrubbing methods, to leave floors immediately safe and dry. FaST is also NSF-certified to ensure plant safety, particularly in and around food processing areas, and has been certified as “high-traction” by the NFSI.

Committed to its vision of creating a cleaner, safer world, Tennant Company supports environmental stewardship and sustainability by developing products that consume fewer natural resources and chemicals and, therefore, dispense less into the waste stream. The Company strives to ensure all of its products meet five environmental standards, including water conservation, decreased detergent usage, increased safety, improved air quality, and reduced noise.

To learn more about Tennant Company’s solutions for the food and beverage industry, visit Tennant during the Wordwide Food Expo in booth S-6729 or visit www.tennantco.com.

Tennant Company

Contact:Tetra Pak Inc. 101 Corporate Woods ParkwayVernon Hills, IL 60061Phone: 800-806-9675, 847-955-6000Fax: [email protected]

With U.S. head-quarters located in Vernon Hills, Illinois: Tetra Pak began in the early 1950’s as a packaging company for liquid milk.

Since then, it has become one of the world’s largest suppliers of processing and packaging systems for milk, fruit juices, drinks and many other products. Tetra Pak structures its organization around customers’ specific need whether in dairy, cheese, beverage or food. In 1991, Tetra Pak expanded into the supply of food processing equipment, cheese manufacturing equipment, engineering and automation through the acquisition of Alfa Laval, who brought with it, over 120 years of experience. Today, it is the only company in the world able to provide integrated processing, packaging, and distribution lines and plant solutions for liquid foods manufacturing. This means that Tetra Pak’s customers enjoy the advantage of being able to get multi-product solutions from a single source, with matching equipment at every stage. The top-quality processing equipment, integrated systems, project management, engineering/technical services, spare parts and maintenance programs make Tetra Pak the preferred choice amongst processors who are looking for more than just an equipment supplier.

Tetra Pak

Cheese Plant

Tetra Therm® Aseptic VTIS

Tetra Centri® Separator


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Contact:Top Line Process Equipment CompanyDave Faes- General Sales ManagerP.O. Box 264Bradford, PA 16701Phone- 814-362-4626Toll Free-1-800-458-6095Fax- [email protected] Number: #6213

Top Line Process Equipment CompanyLooking for Process Equipment Components?

Visit us at Process Expo: Booth 6213.

Top Line Process Equipment Company continues to be a leading supplier of quality hygienic stainless steel process equipment for over 40 years. Our commitment to fine craftsmanship, high quality, unequaled service, and com-petitive pricing has led to our company's successive years of growth which has placed us among the leaders in our industries. Top Line services the Food, Dairy, Beverage, Cosmetics, Pharmaceutical, Biotech-nology and Electronics industries.As experts in the ultra-pure processing we are always upgrading and expanding our product line to bring you the highest quality components and latest innovations at the most competitive pricing including: • Sanitary Stainless Steel Fittings • Hygienic Stainless Steel Gaskets • Hygienic Stainless Steel Tubing and

Tube Hangers • Hygienic Stainless Steel Centrifugal

pumps, Rotary Lobe pumps & Mag Drive pumps.

• Hygienic Stainless Steel Butterfly Valves, Ball Valves, Diaphragm Valves, Sample Valves, Divert Valves, Plug Valves, Ball Check Valves & Disk Check Valves

• Custom-made Specialties • Accessory Items and Component Parts • Hygienic Stainless Steel Gauges • Hygienic Filters and Strainers

Our extensive product line is the most complete in the industry and we maintain critical warehouse facilities for the most responsive service and fast turnaround.Top line specializes exclusively in serving the hygienic processing industries; we understand your requirements for equipment that meets the most stringent speci-fications. Our products are in compliance with industry organizations including the FDA, USDA, ASME BPE and 3A Sanitary Standards, and we offer the documenta-tion necessary for your industry. For top of the line products and service, there’s only one name to remember: Top Line. Call us today for more information on any of our products.

Thermo Fisher Scientific introduces new Thermo Scientific branded products.

Thermo Scientific’s industry-leading expertise in packaging, inspection, and weighing can maximize your performance and quality in critical food, beverage and pharmaceutical processes.

There’s growing pressure to increase profits, conform to new regulatory requirements, and protect your brands and consumers from food safety, bioterrorism, and other evolving threats.

Thermo Fisher’s rich portfolio of life and laboratory sciences, process control, and environmental expertise can respond with comprehensive productivity solutions. Thermo

Fisher has years of intimate knowledge of our customer’s critical process needs.

Our global presence gives us the reach and experience to meet your requirements, wherever you are and wherever you go. The company’s process solutions include:

• Checkweighing Systems• Metal Detection Systems• Constituent Analysis Products• Flow Sensors• Level Measurement & Controls• X-Ray Inspection Systems• Contaminant Detection Systems• Fill Height Detection Systems• Process Monitoring Systems• Quality Assurance Products• Data Collection Systems

Thermo Fisher Scientific

Contact:501 - 90th Avenue NWMinneapolis, MN. 55433Don [email protected] 763 783 2500Fax 763 780 2315

APEX - high performance metal detector

CrystalVision - Inline CO2 concentration measurement

PROx - X-ray contaminant detection


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URSCHEL INTRODUCES THE NEW COMPACT DIVERSACUT SPRINT™ DICER

Applications:Wide variety of vegetables, fruits, and meats

Able to easily switch from one type of cut to another, the latest, more compact DiversaCut Sprint™ Dicer offers processors versatility, flexibility, and efficien-cy. View this machine and others at Process Expo Booth #6316 and WWFE booth #S-3514.

The high performance Sprint accepts a wide variety of vegetables, fruits, and meats. Maximum product input size is approximately to 6.5” (165.1 mm) in any dimension. The dicer produces a myriad of flat or crinkle slices, strip cuts, and dices up to 1” (25.4 mm). Switching over from one type of cut to another is simpli-fied through a changeover advantage: processors benefit from the combination of the built-in circular knife support assembly, in addition to the manageable weight of the crosscut spindle, and a cost-saving, insert slicing knife. The Sprint outputs excel-lent quality cuts due to a compact cutting zone that easily transitions product from one cutting component to the next.

Stainless steel construction throughout the machine along with hinged access panels promotes sanitation. The drive train is completely isolated from the product zone to eliminate contamination concerns. Innovative rounded tube frame reduces soil collection surface areas, while sloped sheet metal simplifies wash downs.

The Sprint features across-the-line start and continuous operation for uninter-rupted production. To further accommodate routine maintenance, all lubrication points are easily accessible on the exterior of the machine.

For a complimentary brochure, please contact: Urschel Laborato-ries, Inc., www.urschel.com, Email: [email protected], PO Box 2200, 2503 Calumet Avenue, Valparaiso, Indiana 46384-2200 U.S.A.

Urschel Laboratories, Inc.TOTAL Lubricants USA, Inc.

Contact:TOTAL Lubricants USA, Inc.5 North Stiles Street • Linden, NJ 07036Phone: 800.344.2241 • FAX: 800.227.1979www.Nevastane.com • www.KeystoneLubricants.comBruce WolfePhone: 908-374-5002See us at PROCESS EXPO Booth #6518

TOTAL’s Nevastane®Food Grade LubricantsTOTAL has been a supplier to the food processing and beverage industry for over 80 years.

Nevastane® products may be used as a lubricant or anti-rust film on equipment and machine parts as well as in hydraulic systems, gear boxes, bearings and drives for inci-dental contact with food.

In 1925, Keystone registered the trade name “Nevastane®”to denote a family of lubricants formulated from ingredients meeting FDA regulation 21 CFR 178.3570. Nevastane®

products are NSF registered H-1, for incidental contact with food or beverages. The NSF Nonfood Compounds registration program is a continuation of the USDA product approval and listing program, which is based on meeting regulatory requirements for appropriate use, ingredient review and labeling verification.

Food processors are confronted with a variety of applications requiring “food grade” oils for incidental contact. Frequently, a food plant uses straight non-fortified white oils. Nevastane® oils and greases contain special anti-wear or extreme pressure additives to extend their usefulness.

Every Nevastane formula is HACCP-compliant, and “Star-K” Kosher pareve approved, including our synthetic, semi-synthetic, mineral base, gear lubricants, system cleaning oils, greases and seamer lubes, along with our unique SafeGard® sprays. Nevastane® products consider safety in regard to operations, human health, and respect for religious standards. Quality and customer satisfaction are paramount priorities.

TOTAL serves its customers with job matched packaging that includes cartridges, pints, gallons, pails, kegs, drums, bulk totes and SafeGard® spray containers. Visit the Nevastane.com website for application, product and MSDS sheet information.


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Contact:VNE Corporation 1149 Barberry DrivePO Box 1698Janesville, WI 53547800-356-1111608-756-4930Fax: 608-756-3643www.vnestainless.comBooth # 6309Contact Name:Chip [email protected]

VNE Corporation, a member of the Neumo-Ehrenberg Group is a privately owned, diversified multi-national organization consisting of 26 companies in North America, Europe, and Asia.

VNE is a leading manufac-turer and supplier of stainless steel fittings, valves, tubing, and specialty related products. Maintaining one of the largest inventories in the industry to support projects and immedi-ate everyday shipments.

We make it easy for you to do business with us by providing the following: • Great Customer Service • Competitive Pricing • High Quality Products • Material Test Reports Online – MaxPure® BioPharm Fittings • No Minimum Order • UPS Tracking Via VNE Website • Same Day Shipments – For Any Requested Mode • Hours Of Operation – 8:00am – 5:30pm CST

Our Commitment to Ultimate Product Diversity

For over 80 years, Valspar Flooring’s high performance industrial and decorative floor & wall systems have been trusted for outstanding performance, reliability and aesthetic enhancement in a variety of industries and applications.

Our low-VOC epoxy and ure-thane coatings & resurfacer systems produce a rugged, long-lasting, seamless surface for excellent resistance to abrasion, chemicals, impact, thermal shock and UV.

Plus, to supplement our core products, we offer innovative concrete additives, preparation products and primers suited for fast track construction and moisture vapor control.

Our Commitment to Sustainability & Our EnvironmentAs a world leader in paint and coatings manufacturing, Valspar Corporation recog-nizes the importance of long lasting products that promote a sustainable future. With this focus, Valspar Flooring offers a diverse selection of low VOC epoxy and urethane coatings and resurfacers that comply with air quality mandates and that help con-tribute toward Green building efforts.• Virtually odor free• Environmentally friendly• User friendly• VOC- and VOS-compliant

Valspar Corporation: If it matters, we’re on it.™Since 1806, Valspar Corpora-tion has been dedicated to bringing customers the latest innovations, the finest quality, and the best customer service in the industry. With more than 7,000 employees in over 80 locations around the world, Valspar Corporation is in a truly unique position to supply customers with the coating solutions they need.

See Valspar Flooring atProcess Expo Booth# 6466 / WWFE Booth# S-3849

VNE CorporationValspar Flooring


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Waukesha Cherry-Burrell

Contact:SPX Process Equipment 611 Sugar Creek Road Delavan, WI 53115 Ph: 262.728.1900 or 800.252.5200 Fx: 262.728.4904 or 800.252.5012 Email: [email protected] Web: www.spxpe.com

Waukesha Cherry-Burrell has been manufacturing valves for the food, dairy and beverage industries for over 48 years. The single seat, mix proof, and manual valve offerings compliment our line of positive displacement and centrifugal pumps, Votator®‚ scrape surface heat exchangers, fittings, and dispersion equipment to provide you with a full selection of quality process components.

PMO Mix Proof ValvesSecure safe separation of products with Waukesha Cherry-Burrell’s PMO mix proof valves. Designed to meet criteria of the PMO for Grade A dairy processes, this durable valve is machined from solid bar construction and has a standard pressure rating of 150 psi (10 bar). The valve is available in1-1/2, 2, 2-1/2, 3, 4, and 6-inch tube OD sizes.

“Set & Forget” Control Top TechnologyProvide reliable valve position feedback on single seat or mix proof valves and eliminate the hassle associated with Micro-Switch or Proximity Switch adjustment with Waukesha Cherry-Burrell’s control top technology. This control top contains multiple outputs for indicating valve open, valve closed, and seat lift and seal wear information. The top also boasts an easy push button “teach” function.

To learn more about our complete line of process equipment and technology, please visit our website at www.spxpe.com.

See us at the Process Expo, Booth #6700 and WWFE, Booth #S-5505

Wire Belt CompanySince 1947, Wire Belt has proudly maintained a reputation for developing advanced conveyor and belting solutions to meet the automated processing needs of the food industry. Our products are extensively used for breading, battering, frying, blanching, cooking, coating, dusting, and cooling.

Wire Belt’s New CompactGrid™ con-veyor belting is the first revolutionary new metal conveyor belt since 1965. It is engineered specifically to handle smaller, delicate products, while giving you a lighter weight, open-mesh belt design that can outperform many competitive offerings. CompactGrid is a viable, cost effective alter-native to Plastic Modular belting. It is easy to clean, USDA accepted, and proven to perform in numerous processing environments.

Wire Belt’s C-CureEdge®

Flat-Flex® belting also has many advan-tages, with it’s patented C-shaped end loops. You can’t afford to have downtime from two conveyor belts catching during tight transfers. Wire Belt’s C-CureEdge patented end loops can help to lessen the chance of this occurring. C-CureEdge also helps to eliminate the “zip-per effect” of belt tangling during unrolling or re-rolling belt.

Wire Belt’s entire line of Flat-Flex and CompactGrid belting products are accepted by the USDA NSF/ANSI/3-A hygiene standards. This is the only acceptance that can assure you that you have the cleanest, safest conveyor belt available in this business segment.

Not sure which belt is right for your application? Call Wire Belt at 603-644-2500. Our friendly and knowledgeable customer service team is ready to help you with any ques-tions you may have. Wire Belt’s commitment to service goes along with every belt we deliver. So remember, when it’s all on the line…make sure it’s a Wirebelt®.

Visit Wire Belt’s BOOTH #326 at the 2007 TIA Tortilla show, Las Vegas September 11-13Visit Wire Belt’s BOOTH S-6712 at the 2007 PROCESS EXPO, Las Vegas October 15-17

Contact:Wire Belt Company of America154 Harvey RoadLondonderry, NH 03053Phone: 603-644-2500Fax: 603-644-3600E-mail: [email protected]


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ClassifiedMarketplaceCLASSIFICATIONS: Auctions • Bird/Pest Control • Construction Engineering • Consulting • Contract Manufacturing • Contract Packaging • Employment Services • Equipment for Sale •• Label Manufacturing • Real Estate • Wanted To Buy

For ad information call Christin Schrei248 393 4450 or fax your ad to 248 502 1025.Food Engineering’s Classified Inside Sales Dept. [email protected]


Dave [email protected]

WWW.OSIJOBS.COM

OSIOptimum Search, Inc.

Excellence in Food Industry Executive Recruitment

Check our listings for plant/project engineers, plant operations, QA, R&D, sales, marketing and purchasing positions on our web-site.

Tim [email protected]

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Plant Eng/Maint Mgrs ----------------------85-100kR&D Project Leader, Bakery, Florida ------65-75kSafety Manager -----------------------------80kProject Engs --------------------------------65-100kProduction Manager -----------------------75-90kProduction Supvs, Beverage ---------------55-70kNational Accts, Beverage — Texas --------95-110k ++Maint Supvs ---------------------------------55-75k

Visit usafoodjobs.com for more information@ f dj b

Beverage Industry RecruitersBeverage Industry RecruitersArnie Holder 727-945-1166Arnie Holder 727-945-1166

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specialists in the consumer goods industry

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TO SUBMIT YOUR RESUME, OR ENGAGE SEARCHES,PLEASE CONTACT:

TINA GANNONDIVISION VP, JUDGE INC. 888-228-7164 EXT 114, FAX 813-286-0668MAILTO: [email protected] SEE A LIST OF OUR CURRENT JOB POSTINGS, CHECK OUT OUR WEBSITE AT

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Looking to Expand your Reach?

Please contact Christin Schreifor more information

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At Henson Partners, our mission is to provide our clients with executive search services of the highest standard. Our pursuit of excellence and our dedication to the Food Processing Industry, has earned our firm a reputation we are proud to have, and one that you can trust. Learn how your business can benefit from our extensive industry knowledge and experience, our highly specialized search methodology, and our dedication to exceptional outcomes for client companies and talented individuals.

If your company is looking for exceptional management to executive level talent, or you are a candidate seeking a once-in-a-lifetime career opportunity, contact us today.

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AdIndex

Company Phone Number Page

A & B Process Systems Inc 888-258-2789 46Admix Inc 800-466-2369 6Aeroglide www.aeroglide.com/food 36

Air Products & Chemicals 800-654-4567 5AGC Engineering 800-825-8820 22

Allpax Products 985-893-9277 88

Alto Cleaning Systems 877-366-2586 74

American Conveyor 718-386-0480 95

Anderson Instrument Co Inc 518-922-5315 37Angelus 323-583-2171 90,91

APV Invensys 800-554-5290 48Ashworth 800-682-4594 40Austin AECOM 312-373-7700 60

AZO 901-794-9480 34

Baldor Electric Company 800-828-4920 19BE&K Building Group 919-781-0054 86

Boston Gear www.altramotion.com/fe 101Breddo Likwifier 800-669-4092 IBCBRUS Pnuematics www.boschrexroth-us.com 81

Burns & McDonnell 816-822-3812 63

Central Sates Equipment 800-654-5635 26

CESCO Magnetics 877-624-8727 30

CH2M HILL ch2mhill.com/food 57

Charles Ross & Son Co 800-243-ROSS 59,61Chester-Jensen co., Inc. 800-685-3750 38

Cipriani Harrison Valves 949-589-3978 27

Clayton Industries 800-423-4585 35

CPM Wolverine Proctor 215-443-5200 62

Crossfield Products Corp 310-886-9100 112

Dalmec 800-935-8686 30

DCI Inc. 800-276-7599 93Demaco Storci Systems 847-836-9033 2

ECO Bionics 866-438-6136 78Emerson Process Management 8005-522-6277 80Endress + Hauser 888-ENDRESS 1ESE 800-236-4778 114

Eriez Magnetics 888-300-3743 83

Evergreen Packaging 319-399-3200 24

Fibergrate Composite Structure 800-527-4043 128

Food Automation and Manufacturing Conference 630-694-4347 117

Forbo Siegling Inc 800-255-5581 112

FMC FoodTech www.fmcfoodtech.com 84Food Control Solutions, Inc. 440-716-5500 110

Food Master www.foodmaster.com 129

Fortress Technology Inc. 888-220-8737 39Fristam Pumps 800-841-5001 7Grundfos Pumps www.grundfos.com 42

Hardy Instruments 800-821-5831 107

Haynes Manufacturing Co 440-871-2188 114

Heat & Control Inc 800-227-5980 123

JAX 800-782-8850 92Kamflex Corporation 630-682-1555 76Kemco Systems 800-633-7055 110

Key Technology 509-529-2161 51KHS www.khs.com 79

Kline Process Systems 610-371-0200 28

Kluber Lubrication 877-255-8237 31KVP 800-445-7898 44

Lawson 800-477-1357 105

LEESON Electric 262-377-8810 BC

Liberty Technologies 800-860-4744 47

Lubriplate Lubricants Co 800-733-4755 97

Mars Air Doors 800-421-1266 32Machine and Process Design, Inc. 763-427-9991 50Martin Brothers 800-652-2532 106

Matcon USA 856-256-1330 43

Material Transfer & Storage 800-836-7068 126

Mennekes Electrical Products 800-882-8110 11

Mepaco 920-356-9900 64

Meyer Industries 210-736-1811 4

Midwestern Industries Inc 877-4-SIZING 14

MOL Industries 800-729-2358 87

MPE Group 800-965-6065 10

Nalco Company 630-305-1000 67,69,71

National Bulk Equipment 616-399-2220 14

Orkin 800-ORKIN-NO 55

Pacific Ozone 707-747-9600 106

Packaging Strategies www.packstrat.com 111

Paul Mueller Company 800-MUELLER 41

Paxton Products-ITW Air Management 800-959-8884 45

Petro Canada 800-268-5850 120

Powder Technologies Inc. 609-914-0521 49PPM Technologies 503-538-3141 12

Praxair Technology Inc. 800-PRAXAIR 113

Process Expo 2007 www.fpsa.org/processexpo 132

Reiser 781-821-1290 77Remco Specialty Products 954-462-0000 108Schenck AccuRate 800-394-2941 58SEW Eurodrive www.seweurodrive.com 98

Seepex, Inc. 937-864-7150 100Shambaugh & Son Inc. 260-487-7777 99

Shat-R-Shield 800-223-0853 32

Siemens www.siemens.com/mes-stimaticit 102

Silverson Machines 413-525-4825 33Slipnot Metal Safety Flooring 800-SLIPNOT 23

Spraying Systems Co. 800-95-SPRAY 9SSA Sterilization 919-661-1911 56SPX Process Equipment 800-252-5200 IFCTennant Company 800-228-4943 17

Tetra Pak 800-806-9675 116The Facility Group 800-525-2463 118

Thermo Fisher Scientific 800-227-8891 75Top Line Process Equipment Co. 800-458-6095 96

TOTAL Lubricants USA Inc. 908-374-5052 115Tyco Flow Control www.tycofloorcontrol 20

U.S. Water Services 866-663-7632 36

Urschel Laboratories, Inc. 219-464-4811 25VNE 800-356-1111 82Wire Belt Company of America 603-644-2500 89World Wide Food Expo www.worldwidefood.com 109Valspar Flooring 800-637-7793 x5050 29

• Further information on these companies can be found in the 2006-2007 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.


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If bacteria-destroying viruses become the next defense against foodborne pathogens, the industry will have to thank a Canadian Commie.

Biologist Felix d’Herelle first discovered the existence of bacteriophage in 1910 while conducting research in Mexico. When d’Herelle smeared feces from sick locusts onto plates of agar, clear spots appeared after a while in the cultures. He deduced an organism was eating the coccobacilli bacteria that had infected the locusts. He modified the Greek word phagin (to eat) and dubbed these germ killers bacteriophage. A phage virus attaches itself to a specific bacterium and injects genetic material into the cell. The bacterium’s metab-olism becomes an incubator, reproducing the phage until its cell wall bursts, releasing hundreds of new phages that attack more bacteria.

An admirer of Josef Stalin, d’Herelle accepted an invita-tion from the Soviet government in 1934 to join the Institute of Bacteriology in Tbilisi, Georgia, where he joined George Eliava, a microbiologist and founder of the Eliava Institute. Eliava scientists worked in obscurity for decades, isolating the phage that attacks specific pathogens and developing purified cultures, until the mid-‘90s, when the emergence of antibiotic-resistant germs revived interest in phages. A num-ber of US and European start-up ventures, most involving Eliava alumni, have sprung up since. While medical applica-tions are the primary focus, phages also hold promise for a number of nano-applications. Among the firms pursuing food pathogen control is Baltimore-based Intralytix Inc.

Intralytix was founded in 1998 by Alexander “Sandro” Sulakvelidze, a Georgian microbiologist, and J. Glenn Morris Jr., a doctor and professor of internal medicine and infectious disease at the University of Maryland School of Medicine. Sulakvelidze was doing post-doctoral work with Morris, who was treating patients, some terminal, who suffered from antibiotic-resistant infections. Phage treatment had promise, but the efficacy had never been demonstrated to the satis-faction of health regulators. Working with US Agricultural Research Service (ARS) scientists in nearby Beltsville, MD, they conducted research and petitioned FDA in 2002 to use phage on food. At the same time, John D. Vazzana, a retired business executive who had guided several start-up ventures to successful IPOs, developed a strategic business plan for Intralytix and was asked to execute it in 2003.

FE: How did Intralytix get involved with the food industry?Vazzana: In the compa-ny’s early years, we signed a research & development contract with Perdue Farms to i so la te and ferment phages to attack Salmo-nella enteriditis and Listeria monocytogenes. We had a basic product by 2001 for Salmonella, but because people cook raw chicken and destroy salmonella, a Listeria control was deemed more useful. At the encour-

agement of Perdue, we pursued regulatory approval for the Listeria phage, which we named LMP-102.

We’ve also worked closely with ARS researchers in their lab in Beltsville, MD. In 2001, two ARS plant pathologists published a largely favorable report on the use of phages on whole and cut apples and melons. Ultimately, we’d like to get a sample of the E. coli 0157:H7 strain in last fall’s spinach contamination to test against our phage cocktail. So far we haven’t, and neither has ARS.

FE: Why did it take four years to win FDA approval for LMP-102?Vazzana: It was partly our fault that it took until August 2006. We didn’t understand what scientific data they needed. The process should go more smoothly in the future.

John D. Vazzana, CEO, Intralytix Inc., Baltimore

ENGINEERING R&D

Foodborne pathogens and other bacteria are devoured from within by viruses known as bacteriophages. This fall, food manufacturers will begin testing this food-safety weapon.


Bacteria busters


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FE: While you have been prepar-ing for commercial testing, EBI Food Safety in the Netherlands entered the market with an anti-Listeria phage. How does that affect LMP-102?Vazzana: After we educated FDA, these guys waltzed in and got limited approval, a letter of no objection for GRAS status. I’m a little hurt. But we don’t look at them as competitors. EBI started a year or two after us and has one product designed for cheese. They are helping to educate end-users and consumers about phage as a food safety tool.

FE: How will phage be applied to food safety?Vazzana: We’ve developed a mixture of six phages that, to date, have been clinically tested and proven effective against 278 strains of Listeria. We used our library of 30 different phages in developing the final cocktail. We can’t say the six phages will kill all Listeria bacteria because there may be rogue strains that we haven’t tested against, but it is quite efficacious.

We’re working with equipment makers on engineering a system to deliver phage to the surface of food immediately before packaging. Once we scale up phage manufacturing, we can experiment with different ways to deliver the product.

In test environments, we’ve had 2.5-3 log reductions of the target bacteria, but those tests were with sample inoculated to high bacterial concentrations. In real-world concentrations, product might be contaminated to 1-2 logs. The phage keeps multiplying as long at there is bacteria present to infect.

We’ve had phone calls, mostly from QA people, about testing LMP-102 at 70 US food companies and some inter-national firms. Most of them make encased meats or import smoked fish and other ready-to-eat foods. They either have had a recall or are sensitive to that possibility. Some see phage as a way to improve their risk classification and do business with top echelon foodservice and retail customers.

FE: What are the human risks with phage?Vazzana: Phages don’t infect mammalian or plant cells; they only infect bacteria. However, unless the strain is pure, they leave behind debris that could be fatal to humans. Our most important proprietary intelligence is techniques that are a slam-dunk for purification of phage on a commercial scale.

Phages are the most ubiquitous organisms on the planet, with many millions of varieties. In a milliliter of unpol-luted water, there are an estimated 2 billion phages. Isolat-

ing the ones that control Staph, E. coli, Salmonella and Listeria out of nature was the focus of our early work. We know every gene in every phage in our library and constantly monitor for rogue genes.

FE: Scientists at Tbilisi’s Eliava Insti-tute complain Western biotech com-panies are exploiting their work and will reap all the profit. Is that a fair assessment?Vazzana: There are a lot of very smart people at Eliava, and we have a lot of respect for their technology. It’s just difficult to convert it to something we can get approval for here. There are steps you have to take early in the process to get that approval, and those weren’t taken in Georgia.

We had some early development agreements with Eliava, but it became evident, in order to meet Western regulatory requirements, we had to apply advanced techniques to isolate and characterize phages. The technology has to yield consis-tent results, meet quality standards and be reproducible.

FE: The inventors of a 2004 patent assigned to Intralytix are from Tbilisi. How would you characterize the relationship?Vazzana: From time to time we have formal arrangements with the Georgian scientists, and we hope to collaborate more with them. Some of their cultures have been used for 30 years to treat chronic wounds, and from an anecdotal view are very effective. The only point you can fault them on is purification. But there are a lot of smart people there. Sandro Sulakvelidze, our founder, is in Georgia as we speak and will be visiting Eliava to see how we can have a closer relationship.

FE: How stable are the phage cocktails that food companies will test?Vazzana: We will ship in a refrigerated state and in very con-centrated form. Companies will dilute the liquid with puri-fied water. In a refrigerated environment, phages will retain their strength for up to six months. They cannot multiply outside the presence of the target bacteria.

We were making cultures in 10-liter fermenters until June, when we contracted with a firm to make 1,000-liter batches. By the fall, we hope to scale up to commercial quan-tities for shipment to plants for pilot tests. Ultimately, the phage will be in powder form that can be warehoused for two to three years. We keep all master seed stocks in our lab in a powder form. Converting fermented stock to powder is one of our challenges, and we will meet it. ◆

ENGINEERING R&D

In this illustration of a phage, the blue area depicts the head, where genetic material is stored. The pink corkscrew tail is the point of attachment to a target bacterium. Genetic material feeds into the target, generating hundreds of new phages until the cell wall bursts. Source: Intralytix Inc.


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Clean-In-Place (CIP) DoubleWater Flush Seal Option

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in Blending

a division of

1230 Taney • North Kansas City, Missouri 64116800-669-4092 • 816-561-9050 • Fax: 816-561-7778

[email protected] • www.breddo.com

When you need to emulsify, liquify, dissolve, disperse,smooth, chop, shear,reclaim, or stabilize,even while you cookor cool, there is aLikwifier modeldesigned just for your application.Find out why BREDDO Likwifiershave been the industries’ choice forover 50 years.

LOR SeriesRound Vessel

Belt Drive

LOS SeriesSquare VesselBelt Drive

Scraped SurfaceHolding Tank

LORSS SeriesScraped SurfaceRound VesselBelt Drive

Standard Impeller

High Shear Impeller

LORSSScrapedSurface

LDT SeriesSquare Vessel

Direct Drive

State-of-the-ArtControl Systems

Complete Icing Systems

Contact us today.

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When a gearmotor fails, the last thing you need is to sitaround waiting for the replacement to arrive. LEESON has Washguard Gearmotors in stock, off-the-shelf whenyou need them. In a matter of days you can receive yournew LEESON Washguard Gearmotor so downtime will be minimal.

Designed and manufactured to provide enhanced performance in wet and humid areas, these newWashguard Sub-Fractional Gearmotors meet IP55 environmental conditions, are wound for either SCR 90 voltsor battery operated 12 volts, and include both parallel andright angle output shafts.

Contact LEESON today to find out which WashguardGearmotor fits your material handling, food processing or packaging application.

Your Choice.How Soon Would You Like ThatGearmotor Delivered?

A Regal Beloit Business A Regal Beloit Business

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food engineering, september 2007

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