Food Engineering 2015 09

September 2015
www.foodengineeringmag.com
THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT
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SPECIAL GREEN SERIES REPORT: WEIGHING ALL THE OPTIONS IN WASTEWATER TREATMENT
September 2015 | www.foodengineeringmag.com
THE MAGA ZINE FOR OPER ATIONS AND MANUFACTURING MANAGEMENT
The Worlds Top 100

Food & Beverage Companies
Change is the
new normal
ALSO THIS MONTH

} SOLUTIONS FOR IMPROVING YIELD
} PACK EXPO LAS VEGAS PREVIEW
} TECH UPDATE: FILLING EQUIPMENT
Meet SPX at Process Expo

McCormick Place, Chicago, IL
September 15-18, 2015
Booth #6505, North Hall
ADDING A POWERFUL NEW TOOL

TO YOUR MAINTENANCE PROGRAM
SPX has recently launched its SPX Connect App allowing users the ability to access
product support information 24/7 using a smart device with internet access.
A quick scan of the products QR code will provide you with immediate access to:
Product Descriptions and General Operating Specications
Maintenance Manuals and Documentation
Maintenance Videos and Product Animations
Distributor Look Up Feature
Submit Quote Requests
SPX is committed to providing you with innovative products and technologies to help keep your
process flowing. Plan your next scan and download the Free SPX Connect App today.
To learn more about SPX Connect, contact SPX at 800.252.5200 or wcb@spx.com.
TRUSTED RELATIONSHIP
KNOWLEDGEABLE RESOURCE
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EXCELLENCE FOR OUR CLIENTS
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September 2015
FEATURES
COVER STORY
62
The Worlds Top 100 Food & Beverage

Companies
Global volatility in both socioeconomic and political
terms, shifting demographics and an explosion in
e-commerce created an increasingly challenging
backdrop to activities during the past year.
77
Weighing All the Options in Wastewater

Treatment
Whether your plant is located in a drought-stricken
area or where water is plentiful, building a wastewater
treatment center on site may be cost effective for
several reasons.
101 Solutions for Improving Yield

Youve done the obvious, so where else can you look to
squeeze out more product? There are gains still to be
realized in managing the risky aspects of operations
from line startup to changeovers to new product
introductions.
121 Tech Update: Filling Equipment

As consumers want a bigger variety of healthier
choices that come in a plethora of sizes, manufacturers
are offering fillers that are flexible while producing
optimal output.
DEPARTMENTS
8
63
Editors Note
10
Calendar of Events
15
Manufacturing News
Barriers to energy savings
Daily food industry headlines

21
Like FE on Facebook
27
Pushing away from petroleum
31
www.foodengineeringmag.com/linkedin
Technology Sourcebook
Focus on Checkweighing & Metal Detection and
Spraying & Washing Equipment
http://twitter.com/FoodEng
Join FEs Group on LinkedIn
Food Safety
Time to use some common-sense protocols
www.facebook.com/FoodEngineering
Follow FE on Twitter
Food Packaging
128
Field Reports
Precision weighing technology increases accuracy.
Follow FE on Google+
132
PACK EXPO Preview
https://plus.google.com/+Foodengineeringmag/posts
155
Classified Ads
Subscribe to FEs YouTube channel
159
Engineering R&D
http://www.youtube.com/user/
FoodEngineeringMag
Lubrication keeps wheels turning in flash freezing

applications.
www.foodengineeringmag.com | Food Engineering | September 2015
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EDITORIAL
Joyce Fassl Editor in Chief
fasslj@bnpmedia.com, 610-436-4220 ext. 8519
Wayne Labs Senior Technical Editor
labsw@bnpmedia.com, 215-345-4548
Schenck Process providing custom solutions for pneumatic & mechanical

conveying, filtration, weighing, feeding and odor control
Debra Schug Features Editor

schugd@bnpmedia.com, 847-405-4068
Jeremy Gerrard Digital/Online Editor
gerrardj@bnpmedia.com, 610-436-4220 ext. 8511
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FEeditors@bnpmedia.com
Richard Stier, Jaan Koel,
Mark Huffman
Contributing Editors
ART & PRODUCTION
Karla Fierimonte Art Director
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Suzanne Fairman
Advertising Production Manager
fairmans@bnpmedia.com, 253-946-6854
PNEUMATIC
CONVEYING
FILTRATION
WEIGHING
FEEDING
For over 40 years Schenck Process has provided custom bulk material and air
handling solutions to some of the worlds most recognized brands in food
manufacturing. Their trust was built with Schenck Process as a result of repeatedly
receiving fully designed safe and successful pneumatic & mechanical conveying,
filtration, weighing, feeding and odor control systems.
Custom solutions in products and systems are available for the following:
Feeders and Weighbelts
Bulk Bag Unloaders
Airlocks
Process Controls
Dilute and Dense Phase Conveying
Vacuum Conveying
Dust Collection
Air Pollution
Contact us to see how we can put our proven experience in material and air handling
for food processes to work for you.
Schenck Process
7901 NW 107th Terrace
Kansas City, MO 64153
888-657-3098
mktg@schenckprocess.com
www.schenckprocess.com
September 2015 | Food Engineering | www.foodengineeringmag.com
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AUDIENCE DEVELOPMENT
Kourtney Genereaux Audience Marketing Project Manager
Megan Neel Corporate Fulfillment Manager
Catherine M. Ronan Corporate Audience Audit Manager
Nikki Smith Online Development Director
Erin Mygal Directory Development Manager
FOOD ENGINEERING Volume 87, Issue 9 (ISSN: Print 1522-2292 and Digital
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EDITORS NOTE
Going far without going too far
or as long as Ive been overseeing

the content of Food Engineering
magazine, the mandate for food and
beverage processors has been serving consumer needs. In the past decade, however, the pressure to deliver the right goods
to consumers has become even more intense.
I am referring not only to formulation
changes and product line ex pansions,
but also to food safety and sustainability
improvements and how food and beverage
makers communicate with the public.
As the cover story of this issue states:
Change is the new normal. As consumers
request formulation changes such as elimiJoyce Fassl, Editor in Chief
nating dyes and incorporating more natural
e-mail: fasslj@bnpmedia.com ingredients, I agree this is a step in the right
direction. However, food and beverage manufacturers walk a fine line whenever changes
are made to formulations. Sometimes when
products contain more natural ingredients,
sales take a dive. Consumers may say they
want the real deal in products, but dont
always like the resulting taste.
Another massive change weve seen in

the past decade is the rise of the digital age.
Who would have predicted that Facebook,
Twitter and specialized blogs and websites
would wield so much power over our industry? In addition, digitally savvy consumers
in some parts of the world are food shopping on cell phones. (See pages 72-74 in this
issue.) I cant see myself doing that any time
soon, but I can understand how it might
become the norm in the next 10 years. Here
again, the industry must walk the fine line
between giving consumers too many digital
messages and providing just enough to support their needs.
In the future, I hope the food and beverage manufacturing industry will be successf ul in going far beyond consumer
expectations, but not go so far that it turns
off consumers. In any event, Im sure the
emerging generation of consumers will not
be shy in letting our industry knowdigitally, of courseexactly what they want or
think they want.
Food Engineering Editorial Advisory Board

Bob Reed
Vice President Global Engineering
Kellogg Company
Ed Delate
Vice President,
Global Engineering and
Corporate Social Responsibility
Keystone Foods LLC
David Watson
Vice President-Engineering
Campbell Soup Company
International and Baking
Technology
Sam Casey
Director of Engineering
Keurig Green Mountain, Inc.
Greg Flickinger
Vice President, Manufacturing &
Corporate Engineering
Snyders-Lance Inc.
Diane Wolf
Former Vice President,
Operations and Engineering
Kraft Foods
Daniel Sileo
Plant Manager
SugarCreek
Pete Hock
Senior Director,
Continuous
Improvement
ConAgra Foods
Retrofit:
verb - to install (new parts)

in something previously
manufactured or constructed
You talked. We listened. You wanted easier
sanitation of the gates and you wanted the
sanitation process to be quicker. You wanted
to just retrofit this new gate into your existing
Slipstick Horizontal Motion Conveyors. The
Triple/S Field Service Team had ideas about this
new gate and set out to build one for our Test
Lab. The new Eco-Gate is tool-less and opens
from the side of the conveyor. One major food
manufacturer retrofitted one Eco-Gate as a test
and liked it so much they installed 15 more!
Visit www.sssdynamics.com or call us today
at 1-800-527-2116 and see how our retrofit can
save you time and money.
It was your idea.
Terlotherm
Scraped Surface
Heat Exchanger
The Smart Alternative
CALEN DAR
OCTOBER 2015
19-21: PORK 101; Iowa State University, Ames, IA; American Association of Meat
Processors, American Society of Animal Science, North American Meat Institute Foundation
and the Southwest Meat Association; 800-517-2672, ext. 12; www.meatscience.org
19-21: Basic HACCP: A Food Safety System; Da Vinci Building, Davis, CA; UC
Davis Extension; 800-752-0881; http://extension.ucdavis.edu/agriculture
23-25: PMA Fresh Summit Convention + Expo; Georgia World Congress Center,
Atlanta, GA; Produce Marketing Association; www.pma.com/events/freshsummit
NOVEMBER 2015
8-11: ProcessTechnologyXchange; The Westin Cape Coral Resort at Marina
Village, Cape Coral, FL; VerticalXchange; www.verticalxchange.com/xchanges/
processtechnologyxchange
DECEMBER 2015
2-3: Global Pouch West; Hyatt Regency Orange County, Garden Grove, CA; BNP
Media; 800-524-7225; www.globalpouchwest.com
JANUARY 2016
11-13: Northwest Food & Beverage Manufacturers Expo & Conference;
Oregon Convention Center, Portland, OR; Northwest Food Processors Association; 503327-2200; www.nwfpa.org
Vertical Unit = Small

Foot Print
(5) Times More Surface
Area Than Conventional
Heat Exchanger Equipment
Quick & Easy Maintenance
and Inspection
26-28: 2016 International Poultry Expo/International Production &

Processing Expo; Georgia World Congress Center, Atlanta, GA; U.S. Poultry & Egg
Association, American Feed Industry Association and North American Meat Institute;
678-514-1977; www.ippexpo.com
FEBRUARY 2016
Lowest Operating &

Maintenance Costs
8-11: 20th Annual ARC Industry Forum; Renaissance Orlando at SeaWorld,

Orlando, FL; ARC Advisory Group; 781-471-1175; www.arcweb.com/events/
arc-industry-forum-orlando
Can handle up to 1 inch

particulates
MARCH 2016
Low shear processing
19-22: Snaxpo 2016; Houston, TX; Snack Food Association; 703-836-4500;

www.sfa.org
Test and Rental Units

Available
Used For:
Heating/Cooking
Cooling
Pasteurizing
APRIL 2016
4-7: MODEX Show; Georgia World Congress Center, Atlanta, GA; MHI; 704-676-1190;
www.modexshow.com
10-13: Food Automation & Manufacturing Conference; Sanibel Harbour
Marriott, Fort Myers, FL; Food Engineering; www.foodautomationconference.com
Ideal For:
Sauces, Spreads, Shortenings,
Beverages and Dairy Products,
Confectionery Products, Soups,
Meat and Poultry Products.
Terlet USA
Phone: 856-241-9970
Fax: 856-241-9975
www.terlotherm.com
April 10-13, 2016

Sanibel Harbour Marriott,
Ft. Myers, FL
www.foodautomationconference.com
2016
SAVE THE DATE!
BUTTER
APPLICATION
PANS COATED
COMPRESSED
SOLVED
5 TIMES
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ELIMINATED
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PROBLEMS
AIR USE
SUPERIOR SPRAY. SERIOUS RESULTS.

Butter Application Problems Solved Uneven application of melted butter on dough was causing
serious quality problems for a pastry producer. Solution: An AccuCoat Heated Spray System precisely
controls the temperature of the butter and automatically adjusts flow rate when line speed changes to
ensure the dough is covered uniformly.
Pans Coated 5 Times Faster A bakery using workers to manually apply release agents on sheet
pans was struggling with the slow, imprecise, costly process. Solution: Pans are now coated quickly and
uniformly by an AutoJet spray system as they pass through a spray station. Waste has been eliminated.
Compressed Air Use Eliminated Costly compressed air used in drying operations was a profit drain
for a beverage processor. Solution: WindJet Air Knife and Air Cannon packages that use regenerative
blowers now provide heated air and thorough drying for a fraction of the cost.
May we help you achieve results like these in your coating and drying operations?
Find dozens of results stories at spray.com/results
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See Food Master, p. 114-115
UNMATCHED GLOBAL ENGINEERING, MANUFACTURING & TECHNICAL SUPPORT

NOZZLES | CONTROL SYSTEMS | HEADERS & INJECTORS | RESEARCH & TESTING
CALEN DAR
APRIL 2016
12-14: International Cheese Technology Exposition; Wisconsin Center,
Solutions for Food

Processing and End of
Line Packaging
Milwaukee, WI; Wisconsin Cheese Makers Association; www.cheeseexpo.org
MAY 2016
3-5: International Powder & Bulk Solids Conference and Exhibition; Donald
E. Stephens Convention Center, Rosemont, IL; UBM Canon; 310-445-8535; www.
canontradeshows.com/expo/ptxi14/htp.html
10-12: Food Safety Summit; Donald E. Stephens Convention Center, Rosemont, IL;
BNP Media; 847-405-4000; www.foodsafetysummit.com
17-20: EXPO PACK Mxico 2016; Expo Bancomer Santa Fe, Mexico City, Mexico;
PMMI, The Association for Packaging and Processing Technologies;
www.expopack.com.mx
JULY 2016
Festo offers a complete
range of products,
systems and selected
services for process
automation and factory
automation in the food
and beverage industry.
16-19: IFT Annual Meeting & Food Expo; Chicago, IL; Institute of Food
Technologists; 312-782-8424; www.ift.org
OCTOBER 2016
8-11: International Baking Industry Exposition; Las Vegas Convention Center,
Las Vegas, NV; American Bakers Association and Baking Industry Suppliers Association;
www.ibie2016.com
NOVEMBER 2016
6-9: PACK EXPO International; McCormick Place, Chicago, IL; PMMI, The
Association for Packaging and Processing Technologies;
www.packexpointernational.com
FEBRUARY 2017
13-15: PACK EXPO East; Pennsylvania Convention Center, Philadelphia, PA;
PMMI, The Association for Packaging and Processing Technologies;
www.packexpoeast.com
MAY 2017
2-6: Metpack 2017; Essen, Germany; Messe Essen GmbH; www.metpack.de
4-10: interpack 2017; Dsseldorf, Germany; Messe Dsseldorf North America;
312-781-5180; www.mdna.com
JUNE 2017
13-15: EXPO PACK Guadalajara; Guadalajara, Jalisco, Mexico; PMMI, The
Association for Packaging and Processing Technologies;
www.expopackguadalajara.com.mx
25-28: IFT Annual Meeting & Food Expo; Sands Expo Center, Las Vegas, NV;
Institute of Food Technologists; 312-782-8424; www.ift.org
For more information:

Call: 1-800-Go-Festo
1-800-463-3786
www.festo.com/us/food
Global manufacturer of process control
and factory automation solutions
MARCH 2018
20-23: Anuga FoodTec; Cologne, Germany; Koelnmesse; +49 1806 578 866;
www.anugafoodtec.com
Im really a
production guy
at heart.
Rick OBoyle has been with Ross
for 29 years, but he spent his first
11 years in manufacturing before
moving into technical sales.
This experience gave him a deep
understanding of the real-world
production challenges our
customers face every day.
Ross Regional Sales Managers are all
full-time, salaried experts who will
consider your whole production
environment then suggest the right
mixing technology and equipment
design to meet your process goals.
Contact Ross today to put our

experience to work in your plant.
Call 1-800-243-ROSS or visit mixers.com
Rick OBoyle
Regional Sales Manager
29-Year Ross Veteran
Employee Owner
Scan to learn more.
VISIT US AT
PACK EXPO
BOOTH S-6133
MAKING A
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MANUFACTURING
NEWS
Kraft Foods plans to spend $114
million to add 25,000 sq. ft. to its
Columbia, MO plant, which makes
Oscar Mayer hot dogs. The new facility will begin production in 2016.
Mars Inc. is investing $100 million
at its Topeka, KS chocolate plant
to build an add-on, state-of-the-art
90,000-sq.-ft. manufacturing facility.
Hardywood Park Craft Brewery
will invest more than $28 million to
add 60,000 sq. ft. to its Richmond, VA
facility for brewing, packaging, distribution and a retail center.
The New Hampshire Food Bank
will open a 2,800-sq.-ft. processing
plant within its 60,000-sq.-ft. distribution center in Manchester. The
processing plant, which will accept
donated produce from local farms
and other donated ingredients, will be
the first in Northeast and the second
in the country run by a food bank. It
will begin operation in six months,
making packaged meals and other
products to distribute to food pantries
around the state.
Wisconsin-based Sargento Foods
is investing $30 million to expand its
production facility in Kiel by 80,000 sq.
ft. and its technical center in Elkhart
Lake by 59,000 sq. ft.
Good Foods Group LLC celebrated
the expansion of its Pleasant Prairie,
WI site, which added 40,000 sq. ft.
to its facility in Lake View Corporate
Park. The processor makes guacamole, cold-pressed juices and other
foods.
DOE lists barriers to

saving energy
n 2012,
Manufacturing delivered energy intensity by subsector, 2002-2010
industry
110.0
(comprised
105.0
Paper
Food
of manu100.0
Non-metallic minerals
facturing,
95.0
agriculture,
90.0
Petroleum and coal products
mining and
85.0
construction)
Total manufacturing
Primary metals
accounted for
80.0
Chemicals
about one75.0
t h i rd ( 3 0 . 6
70.0
quads) of the
65.0
USs total pri60.0
mary energy
2002
2006
2010
consumption,
according to
a recently released DOE report entitled The graph shows the food sector as
Barriers to Industrial Energy Efficien- nearly level through the eight-year period.
cy. (A quad is equivalent to 1 quadrillion Sources: Energy consumption from
BTUs.)
MECS, 2010 and ICF Estimates; Industrial
In 2010, the food and beverage indus- Production from Federal Reserve Board,
try was the fifth-largest energy consumer Industrial Production Indices, 2014; DOE.
(1.25 quads) in the manufacturing subsector. While the industrial sector has with VFDs; replace aging motors with
made steady progress in saving energy, the modern, efficient versions.
rate of adopting energy-efficient technol Steam systemsRetrofit existing boilogies and practices could be accelerated ers with economizers; improve steam trap
to reduce energy consumption another maintenance.
15 to 32 percent by 2025, according to
Plant buildingsUpgrade lighting
the report. From 2002 through 2010, (lamps and controls); improve HVAC
some heavy-duty industries significant- maintenance.
ly decreased their energy intensity (the
Process equipmentEnhance process
measure of energy to produce a product). monitoring through the use of sensors and
For example, the chemical industry and controls; improve maintenance schedules
primary metals manufacturers saw the and procedures for process equipment.
greatest decrease, while the food industry
Plan energy management systems
remained relatively flat during the same Adopt management practices and systems
period (see graph).
that optimize energy use across plant locaEnergy efficiency can be achieved across tions; use enhanced data collection for
a diverse range of technologies such as:
more informed decisions that will drive
MotorsRetrofit existing motors down energy use; share results at all orgaIndex of Energy Intensity (2002=100.0)
PLANT OPENINGS
& EXPANSIONS
15
MANUFACTURING
NEWS
nizational levels to emphasize the importance of achieving energy-saving goals.
According to the report, the benefits of implementing these strategies
include reduced energy and emissions control costs, plus enhanced
competitiveness. Co-benefits include
reduced mater ial loss, improved

product quality and reduced water
consumption.
Manufacturers have shown progress in
using energy more efficiently. However,
barriers still impede greater implementation of energy-reduction techniques. The
PREVENT CONTAMINATION
Sonics HEPA Filter

For any plant that has exposed food product, its critical
to have a filtered drying system that keeps the food safe
from contamination during blow off. Sonic Airs in-line
HEPA filter is perfect for your Sonic Air Knife system.
With the HEPA filter at 0.3 micron, you can be sure your
raw product will be safe on the processing line.
Sonics in-line HEPA filter has an airflow rate up to 1000
CFM so it can easily handle large applications without
the need for a second filter.
The HEPA filtration system has a gauge that notifies you
when the filter element needs to be replaced, ensuring
that your filtration system is operating at peak efficiency.
Email Brittney DuFrane today for a complete catalog

bdufrane@marchantschmidt.com
Marchant Schmidt is a distributor for Sonic Air Systems products

exclusively serving the food, dairy and beverage industries worldwide.
SERVING THE FOOD INDUSTRY FOR OVER 52 YEARS

16
economic, financial and regulatory barriers include:

Internal competition for capital
Manufacturers have limited capital available for projects and expect payback in
one to three years.
Corporate tax structuresDepreciation periods and the handling of energy
bills can be a deterrent.
Program planning cyclesCompanies often split costs and benefits for
energy projects between business units,
complicating decision-making.
Failing to recognize efficiencys nonenergy benefits results in under-procurement of energy-related resources.
Energy price trendsVolatile energy
prices create uncertainty in investment
returns.
Utility business modelUtilities lose
interest in promoting energy-efficiency
projects.
Industrial participation in ratepayerfunded energy-efficiency programs
Opt-out or loosely defined self-direct
programs keep manufacturers from participating in traditional energy-efficiency
programs.
Failing to recognize all the benefits
of efficiency results in fewer implementations.
Energy resource planningEnergy
efficiency should be considered as a part of
the integrated resource planning process.
Environmental permittingUncertainty, complexity and costs associated
with permitting processes such as New
Source Review (NSR) keep manufacturers from moving ahead.
The report also lists several informational barriers that slow energy-saving
implementations. For example, unawareness of federal, state and utility incentives;
a lack of disaggregated energy consumption data (e.g., process unit, equipment
level); many manufacturers lack in-house
technical staff to develop energy-saving
projects.
Download the study at http://www.
energy.gov/sites/prod/files/2015/06/
f 2 3 / E X EC - 2 0 1 4 - 0 0 5 8 4 6 _ 5 % 2 0
Study__0.pdf.
REGULATORY
WATCH
Industry ready to do
business with Cuba
Many US food producers and manufacturers have expressed support for the
renewal of diplomatic ties with Cuba.
While the Obama Administration has
established official ties to Havana,
Republicans in Congress have generally balked at the idea of lifting the
trade embargo.
The North American Meat Institute is among the trade groups urging a lifting of the embargo, saying it
supports a bill pending in Congress
that would remove the current prohibition against private financing for
agricultural sales to Cuba.
Devry Boughner Vorwerk, a Cargill
executive who is chair of the US Agriculture Coalition for Cuba, says agribusiness is firmly in the camp for lifting the
trade embargo.
New proposed rule for

Nutrition Facts label
FDA has issued a supplemental proposed rule that would make two minor
changes to the Nutrition Facts label on
food products: It would require declaration of the percent daily value (%DV)
for added sugars and change the current
footnote on the Nutrition Facts label.
FDA says the percent daily value
indicates how much of a nutrient in a
serving of food contributes to a daily
diet and would help consumers make
informed choices for themselves and
their families. The percent daily value
would be based on the recommendation that the daily intake of calories
from added sugars not exceed 10 percent of total calories.
The change to the footnote on the
label would shorten the current wording.
GMA supports federal

approach to food labeling
The US House of Representatives
approved the Safe and Accurate Food

Labeling Act by a vote of 275 to 150
and moved the legislation to the Senate. The measure would establish a
single, unified standard for food to be
labeled GMO free, preempting various state laws.
A federal approach to food labeling

remains the only way to ensure Americans everywhere can access accurate
information about the food they purchase, says Pamela Bailey, president
and CEO of the Grocery Manufacturers
Association.
FAST TANK DRYING SYSTEMS

Sonic
VT Tank
Dryer
Get your tanks, blender,
or totes dry and back in
production in minutes!
Sonic VT features
include:
Adjustable air
temperatures from
100 F to 200 F
without an external
heat source (just its
own blower heat)
Blowers from 3 to 50
HP produce in-tank
air exchanges of
up to 10 times per
minute
Combine the Sonic
VT with a .3 micron
HEPA filter and you
can dry in minutes.
Email
Brittney DuFrane
today for a
complete catalog
bdufrane@marchantschmidt.com
Marchant Schmidt is a distributor for Sonic Air Systems products

exclusively serving the food, dairy and beverage industries worldwide.
SERVING THE FOOD INDUSTRY FOR OVER 52 YEARS

17
MANUFACTURING
NEWS
INDUSTRY & PEOPLE
Bolthouse Farms appointed Scott
LaPorta as president and general manager.
MOCON named Michael Barto vice
president of engineering and manufacturing.
OMRON Corporation has acquired a

100 percent stake in Delta Tau Data
Systems, Inc.
Zeljko Pockaj was named managing
director of Romaco Innojet.
Dorner
Manufacturing
Group
appointed
Dan
Nasato vice presidentinternational
operations.
Ipack-Ima
CEO
Guido
Corbella
announced his retirement.
NASATO
Pat
Graef
was
named president of
ASHRAE.
Peacock Engineering acquired L&L
Foods.
GRAEF
Mitsubishi Heavy
Industries and Mitsubishi Nichiyu
Forklift will purchase UniCarriers
Corporation.
Thomas DiGiannurio
was promoted to vice
president of engineering at Charles Ross &
Son Company.
Stellar completed its
design-build of the $50
DIGIANNURIO
million Nestl Global
R&D Center for the
advancement of frozen and chilled foods.
Adept Technology, Inc. hired Brian
McMorris as vice president of North
American sales for fixed robotics.
ProSoft Technology named Joe Rick
senior director of North America sales.
Booth
C-1847
800.397.8664 www.Dorner.com/FEM
18
Fristam Pumps hired Jim McCoy as

sales manager.
David Dixon joined Faithful+Gould
as program director for the food and
beverage and consumer packaged goods
subsector.
CONVEY
FLEXICON Manual
Dumping Stations allow
dust-free dumping of bulk
material from bags and other
containers. Automatic reversepulse filter cleaning allows
continuous, efficient
operation. Available
with integral bag
compactors for
total dust
containment.
FLEXI-DISC Tubular Cable

Conveyors gently slide fragile
foods and non-foods through
smooth stainless steel tubing
routed horizontally, vertically
or at any angle, over short
or long distances, dust-free.
Single or multiple
inlets and
outlets.
CONDITION
BLOCK-BUSTER Bulk Bag Conditioners
loosen bulk materials that have solidified
during storage and shipment. Variable height
turntable positions bag for hydraulic rams
with contoured conditioning plates to press
bag on all sides at all heights.
CONVEY
PNEUMATI-CON
Pneumatic Conveying
Systems move a broad
range of bulk materials
over short or long
distances, between single
or multiple inlet and
discharge points in low
to high capacities.
Available as dilute-phase
vacuum or positive
pressure systems, fully
integrated with your
process.
USA
sales@flexicon.com
1 888 FLEXICON
DUMP
FILL
SWING-DOWN, REAR-POST
and TWIN-CENTERPOST
Bulk Bag Fillers can fill
one bulk bag per week or
20 per hour at the lowest
cost per bag. Numerous
performance options.
Available to industrial
or sanitary
standards.
DUMP
TIP-TITE Container Dumpers
dump bulk material from drums
(shown), boxes or other containers
into vessels up to 10 ft (3m) high.
Dust-tight (shown) or open chute
models improve
efficiency and
safety of an
age-old task.
BULK-OUT Bulk
Bag Dischargers
unload free- and
non-free-flowing
solids from bulk
bags automatically.
Allows untying,
discharging, retying
and collapsing of
bulk bagsall
dust-free. Available
with weigh
batching controls.
CONVEY
FLEXICON Flexible Screw
Conveyors transport free- and
non-free-flowing bulk solid materials
from large pellets to sub-micron
powders, including products that
pack, cake or smear, with no
separation of blends, dust-free
at low cost. No bearings contact
material. Easy to clean
quickly, thoroughly.
SUCCEED
The FLEXICON Lifetime Performance
Guarantee* assures you of a successful
result, whether you purchase one piece of
equipment or an engineered, automated
plant-wide system. From initial testing in
large-scale laboratories, to single-source
project management, to
after-sale support by a
worldwide network of
factory experts, you
can trust your process
and your reputation
to Flexicon.
+56 2 2415 1286

+44 (0)1227 374710
+34 647 670 302
+61 (0)7 3879 4180

+65 6778 9225
+27 (0)41 453 1871
2015 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.
*See full Lifetime Performance Guarantee for details.
DD-0732
CHILE
UK
SPAIN
AUSTRALIA
SINGAPORE
SOUTH AFRICA
UNLOAD
A FAMILY OF PACKAGING MACHINERY

FROM ONE TRUSTED SOURCE
732.343.7600
www.imadairyfood.com
F O O D PA C K A G I N G
Debra Schug, Features Editor
Pushing away from

petroleum
Coca-Cola unveils the first 100 percent plant-based PET bottle and
begins work on its commercialization.
s more companies continue to beef up

their sustainable manufacturing practices, Coca-Cola has introduced a PET
plastic bottle made entirely from sugarcane. The companys PlantBottle technology is
designed to reduce the amount of petroleum used
in packaging, replacing it with a more sustainable
alternative that is fully recyclable.
PlantBottle packaging is reducing our dependence on fossil fuel and increasing our use of
renewable materials, says Mackenzie Anderson,
environmental communications manager for CocaCola. We focus on delivering the quality beverages
our consumers expect in the most efficient way possible, with a key focus on recyclability, minimizing
resources and increasing the use of recycled and
renewable materials.
PlantBottle packaging was introduced in 2009
as part of the companys vision to develop more
responsible packaging. Its production involves
converting natural sugars found in plants into the
ingredients for making PET plastic bottles. Over
35 billion PlantBottles in the currently available
version, which is made from up to 30 percent plant-
Coca-Colas 100 percent plant-based PET bottle is made from renewable,

responsibly sourced materials and is fully recyclable. Source: The Coca-Cola
Company.
based materials, have been distributed in nearly 40

countries. The company estimates the technology
has eliminated more than 315,000 metric tons of
carbon dioxide emissions and saved more than 36
million gallons of gas.
We know natural resources are stressed, and communities are forced to do more with less, Anderson
says. Since our packaging is the last interaction we
have with our consumers, it needs to remind them of
our commitment to sustainability.
Introduced at the most recent World Expo in
Milan, Italy, the 100 percent plant-based bottles are
not ready to be shipped just yet. The company is
working on a sustainable, commercial solution to
distribute the bottles in more than 200 countries.
We announced agreements with three biotechnology firms to support the move from lab to
commercial scale, says Anderson. These three
companies will help us make a significant step
toward reaching our goal of commercializing PlantBottle packaging made entirely from plant-based
materials with the next few years.
In a larger effort, Coca-Cola has partnered
with a number of companies, such as H.J. Heinz
and Procter & Gamble, to form the Plant PET
Technology Collaborative. This organization
supports research to enable commercially viable,
sustainably sourced, 100 percent plant-based PET
plastic. The company is also a member of the Bioplastic Feedstock Alliance, which was formed to
help companies responsibly select feedstocks for
biobased plastics.
Additionally, Liquid Light, a process technology
company that makes chemicals from carbon dioxide, recently signed an agreement with The CocaCola Company to develop a more efficient way to
use plant materials to make mono-ethylene glycol
(MEG). MEG is one of the components used to
make the plant-based PET plastic bottle.
Katherine Schermerhorn, 404-676-2683,
info@coca-cola.com, www.coca-colacompany.com/
plantbottle-technology.
21
Feeling fresh
iquid water enhancers allow consumers to flavor their water using a

concentrated formula. The category
is only four years old, but it is quickly
becoming crowded and competitive. That is
why Brite Idea Foods wanted a unique packagesqueezeable with one hand and offering
no-drip dispensingfor its all-natural H2wOw
water enhancer.
Company Co-founder Tim Welch told Berlin
Packaging and its Studio One Eleven design agency that the
packaging needed to have a fresh fruit feeling to communicate H2wOws category-first use of real fruit extracts and other
natural ingredients. The final designsmall enough to throw
into a purse or a gym bagmarries a curvy 2.1-fl.-oz. HDPE
monolayer bottle manufactured from a custom Berlin Packaging mold with an Aptar Group stock flip-top Mini Sense PP
closure and a full-body, tamper-evident shrink sleeve decorated
to showcase the fresh message.
The bottle is palm-sized and features a pinched waist, giving
H2wOw a distinctive shape. The closure incorporates an Aptar
SimpliSqueeze silicone flow control valve to deliver spill-proof
22
H2wOw label graphics are dominated by images of the freshcut fruits and vegetables in the Ginger Lime, Lemon Spearmint,
Mandarin Grapefruit and Cucumber Lemongrass flavors. Source:
Berlin Packaging.
use and protect against leakage, even when the cap is left open.
The bottle and closure are sourced and supplied by Berlin
Packaging. The label is supplied by Century Labels of Bowling
Green, OH.
Andrew L. Gilbert, 978-462-0604,
andy.gilbert@berlinpackaging.com, www.berlinpackaging.com.
The New Path to Profitability
DirectDrive Self-Stacker
Achieve simplified self-stacking with the Intralox DirectDrive
Self-Stacker System. Based on a proven, patented technology,
this lightweight modular plastic solution saves floor space, provides
for horizontal air flow, minimizes incidences of de-stacking,
and ensures hygienic performance.
The award-winning Intralox

DirectDrive technology enhances
carrying capacity and ensures reliable
product orientation.
Visit us at our upcoming trade shows to see this soon-to-be-released technology in action:
PROCESS EXPO 2015
September 15-18
Chicago
Booth #1210
PACK EXPO 2015

September 28-30
Las Vegas
Booth C-3336
New liners for

wine
vailable globally, the Tri-Seal Tri-Vin laminated

aluminum foil/foam barrier liner is engineered for
roll-on pilfer-proof (ROPP) wine closures. It supports the aging of wine and promotes drinkability
while cutting costs and protecting the environment. (Tri-Seal is a
division of Tekni-Plex, Inc.)
Tin/Saran barrier liners are more commonly used for ROPP
wine applications, but the new liner is a cheaper, environmentally friendly option that can easily replace them. Permeation
tests were conducted by an independent laboratory to compare
the performance of the laminated aluminum foil/foam barrier
liner with that of alternate materials currently in use. In addition, the Australian Wine Research Institute carried out sensory
organoleptic testing on the Tri-Vin liner.
We invested significant resources to develop a cost-effective
wine liner with the performance characteristics of tin/Saran liners, while preserving the wines aroma and taste, explains David
Andrulonis, vice president and general manager of Tekni-Plex.
The Tri-Vin liner performs in the oxygen sensitivity range that
allows wine makers to cost-effectively maintain the drinkability
An aluminum foil/foam lamination has been engineered to

replace the tin/Saran barrier liners commonly used for ROPP
wine applications. Source: Tekni-Plex.
window for consumers, according to Andrulonis. In addition,

since the structure is halogen and chlorine free, the aluminum
foil/foam combination is environmentally desirable.
Tri-Seal has been developing extrusion and lamination technologies, as well as sealing applications, for food and beverage
packaging for more than 50 years. It manufactures liners in a
variety of materials, ranging from nine-layer coextrusions and
laminations to a one-piece induction seal.
David Andrulonis, Tekni-Plex, Inc., 419-491-2402,
filmsnorthamer@tekni-plex.com, www.tekni-films.com.
Designers and Manufacturers of

Quality-Affordable Packaging Machinery
Precision PMD Complete Packaging
Systems: We design and manufacture
everything from container D-Nesters,
Conveyors, Piston Fillers, Volumetric Pocket
Fillers, Container Sealers and Lid Applicators
Cup & Tray Application Expertise:

Cereal, Oatmeal, Nuts, Candy, Mac &
Cheese
Soup, Salsa, Humus, Pudding, Fruit
Cocktail, Applesauce
Fresh Salad including Spinach,
Spring Mix
Macaroni Salad, Cole Slaw
Family Meals, Frozen Entrees,
IQF Vegetables and more
Toll Free: 877-567-PPMD (7763)
Contact Precision PMD Today!

Email: sales@precisionpmd.com or
Visit us at
Booth #S-6125
Visit: www.precisionpmd.com
9009 Freeway Drive, Unit 7 Macedonia, OH 44056
24
precision half horiz.indd 1
8/19/15 11:07 AM
EXACTLY WHAT YOURE

LOOKING FOR.
From fill-level monitoring to x-ray and vision inspection, Peco InspX is the full range supplier of high
performance inspection equipment. Its no surprise that 40 of Americas Top 50 food companies rely on Peco
InspX to protect their brands reputation and ensure their customers safety.
X-RAY SYSTEM
Full range of top-down and
side-view platforms for
packaged and rigid containers
Advanced imaging
technology maximizes
performance
FILL-LEVEL
VISION SYSTEM
Best in class accuracy for

fill-level and headspace
Advanced learning
algorithm makes setup easy
High speed operation
Proven cap, label and

product verification solutions
Expertise with challenging

applications
Superior X-Ray service

team and advanced remote
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High performance with

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Expertise with glass in

glass detection
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Proudly made in Silicon Valley, USA
ADVANCED NSF H1 REGISTERED
SYNTHETIC
LUBRICANTS
MADE ESPECIALLY FOR THE FOOD
PROCESSING INDUSTRY
Engineered from the ground up to provide unsurpassed performance
in food processing plants. These high performance, 100% synthetic
lubricants provide extended lube intervals, multiple application
capability, lubricant inventory consolidation and improved
performance. All while maintaining strict H1 safety requirements.
SFGO ULTRA SERIES - MULTI-PURPOSE FLUIDS

100% Synthetic (PAO)-Based, Multi-Purpose, Fluids.
Extremely Versatile, Recommended for Air Compressors,
Hydraulic Systems, Bearings, Gearboxes and Chains.
Available in 13 ISO viscosity grades.
SYNXTREME FG SERIES GREASES

100% Synthetic, Calcium Sulfonate Complex Type Greases.
Super Multi-Purpose, Ideal for a Variety of Applications.
Excellent Anti-Wear and Extreme Pressure Protection.
High Temperature Stability - Effective to 450F.
PGO-FGL SERIES GEAR LUBRICANTS

Ultra High-Performance, Advanced, Polyalkylene Glycol
(PAG)-Based Gear Lubricants.
The Ultimate Gear Lubricants for Demanding Applications.
Backed By:
Lubriplate
ESP
Extra Services Package

Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755
www.lubriplate.com / LubeXpert@lubriplate.com
Plant Surveys / Tech Support / Training

Color Coded Lube Charts & Machine Tags
Lubrication Software / Follow-Up Oil Analysis
FOOD SAFETY
Time to use some common-sense

protocols
Food and beverage processors should commit to properly

evaluating equipment and process changes by doing it right
the first time around.
ts a sad fact that some food processors still buy

equipment based simply on price and the ability to produce a product. But, cleanability, ease
of maintenance, safe operation, user friendliness and other factors should be considered when
purchasing equipment.
The American Meat Institute assembled an expert
panel a few years ago and developed 10 basic principles of the sanitary design of equipment used for
ready-to-eat products:
1. Cleanable to a microbiological level
2. Made of compatible materials
3. Accessible for inspection, maintenance, cleaning
Richard F. Stier,
and sanitation
Contributing Editor
4. No product or liquid collection
5. Hermetically sealed hollow areas
6. No niches
7. Sanitary operational performance
8. Hygienic design of maintenance enclosures
9. Hygienic compatibility with other plant systems
10. Validated cleaning and sanitizing protocols.
However, these principles apply to all food processing equipment, not just those pieces used for
ready-to-eat goods.
AMIs website includes a checklist for evaluating
equipment that can be accessed at https://www.meatinstitute.org/ht/a/GetDocumentAction/i/97261.
Each of the above 10 points has five to 15 sub-elements. For example, validated cleaning and sanitizing protocols include:
Cleaning and sanitizing are considered in the
design process.
Cleaning protocols must be safe, practical, effective and efficient.
Cleaning and sanitation protocols have
been developed by the manufacturer, validated
and provided in a training manual that is easily
read and understood by cleaning and sanitation
employees.
Equipment design and materials are capable of

withstanding standard cleanup procedures, and the
MSDSs for the cleaning and sanitizing chemicals have
been reviewed to ensure compatibility. Special deepcleaning should be scheduled based on indicators
such as mean time failure analysis.
All equipment components including belts and
product contact components should be able to withstand heating to 160F for up to 30 minutes. Procedures to protect sensitive components included in the
manufacturers procedures should be followed.
One of the basic requirements for many companies
is a mandate that a third party must approve their
equipment for use in food processing. USDA evaluates equipment used in meat and poultry operations.
Organizations such as 3A Sanitary Standards (http://
www.3-a.org/) and EHEDG (European Hygienic
Engineering and Design Group) (http://www.ehedg.
org/) have established sanitary and hygienic standards for equipment and list those that pass muster.
However, there is a basic issue that goes beyond sanitary designprogram maintenance. Buying equipment that is easy to clean and maintain is only part of
the equation; the programs to properly maintain and
clean equipment must be scrupulously adhered to. In
addition, managers must ensure these programs are
properly developed, documented, implemented and
maintained. This also includes sufficiently training
staff to do the work and documenting the training
was not only completed, but the staff members fully
understand what they are doing and why.
In addition, food processors should establish basic
guidelines for evaluating and purchasing new equipment. Setting up the program is part of the food safety
management system and should also be part of the
organizations continuous improvement program.
In fact, the program should be all inclusive when it
comes to food processing and handling equipment.
Every change or tweak to equipment should be evalu-
27
FOOD SAFETY
ated prior to making it. Far too often, companies make changes in
line layout or operations only to learn they have had an adverse
effect on food quality, food safety or operational efficiencies.
A wise processor will set up a program to take an in-depth look
at any change to processing operations, whether it is a tweak or a
new equipment purchase. Subjecting any change to a rigid evaluation before it is made will determine whether it will be feasible
and effective.
If management decides the plant requires new equipment to
meet the needs of existing or new customers or as a means of
enhancing quality and safety programs, the following procedures
should be followed:
Top management should review the need for change with key
plant and management personnel (treasurer, production manager, quality supervisor and the food safety team or a designated
member) and discuss options for improvement. Notes of the
meeting should be maintained.
Management should assign staff to research equipment,
materials or proposed changes to ensure they meet the needs
of the plant. This research would include identifying potential
equipment and suppliers, and how the changes would be made.
This step is where the FMEA concept comes in handy; if the
results of the FMEA indicate a potential change poses a potential
risk to the business, that option would be eliminated or modified
to address the identified risks.
Once the equipment has been selected, the team should

review specifications and pricing, and rate the materials. Notes of
this meeting should be maintained.
An individual should be designated to visit one or more facilities that use the equipment or materials to evaluate performance.
Notes from the trip should be prepared and filed. (This is often
a challenge since an individual may not be allowed into a competitors facility.) The focus of this exercise is to not only select
the right equipment but to ensure the equipment will pose no
significant risks to the business.
Some companies take this process a bit further. Instead of
accepting what the equipment manufacturer offers, they work
hand-in-hand with the company to further improve the existing equipment. These tweaks then become the property of the
food processor.
All of this may seem like a great deal of effort, but going
through this process is worth it. Equipment that meets the
10 previously highlighted principles, and is easy to operate,
maintain and clean, can provide significant economic benefits
such as improved operating efficiencies, reduced operating
costs and enhanced product quality. However, managers must
ensure the established systems are adequately maintained.
Food and beverage processors should commit to properly
evaluating equipment and process changes by doing it right
the first time around.
To Keep Metal Out of Your Food, Call Bunting.
quickTRON 07 RH Hygienic
Metal Detector
For the inspection of material in
gravity free fall applications.
See us at the following shows
Bunting Magnetics provides food processors

the most complete, innovative line
of metal detection, separation
equipment, and more.
Manual Self-Cleaning HF Series
Drawer Magnet
For the removal of ferrous tramp metal in gravity
free-fall applications.

Chicago, IL USA
Food Processing
Booth #2640
Suppliers Association
Booth #S-5907
The Leader In Moving & Removing Metal For Over 50 Years
28
316-284-2020
buntingmagnetics.com
2015 Bunting Magnetics Co.
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Call 1-855-754-7659 Today

or visit us online at www.polytron.com/lp/fam-2015
TECHNOLOGY
S O U R C E B O O K
Focus on Checkweighing & Metal Detection

and Spraying & Washing Equipment
ALL-INONE VFD
SANITARY GRATE MAGNETS

MAG-RAM self-cleaning grate magnets collect ferrous metal fragments without human interaction; the design pneumatically retracts magnet rods, rotates them and wipes the magnetic
materials to the end and into a collection chamber. The automatic cleaning can take place during production and before or after production runs. Applications include the extraction of workhardened stainless steel, wear iron and tramp metal from sugar, grain and other bulk products.
Powder-Solutions Inc.; 877-236-3539; www.powder-solutions.com
Combining traditional induction and permanent magnet motors, the Mitsubishi A860
600V all-in-one VFD provides speed, torque
and positioning control for standard 3-phase
motors. It controls shock loads experienced
in machine tools and in lifting and hoisting
applications.
Mitsubishi Electric Automation, Inc.;
us.mitsubishielectric.com/fa/en/
THE MISTCOATER
Better coating
Less downtime
Fully enclosed unit provides easy housekeeping
Easier cleaning and maintenance for less risk
of contamination
Spinning disks atomize the liquid to eliminate
clogged nozzles
PROCESSING THE INGREDIENTS FOR SUCCESS

+1 (616) 374-1000 www.apecusa.com
31
TECHNOLOGY
S O U R C E B O O K
FIBER LASER CODERS

Delivering a fine spot size for permanent codes, Linx fiber laser coders are suitable for a variety of materials used in static applications
and moving production lines. They produce small, discreet codes for
traceability or anti-counterfeiting purposes, bigger codes for highprofile branding or promotions and large amounts of information in a
small area. The coders feature a range of fonts, codes and graphics.
Linx Printing Technologies Ltd; www.linxglobal.com
LARGE-TUBE MAGNETIC SEPARATOR

Engineered for high-flow liquid processing applications, the IMI
T-Trap magnetic separator has 1 large-tube magnet that provides
direct, in-the-flow contact of the product to the magnetic tube. The
separator is typically placed in front of pumps, screens and mills to
ensure product purity and protect plant equipment. Available in 1
1/2- to 6-in. line sizes, the unit can be installed in horizontal, vertical or sloped line orientations. It is intended for liquids, pures and
products that may contain small solids, such as juices, applesauce
or cottage cheese.
Industrial Magnetics, Inc.; 231-582-3100;
www.magnetics.com
PALLET TRUCK
The Raymond Model 8210 walkie pallet truck features AC technology, static torque control, a ductile iron frame and undercarriage
components, and stainless steel undercarriage pins. It comes standard with IP65 protection of its electronics; a range of options for
harsh environments is available.
The Raymond Corporation; 800-235-7200; www.raymondcorp.com
TANK TOP BEARINGS

Hercules Engineering Herculon Type D tank top bearings are installed
under the roof beams of tank tops and other lighter structures in the
food and beverage industries to support them and prevent them from
cracking and breaking. The bearings consist of a thin, stainless steel
slide plate with 2 stainless steel studs flash welded to the upper face.
The plate has 2 slotted holes for uplift through-bolts.
Hercules Engineering; www.hercules-engineering.com
TECHNOLOGY
S O U R C E B O O K
Why should
you filter
your water?
Tekleen Filters will save you
time and money spent every
day in the labor of cleaning
and replacing screens,
spraying nozzles, spraying
bars, heat exchangers, sand
media tanks, sprinklers and
many more.
INVERTING FILTER CENTRIFUGE

The Heinkel inverting filter centrifuge features an axially moveable
filter cloth that can be inverted while under rotation; the filter cloth
remains free of residual cake heel while a totally enclosed, gastight
system is maintained. Capable of thin cake filtering and direct contact
drying of the material, the centrifuge provides homogenous cake
structure and automatic cake discharge.
Heinkel USA; 856-467-3399; www.heinkelusa.com
SORTING, PEELING &

PROCESS ANALYTICS
SOLUTIONS FOR THE
FOOD INDUSTRY
2672 S. La Cienega Bl vd
Los Angeles, C A 90034 USA
(800) 336-1942 (310) 839-2828
www.t ekleen.com inf o@t ekleen.com
TOMRA Sorting Solutions is a leading provider

of sensor- based food sorting machines and
food processing technology for the fresh and
processed food industries. Developing stateof-the-art technologies, optimizing customers
production flow and helping to deliver
consistent high quality food have been
TOMRAs strengths for more than 40 years.
VISIT US AT
PACK EXPO
2015
BOOTH S-8033
www.tomra.com/food
food-sorting-us@tomra.com
33
TECHNOLOGY
S O U R C E B O O K
MULTI-SPECTRUM METAL DETECTOR

Able to detect smaller particle sizes of ferrous, non-ferrous and AISI
316 stainless steel, the CEIA THS/MS21 multi-spectrum metal detector eliminates false rejects caused by product effect conditions. The
auto-learn system selects, displays and stores the optimal sensitivity
settings for hundreds of products. The metal detector has an IP69K
rating for high-pressure, high-temperature washdown protection.
Heat and Control, Inc.; 800-227-5980;
www.heatandcontrol.com
PNEUMATIC CYLINDERS
Constructed with an extruded aluminum body, Bimba MFD compact
double-acting pneumatic cylinders come in 10 bore sizes and a range
of standard stroke lengths; they are available with a magnetic piston
to enhance position sensing. Suitable for a variety of automation
processes, the cylinders are globally interchangeable with industry
alternatives.
Bimba Manufacturing Company; www.bimba.com
New!
New!
Rare
Rare
Earth
Earth
MAGNETIC
MAGNETIC
SEPARATORS
SEPARATORS
RE7
RE7
RARE
RARE
EARTH
EARTH
MAGNETIC
MAGNETIC
SEPARATORS
SEPARATORS
See
See
Head-to-Head
Head-to-Head
Comparisons!
Comparisons!
BoothBooth
S-5901
S-5901
BoothBooth
62006200
TECHNOLOGY
S O U R C E B O O K
WASHDOWN CHECKWEIGHER
Featuring production monitoring and control, the METTLER TOLEDO
C3572 checkweigher incorporates stainless steel conveyors with
an open, accessible frame design. Built for food production areas
with heavy washdown requirements, it offers a weighing range up
to 4,000g with an accuracy of +/-200mg at speeds up to 300 ppm.
Standard features include electromagnetic force restoration weigh
cell technology and a conveyor support structure with 4 solid tubes.
Optional infeed timing and spacing conveyors, reject mechanisms
and stainless steel locking reject bins are available.
METTLER TOLEDO Hi-Speed; www.mt.com/hi-speed
ROTARY HEAD BELT WASHER

The Douglas Cyclone rotary head belt washer washes and removes
allergens from belts. Designed for a variety of open mesh spiral conveyors, freezer tunnels and oven belts, the unit has a spray head with
high-pressure rotating nozzles that cut and remove stubborn soils
from the top and bottom of a belt simultaneously. A portable cart
allows the washer to be moved from 1 belt to another.
Douglas Machines Corp.; 727-461-3477;
www.dougmac.com
When
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designed
designed
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its new
RE7RE7
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magnetic
magnetic
separators
separators
to extract
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and and
eveneven
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magnetic
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intended
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for applications
demanding
demanding
the highest
the highest
levels
levels
of product
of product
purity.
purity.
Purity.Eriez.com
Purity.Eriez.com
888.300.3743
888.300.3743
STRONGEST
MAGNETIC
TECHNOLOGY
S O U R C E B O O K
TUBE DESIGN
IN THE INDUSTRY
THE BULLET
MAGNET
(PNEUMATIC LINE
SEPARATION
MAGNET)
METAL DETECTOR CONVEYORS
FEATURING
Sesotec Rapicon metal detector conveyors include modular components, standard reject systems
and a range of aperture sizes. A fully welded construction, combined with GHF or GLS metal
detection technology, provides a food-safe platform and the detection of small pieces of metal.
Sesotec Inc.; 224-208-1900; www.sesotec.us
52 MGOE
dles hundreds of products per minute with

a potential accuracy of +/-.01g, depending
on the application. Adopting a 2-frequency
magnetization detection method, the systems detect ferrous and stainless metals at
the same time, independent of each other.
Anritsu; www.detectionperfection.com
RARE EARTH
MAGNET MATERIAL
We utilize the strongest,

most stable, commercially
available magnet material
in our Industry leading metal
separation products to
provide the most effective
magnetic separation
solutions available.
ULTRASONIC CLEANER
CHECKWEIGHER/METAL
DETECTORS
Anritsu CW and MD systems combine
checkweighing and metal detection in 1
package; they provide the 2 functions simultaneously. The integrated checkweigher han888.582.0821 ~ www.magnetics.com
With a 24-gal. main tank capacity and

horizontal transducers, the Ultrasonic Ultra
2400FA ultrasonic cleaner requires no solvents. It features an agitation table, dual
filtration, 6-gal. weir tank, sparge bar and
insulated tank and lid; the side-mounted
transducers eliminate dead spots for consistent cleaning. The cleaner offers 1,920W of
ultrasonic power and a 22- x 11- x 5 1/2-in.
basket capacity. A 7-day heat and auxiliary
timer allows programming to suit production
requirements.
Ultrasonic LLC; www.ultrasonicllc.com
TECHNOLOGY
S O U R C E B O O K
METAL DETECTOR
Manufactured for challenging applications, the Fortress Interceptor
NEMA 4X-/IP69K-rated metal detector uses a simultaneous multifrequency operation that processes the transmission and reception of multiple frequencies continuously over a broad spectrum.
Constructed of stainless steel, it features ARM processors, a noiseimmunity structure, single-pass product learn, automatic product
tracing and contact reporter software. Typical applications include
bakery, meats, dairy, prepared meals, confectionery, fresh foods,
frozen foods, powders and grains.
Fortress Technology Inc.; 888-220-8737;
www.fortresstechnology.com
BELT CLEANING SYSTEM

The AmeriVap Houdini jet system automatically cleans continuous
mesh interlocking belts while they are in operation; it dislodges any
accumulated debris and sanitizes with super-heated saturated dry
steam vapor. Designed as a portable solution, the unit is constructed
with corrosion-resistant materials and a water-resistant stainless
steel enclosure. It is powered by an industrial steam generator that
continuously delivers 150 psi.
AmeriVap Systems, Inc.; 800-763-7687;
www.amerivap.com
MEASUREMENT/DETECTION SOLUTION
Designed as a multi-application system, the Eagle FA3/M inline fat
measurement and contaminant detection solution handles various
forms of meat product including fresh, hot-boned, chilled and frozen.
It uses dual energy X-ray absorptiometry technology to discriminate
between fat and lean in meat products with 100% throughput. When
used in collaboration with Eagle SimulTask inspection software, the
system can inspect over 2,400 plastic crates or frozen blocks per hour
or up to 35 tons of bulk meat per hour.
Eagle Product Inspection; www.eaglepi.com
TECHNOLOGY
S O U R C E B O O K
LOW-LINT CLEANING CLOTH

Designed for lint and static electricity-sensitive industries such as food processing, the SCA
Tork industrial low-lint cleaning cloth is used for cleaning, sanitizing and disinfecting surfaces,
tools and equipment. It offers absorbency for working with water, solvents, sanitizers and disinfectants.
SCA; www.sca.com/us
DATA LOGGERS
Compact and portable, Omega OM-90 series
data loggers feature an immediate, delayed
(specific date/time) or pushbutton start; a
real-time mode; user-configurable high and
low alarms; LED status indicators; and a
USB interface for data transfer. The OM-91
version is used to log temperature, while the
OM-92 model logs temperature and relative
humidity.
Omega; 800-TC-OMEGA
WIRELESS PRESSURE
TRANSMITTER
Designed to connect wirelessly to virtually any iPhone or iPad, the GP:50 iDucer
Bluetooth wireless pressure transmitter
measures pressure values from 0 to 1
psi through 0 to 30,000 psi with +/-0.2%
FSO standard accuracy. The supplied iOS
application software allows all collected
data to be downloaded, analyzed and
stored for future use. The unit features
all-stainless steel wetted parts and housings, as well as 1/4-in. NPT (M) standard
process connections.
GP:50 NY LTD; 877-774-4781;
www.gp50.com
38
TECHNOLOGY
S O U R C E B O O K
TRAPPED KEY INTERLOCKS

Enhancing lockout/tagout procedures, KIRK trapped key interlocks ensure energy isolation
procedures cannot be circumvented. Once the key is removed from the interlock, the equipment
cannot be re-energized until the uniquely coded KIRK key is re-entered into the sequence. A
time delay unit can be added to allow hazardous energy to dissipate prior to allowing access.
Kirk; 800-438-2442; www.kirkkey.com
Efficient and durable

utility heating
TANK WASHING
NOZZLE
The BEX TWK molded tank washing nozzle provides 360 and 180 rotation in a
PVDF construction. Operating at up to 80
psi, the self-lubricating nozzle is suitable
for vessels up to 10 ft. in diameter. The
nozzle flow ranges from 1.77 gal./min. at
5 psi to over 7 gal. at 80 psi. Able to be
installed in any orientation, the nozzle
can be used for keg and tank washing,
small tank rinsing, machine clean-inplace and food processing applications.
BEX Incorporated; 734-389-0464;
www.bex.com
MULTI-TOUCH PANEL PCs

Beckhoff CP32xx industrial multi-touch
panel PCs automate HMI and control
applications. Engineered for mounting
arm installation, they feature all-around
IP65 protection. The connecting cables
are laid through the support arm into
the connection compartment for up to 6
IP65-rated connectors. In the basic configuration, 2 of the connection points are
configured with an Ethernet interface or
power supply; the remainder are optionally available for a mini-PCI fieldbus
interface or a further Ethernet, USB or
serial interface.
Beckhoff Automation LLC; 877-TwinCAT; www.beckhoffautomation.com
Alfa Laval has the most complete range of gasketed plate heat exchangers
(GPHE), from potable water or glycol heating and cooling to hygienic hot water
sets. All GPHEs are backed by our leading technology and support.
Alfa Laval M-Series is an efficient solution for general heating and cooling in
hygienic applications. Its also the perfect alternative for heating and cooling
service media.
Alfa Laval TS6 is designed exclusively for steam-to-liquid heating. The
unique plate geometry, combined with heavy-duty gaskets, makes it ideal for
heating water or cleaning-in-place solution.
See our complete range

of heat exchangers:
www.alfalaval.com/gphe-us
39
TECHNOLOGY
S O U R C E B O O K
FILM SPLICER
Used in printing and packaging applications, the Butler Automatic 1000 Series automatic film
splicer run at speeds up to 1,400 ft./min. and can handle non-woven substrates up to 64-in.
wide without interrupting production. It features a roll-over-roll design and does not require a
pit for installation.
Butler Automatic; 508-923-0544; www.butlerautomatic.com
FG Elite
Extended Life
Food Grade
Air Compressor Oil
MULTI-SHAFT MIXER
Up to 10,000 hours of
Dependable Service
Summits FG Elite is a combination of synthetic base fluids

and additives engineered for the increased performance of
food industry rotary screw, rotary vane and reciprocating air
compressors. Summits FG Elite lubricant benefits include:
Up to 10,000 hours depending on operating conditions
Increased solvency reduces deposit and sludge formation
Superior protection against rust, wear and corrosion
Meets the requirements of NSF H1 registered lubricants
Manufactured in an ISO 21469 certified production facility
ISO Viscosity Grades of 32, 46, 68, 100 and 150
Summit
Industrial Products
800.749.5823
www.klsummit.com www.sublimedescaler.com 903.534.8021
40
Featuring a 2-wing anchor, gate agitator and

high-speed disperser, the Ross VersaMix
Model VMC-1000 multi-shaft mixer has a
1,000-gal. working capacity. Each agitator
is independently driven, imparting a range
of mixing intensities and flow patterns as
the product changes rheologically throughout the batching cycle. An air/oil hydraulic
lift raises and lowers the entire agitator
assembly. The mixer rotates 90 and can be
raised or lowered for cleaning and servicing.
Built for atmospheric or vacuum/pressure
operation, it is available with options such
as a jacketed vessel, powder loading chute,
sight ports, automated discharge valves, tank
lights, thermoprobes, a temperature control
unit, vacuum pump, discharge system and
PLC recipe controls.
Charles Ross & Son Company; 800243-ROSS; www.mixers.com
AIR SYSTEM MANAGER

A master control system for all compressed
air production and treatment components,
the Kaeser Sigma Air Manager 2 unit optimizes pressure values, automatically adjusts
system air delivery to accommodate fluctuating air demand and constantly analyzes the
relationship between control losses, switching losses and pressure flexibility. Built-in
maintenance reminders and messaging
capabilities enable predictive maintenance.
Kaeser Compressors; 877-586-2691
A&B provides exceptional concept to completion

services however we also provide the same
exceptional service to clients retrofitting
or expanding an existing system.
Whether you need a small single tank, a transfer
panel, or any single component A&B is here to help!
We will work closely with you to make sure your
expansion or update is seamless.
Our outstanding staff of designers and engineers
will take the time to understand your needs and
provide you innovative and cost-effective solutions.
Storage Tanks
Batch & Blending Systems
VacuShear Mixing Systems
Balance Tanks
CiP Tanks
Hold Tubes
HTST Systems (Modules)
CIP Systems
Transfer Panels
Melt Systems
Modular Process Systems
Platforms
Piping Installation Services
compliant process/storage vessel designs
Please call 888.258.2789

or visit us at
www.abprocess.com
for a virtual tour of our campus
TECHNOLOGY
S O U R C E B O O K
BLAST CHILLERS
Floor standing models, Master-Bilt reach-in blast chillers are designed for high-capacity input.
Each exterior wall is 2.95-in. thick. The MBC80-8A model chills 80 lb. of product, while the
MBC113-6A version chills 113 lb. of product, from 194F to 37F in 90 min.
Master-Bilt; 800-647-1284; www.master-bilt.com
Trust the Product Inspection Industry Leaders

METTLER TOLEDO helps manufacturers ensure product quality,
increase productivity, and protect their customers and brand.
TANK CLEANING NOZZLE
Metal Detection
Designed for the food and beverage industry, the Lechler XactClean HP tank cleaning
nozzle features controlled rotation. The flat
fan nozzles provide high-impact, uniform
cleaning to remove difficult soils. The nozzle
can operate in any direction.
Lechler Inc.; 800-777-2926; www.lechlerusa.com
X-ray Inspection
INDUSTRIAL ROUTER
Checkweighing
PACKAGING
PROCESSING
ONE
POWERFUL
SHOW.
PACK EXPO International

Machine Vision
Connectivity
See live demonstrations on new equipment

in Booth C1814!
4www.mt.com/pius-packexpo
Las Vegas Convention Center
Booth # C1814
42
The KEB COMBICONTROL Ethernet-based

C6 industrial router comes with WAN, LAN,
USB and serial interfaces, as well as standard digital I/Os; for hard-to-access installations, a cellular network option is available.
The router includes standard 2G/3G/3G+
EDGE/HSPA quadriband capable of speeds
up to 5Mbps up/14Mbps down. The unit is
housed in a stainless steel enclosure ready
for DIN rail or wall mount.
KEB America, Inc.;
www.kebamerica.com
BOWL CUTTER
The TIPPER TIE TTChop33 industrial bowl
cutter features a 330L bowl size, AC motor,
integrated stainless steel switch cabinet and
an ejector with an inexpensive wear ring.
Suitable for midrange production, it is available with vacuum, a cooking function and
CO2 or nitrogen cooling capability.
TIPPER TIE, Inc.; 919-362-8811;
www.tippertie.com
Sanitary
Belt ConveyorS
reduCe
Clean-Up time
proven Design. Durable Construction.

Meyer Sanitary Belt Conveyors combine proven designs with durable, highly
sanitary construction that results in a dramatic reduction in clean up time
compared to modular belting.
Highly Sanitary. time-tested Results.

ideal for heavy wash down environments, these units are available in a wide
range of sizes and configurations to accommodate the inspection, storing or
transporting of products.
Contact Meyer industries today for more information on all their bulk material handling and food processing equipment.
Vibratory Conveyors
Sanitary Belt Conveyors
Visit Us at Booth 7401
210.736.1811 www.meyer-industries.com
3528 Fredericksburg Rd. San Antonio, TX 78201
Bucket elevators
Vibratory Weighers
TECHNOLOGY
S O U R C E B O O K
INDUSTRIAL PRINTER
The SATO CL4/6NX-J series Internet of Things label printer features universal functionality and
design with plug-and-play connectivity and multiple languages. Compatible with the SATO
Online Services cloud-based maintenance solution, it offers remote monitoring and preventative
maintenance.
SATO; www.satoworldwide.com
Smarter
Bagging.
the X-Series VFFS Baggers
ROTARY JET MIXER
Able to handle liquid and powder mixing,
gas dispersion and tank cleaning-inplace applications, the Alfa Laval rotary
jet mixer can be used in tanks between
100 and 800,000L in size. Equipped with
2 or 4 nozzles, the mixer is positioned
below the liquid level in a tank. Liquid
is withdrawn from the tank outlet by a
pump and circulated via an external loop
to the mixer.
Alfa Laval; www.alfalaval.com
LINEAR ACTUATOR
scan this code with your smartphone
Smarter. With features such as quick

changeover, optional Ultrasonic sealing,
and integrated zipper applicators, Triangles
X-Series VFFS baggers are nothing short of
brilliant. Cleaner design. Faster production.
Built for the standards the industry and
your customers demand, and backed by the
best service and support team.
44
800.621.4170
www.trianglepackage.com
See Us at Pack Expo

Las Vegas Booth 2620
Providing an advanced positioning

capability, the Duff-Norton CMLA linear actuator features IP66 protection
for interior and exterior applications,
a stainless steel translating tube for
corrosion resistance, an anti-rotational
outer tube and lightweight cast aluminum housing. It comes in configurations from 500 to 2,000 lb. The motors
are available in single- and 3-phase
AC voltages, paired with a selection of
gearing in each load category to provide
a range of lifting speeds.
Duff-Norton; 800-477-5002;
www.duffnorton.com
TECHNOLOGY
S O U R C E B O O K
MAGNET ASSEMBLIES
Suitable for applications where a surface is easily marred, Winco RoHS-compliant GN 51.6
steel-retaining magnet assemblies are comprised of a shielded magnetic assembly with a black
elastomer (TPE) jacket and 2 internal threads. The magnet housing is made of zinc-plated steel,
while the magnet is made of neodymium, iron and boron (NdFeB).
J.W. Winco, Inc.; 800-877-8351; www.jwwinco.com
SINCE // 1855
FORM/FILL/SEAL
BAGGER
Built for the snack food sector, the BVR
230 VFFS continuous vertical form/fill/seal
bagging machine includes an integrated
weigher, rotating sealing tool arrangement
and separately driven cutting knife. Compatible with a range of film qualities, it produces
up to 180 pillow bags/min.
Rovema GmbH; www.rovema.com
TANK CLEANER
Able to remove stubborn residues from vats,
blenders, tanks and more, the Spraying Systems TankJet 360 high-impact tank cleaner
is suitable for vessels up to 100 ft. in diameter. The solid stream nozzles rotate 360
in horizontal and vertical planes to create
a crisscrossing pattern that cleans all the
interior surfaces; dual- or triple-nozzle hubs
are available. Designed for permanent or CIP
installation, the cleaner includes a built-in
strainer and fits in vessels with openings as
small as 6 1/4 in. (for the dual-nozzle version)
and 10 1/4 in. (for the triple-nozzle model).
Spraying Systems Co.; 800-95-SPRAY;
www.spray.com
DELIVERING INTEGRATED PROJECT SOLUTIONS

Serving the food and beverage industry with an
innovative and integrated team working together
early in the design phase and throughout the
life-cycle of the project.
WWW.WEITZ.COM
45
TECHNOLOGY
S O U R C E B O O K
HARD SURFACE DISINFECTANT

EPA registered for food contact surfaces, PURE hard surface disinfectant and sanitizer incorporates a non-toxic, environmentally
friendly SDC antimicrobial molecule. The product eliminates bacteria, viruses and fungi, including multiple drug-resistant organisms,
norovirus, hepatitis B and C, Listeria, E. coli and Salmonella, in as
little as 30 seconds and offers 24-hr. protection. Non-caustic and
non-irritating, the odorless, ready-to-use formula contains no bleach,
ammonia, phosphates, phenols or VOC-emitting compounds.
PURE Bioscience, Inc.; www.purebio.com
POLYPROPYLENE PACKAGING
With the same inside food space as a 9- x 9-in. foam clamshell,
Anchor Culinary Squares packaging includes clear polypropylene vented lids with matching 8 1/2-in. square, black polypropylene bases; the lids and bases are both available in single
and 3-compartment designs. They withstand temperatures up
to 230F.
Anchor Packaging, Inc.; 800-467-3900;
www.anchorpac.com
PROCESS MANUFACTURING
IS COMPLICATED.
IS YOUR ERP SOLUTION
UP TO THE TASK?
Visit IFS at PACK
IFS APPLICATIONS IS.
As one of the most robust ERP solutions on the
market, IFS Applications makes it possible to
maintain a real-time awareness of your manufacturing
operations. IFS Applications has the detailed
reporting, production and planning functions you
need to track everything, everywhere.
IFS-FOR AGILE BUSINESS

www.IFSWORLD.com
46
Expo, Booth S-8394
TECHNOLOGY
S O U R C E B O O K
MAGNETIC SEPARATORS
Suitable for practically any food processing application, Eriez ProGrade magnetic separators come in plate, grate, trap, tube and sight
glass versions in a variety of sizes and strengths. The plate magnets
are installed in chutes, spouts, ducts or pipes, or suspended over
conveyors, to remove tramp iron, while the grate magnets remove
ferrous contamination from dry products such as powders or granules. The traps remove ferrous materials from liquid products flowing
through 2-, 3- and 4-in. diameter pipelines; they use 316L stainless
steel magnetic tubes and various housing designs.
Eriez; 888-300-ERIEZ; www.eriez.com
FLEXIBLE CONDUIT
The AFC Cable Systems LIQUID-TUFF UL Splash Zone Liquidtight
flexible conduit is made with a polyvinyl chloride jacket that inhibits
bacteria growth and withstands bleach cleaning and sterilization.
Designed to meet NSF 169 commercial food equipment standards for
splash zones in food production areas, the conduit comes in steel and
non-metallic versions. It is suitable for meat packing, food processing
and poultry packing applications.
AFC Cable Systems, Inc.; www.afcweb.com
BETTER DRYING, BLOW OFF & RINSING

ENERGY EFFICIENT DRYING
DUST & DEBRIS BLOW OFF
BOTTLE & CAN RINSING
Paxtons high efficiency blowers

and air delivery devices improve
drying of cans and bottles for
high quality labeling and coding,
while using 60 80% less energy,
typically giving a one year ROI.
Paxtons powerful air delivery removes

particulates, dust and debris efficiently
and effectively. And if static cling is
an issue, Paxtons Ionized Air Systems
dissipate the static then blast the
debris away.
NO WATER / COMPRESSED AIR

NEEDED
All Paxton Air Systems are customengineered to maximize performance

and minimize energy usage.
All Paxton Blowers carry a full
three year warranty.
Paxtons New Ionized Air System

replaces both water rinsing and
compressed air rinsing, using less
energy and no wasted resources.
BOOTH
C-3309
800.441.7475 PAXTONPRODUCTS.COM
47
TECHNOLOGY
S O U R C E B O O K
SERVO PUMP FILLERS

Hinds-Bock CIP servo pump fillers sanitize themselves; the front
cover plates are hinged for sanitation swab testing. The servo controller changes over from 1 size container to another without change
parts. Fill adjustment is accomplished by calling up a recipe on the
HMI panel. The fillers can be used for a range of flowable products
including sauces, dressings, jellies, condiments and products with
particulates.
Hinds-Bock Corporation; 877-292-5715;
www.hinds-bock.com
SELF-CONTAINED COMPACTOR
Intended for the sanitary handling of general waste, the SP
Industries SCM Series mini self-contained compactor system is
comprised of an integral compactor, power unit and container.
When full, the entire unit is loaded onto a roll-off hoist truck
for transport to a disposal site. The system features a maximum
packing force of 26,400 lb.
SP Industries; 269-793-3232;
www.bestcompactors.com
FINALLY- an intelligent, wireless washdown temperature probe.

True mobility. Instant Data Collection. Mobile Database Connectivity.
Double gasketed
probe junction
Lithium-ion battery provides

up to 48 hours of use
Sigma CP-90
Up to 300 clear line of
site transmission
Use any K-type

thermocouple
For more Information:

T: 1-800-578-5060
mail@sigma-usa.com
www.sigma-usa.com
48
Our Calibrations are

NIST Certified and
Traceable
Accuracy +/- .5
Multiple send modes

Superior OLED
4 Line display
Plug and Play with

InfinityQS Proficient
Powered by SYNAPSE
2.4 GHz. radio technology
SIGMA EXHIBIT
# 5839
2 015 C H I C A G O
Please stop in!
TECHNOLOGY
S O U R C E B O O K
Non-Drip Epoxy for Food

Equipment Applications
EP21NDFG
BELT MEASURING SYSTEM
The Cambridge Tug Tester measuring system provides tension readings on turn and spiral cage conveyor belts used during the cooling
and freezing stages of bakery and food processing; it uploads data
and tracks changes on a PC for daily plant monitoring. Approved for
operating temperatures from -40F to 120F, the system can be used
on belt loads up to 1,000 lb. with measurements provided every 2
seconds for up to 20 hours at -10F. It includes a belt loading mechanism, rechargeable lithium ion battery and charger, software discs,
pins, adaptors and cables.
Cambridge Engineered Solutions; www.cambridge-es.com
Meets FDA Section 175.105

specifications for indirect
exposure to food
Chemically resistant
Thick paste
154 Hobart Street, Hackensack, NJ 07601 USA

+1.201.343.8983 main@masterbond.com
www.masterbond.com
Complete
knowledge
from one source

Raw materials, logistics, storage, processing, conveying, preparation,
dispensing, mixing, control: we develop extraordinary solutions in all areas.
All key components are developed and manufactured in house, and are
designed for continuous, efficient and reliable operation.
Tel: 813-920-7434 | info@zeppelin-usa.com | www.zeppelin-usa.com
See us at PACK
EXPO Booth
#-S-7816
49
INDEPENDENT
INDEPENDENT
INDEPENDENT
INNOVATIVE
PACKAGING
SOLUTIONS
INTEGRATED
INTEGRATED
INTEGRATED
S O U R C E B O O K
FL
O
W
RA
PP
ER
BO
OT
H
C-
50
03
SE
E
US
AT
:
TECHNOLOGY
LAB HOMOGENIZER
The GEA Pony NS2006L self-contained homogenizer is designed
for continuous operation up to 1,500 bar. Engineered for processing
nanoparticles, nanodispersions, nanoemulsions and cell dispersions,
the homogenizer is used for the micronization of dairy products, fruit
juices, liquid food, food additives and ingredients. Compliant to EU
safety rules (CE standards), it is built according to EN ISO 9001:2008
Quality System.
GEA; 603-606-4060; www.gea.com
PRODUCT FEEDING SYSTEMS
CASE PACKERS
ROLL WRAPPERS
SHRINK WRAPPERS
CARTONERS
ROBOTICS
TECHNOLOGY YOU CAN TRUST
WORM GEAR SCREW JACKS

Nook ActionJac worm gear screw jacks feature 1/4- to 100-ton
load-handling capabilities and can be used individually or in multiple
arrangements; custom configurations are available. The ball screw
jacks use a ball screw and nut made from alloy steel with hardened
bearing balls carrying the load between the nut and screw for a rolling action that reduces friction. The machine screw jacks incorporate
an Acme screw with a 2C thread form and have a 20:1 or greater
gear ratio.
Nook Industries, Inc.; 800-321-7800;
www.nookindustries.com
AC SERVO MOTORS
CARTONING n CASE PACKING n DISTRIBUTION SYSTEMS
n FEEDING SYSTEMS n FLOW WRAPPING n ROLL WRAPPING
n SHRINK WRAPPING n STORAGE SYSTEMS n ROBOTICS
Bristol & Beccles : England n Rock Hill SC : USA
Moscow : Russia n Shanghai : China n Mumbai : India
info@bradmanlake.com
bradmanlake.com
Bishop-Wisecarver DMV Series AC industrial servo motors have

incremental encoders that can be driven by any servo drive with
UVW commutation capabilities. Offered as standalone components,
they can be selected and sized for use with linear actuators. Prewired with 1m-long cable leads, the motors are IP67 protection rated
for harsh environments and UL standard compliant.
Bishop-Wisecarver Group; www.bwc.com
Experience
Quality | Savings | Service
Booth #7395
Selecting the correct cleaning device is about selecting

the correct tank cleaning company.
Experience excellent customer service and industryleading quality, along with all the advantages dynamic
cleaning equipment provides.
www.TrueClean.us
TECHNOLOGY
S O U R C E B O O K
STRAPPING MACHINE
Available in Base and Pro versions, the Mosca fully automated SoniXs
TR-6 strapping machine can be integrated into any food industry
operation. Both versions are constructed with a Standard 6 strap path
system. With 2 coils as an option, when the first coil is empty, the
machine automatically picks up the second and changes the strap,
FEX10054Doug
9/23/05
without interrupting
production.12:25 PM Page 1
Mosca GmbH; www.mosca.com
TEMPERATURE CALIBRATION
SOFTWARE
Compatible with Microsoft Windows 7 and 8 operating systems,
Fluke MET/TEMP II temperature calibration software version 5.0
is used for testing batches of sensors, calculating characterization
of coefficients and generating calibration reports. It automates
batch calibrations of platinum resistance thermometers, liquidin-glass and bimetallic thermometers, thermistors and all types of
thermocouple sensors.
Fluke Calibration; 877-355-3225; www.flukecal.com
PUSH START. SAVE MONEY!

Barrels. Buckets. Belts.
Scale Parts. Bins. Totes.
Any washer, for any need. All push-button

easy to operate! This means saying
goodbye to the time-consuming and
costly routine of handwashing freeing
your 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 visit
www.dougmac.com for
additional details.
2101 Calumet Street

Clearwater, Fl 33765
(727) 461-3477
Fax: (727) 449-0029
Email: info@dougmac.com
WEB: www.dougmac.com
52
TECHNOLOGY
S O U R C E B O O K
MILD-STEEL CONSTRUCTED
CONVEYOR
The Multi-Conveyor mild-steel constructed conveyor provides gap
registration and bent tip detection for tubed products; the tubes fall
directly into position due to the pockets designed in the conveyor
belt. If a bent tip is detected, a stainless steel box-in-box reject pusher
guides the tube into a reject shoot. The tubes are rejected on the fly
for continuous line movement.
Multi-Conveyor LLC; 800-236-7960;
www.multi-conveyor.com
Learn how DynaClean will

save you money. Visit us at:
Our conveyor is clean and ready in minutes.
800.640.6850 www.DynamicConveyor.com
the optimal cold service system
Polyguard now supplies Dow Styrofoam pipe insulation to the refrigeration

market, completing the introduction of its optimal Cold Service System. The
optimal Cold Service System starts with RG-2400 gel on the pipe to prevent
corrosion. Install Dow Styrofoam insulation which provides long-term stable
R values. Finally, cover the insulation with either Polyguards ZeroPerm or
Insulrap vapor retarders to keep the insulation dry or complete the system with
Polyguards Alumaguard214-515-5000
family of flexible weatherproof cladding products.
To learn more, visit www.PolyguardProducts.com/max
Innovation based. Employee owned. Expect more.
Phone: (1) 214.515.5000
www.PolyguardProducts.com
53
TECHNOLOGY
S O U R C E B O O K
COOLING WATER TREATMENTS
NOW AVAILABLE
PT BOOTS
TOP QUALITY FOR THE BOTTOM LINE
U.S. Water PhosZero cooling water treatment products provide scale

and corrosion control. They contain a synergistic blend of ingredients
that replaces the most common uses of phosphorus in cooling water
applications, eliminating phosphorus discharge to the environment
and phosphorus removal from waste streams.
U.S. Water Services; 866-663-7633;
www.uswaterservices.com
Flowtrend's valves, pumps, tank equipment, and

service parts are manufactured to accommodate
the demanding operating conditions needed to
create safe, high-quality products. Flowtrend is
helping the dairy industry meet its high standards
cost-efficiently, with equipment thats
equally exceptional.
VISIT US AT | FLOWTREND.COM
SEE OUR NEW PT BOOTS AT
INTERNATIONAL DAIRY
SHOW BOOTH 7446
CASE PALLETIZING SYSTEM

Designed for the food and beverage industries, the Dematic AMCAP
automated mixed case palletizing system arranges cases on a pallet
in a specific sequence. Full pallets of an SKU are de-layered by a
robot. The cases are singulated and placed into an automated buffer
staging module. Performance optimizing software releases the cases
from the buffer in a precise sequence for pallet assembly. A robotic
palletizer receives the cases and automatically builds the pallet.
Dematic; www.dematic.com
TECHNOLOGY
S O U R C E B O O K
CIRCULATION HEATERS
SECURITY ROUTERS
The Phoenix Contact RS2005 security router has 5 unmanaged
Ethernet ports and a 4-port managed switch for multiport security
applications in Ethernet networks. The RS4004 model has 4 managed
ports and a 5-port unmanaged Ethernet switch with an auto-crossing
function. Both versions include a demilitarized zone port to secure
multiple networks.
Phoenix Contact; 800-322-3225; www.phoenixcontact.com
Capable of heating liquids or gases, CAS PUR-X circulation heaters are intended for the food and beverage industries. Available in
2 sizes, the heaters feature a Teflon-coated cast aluminum body
and a replaceable PFA fluid tube that withstands temperatures to
500F. Typical applications include the heating of water, juices, milk
or foods; the heating of mixing agents and flavoring liquids; and processes for cleaning and disinfecting. The heaters are equipped with
explosion-proof electrical enclosures for deployment in hazardous
environments.
Cast Aluminum Solutions; www.castaluminumsolutions.com
Is your facility up to speed?

we make it certain.
www.haskell.com
4food & beverage facility renovation

4process & packaging systems
4master planning
4architecture & engineering
4building construction
4utility systems
4material handling & distribution
4manufacturing consulting
4power automation & information
55
TECHNOLOGY
S O U R C E B O O K
X-RAY FLUORESCENCE SPECTROMETER

Enabling at-line analysis for food producers and manufacturers, the
SPECTRO portable SPECTROSCOUT X-ray fluorescence spectrometer offers laboratory-quality elemental composition monitoring,
quality control testing and audit-traceable results. Offering sensitivity
at a range of detection levels, it provides precise analysis from highpercentage concentrations to trace elements. The unit includes an
intuitive interface, software that interacts via a standard computer
and predefined applications packages.
SPECTRO Analytical Instruments; www.spectro.com
STRETCH HOOD MACHINES

Lachenmeier stretch hood machines include an ICPA interface panel
that allows operators to control, monitor, diagnose and manage wrap
applications; specially designed icons illustrate every step of the
process and provide information on the wrap cycle. The system can
assign each user varying levels of access with unique password logins. In the event of a fault or part wearing, an alarm screen appears,
alerting to the specific issue.
Lachenmeier; 877-859-7205
Your first choice

for technical solutions
and consulting expertise
in the world of food
and drink
Innovation Nutrition Safety Regulatory Insight Sensory
T +44 (0)1372 376761, E help@leatherheadfood.com

www.leatherheadfood.com
56
TECHNOLOGY
S O U R C E B O O K
water & wastewater

issues giving you a
headache?
For over 100 years, HR Green has provided
water and wastewater treatment services.
ENGINEERING DESIGN
EPC
PROJECT MANAGEMENT
PROCESS AND
OPERATIONS
IMPLEMENTATION
FACILITY COMMISSIONING
PERMITTING
ELECTRICAL
MECHANICAL
SCADA/CONTROLS
DIGESTER/BIOGAS
PALLET TRUCKS
Able to perform in harsh environments such as coolers, wet
rooms and freezers, UniCarriers 5.2hp, AC-powered Platinum RPX
walkie/rider pallet trucks come in 6,000- and 8,000-lb. capacities. The fork design features a push-type linkage and tie rods to
absorb high-impact shocks, while alloy steel fork slides facilitate
pallet entry and exit.
UniCarriers Americas Corporation;
www.unicarriersamericas.com
Phone 800.728.7805
Learn more at HRGreen.com
TEST DRIVE A MINI.

Introducing the WaveMix Mini - Marions lab-sized
microwave mixing system. Think of it as your test
labs killer app, and create your own competitive
advantage in:
Rapid, Controlled Heating
Microbial Reduction
Low-Temp Drying
Change of State
Secondary Drying
Take the Mini for a spin using Marions 3-6 month
lease program.
For more information, call 800-397-6371 or visit
MarionSolutions.com today.
57
TECHNOLOGY
S O U R C E B O O K
IML SYSTEM
ROTARY LOBE PUMP
Designed for applications on injection molding machines, the BeckFlex side-entry automated IML system handles molds with as many
as 4 cavities. It can decorate labeled lids and containers up to 220 x
100mm in size; the maximum product height is 170mm. The system
is compatible with flat labels, 3- or 5-sided labels, 5-sided labels with
closed edges and 360 labels. A servo portal enables job-specific
label feed and product placement.
Beck Automation AG; +41 (0) 44 751 84 44;
www.beck-automation.com
The NETZSCH all-metal TORNADO T2 rotary lobe pump is engineered for the hygienic processing of sensitive food industry products. It comes in a variety of sizes delivering quantities of 2,113
to 36,980 gal./hr. Used for intermittent, continuous and metering
applications, the self-priming, valve-less, positive displacement pump
handles any kind of liquid, including media containing gas, solids or
fibrous matter. It features a deflection-resistant shaft material and
sealed-for-life, angular contact ball bearings.
NETZSCH Pumps & Systems; www.netzsch.com
FDA APPROVED
Strength and flexibility.

Strength and flexibility define Kent Elastomer. From the
food-grade TPE, PVC, TPV and latex tubing we produce to the
way we do business. Rely on us for standard or crimped aseptic
fitment hoses for a variety of food and beverage applications.
All manufactured to your exacting specifications and the highest
quality control standards using FDA and NSF approved
compounds. Delivered on time and on budget. And supported
by a degree of quality and service rarely found elsewhere.
Discover what we can do for you. Call Kent Elastomer today.
Made in the USA since 1960.

58
KEP_HalfPage_FoodEngineering_2015.indd 1
888.239.3940
kentelastomer.com
3/20/15 4:30 PM
TECHNOLOGY
S O U R C E B O O K
Introducing
Ultra Safe Technology

Brooms and Brushes
What is Ultra Safe Technology (UST)?

UST is a revolutionary new line of brooms and brushes
with innovative technology that utilizes enhanced bristle
security units directly molded to the brush block, removing
any gaps or seams while offering unprecedented bristle
retention strength.
LASER DISTANCE SENSOR

Available with an analog output, the Banner Q4X laser distance sensor is used for fill level indication, part positioning, roll diameter, loop
control and thickness/height verification; the sensor offers continuous measurement and sensing performance, in addition to resolutions as small as 0.15mm. It provides analog (V or mA) or distance
(mm) readouts from the angled 4-digit display that can be viewed
from multiple vantage points.
Banner Engineering Corp.; 888-373-6767;
www.bannerengineering.com
The hand brushes, deck scrubs, and sweeping brooms each

have a unique bristle pattern to optimize function, while
spacing between the bristle units makes each tool easier to
clean, dry, and inspect.
Contact us today for more information.
1-800-826-8302
nelsonjameson.com
protectinG you
wHile you Feed tHe world
our job is mitiGatinG your exposure to pest manaGement associated risK

Protecting the food supply chain of custody is our number-one priority. Utilizing a scientific
data-driven pest management approach contributes to long-term protection from risk to
brand, human health, environment and profitability.
Food manuFacturers & processors | Grain industry | pacKaGinG suppliers | transportation & loGistics providers
www.mccloudservices.com | contact@mccloudservices.com | 800-332-7805

illinois | iowa | indiana | Kansas | KentucKy | missouri | tennessee | wisconsin
59
TECHNOLOGY
S O U R C E B O O K
SEALS AND REPLACEMENT KITS

AGD DURA-SHIELD seals for the dairy and food processing industries are manufactured under
CEMA dimensional standards. They can be used in applications such as screw conveyors,
bucket elevators, mixers, screw feeders, crushers, ribbon blenders and powder or slurry processing. Rebuild kits with step-by-step instructions are available.
Colonial Seal Company; www.colonialseal.com
Where Your Conveyor

Solutions Start
CHECKWEIGHERS
The fixed-height Thermo Scientific Global
VersaWeigh checkweigher is used with products up to 22 lb. in weight, while the cantilevered, height-adjustable Global Versa GP
model is suitable for products weighing up
to 6.6 lb. Designed for companies that package products in pouches, bags, cartons and
more, the checkweighers are engineered for
wet or dry environments.
Thermo Fisher Scientific Inc.; 763783-2500; www.thermofisher.com
SPOUTED DISPENSING
With pre-engineered and standardized core product

offerings, Nercon can quickly and easily tailor our conveyor
systems for your specific application.
This provides you with:
Savings in time & money
Faster deliveries
Proven, durable and reliable conveyors
Greater flexibility for modifications
Exceptional start-up & install service
Visit us at Pack Expo Booth #C4200
www.nerconconveyors.com
844-293-2814
60
A flip-top, 1-piece, spouted dispensing unit

for flexible pouches, the WestRock FlexFit
closure has a latch-back design that keeps
the cap away from product during dispensing; it comes in a range of orifice sizes and
shapes. Made of high-density polyethylene,
the closure can be used in food applications, such as condiments, flowable powders,
sugar and dehydrated beverages.
WestRock Company;
www.westrock.com
FLAT PANEL DISPLAYS

Suited for harsh environments, AbraxSys
industrial rack mount LCD flat panel displays have a range of controls and standard
spaced holes for 19-in. rack mounting. The
front bezel and rear housing are constructed of aluminum dipped in zinc chromate
and finished with a corrosion-resistant,
thermal-set black powder coating.
AbraxSys Corporation; 800-8839050; www.abraxsyscorp.com
The worlds top 100

food & beverage
companies
Change is the
new normal
Global volatility in both socioeconomic and political terms, shifting

demographics and an explosion in e-commerce created an increasingly
challenging backdrop to activities during the past year.
} Claire Rowan, Contributing Editor
perating in todays uber-global, volatile three-quarters of the global population liveenabling us

world is challenging existing corporate to dedicate more attention to countries and regions that
str uctures and forcing the food and are highly complex but have huge potential.
beverage industry s leading players to
The Coca-Cola Company, which slipped from third to
become ever more adaptable, responsive, fifth place in 2014, also began reshaping its organization
proactive and innovative. Competition remains tight as early last year, only to accelerate the pace and broaden the
growth in the developing world continues, although at scope of this change during the ensuing months.
a slower pace than
in the initial boom
years. Developed
Globally, families and individuals spent less
nations grapple
on consumer goods in 2014, slowing growth in
with ongoing costs
and legac y inf ranonalcoholic beverages,
structure pressures.
which had an impact on our
The business
env ironment was
performance, says Muhtar
aga i n m a r k e d b y
Kent, CEO of The Coca-Cola
great uncertainty in
Company. We knew we
2014, Nestls leadership team said in
needed to move faster and execute faster,
a presentation to
and we believed we could improve.
shareholders. Disruptive socioeconomic and political
change continued to affect growth in many parts of the
Globally, families and individuals spent less on conworld. In the emerging markets, economic volatility wors- sumer goods in 2014, slowing growth in nonalcoholic
ened as growth rates slowed and currencies weakened. In beverages, which had an impact on our performance, says
the developed markets, deflationary pressures and soft Muhtar Kent, CEO of The Coca-Cola Company. We
consumer demand resulted in a continued challenging knew we needed to move faster and execute faster, and we
trading environment.
believed we could improve.
During 2014, Nestl, which again remained firmly in
During 2014, the company streamlined and simits top spot in the food and beverage industry, integrated plified its operating model, reducing the size of its
its Maghreb, Middle East, North East Africa region, Tur- group-level organizations around the world, standardkey and Israel into Zone Europe to form Zone EMENA izing its operating approach and key processes across
(Europe, Middle East and North Africa).
business units and, most notably, forming a single
This, Nestl says, balances the different consumer business unit in Western Europe, where it previously
dynamics and opportunities in these geographies. Addi- had three. The company also put greater emphasis on
tionally, it allows a sharper focus in zone Asia, Oceania revenue and profit growth by segmenting activities in
and Africa the fast-growing parts of the world where each of its core markets.
63
TOP 100
I am honored and humbled to
be the CEO of the Kraft Heinz
Company. Kraft and Heinz are
both world-class organizations
with storied pasts and together
an even brighter future, says
Bernardo Hees.
In emerging markets, were striving to grow mostly via
greater volume to drive awareness and build our brands.
In developing markets, we know ideal growth takes a balance of volume and pricing, while in developed markets,
we see price/mix as our most powerful growth lever,
Kent explains. Overall, these steps will allow us to speed
decision-making and enhance our local market focus, both
of which will help unlock growth. Well also have a more
nimble organization, one better equipped to outpace the
change in our industry.
such as North America and

Southeast Asia. It has already
earmarked the US beverage
manufacturer Country Pure
Foods, which it will acquire
with Toyota Tsusho America
Inc. through the two companies US fruit beverage
manufacturing joint venture
organization, Silver Springs
Citrus Inc.
Fellow leading Japanese
player, Nissin Foods Holdings, has adopted a strategy of
acquisition and innovation to become more competetive. For example, last year, it acquired a 49 percent stake
in Indonesias PT Nissinmas to strengthen its position
in instant noodle products, such as Cup Noodles and
Top Ramen Baru. Facing limited growth in the domestic
market, Japanese food companies are keen to expand in
Indonesia as it has the worlds fourth-biggest population
and is Southeast Asias biggest economy, according to Nissin Foods.
In 2014, the company also inaugurated a new research
and development center in Tokyo. We named it the WAVE
to express our desire to spread a new wave of innovation
worldwide by pioneering leading-edge food technologies,
says Koki Ando, CEO of Nissin Foods Holdings. The WAVE
houses two research facilities, one of which is the Nissin
Global Innovation Center, which provides technical support
for innovation.
Innovation in Japan
At the beginning of this year, the Sapporo Group formulated
a completely new management plan in response to the progression of business operations during 2014 and the current
business environment.
We recently announced the Sapporo Groups New Management Framework, which sets its sights on 2016, our 140th
anniversary, says Tsutomu
Kamijo, president of SapThe business environment was again
poro Group, who explains
that in the past, plans were
marked by great uncertainty in 2014,
grounded on the conditions
according to Nestl. Disruptive
current at the time they were
socioeconomic and political change
conceived. In contrast, the
New Management Framecontinued to affect growth in many
work envisions the company
parts of the world. In the emerging
in the year 2016 and outlines the policies to make the
markets, economic volatility worsened
changes required to achieve
that vision. We will pursue as growth rates slowed and currencies weakened. In the developed
greater synergies among our
markets, deflationary pressures and
businesses by promoting
soft consumer demand resulted
flexible collaboration and
in a continued challenging trading
cooperation, unconstrained
by our current group comenvironment. Pictured above are
panies or existing organizaNestl CEO Paul Bulcke (left) and
tional boundaries.
As part of the plan, SappoChairman of the Board of Directors
ro will look for further marPeter Brabeck-Letmathe (right).
ket penetration of its brand
in premium beer markets
64
2015 Ingersoll Rand
Compressed air shouldnt

be a food additive.
[We wont let it become one.]
With growing concerns

over food safety, its critical to
have a compressed air partner you can
depend on for a full range of solutions that deliver
productivity without sacrificing quality. From processing
to packaging, well help you assess the risk of contamination and
choose the appropriate equipment for your individual air needs
so you can Stress Elsewhere.
IngersollRand.com/StressElsewhere
Ready to manage your contamination risk?

Download our white paper to learn more.
Top 100 Food & Beverage Companies

Rank
Company
Food Sales ($ millions)
Year Ending
Company
Food Sales ($ millions)
Year Ending
1
2
Nestl
PepsiCo, Inc.
72,245
66,683
Dec. 14
Dec. 14
51
52
Campbell Soup Company

Coca-Cola Enterprises
8,268
8,264
Jul. 14
Dec. 14
3
4
JBS
Anheuser-Busch InBev
52,580
47,063
Dec. 14
Dec. 14
53
54
Kerry Group
Parmalat
7,770
7,490
Dec. 14
Dec. 14
The Coca-Cola Company
45,998
Dec. 14
55
The Hershey Company
7,422
Dec. 14
6
7
Archer Daniels Midland Company

Tyson
43,232
37,580
Jun. 14
Sep. 14
56
57
DMK Deutsches Milchkontor

Sodiaal
7,365
7,290
Dec. 13
Dec. 14
8
9
Mondelez International
Cargill
34,244
33,700
Dec. 14
May 14
58
59
Oetker Group
Red Bull
7,100
6,900
Dec. 13
Dec. 14
10
Mars
33,000
Dec. 14
60
McCain Foods Limited
6,860
Jun. 13
11
12
Unilever
Danone
29,070
28,545
Dec. 14
Dec. 14
61
62
Muller Group
Ajinomoto
6,810
6,485
Dec. 13
Mar. 15
13
14
Kraft Heinz
SABMiller
28,000
26,177
Dec. 14
Mar. 15
63
64
Savencia Fromage & Dairy

Dr Pepper Snapple Group
6,220
6,121
Dec. 14
Dec. 14
15
Heineken
26,000
Dec. 14
65
Constellation Brands
6,028
Feb. 15
16
17
18
Lactalis
Suntory
Kirin Holdings
22,240
21,540
18,653
Dec. 13
Dec. 14
Dec. 14
66
67
68
Ingredion Inc.
The JM Smucker Company
Morinaga Milk Industry
5,998
5,963
5,948
Dec. 14
Apr. 15
Mar. 15
19
20
21
22
23
24
Fonterra
General Mills Inc.
ConAgra Foods Inc.
Asahi Group
Diageo
Royal FrieslandCampina
18,565
17,910
17,703
17,017
15,900
15,320
Jul. 14
May 14
May 14
Dec. 14
Jun. 14
Dec. 14
69
70
71
72
73
74
Nissui
Bacardi
LVMH
Barry Callebaut
Land O' Lakes Inc.
ThaiBev
5,818
5,800
5,365
5,300
5,098
5,065
Mar. 15
Mar. 14
Dec. 14
Aug. 14
Dec. 14
Dec. 14
25
26
27
28
29
30
Kellogg Company
CHS Inc.
Grupo Bimbo (Mexico)
Arla Foods
Smithfield Foods Inc.
Brf Brasil Foods
14,580
14,500
14,390
14,330
13,221
13,185
Dec. 14
Aug. 14
Dec. 14
Dec. 14
Apr. 13
Dec. 14
75
76
77
77 tie
79
80
Barilla
Tsingtao Brewery
Itoham Foods
Maxingvest/Tchibo
Schreiber Foods
Sapporo Holdings
4,915
4,840
4,810
4,810
4,800
4,650
Dec. 13
Dec. 14
Mar. 15
Dec. 13
Dec. 14
Dec. 14
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
NH Foods
Carlsberg
Ferrero
Femsa
Pernod Ricard
Vion
Danish Crown
Meiji Holdings
Bunge
Saputo
Marfrig Group
Dean Foods Company
Yili Group
Hormel Foods Corporation
Yamazaki Baking
Sudzucker
Associated British Foods
Coca-Cola HBC
Maruha Nichiro Corporation
China Mengniu Dairy Company
12,108
11,730
11,355
11,330
11,045
10,975
10,550
10,218
10,035
9,690
9,580
9,503
9,390
9,316
9,220
9,180
9,020
8,790
8,390
8,340
Mar. 15
Dec. 14
Aug. 14
Dec. 14
Jun. 14
Dec. 13
Sep. 14
Mar. 15
Dec. 14
Mar. 15
Dec. 14
Dec. 14
Dec. 14
Oct. 14
Dec. 14
Feb. 15
Sep. 14
Dec. 14
Mar. 15
Dec. 14
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
Nisshin Seifun Group

Dole Food Company, Inc.
Coca-Cola Amatil
Nissin Foods Group
Ito En
McCormick Corporation
Agropur Cooperative
Tate & Lyle
Molson Coors Brewing Company
QP Corporation
J R Simplot
Brown-Forman
Coca-Cola West
E & J Gallo Winery
Groupe Bel
Flowers Foods
DE Master Blenders 1753
Keurig Green Mountain
WhiteWave Foods
Japan Tobacco International
4,507
4,500
4,495
4,315
4,305
4,243
4,240
4,175
4,146
4,105
4,000
3,946
3,905
3,800
3,757
3,749
3,645
3,605
3,437
3,425
Mar. 14
Dec. 14
Dec. 14
Mar. 15
Apr. 15
Nov. 14
Dec. 14
Mar. 15
Dec. 14
Nov. 14
Aug. 14
Dec. 14
Dec. 14
Dec. 14
Dec. 14
Dec. 14
Dec. 14
Sep. 14
Dec. 14
Dec. 14
Source: Global Food Markets (GFM), Leatherhead Food Research; www.leatherheadfood.com.
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TOP 100
the sale allows it to focus
more intensely on pursuWinning the race for new products and markets is
ing growth opportunities
fierce in the instant noodle industry, and shortening
by expanding its Keystone
foodservice business in both
development times is
Asia and the US; increasimportant for successfully
ing beef exports from Brazil, especially to Asia and
competing in the market,
the US; and strengthening
says Koki Ando, CEO Nissin
its capital structure and
Foods. Our new research
increasing its cash flow.
These moves meet the
center will now assume a central role in an
requirements of the comeffort to develop completely new products
panys strategic plan, Focus
to W i n , w h i c h co n ce n that fuse the Nissins various food processing
trates on organic growth,
technologies.
margin expansion and cash
generation.
Until now, it was necessary to confirm and establish proAccording to Marfrig CEO Martin Secco Arias, The comduction conditions for trial products through line tests on mitments we assumed under Focus to Win will continue to
actual production lines, says Ando. The installation of a full- guide Marfrigs day-to-day operations and allow us to focus
specification, continuous, multi-product, configurable pro- on the importance of cost management, high productivity
duction line within the research center will enable us to study and operational efficiency.
full-scale production conditions in advance and shorten the
New in at number 99 this year, WhiteWave Foods, the spitime for product launch.
noff from Dean Foods that began operation as a standalone
Winning the race for new products and markets is fierce company in 2013, has also been busy forging its growth
in the instant noodle industry, and shortening development through acquisition. Last year, via a joint venture established
times is important for successfully competing in the market, earlier with China Mengniu Dairy, WhiteWave entered an
adds Ando. Our new research center will now assume a cen- agreement to purchase Yashili Zhengzhou in China. In Octotral role in an effort to develop completely new products that ber and closer to home, WhiteWave completed its acquisifuse Nissins various food processing technologies.
tion of So Delicious Dairy Free, and very recently, it seized
Nissins second research facility, the Nissin Global Food the opportunity to extend its plant-based food and beverage
Safety Institute, will be responsible for ensuring food safety.
offerings through the acquisition of Vega, a leader in plantbased nutrition productsprimarily powdered shakes and
Focus on the Americas
snack bars containing nutrient-dense, superfood ingredients.
In the meat world, acquisition and divestiture punctuWe highlighted our first full year as a standalone company
ated activities at the top. For instance, JBS, at number three, not only by achieving strong market and financial results, but
pounced at the opportunity to purchase the British poultry also by acquiring Earthbound Farm and So Delicious. We
producer Moy Park from
fellow Brazilian meat giant
Putting the companys
Marfrig just a few months
ago. The acquisition gives
information technology and
JBS access to markets in
e-commerce organizations
Britain, Scandinavia and
other parts of Europe, where
under the sight of a vice
consumption of processed
chairman will accelerate
food is rising. Although
new solutions and further
most of Moy Parks sales
come from fresh produce,
strengthen PepsiCos digital
processed meat accounts for
technology capabilities, according to PepsiCo.
40 percent of its sales.
For Marfrig, which has Indra Nooyi, PepsiCo CEO, is shown above.
recently relaunched itself
as Marfrig Global Foods,
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According to Marfrig CEO Martin Secco Arias, The

commitments we assumed under Focus to Win will
continue to guide
Marfrigs day-to-day
operations, as well the
importance of cost
management, high
productivity and operational efficiency.
also launched our plant-based joint venture in China, says
Gregg Engles, chairman and CEO. WhiteWave is the fastestgrowing food company in America, and our Alpro plantbased foods and beverages are experiencing enviable growth
in our core Western European markets. In North America, we
hold the top market share in plant-based foods and beverages
[with Silk and So Delicious].
In 2014, WhiteWave introduced Silk cashew milk and
relaunched its dairy-free yogurts in the US. Plus, via its joint
venture with Mengniu Dairy, it completed the construction
of a production facility in Zhengzhou, launching almond and
70
walnut beverages in China

under the Silk ZhiPuMoFang
brand in December.
Dairy industry
challenges
Pursuing investment in the
complex dairy sector, which
is plagued by f luctuating
commodity prices and the
challenge of meeting Asias
insatiable demand for its
products, Fonterra recently
inaugurated its first production site in Europe. The site at Heerenveen in the Netherlands is now one of Fonterras three key global production
pools alongside plants in New Zealand and Australia.
The commissioning of this new plant further strengthens
our ability to deliver high-quality, advanced dairy nutrition
that meets the needs of our priority markets and global customers, says Theo Spierings, Fonterras chief executive. Last
year, Spierings oversaw the formation of the global partnership between Fonterra and Beingmate that is strategically
designed to help meet Chinas growing demand for infant
formula (from foreign suppliers in particular).
In 2014, we focused
on building volumes and
We highlighted our first full year
value in our key markets,
as a standalone company not only
especially Asia and Latin
America, Spierings conby achieving strong market and
tinues. In Asia, we saw 12
financial results, but also by acquiring
percent volume growth,
Earthbound Farm and So Delicious.
primarily driven by our
excellent performance in
We also launched our plant-based joint
China. In Latin America,
venture in China, says Gregg Engles,
our Soprole businesss
focus on new product
chairman and CEO, WhiteWave Foods.
development and innovation contributed to the
regions 3 percent volume growth. But, unfortunately, our increase its stake in Mengniu Dairy. The move also will allow
New Zealand and Australian business had a challenging year Danone to exit Chinas infant formula sector following a
decline in demand for Chinese-made products, due to condue to much higher input costs.
Commenting on Fonterras revision of its forecast for last tinuing food scandals such as the June 2015 recall of infant
year, Chairman John Wilson says, It reflects an uncertain formula powders contaminated with dangerously high levels
outlook for the global economic environment and an expecta- of nitrate.
Falling consumer confidence in the Chinese market has
tion of continued volatility for dairy prices driven by geopolitical events and the supply/demand imbalance.
led to increased investment overseas, particularly in New
Tackling the dairy market volatility, Danone plans to sell Zealand, where infant formula products are seen as being of
its Dumex infant milk powder business in China to Yashili higher quality. The preference for foreign products has led
International Holdings, giving Danone the cash it needs to to a changing dynamic for Chinas digi-savvy consumers.
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Excitemen and prosperin
t and optim g.
builds
as
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complete designs are
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red and
But unlik
installed. ment
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processinvation of a food
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or
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ation
processin al food
g facilit
seem
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overw
helming. s and
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Given
risk
the
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food
often strugg companie
s
solutions gle with findin
g
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that can d of
during
occu
a
But if execrenovation procr
ess.
planning uted well,
prop
will grea and managem er
ent
eliminate,tly reduce, if
not
the
pote
for prob
lems durin ntial
renovatio
ga
requires n project. This
by the a conscious
entire
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to ident
team
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can arise the problems
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ntial
specific and then deve
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According to the Institute of Grocery Distribution (IGD),

Chinas online grocery market is the largest in the world and
is set to be five times its current value by 2020.
Foreign brands are popular with Chinese shoppers who
are wary of the safety scares surrounding locally sourced
food and drink. Consequently, companies such as Alibaba
and Amazon have recently introduced sites dedicated solely
to imported goods, says Joanna Denney-Finch, IGD chief
executive. Many Chinese people also prefer shopping
using their smartphones, so retailers are offering mobileonly promotions, which are updated regularly to encourage
shoppers to keep visiting their websites for the latest deals.
Enter the digital age
This shift to digital is altering the entire operation landscape
for food and beverage manufacturers. For example, in its bid
to keep up with the changing face of e-commerce, Pepsico
has named its executive vice president and chief financial
officer, Hugh Johnston, as vice chairman. In this new role, he
will oversee the companys global e-commerce organization,
plus its global business and information solutions function.
According to PepsiCo, the move allows the company to
respond to global trends such as the rise of digitally connected consumers and the emergence of e-commerce as a
new distribution channel. Putting the companys information technology and e-commerce organizations under the
oversight of a vice chairman will accelerate new solutions
and further strengthen PepsiCos digital technology capabilities, the company states.
Mondelz International is tapping into digital trends and
has renewed its global strategic partnership with Facebook
to deliver creative video content and drive impulse snack
purchasing online. Nestl is increasing its presence in Silicon Valley, forging partnerships with startups and leading
technology companies to build on its digital innovation and
relationships with consumers by providing them with innovative online experiences and services. But, such activity is
just the tip of the iceberg in this changing digital world.
It took radio 38 years to attract 50 million listeners, but
Facebook attracted 6 million users in its first year, and that
number multiplied 100 times over the next five years. Chinas mobile text- and voice-messaging service WeChat has
300 million users, more than the entire adult population of
the US, says the McKinsey Global Institute in its new book,
No Ordinary Disruption: The Four Global Forces Breaking All the Trends. Accelerated adoption invites accelerated
innovation. But, despite how fast innovation has multiplied
and spread in recent years, it is poised to change and grow at
an exponential speed.
According to the McKinsey Global Institute, Twenty
years ago, less than 3 percent of the worlds population had a
mobile phone; now two-thirds of the worlds population has
one, and one-third of all humans are able to communicate
on the Internet. Entrepreneurs and startups now frequently
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No comment on the turbulent times in the industry and
activities at the top would be
complete this year without
mentioning the landslide deal
completed in July between
Kraft Foods and Heinz. The
two iconic names merged to
create the Kraft Heinz Company, which, under the leadership of new CEO Bernardo
Hees, took the 13th position
among the global top 100.
I am honored and humbled to be the CEO of the Kraft
enjoy advantages over large, established businesses. The
furious pace of technological adoption and innovation is Heinz Company. Kraft and Heinz are both world-class orgashortening the lifecycle of companies and forcing executives nizations with storied pasts and together an even brighter
to make decisions and commit resources much more quickly. future, says Hees. He adds that the companys immediate
The institutes book makes for stimulating, if not alarming, focus is on integrating the two businesses and establishing a
reading, and it is clear only the flexible and fit companies will new organizational structure, while delivering on its financial
prevail in such a changing environment. But, that will require objectives for 2015.
The developments of 2014 may just be the beginning.
adaptability and resilience.
Although we are operating in a challenging and turbulent Global mergers, acquisitions and restructuring are likely to
economic environment, we see these as fascinating times, full continue for the foreseeable future as the operating landscape
STVM_Ad_HalfPage_foodEng_Layout
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cooperation, unconstrained by our current group
companies or existing
organizational
boundaries, says
Tsutomu Kamijo,
president of Sapporo Group.
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Weighing all
the options in
wastewater
treatment
Whether your plant is located in a drought-stricken area or
where water is plentiful, building a wastewater treatment center
on site may be cost effective for several reasons.
} The ADI-BVF
reactor (a low-rate
anaerobic process)
at the Shearers
Foods Massillon,
OH site handles
degradable TSS and
reduces BOD from
3,000 to 5,000mg/l
to an effluent level
less than 300mg/l.
The plant processes
corn and potatoes
for snack foods,
including potato
chips, tortillas, rice
crisps and cheese
curls/puffs. Source:
ADI Systems Inc.
} Wayne Labs, Senior Technical Editor
ith the Sun Belt states experiencing serious droughts and the cost
of processing wastewater escalating in many municipalities, conserving and reusing water at food
and beverage processing facilities just makes plain
business sense. There are two ways to cut expenses
on water: conserve it and pretreat wastewater before
sending it off to publicly owned treatment works
(POTWs) since many of them charge extra for
untreated sewage or may not take it at all.
You can, of course, conserve water throughout
your plant by preventing wasteful amounts from
going down the drain, because the more you process
it (e.g., create steam or hot water, pump or filter it,

etc.), the more valuable a loss it is.1 Many processors
are already up to speed on pretreatment systems and
have found these systems can evolve into a largerscale processing facility where wastewater can not
only be pretreated, it can be recycled as clean or
even potable water for other uses within the facility.
Processed wastewater also can produce energy.
Although some food and beverage processors
have discovered onsite pretreatment or further
polishing (i.e., refining) of wastewater for use within
the facility ultimately saves money, local municipalities are just catching up with the concept of wastewater reuse, and this is mostly in the states affected
77
GREEN SERIES
An ADI-BVF low-rate anaerobic reactor helps the

Bellisio Foods Jackson, OH facility meet the citys POTW
discharge limits for COD and TSS. The system includes
a 250,000-gallon EQ tank, 5.25 MG above-ground
anaerobic BVF reactor, 300,000-gallon once-through
aeration tank and a standby power generation unit.
Source: ADI Systems.
by ongoing drought. Only 6.4 percent of municipal wastewater

flows in the US are reused for industrial, irrigation or municipal purposes, according to the Bluefield Research report, US
Municipal Wastewater & Reuse: Market Trends, Opportunities & Forecasts, 2015-2025.2
Whats your raison dtre for wastewater treatment?

Though processors often place different priorities
on setting up an onsite wastewater pretreatment
or complete treatmentsystem, altruism is usually not the first reason. CDM Smith Associate Al
Goodman lists four typical reasons for setting up a
wastewater treatment system:
Compliance with discharge requirements.
High BOD (biological oxygen demand) or TSS
(total suspended solids) in wastewater generally
needs treatment to comply with city or stream discharge requirements.
Reduction of sewer surcharges for excessively strong
wastewater.
Recovery of useful products for resale, e.g., onsite solids
used as animal feed or compost production.
ROI wastewater treatment system development

cost factors
The following factors (where applicable) should be considered
when determining the ROI for onsite wastewater treatment:
Planning and design cost
Environmental compliance (e.g., reporting)
Permitting costs
Capital cost for the wastewater treatment plant
Operating costs, including:
-- Electrical power required to operate the treatment plant
-- Maintenance costs, including allowance to replace
large equipment, membranes, etc. at the end of their
serviceable lifetime
-- Manpower to operate the treatment plant
-- Hauling dewatered sludge or out-of-spec product not suitable to be discharged to the wastewater treatment plant
-- Chemicals for operating the wastewater treatment
plant (nutrients, polymer, cleaning chemicals, etc.)
Savings or elimination of POTW surcharges
Reduction in volume of waste product to haul off site
Value of water that can be reused
Value of biogas energy that can be recovered
78
Value of granular anaerobic sludge generated in a highrate anaerobic digester

Incentive programs for instituting onsite wastewater treatment, green energy production, water recovery, etc.
Additionally, the following factors, which may not be easy
to quantify in an ROI analysis, should be considered when
weighing the choice to conduct onsite wastewater treatment:
Threat of lost production days for severe discharge violations
Installing water reuse technology serves as a form of insurance against a future restriction of water supply. Water
reuse serves as a form of risk management by facilitating
internal management of the plants water supply needs.
Positive publicity from instituting green energy production
or water recovery systems, showing the production plants
environmental responsibility
Improved relationships with neighbors, suppliers and
vendors.
Source: ADI Systems.
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Recovery of water for reuse. This involves more
extensive wastewater treatment, but is becoming a
significant driver to industries in water-stressed areas.
While these reasons are certainly practical, it may
be harder to put a value on social pressures, as
Lisa Schilling, marketing manager at Veolia Water
Technologies notes. With the social right to operate a plant in a community, manufacturers are doing
everything they can to retain or develop a positive
local reputation to protect their brand. Installation and operation of effective onsite wastewater
treatment is one way a manufacturer can ensure it
will be viewed positively by the local community it
operates in.
Having the right kind of waste stream also allows
processors to recover energy, according to Scott
Christian, ADI Systems vice president, business
development. Food and beverage processors can
generate high-strength wastewater that is amenable
to anaerobic digestion. Employing anaerobic diges-
tion wastewater treatment onsite not only drastically reduces the COD [chemical oxygen demand]
and TSS concentrations of the wastewater, it also
generates biogas that can be used onsite in boilers
and/or dryers, or to generate electrical power.
Specific compliance issues besides BOD and TSS
include a processors inability to meet wastewater
limits for pH; fats, oil and grease (FOG); and excess
nutrients such as nitrogen and phosphorous, which
have been problematic in many areas with ground
water contamination, says Stephen Schulte, manager,
environmental, health & safety, Hixson Architecture
& Engineering. Schulte also points out that in some
areas, there just isnt a POTW to handle processors
wastewater, so having one onsite is a necessity.
Dry times
Not every food and beverage plant has all the water
it needs, and many states are feeling the pinch of
decreasing water supplies as the climate changes.
Wayne Farms upgrades existing system to MBR

Anticipating increases to production, the Wayne Farms Pendergrass, GA facility wanted to update its existing SBR, lagoons
and land application system (LAS) wastewater treatment system.
The single-tank SBR and LAS had reached capacity and couldnt
handle significant additional flow. Wayne Farms applied for and
was issued a National Pollutant Discharge Elimination System
(NPDES) permit for direct discharge to Allen Creek, a tributary
of the Middle Oconee River watershed.
To meet the NPDES limits, Wayne Farms had to upgrade the
existing wastewater treatment plant to provide higher removal
efficiency. Considering the potential water shortage and drought
issues within Georgia, the processor wanted to recycle and reuse
the treated effluent in non-food contact areas within the plant.
The facilitys existing activated sludge (AS) system used
a 1.6 million-gallon SBR and aerated lagoon. Effluent
from the production facility was screened and had limited
equalization (EQ). From the EQ, the wastewater flowed to a
DAF unit, then an aerated lagoon, the SBR and a series of
lagoons for further treatment and storage. Treated effluent
flowed through the lagoons and was discharged through
the LAS. Waste-activated sludge (WAS) was stored in the
sludge lagoon.
As part of the new system design, the processor instituted a
multiple-polymer system for the existing DAF. The table shows
the influent design parameters following the DAF upgrade.
To meet the three main objectives for the wastewater treatment system upgrade, Complete Water Services LLC recommended an MBR system with de-nitrification, phosphorus
80
removal and ultraviolet (UV) sanitation. Since MBRs dont rely

on conventional settling and clarification, the concentration of
biomass can be increased, therefore, decreasing the overall
size of the system while increasing the amount of loading
the system can handle. Ultra-filters separate the mixed liquor
suspended solids (MLSS), providing a high-quality effluent
as permeate.
With the MBR, Wayne Farms existing SBR tank was converted to a bioreactor. The existing towers are sufficient to
maintain the biomass. The wastewater is intercepted after the
DAF, keeping the existing screen, limited EQ and DAF in service. De-nitrification and phosphorus removal add to the recyclability of the treated wastewater, which meets and exceeds
USDA FSIS requirements for reuse in poultry plants.
Influent design parameters

following the DAF
Parameter
Flow (MGD)
BOD (mg/l)
TSS (mg/l)
NH3 (mg/l)
Total nitrogen (mg/l)
P (mg/l)
Fecal coliforms (counts/100ml)
Source: Complete Water Services LLC.
Influent
0.8
450
100
22.1
100
24.3
TNTC
Effluent limit
<16
<10
<4
<103
<1.2
<200
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Key pluses/minuses of
aerobic/anaerobic systems
Aerobic systems:
+ Can achieve very low levels of BOD, NH3 and TN
+ Simultaneous N and P removals possible
+ Minimal odor when properly maintained
+ High-rate options allow for very small footprints
+ Dissolved oxygen in effluent reduces immediate O2 demand on receiving
waters
+ Less susceptible to load variations/upsets; quick recovery
+ Best for low-concentration effluents
+ Best option for colder climates/wastewaters
+ Low to medium capital cost
+ Good for all sizes of plants
+ Discharges from aerobic systems are often suitable for beneficial reuses
+ Depending upon the type of aerobic treatment technology, operations can
range from very simple to relatively complicated.
- Higher energy cost (compared to anaerobic treatment)
- Higher sludge production (compared to anaerobic treatment)
- May require nutrient supplementation
- Maintenance costs associated with blowers/mixers, aeration systems
- Require continuous operations; long shutdowns not suggested.
Anaerobic systems:
+ Ideal for heavily loaded systems
+ Produce biogas
+ Very low sludge production
+ Low operating costs
+ Minimal nutrients required
+ Seasonal operations possible
+ Generally low maintenance costs.
- May need to be constantly fed sodium bicarbonate to keep them basic for
methane formers
- Highly susceptible to toxic events
- Medium to high operating cost
- Not ideal (economically) for smaller plants
- May need to heat systeman issue in colder climates
- No significant N or P removal
- Low effluent values achieved only with aerobic post-treatment
- May require Class I, Div. 1 buildings for ancillary systems/equipment/buildings
- Higher capital costs (depending upon system/design)
- Effluent needs additional treatment (aerobic) prior to any potential reuse.
Source: World Water Works.
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} In an MBR, the membrane can be placed next to the
aeration basin (external or separate system, as shown in the top
image) or in the basin (internal or submerged, as shown at the
bottom image). External systems involve continuous crossflow
circulation along the membranes. Both tubular and flat plate
membranes are used to achieve this action. An internal system
involves the effluent being extracted from the active sludge
through the membrane by a permeate pump pulling water from
the biomass in the aeration tank. This normally involves the use
of hollow fibers or flat plate membranes. Source: CDM Smith.
States with POTWs that have been active in setting up water

reuse systems include California, Florida, Texas, Arizona,
Colorado and Nevada, according to the Bluefield study.
In a drought-stricken area, the cost of water can be a
significant operational expense or limitation, observes
Jeff Cumin, GE Water and Process Technologies senior
product manager. Wastewater reuse provides an
opportunity to avoid local limits of water consumption
and maintain or increase production without exposure
to increasing freshwater costs.
But, its not just availability or local limits on water
use that cause operational problems for processors.
Drought-stricken areas are being regulated more heavily than wet areas, says CDM Smiths Goodman. These
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GREEN SERIES
Alliance Dairies installed a DVO Two-Stage Mixed
Plug Flow anaerobic digester, which protects community
water and environmental quality by preventing runoff,
odor and greenhouse gas emissions in addition to
powering a 1,000kW on-site generator. Source: DVO Inc.
new regulations protect the pressures put on groundwater

use and include parameters for total dissolved solids [TDS],
nitrogen and phosphorus. Hence, more advanced wastewater
treatment processes for biological nutrient removal [BNR]
and membranes such as reverse osmosis [RO] for TDS
removal are necessary.
In drought-stricken areas, wastewater is valued as a potential
water supply source. Additional treatment technologies such
as filtration, membrane filtration, ultraviolet disinfection, carbon filtration and/or chlorination may be
employed to reclaim all or a portion of the wastewater
flow, says Schulte. Then, this reclaimed water can
be used for evap-condenser makeup, boiler makeup,
flume water and gray water for toilets, landscape
drip irrigation and cooling water.
A wastewater treatment plant can process water for
reuse to industrial standards, and its output stream can
be upwards of 40 percent or more, according to Darren
Gurney, senior process & business development, applications technology & innovation water treatment, Linde Gases. A
system can provide tertiary treatment and even produce potable
water by applying further refinement techniques such as ultrafilter (UF) membranes, RO and ozone/UV treatment. Some
plants may invest in techniques to get zero discharge, where they
recover effluent water from RO, sludge drying and dewatering.
This is practiced in some Persian Gulf States where water is very
expensive, adds Gurney.
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In some cases, water turnaround can be greater than 40 percent. For instance, utilizing a membrane bioreactor (MBR) system with Mitsubishi Sterapore hollow fiber membrane units,
Branston, a potato product producer in Somerset, UK, has
realized a 52 percent reduction in mains water usage. This was
accomplished by recycling process water through the system,
which includes extremely tight control of its 25 closed loops
and 50 analog measuring points, according to Heiko Gramsch,
Branston development project manager.
Aerobic digester systems
Aerobic wastewater treatment is a process where a mixed population of bacteria uses oxygen to degrade organic mattergenerally
quantified as BODand other pollutants, says ADIs Christian.
To facilitate the biochemical reactions, the biomass [activated
sludge] requires oxygen, nutrients [e.g., nitrogen, phosphorus] and
the adequate environmental conditions [pH, temperature, etc.].
The digestion of the wastewater organic material by the activated
sludge primarily generates carbon dioxide [CO2] plus additional
biological cells. While the CO2 escapes into the atmosphere,
the biological cells are wasted from the system at the rate theyre
generated to maintain a stable concentration of biomass within the
activated sludge system, adds Christian.
There are several types of aerobic configurations, with
the most common being activated sludge, sequencing batch
88
reactors, MBRs, trickling filters [bio-towers] and moving bed

biofilm reactors, explains Rick Molongoski, CDM Smith
Industrial Services Group, food & beverage division vice president. The effluent from an aerobic treatment can vary, based on
the influent and type of treatment, but can generally produce
an effluent with BOD, COD and TSS concentrations less than
30mg/l (30 ppm). While this water is suitable for discharge
to a public sewer or for stream or land application, it would
need additional treatment to be reused, adds Molongoski.
Modifications to conventional activated sludge systems,
such as MBRs that rely on physical membranes for solids retention as opposed to gravity clarification, can further improve
final effluent quality [free of suspended solids and containing
BOD concentrations less than 3mg/l], says Christian.
With subsequent unit operations after the aerobic treatment, the wastewater can be cleaned sufficiently to allow
direct discharge to the environment, says Bill Guarini, Kusters
Water industrial sales manager, food and beverage. Typical
post-aerobic operations include dissolved air flotation (DAF),
clarification, screening and filtration.
By combining aerobic technology with membrane filtration
or MBR, solids- and organics-free effluent can be produced,
which can be reused for non-food contact applications or further polished by RO treatment, offers Jeff Peeters, GE senior
product manager.
Effluent from activated sludge systems is known as secondary effluent, says Christian. It is suitable for reuse in grey-water
industrial applications such as makeup water for cooling towers or wash water for tanks and equipment. However, tertiary
treatment [such as nano-filtration and disinfection] is typically required to further polish the secondary effluent to meet
potable water standards, continues Christian.
There is no usable byproduct from an aerobic system, says
Ariel Lechter, president and CEO, Clean Water Technology,
Inc. The drawbacks are that [it] is more expensive to operate and generates a lot of sludge compared to an anaerobic
system. However, the aerobic system can be designed to make
the effluent stream as clean as necessary, according to Lechter.
While aerobic treatment is less susceptible to upset or
toxicity compared to anaerobic treatment, large pollutant
load swings can upset the balance of the overall system, says
Hixsons Schulte. In addition, aerobic treatment requires high
energy use for aeration, produces a high biosolids-to-sludge
yield and does not remove TDSs, he adds.
So why not combine an aerobic system with an anaerobic
system to handle really large applications? After all, nearly all
food and beverage plants generate wastewater that is amenable
to aerobic treatment. However, for some of these plants, the
operating costs associated with mixing and aeration, sludge
dewatering and disposal, and chemical addition [nutrients,
polymer, etc.] can prove to be very high, particularly for those

that generate a high-strength wastewater stream and/or a large
organic load, says ADIs Christian.
In some cases, the wastewater organic load generated by a
single food or beverage plant can be comparable to that of a
small town or city. When evaluating onsite wastewater treatment at a food or beverage plant, anaerobic pretreatment
followed by aerobic polishing often provides a more attractive
ROI than a system consisting solely of aerobic pretreatment.
Anaerobic systems produce energy
Anaerobic digestion is a complex biochemical reaction carried out in a number of steps by several types of microorganisms that require little or no oxygen to live, states Greg Parks,
World Water Works VP of technology. During this process, a
combined gas product composed mainly of methane [CH4]
and CO2, also referred to as biogas, is produced. The amount
of gas produced varies depending on the amount of organic
waste fed to the digester; temperature influences the rate of
decomposition and gas production, adds Parks.
Anaerobic treatment produces biogas, which is typically 65
to 75 percent methane and can be used as a renewable energy
source, says CDM Smiths Molongoski. A reliable and fairly
consistent loading to the anaerobic treatment process provides
a more dependable supply of CH4 biogas. However, the bio-
www.foodengineeringmag.com | Food Engineering | August 2015
89
GREEN SERIES
gas will generally require some pretreatment to remove water
vapor, sulfides and perhaps siloxanes prior to reuse, according
to Molongoski.
Since an anaerobic system needs a constant supply of rich
input, it can be a good option for a dairy operation. For example, the DVO Inc. two-stage mixed plug flow anaerobic digester
installed at Alliance Dairies (Trenton, FL) delivers enough
biogas to run a 1,000kW generator, supplying more than 70
percent of the dairys electricity. The digester also protects the
community and the quality of its water by reducing nutrient
runoff, odors and greenhouse gas emissions, according to Steve
Dvorak, DVO president.
Anaerobic treatment is generally not as effective at removing TSS, says Molongoski. It will not reduce nutrients.
Plus, it requires higher organic loading than aerobic [i.e.,
BOD>2,000mg/l] to be cost effective, produces an effluent
BOD typically in the 400 to 500mg/l range and may require
heating of the reactor if wastewater temperature is low. On
the other hand, anaerobic systems require no oxygen, so
energy costs are lower than with aerobic treatment. Disposal and dewatering costs also are significantly reduced as
a result of low sludge production. Consequently, anaerobic
treatment is typically the first step in reducing high-strength
wastewaters.
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Anaerobic treatment is well suited to the food and beverage

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waste produced in sugar beet, dairy or meat processing, says
AT&I Water Treatments Gurney. Disadvantages include an
effluent that needs further polishing, potential odor problems
and the risk of the sensitivity in the process itself. For instance,
to maintain a medium- to high-operating pH, the process needs
a continuous supply of influent substrate.
An anaerobic treatment system is typically energy positive,
says Mike Theodoulou, GE senior product manager. In other
words, the system generates more energy than it consumes. As
[biogas] is a byproduct of the treatment of organic waste, [an
anaerobic system] also reduces or eliminates disposal costs of
organic wastes.
MBR: A good polishing step
If a processor already has an aerobic or anaerobicor combinedsystem, but needs further polishing, an MBR can be
added. An MBR is the combination of a membrane process
like microfiltration or ultrafiltration with a suspended growth
bioreactor. MBRs are now widely used for municipal and
industrial wastewater treatment with plant sizes up to 80,000
population equivalent [i.e., 48 million liters per day], explains
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Ola Wesstrom, Endress+Hauser senior
industry manager, food & beverage. An
MBR separates clean water from the
activated sludge using membranes that
act as a filter.
Fresh Del Monte Produce Inc. is one
processor that uses an MBR to treat process wastewater. Installed at the companys
new plant in Oshawa, ON, the ALTECH

HydroKleen system treats 40,000 gallons
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An MBR system works by combining aerobic treatment with ultrafilters
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pended solids, says Jim Lewis, president,

Complete Water Systems, LLC. This process produces a very high-quality effluent and can offer many other benefits
including reuse-quality water, smaller
footprints and reduced chemical usage.
An aerobic MBR doesnt produce energy
byproducts, but it does require periodic
cleaning of the membranes. (Although
not common, there are also some anaerobic MBRs.) The MBRs biological system
must be maintained like any other aerobic system.
Among the three major types of systems, membrane bioreactors have the
highest rates of BOD, suspended solids
and phosphorus removal, says Hixsons
Schulte. These membranes create a positive
barrier at the end of the treatment process. In addition, they can pretreat process
water for reuse in the plant or for irrigation,
require a smaller footprint versus conventional aerobic systems and create a lower
biosolids-to-sludge yield than conventional
aerobic systems. However, membranes are
generally more expensive than conventional aerobic systems and are much more
complex because of the pumps and controls
required to operate them. More aeration
is also needed than with conventional systems, according to Schulte.
Aerobic MBR is becoming more common in the industrial wastewater market,
observes ADIs Christian, although it
does have some limitations with influent
FOG. Aerobic MBR systems produce
very high-quality effluent (nondetectable BOD and TSS), and extremely low
levels of nitrogen (<4mg/l total nitrogen [TN]) and phosphorus (<0.05mg/l
total phosphorus [TP]) are achievable.
Aerobic MBR effluent alone can be used
for water reuse in some applications and
provides ideal feed water quality to RO
systems for tertiary treatment, according
to Christian.
A number of MBR plants in the US
currently treat raw wastewater or anaerobically pretreated effluent. These include
beverage (juice and sports drink), dairy
processing (yogurt), potato processing,
breweries, snack foods and sauce processing facilities, adds Christian.
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Anaerobic or AnMBR technology is
ideal for treating high-strength wastewater
with high concentrations of TSS and FOG
that conventional anaerobic systems dont
handle well. It also produces a very highquality anaerobic effluent, free of TSS
and low in COD/BOD. (In some cases,
effluent BOD has been <25mg/l from an
AnMBR). In addition, AnMBR generates

biogas and maximizes the amount of its
production compared to other anaerobic
technologies, says Christian. Like aerobic system membranes, AnMBR systems
require membrane cleaning.
AnMBR systems are now operating at
a variety of food and beverage processing
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production, confectioneries, breakfast
foods and food waste-to-energy applications. AnMBR technology can be used to
upgrade existing anaerobic systems that
need additional treatment capacity and/
or require better effluent quality. Anaerobic systems can be retrofitted to AnMBR
systems by adding membrane filtration
and control systems, says Christian.
BNR protects the environment
In some wastewater effluents, nitrogen and phosphorus may be inherent.
Depending on the required use or disposition of the treated effluent, the inherent nutrients may need to be removed
to meet discharge requirements, so the
receiving municipal treatment facilities
or watersheds are not overloaded, says
GEs Theodoulou. BNR is an aerobic
process that is commonly coupled with
MBR treatment.
BNR systems are used for nitrogen
and phosphorus removal before discharge, says Veoilas Schilling. Aerobic BNR systems convert nitrogen
compounds and ammonia to nitrates
(known as nitrification), followed by
a denitrification process that converts
the nitrates to nitrogen gas, which is
given off to the atmosphere. The phosphates in the wastewater are typically
removed through precipitation and settling and/or filtration and remain in the
sludge produced by the processalong
with any minute amounts of nitrogen
compounds that may not have been
completely converted to nitrogen gas,
according to Schilling. Sludge containing phosphates may have economic
value as enriched bio-solids for fertilizer.
Using BNR combined with the membranes in an MBR can make effluent
as clean as needed. Additional biomass
can be processed by adding more oxygen to the system, adds Theodoulou.
This can make the solids in the effluent
negligible and reduce total nitrogen to
under 10mg/l. Phosphorus concentrations are dependent on how much chemical is added, but if needed, can be below
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A conventional activated sludge system can be upgraded to a BNR process by adding the appropriate tanks
and recycle arrangement, says ADIs
Christian. However, some activated
sludge technologies have an inherent
ability to achieve BNR. For example,
in a sequencing batch reactor (SBR), a
w w w. b e l t t e c h n o l o g i e s. co m
96
series of process events (fill, mix, aerate,

settle, decant or a combination of multiple events) occur in a single vessel. The
sequence and duration of event times
can be arranged so that BNR is achieved
with SBR technology, eliminating the
need to have multiple tanks dedicated
for single-process reactions. Further-
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comprehensive resource for applicationspecic design and manufacture of metal
belts, metal tapes, and pulleys. We invite you
to contact Belt Technologies to discuss your
ideas with a member of our engineering staff.
Belt Technologies, Inc. 11 Bowles Road, Agawam, MA 01001

Tel: (413) 786-9922 Fax: (413) 789-2786
E-Mail: engineer@belttechnologies.com
www.belttechnologies.com
more, SBR technology provides a higher

level of process control, as the sequence
and duration of events can be changed by
the operator on the fly to quickly respond
to process requirements.
Incorporating MBR technology into
an activated sludge system capable of
achieving BNR results in complete control of solids retention time and eliminates problems with poor sludge settling,
adds Christian. Conventional BNR
systems may experience problems with
sludge settling, causing biomass washout, which can result in process upsets
while the biomass recovers, particularly
a slow-growing nitrifying population.
However, membranes provide complete
retention of suspended solids, eliminating the problems associated with sludge
settling. Additionally, membrane barriers
provide an effective means of preventing the chemical phosphorus precipitate
from being discharged into the effluent.
Have it both ways: Clean water
and a good ROI
Many processors must implement an onsite
wastewater treatment system to keep costs
under control, reuse water, meet regulatory
requirements and/or keep up a good public
image. But, can an ROI be expected soon
after implementation?
Each wastewater stream has to be
considered separately, says Veolias Schilling. Some streams require little or no
treatment, so they may be the first candidates for reuse. Water reduction can
be achieved by charting the process for
water usage and minimizing excessive
use before employing water treatment
methods. Keep in mind that most water
recycling applications require a combination of treatment approaches.
AT&Is Gurney has seen MBR applied
to brewery, malting, salad, vegetable,
dairy and other food operations. Some of
them recycle wastewater back to the process. The number of plants is not huge,
but there is an increasing trend in water
reuse being driven by the turnaround
cost of water.
Its important, however, to look carefully at all the potential costs of setting up
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GREEN SERIES
a system. We have found four operating cost factors that are typically underestimated when ROIs are performed:
labor, chemicals, maintenance and disposal, says Hixsons Schulte. The hiring and licensing of operators can be
another significant factor. Licensed
operators are typically certified by the
state in which they work. There are

several classes of operators, with each
certified for a certain level of treatment
type and complexity. If the wastewater
treatment system discharges directly to
surface water, an onsite licensed operator will be required by the state. If the
wastewater treatment system discharg-
SlipNOT
countless safety solutions
es into a sewer system, an onsite licensed

operator may or may not be required
by the state or the local sewer district,
explains Schulte.
The potential costs of power, restrictions on manufacturing capacity, steam
and external funding also should be
considered. Speaking of external funding, it doesnt hurt to check in with local,
state and federal authorities to see what
money may be available to aid in the
implementation of a wastewater treatment system. Most A&E/C firms and
wastewater treatment equipment suppliers can help with this determination. For
a more detailed checklist of factors to be
considered in determining the ROI of a
system, see box, ROI wastewater treatment system development cost factors,
on page 78.
References:
1
Water Recovery and Reuse: Guidelines for Safe Application of

Water Conservation Methods in Beverage Production and Food
Processing, ILSI Research Foundation, Washington, DC, 2013,
www.ilsi.org.
US Wastewater Market to Total $11.0 Billion Through 2025,

Bluefield Research, July 2015, www.bluefieldresearch.com.

Al Goodman, CDM Smith, 502-339-0988,
goodmanaw@cdmsmith.com, www.cdmsmith.com
Lisa Schilling, Veolia Water Technologies, 815-609-2000,
lisa.schilling@veolia.com, www.veolia.com
Scott Christian, ADI Systems Inc., 506-452-7307,
scott.j.christian@adi.ca, www.adisystemsinc.com
Stephen Schulte, Hixson A&E, 513-241-1230,
sschulte@hixson-inc.com, www.hixson-inc.com
Jeff Cumin, GE Water & Process Technologies, 215-355-3300,
stainless steel plates
and stair treads
jeff.cumin@ge.com, www.gewater.com
Darren Gurney, AT&I Water Treatment, Linde Gases, +44
01483 579 857, darren.gurney@linde.com,
www.lindewatertreatment.com
Bill Guarini, Kusters Water, 864-576-0660,
bill.guarini@kusterszima.com, www.kusterszima.com
Rick Molongoski, CDM Smith, 518-782-4500,
molongoskira@cdmsmith.com, www.cdmsmith.com
Photo courtesy of A&B Process Systems
Ariel Lechter, Clean Water Technology Inc., 310-380-4648,

www.cleanwatertech.com
See us at Pack Expo | Booth #S-7631
Jeff Peeters, GE Water & Process Technologies, 215-355-3300,

jeff.peeters@ge.com, www.gewater.com
Greg Parks, World Water Works, 405-943-9000,
slip resistant metal ooring products

NSF registered for use in food processing facilities; SlipNOT slip resistant stainless
steel oor plates are designed for applications where sanitation, durability, and
safety are vital. Chemical and corrosion resistant, SlipNOT stainless steel products
are custom manufactured to meet specic project needs.
gparks@worldwaterworks.com,
www.worldwaterworks.com
Mike Theodoulou, GE Water & Process Technologies,
215-355-3300, michael.theodoulou@ge.com,
www.gewater.com
Ola Wesstrom, Endress+Hauser, 888-363-7377, ola.
wesstrom@us.endress.com, www.us.endress.com
Jim Lewis, Complete Water Services, LLC, 678-355-9270,
jlewis@cwaterservices.com
Steve Dvorak, DVO Inc., 920-849-9797,
meat processing dairy beverage processed foods poultry
www.slipnot.com 800.754.7668
Photo taken by: A&B Process Systems Corp.
98
steved@dvoinc.net, www.dvoinc.net
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AUTOMATION SERIES
Solutions for
improving yield
are within reach
} Finlands biggest
dairy company,
Valio, boosted the
production of its
Lapinlahti whey
powder plant
by more than
10 percent after
implementing a
NAPCON APC
solution from Neste
Jacobs. While
boosting yield, the
drying system uses
the same amount of
energy it did before
installation of the
model-predictive
control-based APC
system. Source: Neste
Jacobs.
Youve done the obvious, so where else can you look to squeeze
out more product?
} Wayne Labs, Senior Technical Editor
ou add up the mass of raw materials

your facility consumes each day, look
at the products its made, and the
numbers just dont balanceuntil
you look at skids of rework and a
dumpster topped off with the days malformed
products and/or damaged packages. What went
wrong, and how do you get a handle on it?
There are many places in a food plant where
yield can be improved and, most likely, quality too.
Some are more obvious than others. Sometimes, a
multitude of factors comes together and stacks up
against a days production. Issues may be found,
for example, in controlling the ingredients being
combined into the recipe, filling and packaging
not to mention controlling temperatures in critical
applications. Fill weights, quality and food safety

can also affect yield. But finding the root causes of
these yield problems takes an investment in measurement and control solutions, which have been
shown to pay for themselves rather quickly.
When it comes to finding solutions to increase
yield, it may seem all the low-hanging fruit has
already been picked. But for many processors,
some of that low-hanging fruit has been missed,
and it can easily be found by making some measurements. The old adage, You cant control what
you dont measure, still applies.
There are still gains to be realized in managing
the risky aspects of operationsfrom line startup
to changeovers to new product introduction, says
Eric Lemaire, Schneider Electric Global Solutions
101
AUTOMATION SERIES
A simple solution for improving machine control and yield, a small

PLC/HMI combination (IDEC FT1A SmartAXIS Touch) controller can
work with a bag filling or other application to provide automated cycle
and process control, in addition to providing data output to other
hardware and data collections systems. Source: IDEC.
director, food and beverage strategy.

Directing the steps and activities,
monitoring for problems, detecting
leading indicators or an actual event
and notif ying and orchestrating a
response can become a competitive
advantage to those who invest in a
sense-and-respond solution.
According to Ron Pozarski, senior
marketing manager for Rosemount
Flow Products, Emerson Process
Management, process optimization
and maintaining an optimized operation over the life of the process can
significantly improve and maintain
yield, increase uptime and reduce
energy usage. But processors often
find themselves tr ying to reduce
downtime while coping with reduced
effective capacity due to both internal
and external regulatory compliance requirements.
To improve yield, the focus of food manufacturers is
usually on optimizing the areas of an operation that cause a
production run to be outside the processs standards, says
Arvind Rao, Rockwell Automation NA food and beverage
Improving yield big time

Kangaroo Brands Inc. is a fast-growing maker of ready-to-serve
pita bread and sandwiches. To keep up with demand, the processor realized investing in an end-of-line automated cartoning system with the ability for quick changes was an absolute
necessity. Floor space, however, was limited. It chose an Ultra
Packaging, Inc. compact, servo-driven Veronica VHL vertical
cartoner, powered by a complete drives/control system from
Bosch Rexroth Corporation.
The seven-axis cartoner enables 10 to 15 minute changeovers
and uses servo technology that reduces linkages and machine
components by 60 percent compared to prior models. Cabling
costs were down by 40 percent, and field wiring dropped by 40
percent due to industrial networking (such as Sercos III, PROFIBUS, PROFINET and EtherNet/IP).
Since the installation, Kangaroo monthly production has
grown exponentially from the original throughput of 250,000
pieces per month. Now, the processor produces seven different
types of frozen RTE sandwiches made with pita bread baked on
the premises and packaged in multiple carton sizes (four-, six-,
12- and 14-count) for large retailers and big-box stores.
According to Kangaroo Plant Manager Justin Rice, During
an average week, we may perform 16 to 18 carton changeovers
for various customers. Typically, they only take 10 to 15 minutes.
Plus, with a Rexroth VCP 35 HMI, operators have complete
102
Bosch Rexroth automation provides the backbone for the

Ultra Packaging Veronica vertical cartoner, boosting yield for
Kangaroo Brands by a factor of 10. Source: Bosch Rexroth.
machine control; IndraWorks software provides the tools for

project planning, programming and diagnostics.
The new system has provided a 10-fold increase in production
compared to the older manual methods, fits the existing floor
space and has saved $130,000 per year in workforce costs. In
addition, the cartoner saves about $20,000 per year in cartoning
supplies.
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Shredding
Granulating
Milling
Grinding
Pureeing
AUTOMATION SERIES
to the divider to
improve precision.
But first, finished
pack age weights
would need be
measured to determine the baseline
giveaway loss.
W hen it comes
to c h a nge ov e r s ,
not executing them
ef fectively may
result in more loss
or bad product
being made from
one run to another.
But, implementing
continuous improve ment methLegend
Input costs (total)
Processing costs
Average per unit cost versus mean
Current Distribution
Optimal Distribution
odolog ies along
with software tech} Newly patented,
industry commercial manager. A less common nologies to measure this data automatically can begin
WinSPC Cost
focus is refining the limits of a processs con- to shine a light on opportunity areas, adds Moore.
With complex systems, software can be an issue
Inspector from
straints, which allows manufacturers to know how
DataNet Quality
much material should go into each product and in itself. Developing software to automate material deliveries can quickly become complicated
Systems translates
create less waste with every production run.
traditional process
However, many food manufacturers systems when programming a process control system, says
metrics into
may be unable to maintain process control with Randy Otto, vice president of ECS Solutions, a
dollars saved
more refined constraints, adds Rao. This lost member of the Control System Integrators Assothrough process
opportunity to improve yield is why an advanced ciation (CSIA). Systems with valve clusters that
improvement.
process control system is important for manufac- allow ingredients to be sent to multiple vessels can
complicate the software. Common solutions to
Traditional SPC tools, turers that need to increase efficiency over a large
obtaining accurate deliveries include slowing the
such as Cpk statistics variety of product lines to remain competitive.
delivery of a material throughout the delivery cycle
and cost estimation
or toward the end of the delivery cycle (dribble
methodologies
It starts with the ingredients
like Taguchi Loss
The most common raw material loss areas in flow or dribble speed). Herein lies the issue, continues Otto. The end-user must sacrifice speed
Functions, are helpful the food and beverage industry are related to
but typically provide
net-weight fill and changeovers, observes Katie [performance] to obtain quality. Overall yield is
partial costing
Moore, GE Intelligent Platforms global industry a product of performance and quality, so reducmanager. Consequently, many manufacturers ing one to increase the other produces a minimal
solutions. Source:
focus on these first. Moore, who once served as a result. Yield is significantly improved when you
DataNet Quality
Systems.
food plant manager, has seen these issues firsthand. can increase performance or quality while mainThe limitations around net-weight fill may be due taining or increasing the other.
to the precision (or lack thereof) of the equipment
Performance issues are reflected back to yield
processing the products. For example, when a cer- and quality opportunitiesand even more on
tain large snack food manufacturer employed tools high-speed production lines, says Tom Braydich,
to check fill, daily waste went down from 2,000 to senior consultant at Matrix Technologies, a mem200 lbs., film was saved, and net-weight fill opti- ber of CSIA. Some of the issues are improper
mization resulted in six to seven figures of dollar line balancing to prevent surges and stoppages,
savings per plant.
ill-maintained equipment, product and material
Moore offers another example: In baking, a supplies (cans, bottles, cartons, labels, etc.).
processor may have a divider that doesnt measure
Matrix Technologies can help with an overall
each dough ball precisely. In this case, modifica- equipment evaluation and modification of filling
tions or improvements may need to be made and packaging systems to ensure line coordination
Current Process Mean: 20.057 (oz)
Optimal Process Mean: 19.548 (oz)
Process Shift: 0.509 (oz)
104
Avg Cost/Unit: 0.8023 ($/unit)

Cost of Process Variably: 0.0219 ($/unit)
Optimal Cost/Unit: 0.7819 ($/unit) Process Variability Sensitivity: 0.2915 (%/10%)
Cost of Process Shift: 0.0204 ($/unit)
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AUTOMATION SERIES
among OEM vendors. When a line is designed so

all the equipment operates as one coordinated unit
multiple staffing
[regardless of the OEMs involved], the throughput
levels to view
can increase dramatically, adds Braydich. Large
SPC data and
improvements can be realized through a simple
other production
investment in automation for the overall line verparameters that
sus the individual machines.
affect product
Other issues also can complicate raw ingredients
quality. The system
and formulation. Production yield for a given forleverages ICONICS
mulation varies depending on the raw ingredients
Hyper Historian for its being used [e.g., the quantity of denatured proteins
core data collection
in milk affecting yield in cheese making], says
and calculations; its
John Tertin, director of manufacturing informaarchitecture supports tion systems, ESE Inc., a member of CSIA. Makenterprise-wide SPC
ing in-process adjustments to account for variance
quality programs, as
in the raw materials can recover yield that would
otherwise be lost in processing.
well as applications
Another issue related to measuring ingredients
that require very fast
is the mating of piping with the flow meters in a
sample rates. Source:
system. When adding new flow meters to improve
ICONICS.
data collection, we check the piping design to
Quality Analytix
software enables
improve the performance of the flow meters, says

Robin Cobb, project manager at Polytron, Inc.
We often find a piping design is not conducive to
the best practices for measuring density set points.
Related to mass flow meters, Cobb suggests automating density set points to ensure standardization of how density is measured, taking it out of
the operators hands and guaranteeing accurate,
apples-to-apples comparisons.
Another common issue is the control of product
loss at transfer points, according to Arun Madangarli, Polytron senior engineer. In a beverage
process, for example, loss typically occurs in two
areas: the unit operations that are part of the
process and during the transportation of product
through the process line when it is transferred
from one stage to the next. Over time, the loss at
these points can be a significant amount.
For a small operation, however, waste can be
improved with relatively simple automation. For
example, a bag filler can be automated with a
Tackling previously untackled quality/

production yield issues
Many manufacturing plants dont know they have quality/production yield issues until they implement various lean manufacturing initiatives. Some of these issues include:
The products are in spec (meeting the recipe for quality), but
the filling process is not capable of being stable, e.g., over- and
under-filling.
No plant visualizationOperators have no real-time visualization of a control process and can only react to past events.
Random defects such as product contamination, incomplete
coating or enrobing.
Systematic defectsDefects are predictable, based on past
measurements.
106
Lack of process knowledgeOperators adjust set points to

compensate for new or perceived problems.
First pass yield is low, and scrap/waste count is very high.
Not performing 100 percent inspection.
Not logging the correct critical parameters.
Environmental controls affect process quality.
Performing SQC only catches 80 percent of the defects.
Changing to a real-time SPC solution can increase that percentage.
Source: Iconics.
AUTOMATION SERIES
When reliable sensor data is needed to improve throughput and
yield, slip rings on moving machinery are a constant maintenance
headache. The Clever Sleever machine places and wraps decorative
sleeves on bottles at a rate of 15,000 pieces per hour. To maintain data
integrity, the machine builder installed ProSoft Technology Hotspot
radios and radiating cable to move sensor data from rotating rounding
tables to stationary terminal devices, increasing uptime and yield.
Source: ProSoft Technology.
weigh scale and a small PLC and HMI in the same housing,
according to Don Pham, IDEC product manager. The IDEC
combined HMI+PLC unit provides the automatic cycle and
process control required for a bag filler and frees up the operator to tend to other plant operations. Variable fill rates and
impeller speeds are controlled by the unit based on readings
from the electronic weigh scale. The automation assures each
bag will be filled to the correct level, without overfill.
Beyond the low-hanging fruit
Sometimes, figuring out what is causing a yield and/or quality
problem can be difficult, but often, it is very process specific
and can be tied in with ingredients. If the product is baked,
there may be issues around a consistent, thorough bake in
the oven, states GEs Moore. Another partially ambiguous
loss areaor one that may be harder to pinpointis the
Are Your Retorts Using

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regular processing cycle. And many plants consume large
volumes of hot water through the use of CIP systems,
heat exchangers and plant environment heating systems.
Allpax water recovery and reclamation systems reduce your
water usage by as much as 50% and save you money on
energy costs by recapturing and diverting the hot water
created by retorts for use in other areas of your plant.
Go to www.Allpax.com or call 1-888-893-9277 to learn
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108
YOURE LOOKING AT TWO

PRODUCTION LINES.
CAN YOU SPOT THE
DIFFERENCE?
No? Thats because the difference between these two lines is
their bottom lines. One produces 5% less waste and 8% more
output. The manufacturer even added a SKU without adding
another line, which lowers costs and maintenance needs.
Just picture the possibilities for your operations.
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Get connected. Get insights. Get optimized.
AUTOMATION SERIES
actual effect of varying raw material specifications on finished
products. For example, in baking, slight fluctuations in protein
in the flour [negative or positive] affect yield. This can be hard
to determine if the specifications arent tied to the lot digitally.
Incorporating actual raw material properties into the production process saves time and ensures product quality. For
example, in an extraction process, the amount of water needed to reach a desired finished product total acidity [TA] is
dependent on the TA of the raw ingredient, says ESEs Tertin.
You could add about 80 percent of the water, test to determine how much more is necessary and add the remainder.
But, [if you incorporate the quantity and TA of the raw material into the process], you can add exactly the right amount of
water to begin with and ensure consistent yield and save time
in that portion of the process.
Human factors, such as a lack of process knowledge,
are additional considerations, according to Carl Harper,
ICONICS project engineer. Increasing set points to make
production line or individual machines run more quickly to
meet targets affects quality. But, without process knowledge,
employees may believe, If the line/equipment is running, we
are in control, and all is well. Consequently, when it isnt running properly, nobody knows why or how to fix it.
In addition, when working with dense products like soup,
bread and cookie dough, end-of-line checkweighers can pro-
vide a false sense of control over product final weight, says

Matrix Technologies Braydich. The fluctuation of weights
may be the result of recipe errors due to a faulty flow meter,
scales or worker behavior. Whatever the cause, an operator
will repeatedly adjust the filler or depositor weight all day
long. The consumer will get the correct weight, but the quality of the product will be the big question.
Maintenance and control software also can have a positive
or negative effect on yield. Processors are becoming increasingly aware that reliability centered maintenance [RCM] can
keep equipment in optimal operating condition and provide
the highest availability [improving yield and meeting quality
targets], says Schneiders Lemaire. Technology developed
and used in heavy industries is finding its way into food and
beverage processing plants maintenance practices. (For
more on RCM and predictive maintenance, see The future
looks smarter, FE, July 2015.)
Software solutions
Control software plays a big part in improving yield. However, more obscure yield and quality problems frequently can
be masked or made unattainable by just-average controller
software, according to ECS Solutions Otto. Controller software is only as good as the engineer who developed it, and
often, the developer is under critical constraints [e.g., time,
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AUTOMATION SERIES
budget or scope issues] that prevent him or her from developing the best solution. The controller software can become
complicated, especially over time with multiple developers
adding to it, creating greater challenges and barriers to make
improvements to the system performance.
Many processors turn to commercial off-the-shelf (COTS)
software packages that log, analyze and report data in numerous ways to identify the greatest problems in a system. Otto
says that while MES packages with these options promise
great benefits, they are costly to purchase and implement.
Plus, while they may identify areas of constraints, they seldom offer solutions. ECS has implemented numerous flexible
solutions, replacing or enhancing controller software, and
providing a means for end-users to optimize performance
gradually. Our customers have discovered low-hanging fruit
they were unaware of, realizing performance increases of 20
to 40 percent, as well as improved quality and a 5 percent
increase in availability, concludes Otto.
Implementing a manufacturing intelligence solution
enables long-term process improvements that can help make
a plant more flexible and improve margins. Tyson Foods
was experiencing unacceptable variances in the weight of
Hillshire Brands plastic-wrapped breakfast sausage, or chubs,
causing waste and rework, recalls Rockwells Rao. The
MATERIAL MASTER
company turned to FactoryTalk software to better understand exactly where the variance issues were being created.
This [software] update changed Tysons available data from
an ex post facto report on how much waste was produced to
dynamic, real-time data on weight fluctuations along the line,
the exact giveaways on finished product, machine downtime,
OEE and meat temperature. The plant ultimately saw an
increase in yield of 0.50 percent, which is more than half a
million pounds of sausage annually.
Methods and procedures to find yield problems
What methods or systems should processors employ to find
and fix yield issues? First and foremost, are the collection
of key information [set points, temperatures, weights, flows,
counts, etc.] in the process and linking it by time, schedule
and batch, says Braydich. Simple SPC [statistical process
control] methods like upper and lower control limits applied
against the data will identify variation in blending and batching processes. Braydich reports food processors realizing
ROIs from 20 to 30 percent. Typically, yield improvements
precipitate savings in other areas like OEE.
Using SPC helps operators monitor processes in real time
and reveals process variations including out-of-control and
trend issues, says ICONICS Harper. In addition, perform-
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Legacy Food Processing Equipment

Giving You A Headache?
Reliability Problems?
Cleanability Problems?
Standard, food grade, and even some stainless steel servo
motors were not designed to withstand wash-down environments
or be hygienic. Motors fail prematurely causing significant
downtime. These motors are difficult to clean and the covers that
protect the motors or the motors themselves become pathogen
grow niches.
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2015 Kollmorgen Corporation. All rights reserved. KM_AD_000243_RevA_EN Specifications are subject to change without notice. All trademarks are the property of their respective owners.
AUTOMATION SERIES
ing 100 percent inspections allows users to capture and store
more data. SPC informs operators of process stability and
capability by exposing key metrics like Cpk (process capability) and Ppk (process performance). Harper also suggests
implementing a solution for Six Sigma, ISO 9000 and Total
Quality Management (TQM) initiatives. In addition, using
fault detection and diagnostics (FDD) technology helps
identify faults in the process (e.g., an oven temperature greater than x for five seconds). An FDD solution can also point
out energy surges and detect how many times they occur.
A mass-balance reporting system that encompasses the
entire production line (from bulk material intake to finished
product storage) is another method that can track and quantify product loss, says Polytrons Madangarli. While a typical
report measures yield in terms of units relevant to the corresponding process area [gallons, cases, bottles, etc.], massbalance reports compute yield in units of mass [lbs. or kg].
This gives a much more accurate picture of the process yield,
especially if a precise, real-time measurement of the product
density is available.
ESEs Tertin recommends using advanced control techniques
and inline instrumentation plus maximizing data integration
between the ERP/MES and control system layerseither
directly (in a non-isolated networked environment) or by the
LAN Handling Systems
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114
use of barcodes/RFID tags. SPC calculations are part of ESEs

Q5 analytical software package. One Midwest cheese processor achieved a complete payback on a Q5 analyzer in 150 days,
based on QC consumables and lab hard-cost savings.
For material deliveries within process systems, ECS uses
statistical spill value tracking to meter every ingredient to
every location, explains Otto. With this method, we can not
only substantially increase accuracies in material deliveries,
which improves quality, but also increase yield by calculating
a very accurate spill value at full speed. By employing this
method, one food processor recently realized a 30 percent
increase in performance, improved quality and a 5 percent
greater equipment availability.
Advanced process control [APC] and model predictive
control [MPC] are effective in increasing process yield and
reducing out-of-spec product at the beginning and end of a
process run, says Emersons Pozarski. Precision measurements can decrease overfill without risking under-fill in packaging and filling applications.
While APC or MPC applications arent for everybody, they
can be very effective in certain applications. According to
Pozarski, a major brewery reduced beer loss by 1 percent, saving over $70,000 per 1 million barrels brewed, by identifying
the unexpected loss of yield in a process unit and correcting
AUTOMATION SERIES
the root cause. In another case, a beverage processor eliminated a process
bottleneck in its mix room, increasing
available capacity by a factor of four, by
updating its traditional batch weigh system to one that simultaneously blends
liquid components into the mix tank
through precision flow meters.
Many software packages that may

provide incremental value have different
capabilities including SPC and nonconformance management, says GEs
Moore. But, the fundamental priority
for a manufacturer is to make sure the
system is built on an open platform to
be able to access the data and work with
Innovative extrusion processes without limits. With our

extensive extrusion know-how and passion for customized
solutions, Bhler strives to generate added value for any
product concept breakfast cereals, snack foods, modified
flours and starches, and texturized proteins. We offer one of
the most complete lines of process technology available:
from raw material handling, cooking and shaping, through
extrusion to drying. In short, extrusion processes without
limits.
Visit us at Pack Expo 2015; booth 8001.
September 28 - 30, 2015. Las Vegas, NV.
Bhler Inc., PO Box 9497, Minneapolis, MN 55440, 763-847-9900,
buhler.minneapolis@buhlergroup.com, www.buhlergroup.com
Innovations for a better world.
116
other systems for scalability and repeatability purposes. A standalone, disparate

system may provide initial value, but over
time, the cost to manage and maintain
another system outweighs the benefits.
Prepare for improving yield
Sensors are at the edge (or periphery)
of holistic systems that measure plant
operations, says Schneiders Lemaire.
They sense and measure the process and
primarily detect when things go wrong.
At a minimum, control systems, as
well as some automation and instrumentation, should be installed wherever
possible, observes Moore. A processor
must be able to measure product flow as
it moves throughout the entire process.
Software can then be added to aggregate
and correlate that data and information.
In many applications, weigh scales can
be upgraded or replaced to obtain this
data, says Braydich. Plus, flow meters
can both improve throughput and
increase accuracy in batch applications.
When materials can be added simultaneously, batch time can be reduced significantly while improving consistency
between the batches.
According to Tertin, depending on
the process area, additional hardware
may include analytical instrumentation,
2D barcoding systems, Coriolis flow
meters, proximity sensors and smart
devices such as Ethernet-connected
VFDs, weight controllers, load cells,
X-ray systems and metal detectors.
Fortunately, new systems come with
sensing devices, but sometimes, they
require a little adjustment. For example,
ECSs Otto describes a recent optimization of a bourbon bottling line: The
optimization required software changes and moving existing bottle sensors
around on the line to increase performance and quality. New and additional
VFDs and sensors were recommended to
help reduce impacts of the glass bottles
and further optimize the performance.
Integrating sensors with process control
systems also improves a systems performance. Otto notes that one CIP system
delivered by ECS with integrated sensors
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AUTOMATION SERIES
and software helped the end-user reduce
CIP time from 13 hours per week to four
hours per week, improving the availability and yield of the process equipment.
Is historical data needed?
One final question: Does a processor need a repository of archived pro-
cess data to install software systems that

can monitor yield and performance?
Historical data will always be helpful
in implementing new systems, although
new systems for improving yield have
been implemented without it, answers
Rockwells Rao. What makes historical
data significant is its ability to provide
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context to the improvements made by a

new system. For instance, historical data
can set a good baseline for understanding
how much value a project will add.
Without hard data, there w ill
always be a certain amount of conjecture regarding the potential gain [of a
new project], says Tertin. For some
customers, this is acceptable, given
their desire for short-term, incremental
improvement; for others, it is not.
Historical data can be used to compare
improvements made by automating a
particular work step. For instance, with a
bagging machine, the data could include
the amount of labor necessary to operate
it manually, the required rework from
operator errors and the reduced throughput due to waiting on required operator
actions, according to IDECs Pham.
GEs Moore suggests that while a processor does not need to have any historical data
to begin implementing a system, reviewing
the data should be the first step in looking
at technology to aid yield improvement. A
processor should ask three questions about
collected data before embarking on this
process: Am I collecting meaningful data?
Do I have a strategy to store and access the
data I collect? Have I prioritized the outcomes I desire?
Eric Lemaire, Schneider Electric, 949-727-3200, eric-s.
lemaire@schneider-electric.com, www.schneider-electric.com
Arvind Rao, Rockwell Automation, 440-646-3434,
avrao@ra.rockwell.com, www.rockwellautomation.com
John Tertin, ESE Inc., 715-387-4778, tertinj@ese1.com,
www.ese1.com
Katie Moore, GE Intelligent Platforms, 800-433-2682,
katie.moore@ge.com, www.ge.com
Randy Otto, ECS Solutions, 812-479-5170,
randy.otto@ecssolutions.com, www.ecssolutions.com
Robin Cobb, Polytron Inc., 855-794-7659,
rcobb@polytron.com, www.polytron.com
Arun Madangarli, Polytron Inc., 855-794-7659,
amadangarli@polytron.com, www.polytron.com
Tom Braydich, Matrix Technologies, 419-897-7200, ext. 306,
tmbraydich@matrixti.com, www.matrixti.com
Don Pham, IDEC, 408-747-0550, donp@idec.com,
www.idec.com
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Carl Harper, ICONICS, 508-543-8600,

carl.harper@iconics-uk.com, www.iconics.com
Ron Pozarski, Emerson Process Management, 952-8283434, ron.pozarski@emerson.com, www.emersonprocess.com
Frank Tappen, DataNet Quality Systems, 248-447-0120,
ftappen@winspc.com; www.winspc.com
609-265-0101 | www.volkmannUSA.com
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118
Dave Boeldt, Bosch Rexroth, 1-800-REXROTH, dave.

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2015 Hapman. All rights reserved.
T E C H U P D A T E : F I LLI N G EQ U I P M E N T
Debra Schug, Features Editor

The SIG Combibloc
high-speed filling
machine requires
almost the same
space and manpower
as previous models,
but has six tracks
instead of the
previous four. Source:
SIG Combibloc.
Meeting great expectations

As consumers want a bigger variety of healthier choices that
come in a plethora of sizes, manufacturers are offering fillers that
are flexible while producing optimal output.
lame social media, changing tastes and

needs or just the Have it your way attitude inspired by Burger Kings decadeslong slogan, but modern consumers are
demanding. In fact, a recent GNT Group study
reports two-thirds of shoppers are checking the
labels of food and beverage packages before purchasing the products, and the majority of these consumers are ensuring the products have no artificial
additives or preservatives.
According to Innova Market Insights, the number
one trend of 2015 is From Clean to Clear Label,
which underscores the growing demand for more
naturally based food and beverage products. Food
processors are responding; companies like General

Mills and Kraft continue to announce they are ridding their products of artificial flavors.
Food and beverage companies are certainly looking for ways to tap into the clean eating trend, says
Roberto Mastri, technical support and quality director of North, Central and South America for Tetra
Pak. And, thats impacting how manufacturers are
looking at processing and packaging technologies.
Moreover, todays consumers are looking for a
wider variety of foods and beverages in an assortment of flavors and a number of different sizes. With
all of these rapid changes in consumers preferences, food and beverage producers must be able
121
T E C H U P DAT E

The JBT rotary,
volumetric Unifiller
unit is designed
for accurate filling
with fast and
efficient product
changeovers. The
clean-in-place
feature makes
disassembly and
manual cleaning
unnecessary.
Source: JBT Food
Tech.
122
to respond to trends quickly. Thus, the flexibility

of filling machines has become a crucial part of the
production lineequipment that can handle different products filled into various types of containers
without sacrificing accuracy or speed.
Improved product flexibility
Some processors looking to offer more natural
foods and beverages are increasingly turning to
aseptic processing. In fact, the aseptic market has
grown 9 percent annually and is estimated to be
worth over $35 billion, according to research by The
Freedonia Group.
As consumers continue to analyze ingredient
panels, we see a growing demand for products that
dont contain added chemicals or preservatives,
says Mastri. Aseptic processing and packaging meet
this demand by protecting food and beverages without the need for these additives.
According to Mastri, processors should take into
consideration the types of foods and beverages they
process and consider their impact on the final product. For example, tea is a naturally alkaline product
that can be processed using high-acid hot fill, but
aseptic is a much better match.
Rather than adding acid and masking that bitterness with sweeteners as you would with a hot
fill process, aseptic processing enables the cleanest
possible label for packaged shelf-stable tea: tea plus
water, Mastri explains.
SIG Combibloc offers aseptic food filling machines
that accommodate a wide variety of foods, such as liq-
uids or foods with a pasty or chunky

consistency that can be packaged with
long shelf lives. The machines can
aseptically fill into carton packs food
products containing particulates up
to 25mm in length and with up to 50
percent particulate content.
These types of filling machines are
important since one of the changes
in product formulations spurred by
a focus on healthier foods, as well
as manufacturers efforts to differentiate brands, is the call for larger,
better defined particulates in products. These types of [more natural]
products are typically much thicker in
viscosity, observes Rod Gregg, vice
president of sales for Hinds-Bock.
Without the right options on the
machines, these products can be troublesome for a filler.
Food products with a very high
particulate content have difficulty flowing freely and
passing through a pumping system and an aseptic
process. For these kinds of products, SIG Combibloc offers the heat-resistant, retortable combisafe
carton pack. This system uses three modular filling
units with a high-precision multi-head weigher. The
three-stage filling technology allows varying sizes
and quantities of an ingredient to be added according to user specifications.
Precision and accuracy are still top of mind for
processors. Particulate product damage and drain
weight inconsistencies are not tolerated anymore,
says Jan Sundberg, application development manager for JBT Food Technology. This has led to
requests for new types of fillers to obtain previously
unreachable goals.
With this in mind, JBT created the Unifiller unit,
which has large porting and short product paths to
handle much larger particulates without damaging
them. Additionally, the cutoff points have been
reduced to ensure the product is dosed accurately
into containers. The combination of features allows
the unit to handle 50 to 60 percent solid content of
very large particulates without any issues.
Additionally, due to the demand for wider ranges,
fillers need to be able to handle an entire variety of
high-viscosity, large-particulate products, as well as
water-like products, without making modifications
to the equipment.
The JBT Unifiller design is well suited for this
type of large product range and can fill cold and
hot, all on the same filling machine, Sundberg says.
T E C H U P DAT E

With the food
industry demanding
more hygienic
designs to ease
contamination
concerns, HindsBock introduced its
new 8P-06 UltraHygienic filler.
Source: Hinds-Bock.
124
There is no more need to use two different types of

fillers and filling concepts.
Improved packaging flexibility
Processors looking to differentiate their products on
an increasingly cluttered retail shelf are using more
creative packaging. However, different types of containers can affect line operation.
As a filling company, you need to get the product
into the container, states Timm Johnson, vice president of sales and marketing for Spee-Dee Packaging
Machinery. Odd-shaped containers, small openings, small pouch sizes and handles can all affect the
way products are filled.
He notes that, in particular, smaller openings of
containers can be difficult to work with since they
limit the speed at which a product can be filled.
Different package shapes or packages with smaller overall dimensions need very special features
on the filling machines and specifically the filling
nozzles, explains Hinds-Bocks Gregg.
He says Hinds-Bock fillers with adjustable nozzles
connected to their traveling or diving spout bridges
work with several different packaging center lines.
Filling lines are now designed with considerations
for future unique packaging flexibility, says JBTs
Sundberg. A single filler has to be able to handle all
sorts of containers, such as glass, plastic, cans and
bottles. Optional quick container change parts are
becoming standard in these kinds of applications.
These easily adjustable parts are important for

reducing changeover time to less than 10 minutes and
involve just one person. Additionally, automation is
playing a role in handling different package sizes.
With the latest PLC [programmable logic controller], fillers can store multiple package recipes and,
through servo motors, can automatically adjust to the
correct full weight or number of times the filler needs
to cycle in each respective package, Gregg says.
To help food and beverage manufacturers keep
production nimble and cost effective, SIG Combibloc has focused on the flexibility of its filling lines,
says Heike Thevis, communications officer. Processors can use one filling machine to fill carton packs
with different formats, if they have the same base
dimensions.
This can be done in a range of different volumes and with any required design, adds Thevis,
enabling a processor to position products optimally, in exactly the right way to suit the market and
the target group in each case.
For example, soup in a one-liter family carton
pack and a smaller volume size geared toward a
single-person household can be processed by one
Combibloc filling machine; up to seven different
volumes can be filled.
At this years Anuga FoodTec Show, Bosch Packaging Technology presented its Ampack AF 8/8
inline cup filling machine, which features a pulsed
light decontamination system for ultra-clean applications. Jonathon Titterton, director of sales and
marketing for Bosch, says the equipment offers
more format flexibility for different cup shapes and
sizes by using preassembled cell plates for two different diameters. It also reduces changeover time to
15 minutes.
Continuing need for speed and
efficiency
More than a decade ago, servo-driven fillers began
replacing older, pneumatically driven machines.
Servo-driven fillers are much faster than conventional pneumatic fillers as they have no suction
stroke. They are always primed ready to cycle and
fill the package, explains Hinds-Bocks Gregg. The
pneumatically driven fillers have a suction stroke to
prime the product cylinder prior to the discharge
stroke, taking much more time to fill a package.
However, as important as the filling line speed
is, output and efficiency are the criteria more
companies are focusing on. Globally, improving
plant performance to make production as efficient
as possible and ensure long-term presence in the
market is of paramount concern for filling com-

SIG Combibloc equipment allows switching between
different fill volumes in minutes, making it easier to create
products tailored to specific target groups. Source: SIG
Combibloc.
panies, Thevis says. With servo drives and a total of six

tracks, SIG Combiblocs new aseptic filling machine can
fill 24,000 carton packs per hour, making it the fastest for
125 to 350ml packages.
Also important to efficiency is avoiding product giveaway
by ensuring each valve and component works to identically
fill every container. Continued operation at a high accuracy
level is often something processors do not consider when
buying a filler, but it is probably one of the most important
factors to look at, offers Sundberg. He explains a simple,
seal-less design with fewer moving parts that can wear
down is needed for reliably accurate volumetric fillers. For
example, an accuracy of less than 0.1 to 0.4g per standard
deviation is becoming the new sustained norm.
Another way some filling equipment manufacturers are
speeding up the line is through innovations in package
sterilization. For instance, Tetra Pak recently launched a
new filling machine that uses electron beams, not hydrogen
peroxide, to sterilize packaging material.
The Tetra Pak E3 eBeam filler removes a long-time
physical limitation to carton packaging speed: the hydrogen peroxide sterilization process, says Mastri. With the
machine, speeds of up to 40,000 portion packs per hour, or
11 packs every second, can be achieved.
Market tests conducted by Tetra Pak showed this
increased capacity can save beverage manufacturers 20
percent in operational costs and improve environmental
performance by making water recycling easier, lowering
energy consumption and cutting waste.
Sanitary design and automation
Facing more pressure and further regulations concerning food safety and contamination prevention, food and
beverage processors need more hygienic designs of filling
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T E C H U P DAT E

To ensure
accurate filling
and gentle product
handling, the
Unifiller machines
design, number
of valves, nozzles
and other parts are
custom-fit to suit
specific product
requirements and
the necessary line
speed. Source: JBT
Food Tech.
machines. A number of manufacturers are answering the call by offering equipment that is easier to
clean and break down.
For example, Hinds-Bock recently introduced
the 8P-06 Ultra-Hygienic filler, which has stainless steel enclosures and minimizes flat surfaces by
using slope-top covers. The tubular frame allows
easier cleaning of all the fillers parts, while the
tilt hopper provides access to the product ports.
Wire looms separate all wiring and air lines, which
can be quickly disconnected for faster setups and
teardowns.
Some filler manufacturers are employing automated cleaning processes such as clean-in-place
(CIP). Recent improvements are aimed at reducing
overall cleaning time, as well as water, chemical and
energy usage.
New two-stage CIP cleaning with complementing dual chemicals is the latest trend to reduce cleaning time and overall energy usage, says Sundberg.
Performing CIP at lower temperatures decreases
overall cleaning time by reducing ramp-up and
ramp-down times.
Automating the cleaning process also ensures
the final sanitary condition of the machine and
minimizes the use of chemicals by recirculating and
reusing them in the process.
A higher level of hygienic design allows extended
runs between cleanings and is very important in
24/7 operations, continues Sundberg. Performing
CIP only once a week, instead of daily, is becoming
more and more prevalent.
Advancements in automated technology are
improving operation in other areas as well. For
instance, SIG Combibloc offers the R-CAM robotic
magazine that automatically opens and removes
carton sleeve shipping boxes and loads a filling
machine without employee involvement.
The robotic magazine basically consists of two
modules: a pallet magazine and an unpacking station. The pallet magazine offers space for a Euro
pallet, industrial pallet or Australian pallet. Once
a pallet is inside the magazine, a scanner records
the arrangement of the shipping boxes on the pallet, and the gripper arm moves a shipping box to
the unpacking station. An internal buffer provides
continuous, smooth operation, even while a new
pallet is being loaded into the pallet magazine. The
buffer can accommodate up to 20 shipping boxes of
carton sleeves. The magazine can operate for up to
2.5 hours without the need for a new pallet. Inside
Vertical form/fill/seal offerings

Jonathon Titterton, director of sales and marketing for Bosch
Packaging Technology, says the company saw the need to provide processors with tools to create more shelf differentiation
and enhanced consumer convenience. To fill this need, Bosch
now offers a continuous motion bagger that produces up to
100 high-quality doy-style bags per minute with a zipper reclosure. The SVE 2520 DZ machine helps snack and confectionery
manufacturers boost shelf appeal and offer reclosable features
while increasing production efficiency.
At six square metersone-third the required space for an
equivalent horizontal pouch machinethe Bosch bagger offers
up to 50 percent higher output per square meter. It can also
produce other common bag styles such as pillow, gusseted,
block bottom, corner seal, full corner and three-side sealed.
126
The SVE technology is designed for easy operation and maintenance; changeover from pillow to the Bosch Doy Zip bag
takes less than an hour, according to Titterton.
Bosch offers its SVC platform for fresh and frozen food
producers. The hygienic design is especially suitable for manufacturers that must comply with more stringent food handling
regulations. It offers quicker setup and tool-less changeovers
and can handle pillow, gusseted and corner seal pack bags.
Engineered for brand marketers utilizing stand-up pack
styles, the new corner seal option will be launched at PACK
EXPO Las Vegas 2015. The option can be integrated into the
existing SVC machine and enables frozen foods manufacturers to use film material other than the standard polyethylene
traditionally applied for pillow bags.

Hinds-Bock single- or multiple-spout/pump models can be
used for a wide range of flowable products. The servo controller
allows quick, easy changeovers, and the sanitary pumps are
CIP-able. Source: Hinds-Bock.
The robotic magazine is a key component in building the

fully automated filling line of the future, in which automatic
guided vehicles [AGVs] transport pallets of packaging material
automatically from a central store to the R-CAM unit, says
Jan Gansow, global product manager at SIG Combibloc. Its a
major step toward the smart factories of tomorrow.
Currently, the robotic magazine is available for the CFA
724 high-speed filling machine for products in the small-size
combibloc carton format. The first R-CAM 724 prototype is
in operation at Arla Foods Germany in its Pronsfeld factory.
the unpacking station, the shipping boxes are opened, and the
sleeves are removed from the box. The sleeves are automatically filled into the appropriate track of the filling machine, and
the shipping boxes are folded flat and collected in a specially
provided container for subsequent disposal.
Heike Thevis, SIG Combibiloc, 0049-2462-79-0, info@sig.biz, www.sig.biz

Jan Sundberg, JBT Corporation, 559-661-3200, jbtcorporation@jbtc.com,
www.jbtfoodtech.com
Jonathon Titterton, Bosch Packaging Technology, Inc., 715-246-6511,
sales.packaging-nrd@bosch.com, www.boschpackaging.com
Larine Urbina, Tetra Pak, 940-380-4630, larine.urbina@tetrapak.com,
www.tetrapakusa.com
Rod Gregg, Hinds-Bock, 425-885-1183, info@hindsbock.com,
www.hinds-bock.com
Timm Johnson, Spee-Dee Packaging Machinery, 262-886-4402,
tjohnson@spee-dee.com, www.spee-dee.com
127
FIELD REPORTS
Precision weighing technology

increases accuracy
When the University of Wisconsins dairy department updated

its mixing system, the switch to load cells helped produce a more
consistent product.
he University of Wisconsin-Madison
Babcock Hall Dairy Plant uses a handson approach to research and teach
cutting-edge dairy science techniques
to its food science students. The plant also turns
2 million pounds of locally sourced milk, including some from the universitys own herds, into ice
cream, yogurt, fluid milk products, butter, cheese
and fermented products.
The plant was built in 1951, making it the oldest university dairy building in the US. Planning is
underway to fully renovate the factory by 2018 and
outfit it with the latest industrial technologies. Part
of this renovation is the updating of the old mix processing vats, switching from side-mounted pressure
gauges to load cells for monitoring and controlling
manufacturing processes. The production method
requires monitoring the level of each ingredient
before it is added to a mixing vat and then passed
along the production line.
In the past, we measured the liquid levels either
by pressure sensors or measuring sticks and had to
adjust for product density, explains Plant Manager
Bill Klein.
Load cells were recommended due to their potential for greater accuracy, producing more consistent
There is strength in numbers.

Perhaps the only thing more reassuring than having the extrusion leader work on your behalf is
having their dedicated subsidiaries work for you, as well.
Anchored by Wenger and their nearly 80 years of process experience, the Wenger Group includes
Corporate Project Services specialists in complete project planning and food safety requirements;
and Source Technology innovators of inline sampling and analysis equipment, fully integrated
with Wengers automation for total system communication.
Rally the power of three to address the entire scope of your extrusion-based project. Youll
experience the dedication, ingenuity and responsiveness of the one and only Wenger Group.
See us at Pack Expo Booth #58447!
128
corporateprojectservices.com
sourcetechnology.dk
wenger.com
The three-legged tank system uses a

compression load cell, in combination with a
flex-lock mounting kit and process controller
capable of developing and storing multiple
recipes. Source: Sartorius Intec.
ingredient mixtures and cost-effectiveness. The

tanks the plant chose were designed and built
by Sprinkman Corporation; the load cells were
supplied by Sartorius Intec, a manufacturer of
industrial technologies headquartered in Hamburg, Germany.
The Sartorius Intec PR 6211 compression
load cell was chosen in conjunction with a
PR6011 flex-lock mounting kit to fulfill the
plants requirements. Available in versions from
500kg to 10t, the cell is fully constructed from
stainless steel and allows for calibration without
weights, simplifying the installation. The X5
system controller was installed alongside the
load cells and mounting kits to accurately control the plants manufacturing processes.
Using precision weighing technology in production processes offers manufacturers the
chance to greatly increase the accuracy of their
Pre-Manufactured
Food Grade Platforms
systems and reduce product giveaway and inconsistencies. Babcock

Hall Dairy Plants original system
relied on volume; however, with a
range of products at varying densities, a conversion was necessary to
reliably calculate how much product was required. In the past, as
soon as the levels in the 600-gallon
vat dropped below 100 gallons, the
accuracy of the whole system was
reduced, causing large discrepancies in the end product. However,
this no longer happens with the
upgrades.
We have found that using load
cells is far more accurate, sanitary,
faster and altogether easier, says
Klein. We hope to add load cells
to additional vats in the future.
Chad Stedman, 720-431-6985,
chad.stedman@sartorius-intec.com,
www.sartorius-intec.com.
VISIT US AT PACK EXPO.

BOOTH #7933
Cubic Designs delivers custom-designed,

pre-manufactured platform systems to
your plant ready to install in your facility.
Minimize plant disruption because all of our
manufacturing is done off site. No welding.
No cutting. No drilling.
Quick, easy installation with little
plant disruption
Stainless and carbon steel designs
Bead blast and powder coat finishes
Can meet USDA/FDA requirements
Closed shapes, bolted connections,
enclosed steel tube
Want a mezzanine without the fuss,
mess and problems? Call Cubic Designs.
800.826.7061
www.cubicdesigns.com
2015 Cubic Designs
the perfect fit
No Mess. No Fuss.
NO PROBLEM.
129
FIELD REPORTS
Sanitary, reliable drum motor

drives success
Poultry processor strives to meet customer demands without

sacrificing the highest hygienic standards, so minimizing
downtime is a must.
custom food processor, AlaTrade Foods

provides large poultry processors with a
service that requires intensive amounts
of labor. AlaTrade Foods takes in the
front-halves of chickens and debones and disassembles products based on customer specifications
whether it is for the breast meat, wings, tenders or
dark meat. AlaTrade debones approximately 1 million
fronts (approximately 2 million pounds) a week.
To meet customers requests while maintaining sanitation standards, AlaTrade leverages process efficiencies, cutting-edge technologies and superior customer
130
service, which results in better quality, better yield and

better response times for customers.
To minimize downtime and reduce maintenance
costs, AlaTrade employs a Van der Graaf drum motor to
drive its conveyors. The company started working with
Van der Graaf over a decade ago when it was looking to
solve internal failures on conventional conveyors.
Since then, we have seen the potential for us to
limit our amount of downtime and create a safer
work environment, says Kevin W. Parnell, plant
manager for Alatrade Foods LLC. Being a player in
the poultry industry, we believe food safety ishas
to beat the top of our priority list. Van der Graaf plays a huge
role in us doing that.
Industry requirements demand all chicken processors exceed
food hygiene standards; thus, the highest level of sanitation
must be maintained. The overall construction and engineering
behind the Van der Graaf drum motor is intrinsically hygienic
to address sanitation requirements.
The VDG motor withstands 3,000 psi of water pressure,
preventing the harboring of bacteria and other contaminants,
explains Ray Hayes, quality control supervisor for AlaTrade
Foods LLC, so we can wash things quickly, apply our chemicals
to kill the microbes and get back up and running again. In any
manufacturing environment, downtime is money.
The engineered design of the drum motor puts all the working
components to power the conveyor inside the roller of the head
pulley. Van der Graaf is the best in the industry as far as the concise fit of the motor and the reduced room it takes up, says Hayes.
The motors mechanical components are in a constant foodgrade oil bath, which allows it to have a maintenance interval of
50,000 hours between oil changes. With nothing external and,
therefore, nothing subjected to the working environment, a
drum motor outlasts a conventional drive, while offering reduced
downtime and lower maintenance costs.
From a management standpoint, having something that
is not going to fail allows you to focus on other things that
The Van der Graaf drum motor is a one-component conveyor

drive, with the motor, gear drive and all moving parts enclosed
inside the drum. Source: AlaTrade Foods.
improve your process instead of worrying about whether a

motor is going to go out, says Parnell.
Melissa Lara, 888-326-1476, info@vandergraaf.com,
www.vandergraaf.com/improvesanitation.
Which static mixer is right

for you? Let me show you.
Ross offers expert support and the worlds broadest selection of
static mixers for applications involving turbulent or laminar flow.
With no moving parts, our heavy duty LPD, LLPD and
ISG designs are ideal for sanitary and non-sanitary mixing,
with choices for ultra-low P and unlimited viscosity.
For a free white paper, visit StaticMixers.com/Learn
Or call Christine Banaszek today: 1-800-243-ROSS
Christine Banaszek
Applications Engineer
Employee Owner
Scan to learn more.
131
PACK EXPO Las Vegas Preview
Industry show celebrates its

20th anniversary
PMMI, the Association for Packaging
and Processing Technologies,
produces the largest-ever edition
of its Las Vegas show.
ver the 20 years of its existence, PACK EXPO Las

Vegas has grown from a regional show to one of the
most expansive events for packaging and processing innovation. This year, the show will feature
more than 800,000 net sq. ft. of exhibit space.
PMMI anticipates the attendance this year will reach near
30,000, and the event will attract over 2,000 exhibitors, including industry leaders that serve more than 40 vertical markets.
It will include the Las Vegas debut of Pharma EXPO, jointly
produced by PMMI and the International Society for Pharmaceutical Engineering (ISPE). PACK EXPO shows have
evolved alongside the needs of attendees and exhibitors, and
weve come a long way from where we started, says Charles D.
Yuska, president and CEO of PMMI.
In 1995, PMMI introduced the industry to PACK EXPO
West, featuring packaging equipment from 532 exhibitors and
attracting 9,334 attendees. Exhibit space was approximately
200,000 net sq. ft.about 25 percent of this years event. The
international flavor of the show has grown as well. While visitors from outside the US made up 8.3 percent of the attendee
base in 1995, they accounted for 18 percent at the most recent
event in 2013. The number of international exhibitors also has
increased from just 54 at the debut PACK EXPO Las Vegas to
more than 310 expected for this years event.
PACK EXPO Las Vegas will be bringing back its Innovation Stage, which will occupy three different spaces. All the
stages will offer free, 30-minute educational sessions running
concurrently throughout each day of the show. Attendees can
also learn about new technologies in seminars at the Food
Safety Summit Resource Center and the Center for Trends
and Technology: Improving Production Through Innovation, sponsored by Rockwell Automation and its PartnerNetwork Program.
To help attendees maximize their time at the show, industryspecific lounges and specialized pavilions, such as The Brand
Zone, will provide access to current developments in specific
132
} PMMI expects the 2015 event will be triple the size of 1995s
inaugural PACK EXPO West. Source: PMMI.
market niches. The Biscuit and Cracker Manufacturers Association (B&CMA) will host the BakingSnack Break Lounge.
The International Society of Beverage Technologists (ISBT)
will be providing resources at The Beverage Cooler Lounge,
designed for beverage industry professionals to network and
learn about solutions from ISBT subject matter experts.
PACK gives BACK will take place on Monday, September 28
at 4:00 p.m. featuring the band Chicago. Tickets for the show
are $100 each and are available to all industry professionals. A
portion of this years ticket sales will support the Fisher House
Foundation, best known for providing a network of homes
where families of injured veterans can stay for free while their
loved ones are receiving medical treatment.
Over the years, weve added features and events, but one
thing hasnt changed, Yuska says. PACK EXPO Las Vegas is a
venue where industry professionals come together, do business
and find the solutions they need for operational excellence.
PACK EXPO Las Vegas 2015

at a glance
} Where: Las Vegas Convention Center
} When: Monday, September 28, 2015 through Wednesday,
September 30, 2015
} Exhibit Hours: 9:00 a.m to 4:00 p.m. Monday through
Wednesday
} Contact: 571-612-3200 or packexpolasvegas.com
2015 PACK EXPO LAS VEGAS

SHOW PREVIEWS
SPECIAL ADVERTISING SECTION
A&B Process Systems Corp.
ALLPAX
If its in the Retort Room, WEVE DONE IT!
Allpax Products, powered by Pro Mach, designs, manufactures, and
supports customized retorts for in container sterilization of packaged foods
and beverages. Allpax also designs automated material handling systems to
load, unload, and transport product before and after processing.
A&B Process Systems is a proven leader in the design, fabrication, automation,

testing and installation of high quality stainless steel process skids/super skids,
tanks, auxiliary equipment and piping systems.
A&B has five plants in Stratford, Wisconsin, with over 175,000 square feet of
manufacturing capacity including its controlled environment facility that prevents
the contamination of high purity tanks & systems. Since 1973, A&B has steadily
grown to 400 associates and become a strategic supplier to many Fortune 500
Companies in the pharmaceutical/personal care, food/beverage, dairy, and industrial/renewable energy industries.
A&B has the
internal resources
to execute a project
from concept to
completion. A&Bs
make it happen
attitude helps it
stand apart from
its competitors by
reducing overall
project costs and improving lead times.
A&B works directly with its clients, or if desired, their contracted engineering firms
to ensure the process systems and equipment are designed to match the client
needs and the installation requirements. A&Bs efforts are supported by an inhouse staff of design and automation engineers, welders, fitters, QA/QC professionals and project management personnel.
Allpax is the leader

in bringing new
batch sterilization
technologies to the
market. We specialize
is manufacturing
customized solutions
for in-container
sterilization using the
latest technology to
provide our customers
the highest quality
products combined with cycle time reductions. We offer turn-key solutions
for both sterilization and material handling. At Allpax, we design the line
around your containers to provide customized equipment that maximizes
efficiency.
We will be at Pack
Expo Last Vegas
showcasing our latest
retort and pasteurization
technology along with
energy management
controls solutions.
We hope that you will
take the time to visit
us at booth C-2818 to
discuss your retort sterilization and material handling needs because if it is in
the retort room, weve done it.
From concept to completion, A&B can ensure your success through

every phase.
Contact:
Andrea Wiese
201 S. Wisconsin Ave.
Stratford, WI 54484
Phone: 715-687-4332
Fax: 715-687-3225
www.abprocess.com
See us at PACK EXPO Booth # 7404
Contact:
Greg Jacob
Allpax Products
13510 Seymour Meyers Blvd.
Covington, LA 70433
Phone: (888) 893-9277
Fax: (985) 893-9477
Web: www.Allpax.com
Email: info@Allpax.com
See us at PACK EXPO Booth C-2818
133

SHOW PREVIEWS
Atlas Copco
Beckhoff Automation
Compressors is showcasing
its newest game changing
technology at the 2015 PACK
EXPO show. The products on
display are perfectly matched
for the processing and
packaging industry.
Among these products is the
newly released GHSVSD+
range of oil-sealed rotary
screw vacuum pumps that
feature quiet operation, and
state-of-the-art variable
speed drive technology. These
vacuum pumps consume
approximately 50% less energy
than alternative technologies. Visitors will also have the opportunity to
interact with the highly reliable GAVSD+ range compressors. This innovative
compressor reduces energy consumption and allows for a compact footprint
and low noise levels.
Beckhoff Debuts CP32xx Series: Pole-Mountable Multi-touch Panel PCs

with Multi-core Power
With the new CP32xx Panel PC series from Beckhoff Automation, industrial
multi-touch display technology can now be used in an all-in-one, highperformance automation device for HMI and control applications. These
powerful devices for mounting arm installation feature all-around IP 65
protection and integrate best-in-class multi-touch Control Panel technology
with a high-performance Industrial PC (IPC)- all in one rugged, yet compact
housing.
The area at the rear of the CP32xx Panel PC, which is required for swiveling
and tilting the connected mounting arm, is also efficiently used to accommodate the added IPC components while saving space. The components
in this solution are thermally decoupled from each other; to save space,
the computer is actually built around the integrated mounting arm in a
u-shaped housing with cooling fins for passive cooling.
Atlas Copco Compressors is an industry-leading global manufacturer and

service provider of compressed air technology and quality air accessories
with 24/7 service support.
Contact:
communications.information@us.atlascopco.com
866-688-9611
www.atlascopco.us
134
Another advantage is the excellent heat dissipation characteristics despite

the compact design, achieved using internal fans; this ensures even temperature distribution to all walls of the housing. This results in an impressive
operating temperature range from 0 to 45 C. Moreover, all components
and connectors are easily accessible, which is convenient when using
removable storage media such as a CFast card or SSD.
Contact:
Beckhoff Automation LLC
13130 Dakota Ave
Savage, MN 55378
Phone: 952-890-0000
Fax: 952-890-2888
e-mail: beckhoff.usa@beckhoff.com
www.beckhoffautomation.com
PACK EXPO Las Vegas 2015 Booth #S-6163, Lower South Hall
2014
EXPO
INTL
PACK
EXPO LAS VEGAS
2014 PACK
PACK2015
EXPO
INTL
SHOW PREVIEWS
Show
Show Previews
Previews
ADVERTISEMENT
ADVERTISEMENT
Bimba
Bimba
Bunting
Bunting
Bunting
For more than 50 years,
Bunting Magnetics Co. has
developed and manufactured
precision magnetic products
for the worldwide printing,
automobile, plastics, food,
electronics and recycling
industries.
Bimba Announces New Blue and Improved

Bimba Announces
New Blue and Improved
Original
Line Cylinders
Original Line Cylinders
Bimba Manufacturing Company, a provider of pneumatic, hydraulic, and
Bimba Manufacturing
Company,
a provider
of pneumatic,
hydraulic,
and
electric
solutions, announced
a series
of product
enhancements
to its
induselectric solutions,
announced
a series Original
of product
to its indus
try-leading
round line,
non-repairable
Lineenhancements
product series.
try-leading round line, non-repairable Original Line product series.

These changes include design modifications to further extend the catalog
These
changes
modifications
furthermiles,
extend
life
rating
of the include
cylindersdesign
from 1,400
miles to to
3,000+
as the
wellcatalog
as new
life
rating
of
the
cylinders
from
1,400
miles
to
3,000+
miles,
as
well as new
product labeling and packaging.
product labeling and packaging.
These design enhancements are the culmination of more than three years
These
design
enhancements
are the culmination
of more than
three
years
of
product
testing
and communications
with our customers.
It will
more
than
of
product
testing
and
communications
with
our
customers.
It
will
more
than
double the life of our Original Line , enhancing the value to our customers
of
double
the lifehardest
of our Original
, enhancing
the valuesaid
to our
customers
the
industrys
working,Line
longest
lasting cylinder,
Jerry
Scherz- of
the industrys
working,
longestManager.
lasting cylinder,
said we
Jerry
inger,
Bimbas hardest
OL Product
Marketing
Additionally,
areScherzupdatinger,
Manager.
Additionally,
we are
ing
theBimbas
look of OL
the Product
cylinder Marketing
by replacing
our pre-existing
red logo
withupdatan
ing the look
the cylinder
byintroducing
replacing our
pre-existing
an
updated
blueoflogo,
as well as
new
packagingred
thatlogo
will with
be easier
updated
blue logo,
as well
as introducing
packaging that will be easier
for
customers
to remove
prior
to installing new
our cylinders.
for customers to remove prior to installing our cylinders.
Scott Meldeau, Bimbas Vice President of Sales and Marketing said, These
Scott Meldeau,
Bimbas
Vice President
of approach
Sales andBimba
Marketing
said,toThese
changes
reflect the
aggressive
corporate
is taking
changes
reflect
the
aggressive
corporate
approach
Bimba
is
taking
to
strengthen our existing products, in addition to developing new products
to
strengthen
ourfuture
existing
products,
in addition to developing new products to
position
us for
growth.
position us for future growth.

To learn more, visit www.bimba.com.
To learn more, visit www.bimba.com.
Contact:
Contact:
Contact:708-534-8544
Telephone:
Telephone:
708-534-8544
708-534-8544
orTelephone:
800-44-BIMBA
oror800-44-BIMBA
800-44-BIMBA
Fax:
708-235-2014
Fax:
Fax:708-235-2014
708-235-2014
support@bimba.com
support@bimba.com
support@bimba.com
www.bimba.com
www.bimba.com
www.bimba.com
See
us at PACK EXPO International booth # 1554
See
EXPO
International
booth # 1554
Seeus
usatatPACK
PACK
EXPO
booth # S-6133
134
134
October 2014 | Food Engineering | www.foodengineeringmag.com

October 2014 | Food Engineering | www.foodengineeringmag.com
The most common of

foreign material within food
processing is metal. This contamination can cause damage to further
processing equipment, but is also a safety hazard for consumers. Metal
contamination that makes it into the food supply can cause untold brand
For over 50 years, Bunting has established itself as an industry-leading
supplier. Bunting Metal Detectors sense
and
damage
to the
has established itself as an industry-leading
Forreputation
over 50 years,
Bunting
manufacturer in several product lines. Since our founding, we have been
and
remove theinpresence
of ferrous,
non-ferrous
and stainless
metals
in
manufacturer
several product
lines.
Since our founding,
we have
been
solving problems with magnetic energy
a process flow, or as a packaged item.
These
solving
problems with magnetic energy
for manufacturers of everything from
units can also find metal encapsulated
in the
for manufacturers
of everything from
paper towels and cardboard boxes to
individual food particle.
paper towels and cardboard boxes to
automobiles, plastic housewares, food
automobiles, plastic housewares, food
products, and electronic equipment.
Successful detection and separation
of metal
products,
and electronic equipment.
will protect your processing equipment from
At this years Process Expo show we
damage, which saves your organization
At thismoney
years Process Expo show we
will be featuring equipment from our
and down time. Assuring the highest
will product
be featuring equipment from our
metal detection and magnetic separation
quality and absence of metal contamination
metal detection and magnetic separation
lines. Our meTRON 07 CI metal
in your product, protects your reputation,
and
lines. Our
meTRON 07 CI metal
detector has the latest in electronics,
keeps you viable in the market. detector has the latest in electronics,
aptly named, imagePHASE and is the
aptly named, imagePHASE and is the
newest product recognition software
Buntings extensive line of magnetic
separation
newest
product recognition software
in the world. imagePHASE allows for
equipment removes metal contaminants
in the world. imagePHASE allows for
greater sensitivities and fewer false rejects. This combined with our DCM
from
dry particulates,
liquids,
andfalse
slurries.
greater
sensitivities and
fewer
rejects. This combined with our DCM
washdown conveyor ensures your product will be free from contamination
Our
lineup includes
units
designed
removewill be free from contamination
washdown
conveyor
ensures
yourtoproduct
as it moves down the line.
metal
from
gravity, mechanical, or pneumatic conveying
as it contamination
moves down the
line.
systems. Our specially built sanitary-grade metal separators are the first
From our magnetic separation equipment we will feature our popular
separators
earn USDA,
AMS-Acceptance.
From our to
magnetic
separation
equipment weOur
will engineers
feature ourrefined
popular
Center-Flow magnet (CFM). Our CFM has been redesigned for easy and
existing
designs
to
help
processors
meet
increased
marketplace
demands
Center-Flow magnet (CFM). Our CFM has been redesigned
for easy
and
quick cleaning capability. Bunting Center-Flow Magnets are designed to
and
governmental
requirements
for
safer
and
purer
foodstuffs.
quick cleaning capability. Bunting Center-Flow Magnets are designed to
handle materials that are non-abrasive or not subject to damage by impact.
handle materials that are non-abrasive or not subject to damage by impact.
It can be installed easily in any position or angle with factory supplied
You
canbe
rely
on our easily
equipment
expertise
to eliminate
product
It can
installed
in anyand
position
or angle
with factory
supplied
compression couplings. This product is ideal for use in dilute-phase
contamination
damage
to product
machinery
fromfor
tramp
in an
compression and
couplings.
This
is ideal
use inmetal
dilute-phase
pneumatic conveyor systems.
economical
cost-effective
pneumaticand
conveyor
systems. way.
For more information on Bunting Magnetics Co., call +1-800-835-2526

(in U.S. & Canada) or +44 (0) 1442 875081 in Europe or visit our web site at
For more information call 316-284-2020, email bmc@buntingmagnetics.com
www.buntingmagnetics.com
For more information call 316-284-2020, email bmc@buntingmagnetics.com
or visit
ourPACK
website at www.buntingmagnetics.com.
See
us at
booth # 5907
or visit
our websiteEXPO
at www.buntingmagnetics.com.
See us at PACK EXPO International booth # 5516
135

SHOW PREVIEWS
Cone Drive
Expertly Engineered for Precision, Power and Performance
The new Stainless Right Angle Drive from Cone Drive is expertly engineered
to withstand the harsh cleaning processes required in sterile manufacturing
environments. Featuring a smooth, stainless steel housing that is easily
cleaned to ensure bacteria-free surfaces, the Stainless Right Angle Drive is
NSF and A3 certified and is the industrys only IP69K tested and rated worm
gear assembly.
IP69-K tested and rated

NSF and A3 certified
5-Year warranty
Patented non-fretting blue bushing prevents micro-welding
Stainless finish withstands harsh cleaning practices
Smooth housing eliminates bacteria growth
Made in the U.S.A.
The Cone Drive Difference

Cone Drive is the industry leader in precision motion control and power
transmission solutions, delivering the highest level of accuracy, torque
and shock load capacity in the smallest amount of space. Renowned
for precision, quality, durability and consistency, Cone Drive specializes
in designing modified and custom solutions across multiple industrial
applications around the globe.
ON THE RISE
VISIT US AT PACK EXPO.

BOOTH #7933
the perfect fit
Stainless Steel Platforms

Elevate your operations with a Cubic Designs
pre-manufactured stainless steel platform.
These systems are custom designed by
on-staff engineers to meet your exact
facility needs.
Stainless and carbon steel designs
Bead blast and powder coat finishes
Can meet USDA/FDA requirements
Professionally-Engineered for any
seismic zone
Quick, easy installation with little
plant disruption
Looking for an attractive, sanitary
solution to increase your footprint?
Call Cubic Designs today.
Contact:
Cone Drive
240 E. 12th Street
Traverse City, MI 49684
888-994-2663
+1 231-843-3393
www.conedrive.com
See us at PACK EXPO Booth # S-6315
136
800.826.7061
www.cubicdesigns.com
2015 Cubic Designs

14 | CORPORATE PROFILES
SHOW PREVIEWS
Dorner Mfg. Corp.
Safety
ovative
nology
es the
one to
s Food
signed
egrate
n and
DELs
itation
ement,
ditional
iques
tation
fe and
Douglas Machines Corp.
Founded in 1969 and based

in Hartland, Wisconsin, Dorner
Mfg. Corp is a privately held
World Leader in the design,
applications, manufacturing, and
integration of conveyor systems.
Companies from over 1,200
different industries worldwide
turn to Dorner to achieve
improved efficiency, productivity,
and a positive ROI.
2014 PACK EXPO INTL

Show Previews
ADVERTISEMENT
Dorner conveyor systems are flexible, easy to select and easy to integrate.
Dorners line of stainless steel, food handling conveyors are designed for fast and
effective sanitation. They are ideal for environments that require anything from
wipe down cleanings to daily high-pressure wash-downs with caustic cleaners.
Dorner
This year at PACK EXPO International Dorner will be displaying some ofD o r n e r s Douglas
A q Machines
u a G a r dCorp.
offers
line of automated washing
the newest conveyor technologies including the 3200 Series Modular Belt
conveyors a full
offer
maximum
and sanitizing equipment
Conveyor, the AquaGard 7100 Series and the 2200 Series SmartFlex
layout flexibility for a wide
Ozone
for all containers commonly
Conveyor.
v a r i e t y used
o f in pfood
a cprocessing
k a g i n g and
hensive
applications.
They
also
provideOver
ent to
distribution
industries.
Dorners new 3200 Series Modular
the industrys
best transfers
ethods
80 standard
models exist to
Belt Conveyor is ideal for part
which reduces
product
quality
quickly and efficiently
clean
handling, accumulation, positioning,
pans, trays, moulds,
loss. The AquaPruf
line scale
of parts,
high speeds, long runs, and product
y food
screens,
pallets, lugs,
totes,
transfers. Designed
withdesigned
ease
hygienic
wash-down conveyors allows for sanitation
in systems
that
from
racks, is
smoke
trucks, bins,
of integrationcarry
in mind,
the 3200 from ready-to-eat foods to protein. AquaPruf
everything
designed
to vats,
USDA,
barrels and buckets. Batch and
Modular Belt conveyor features
provide access to the internal frame in seconds and can be disassembled in less
proved
continuous cleaning systems
innovative transfer options as well as
than five minutes, reducing change over and sanitation down time.
existing
are available to clean several
complete flexibility in layout including multiple curves, inclines and declines.
em you
hundred to several thousand
Both styles are constructed
with
a stainless
steel, open containers
frame design
reduce
an hour.with
7100
Series Stainless
The AquaGard
dborne
s, DEL
en and
minimal horizontal surfaces,

andChain
are available
flat belt or plastic chain. They
Steel Flexible
Conveyor with
can twist
Eachcurves,
model isinclines,
designed to
are available in a variety
of into
configurations,
such as straights,
and turn
the tightest of spaces.
labor,
water, chemical
It is ideal
for productinrouting
in wipe leading 7save
declines, and z-frames.
All delivered
an industry
to 10
days.
down sanitary applications in the

food, packaging and pharmaceutical
industries. As the footprint in
production areas and plants continues to shrink, the 7100 Series Conveyor
is the ideal platform to maximize available space.
Dorners SmartFlex 2200 Series
flexible conveyor is a highperformance, modular table-top
chain conveyor that is simple
to configure and even simplifier
to acquire. Its ideal for part
handling, tight spaces, buffering,
accumulation, and elevation
changes. And with Dorners industry leading delivery time, the conveyor can
be shipped pre-assembled
Contact: in only 5 working days.
Dorner Mfg. Corp

975 Cottonwood Ave
P.O. Box 20
Hartland, WI 53029
Tel: 800.397.8664
Contact: Fax: 800.369.2440
Dorner Mfg. Corp
info@dorner.com
975 Cottonwood Ave
www.DornerConveyors.com/FEM
P.O. Box 20
See us at PACK EXPO Booth # C-1847
and energy, plus help you

consistently meet todays
high standard if cleanliness
and sanitation. Ensure an
effective Food Safety Program
with Douglas Washing and
Sanitizing Systems. For a
complete overview or for
literature and specifications on
a particular model, visit
www.dougmac.com or call
800-331-6870 today.
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. This years booth features some
of their most popular models: a Rack
Washer for detachable weigh scale parts,
a Tunnel Washer for shipping containers,
a Belt Washer for spiral conveyors, a Barrel/Drum Washer and Bucket and Utensil
Washer. Other models are available for
baking pans, trays, baskets, moulds,
pallets, lugs, totes, vats, bins, screens,
smoke sticks and smoke racks .
Call 800-331-6870, or visit www.dougmac.com to get additional information
on a model suited to your specific needs.
Contact:
2101 Calumet Street, Clearwater, Florida 33765
Phone: 727-461-3477 or 800-331-6870
Fax: 727-449-0029
Web Site: www.dougmac.com
Contact:
Hartland, WI 53029
2101 Calumet Street, Clearwater, Florida 33765
Tel: 800.397.8664
Phone: 727-461-3477
(U.S. and Canada)
Fax: 800.369.2440 www.foodengineeringmag.com | Food Engineering
| June 2014or 800-331-6870
125
Email: info@dougmac.com
info@dorner.com
Web Site: www.dougmac.com
www.DornerConveyors.com/FEM
137

SHOW PREVIEWS
Eriez
Eriez is the #1 name in Magnetic Separators, and continues to out
perform all other magnets on the market today. Be sure to visit our booth
to see latest advancements in magnetic strength including head-to-head
comparisons!
Rare Earth Magnetic Separators
In order to continually improve separation quality, Eriez has designed a new
permanent Rare Earth magnetic separator capable of extracting the very
smallest of ferrous objects and
even work-hardened stainless steel
from product flows. Eriez employed
sophisticated finite element analysis
to produce this incredibly powerful
magnetic circuit intended for
applications demanding the highest
levels of product purity.
Eriez will display these magnetic separators in tube, grate, liquid-line trap and
a wide variety of self-cleaning designs.
Xtreme Metal
Detectors
Combine the Xtremes
benchmark-setting
sensitivities with its
feature packed controls
in a high-pressure
wash down aperture
head... all at an xtremely
attractive price, and
youve got the best
dollar-for-dollar value
on the market today.
Flexicon Corporation
Handle virtually any bulk food product
Flexicon stand-alone equipment and automated plant-wide systems convey,

discharge, condition, fill, dump
and/or weigh batch bulk foods
dust-free
engineers and manufactures a
broad variety of equipment that
handles virtually any bulk food
material, from large pellets to
sub-micron powders, including
free-flowing and non-freeflowing products that pack,
cake, plug, smear, fluidize, or
separate.
The line includes: Flexible Screw Conveyors, Tubular Cable
Conveyors, Pneumatic Conveying Systems, Bulk Bag Unloaders, Bulk Bag
Conditioners, Bulk Bag Fillers, Pallet Dispensers, Bag Dump Stations, Bag
Compactors, Drum/Box/Container Dumpers, Weigh Batching and Blending
Systems, and Automated Plant-Wide Bulk Handling Systemsall to food,
pharmaceutical or industrial standards.
Ideal for fragile bulk food products is the companys Flexi-Disc
Tubular Cable Conveyor, shown at left.
Custom engineered systems incorporate equipment manufactured
by Flexicon as well as packaging machines, blenders, weigh feeders, screeners
and any other process and storage equipment required all integrated with your
process and guaranteed to perform.
Large-scale bulk handling systems are managed by Flexicons Project
Engineering Division that offers dedicated Project Managers as your single pointof-contact, Engineering Teams that ensure
smooth integration with new or existing systems,
and the resources and effectiveness only a major
Now Xtreme is available with an optional Enhanced Platform using

advanced technology to detect metals in the most challenging
applications. EP has shown significantly improved sensitivities in a range of
dairy, cheese, meat and even rubber products. Stop by the Eriez booth to
see if EP is right for you.
Eriez offers the Xtreme in tunnel, tunnel conveyor, vertical and liquid-line
models with a wide range of reject options.
Contact:
Eriez
2200 Asbury Road
Erie, PA 16506
814-835-6000
www.purity.eriez.com
See us at PACK EXPO # S-5901
138
Flexicon offers stand-alone bulk handling equipment

as well as plant-wide systems integrated with new or
existing processes
bulk equipment manufacturer can provide.

Flexicons worldwide testing facilities simulate
full-size customer equipment and validate
system performance.
The company has recently doubled the
size of its manufacturing facility and world
New Flexi-Disc Tubular Cable
Conveyor for friable bulk foods
is available integrated with
upstream and downstream
equipment
Contact:
2400 Emrick Blvd.
Bethlehem, PA 18020-8006
Phone: 888 353 9426
Fax: 610 814 0600
sales@flexicon.com
www.flexicon.com
headquarters located in Bethlehem, PA, and also

operates manufacturing facilities in Kent, United
Kingdom; QLD, Australia; and Port Elizabeth,
South Africa.

SHOW PREVIEWS
Fortress Technology
Fristam Pumps
Introducing the Interceptor Metal Detector

President, Steve Gidman will be in
attendance at Pack Expo to introduce
and demonstrate the impressive
effectiveness of their New Interceptor
Metal Detector.
At a much lower cost of ownership
than x-ray systems, this new
simultaneous multi-frequency
technology provides food producers,
especially those with difficult
applications, a cost effective alternative for their food safety programs. Steve
will be speaking about the Interceptor at an Innovation Stage on Monday
September 28th at 3:00pm.
Never Obsolete: Fortress Metal Detectors Are Always Supported
On display at Pack Expo, will be several models from their range of
sustainable metal detectors. Fortress metal detectors have always been
engineered with a Never Obsolete Commitment. Their customers have
peace of mind that a Fortress metal detector will always be supported
with parts, software upgrades and a global service team for the life of the
detector. Stay up to date without having to purchase a new detector.
Optimized Metal Detection
Fortress Technology is the only North American Metal Detection
Manufacturer that, since its inception in 1996, custom manufactures their
equipment to suit their customers needs, application and specifications to
ensure optimal metal detection, without an exorbitant price tag.
Fristam is a leading global

manufacturer of highperformance stainless steel
pumps, blenders, and mixers.
Our equipment is designed
for precision and durability
to outlast and outperform all
others and provide the highest
lifetime value.
Powder Mixers
Fristams Powder Mixer blends
dry and wet ingredients into
a fluid stream. The Fristam
Powder Mixer provides consistent batch-to-batch repeatability and
reduced blend times. Powder induction rates up to 600 lbs/min.
Shear Blenders
FS Shear Blenders improve product consistency by removing agglomerates
and preventing lumps and masses in product. It produces repeatable
results and reduces raw material usage and processing times.
Positive Displacement Pumps
Fristam positive displacement pumps provide gentle product handling,
easy maintenance and hassle-free operation. Our heavy-duty FKL series is
built for no-disassembly, rotors-in
True CIP. Its balanced rotors
and large-diameter shafts make it
durable and reliable. In addition,
we manufacture standardduty and dual-duty PD pumps
(transfer and CIP in one pump).
Centrifugal Pumps
Fristam centrifugal pumps serve as
the industry benchmark for quiet, efficient, low-maintenance operations.
Our line includes standard-duty, heavy-duty, front-loading seal and self
priming centrifugal pumps.
Contact:
Fortress Technology Inc.
1-888-220-8737 or 416-754-2898
sales@fortresstechnology.com
www.fortresstechnology.com
See us at PACK EXPO Booth #C-2430
Contact:
Fristam Pumps USA
2410 Parview Road
Middleton, WI 53562
800-841-5001
www.fristam.com/usa
See us at PACK EXPO Booth #7508 South Upper
139

SHOW PREVIEWS
GEA Group
Heat and Control, Inc.
GEA provides innovative

solutions for preparing,
further processing,
preserving, chilling,
packaging and freezing
a wide variety of meat,
poultry, fish, seafood, fruit,
vegetables, dairy products,
bread, confectionary and
food ingredients.
From standard plant systems
to customized solutions,
all GEA food technology is
designed to meet optimum
hygiene and quality
standards, while operating
efficiently and sustainably.
Our technical expertise is
complemented by project
management, planning and
cost control services to
help our customers achieve
flexible and cost-effective
food production.
GEA has a wideranging portfolio that
spans almost the entire
food chain around 70%
of the products sold
in supermarkets have
been in contact with our
technology.
Contact info:
GEA Group, 9165 Rumsey Road, Columbia MD, 21045
410-997-8700
gea-pe.us@gea.com
www.gea.com
See us at PACK EXPO Booth # C-5000 & C-5200
140
Heat and Control is a single-source global manufacturer and supplier

of equipment for weighing, conveying, tray sealing, packaging, snack
bagmaking, metal detection, X-ray inspection, checkweighing, food
processing and cooking, seasoning and coating application. With our
partners Ishida, CEIA, and Spray Dynamics, we can provide one machine or
the complete line. We stand behind you with the industrys best pre- and
post-sale technical support, including applications assistance, engineering,
installation, parts, service, and training. Visit one of our demonstration centers
where you can test your products on some of our latest equipment. Contact
Heat and Control today for full-service assistance with your next project.
Lets Talk Solutions at Pack Expo Las Vegas!
Contact:
Heat and Control, Inc.
Phone: 800 227 5980 / 510 259 0500
Fax: 510 259 0600
Email: info@heatandcontrol.com
www.heatandcontrol.com

SHOW PREVIEWS
IFS North America
IMA Dairy & Food USA
IFS is a globally recognized leader in developing and delivering enterprise

software for enterprise resource planning (ERP), enterprise asset
management (EAM) and enterprise service management (ESM). IFS brings
customers in targeted sectors closer to their business, helps them be more
agile and enables them to profit from change.
Company Description
IMA Dairy & Food USAs equipment portfolio covers nearly all areas of
packaging machine applications. The company provides filling and sealing
machines (FS) for preformed cups and bottles, and forming, filling and
sealing machines (FFS) for packaging products in the food, dairy and
beverage segments (aseptic filling available), as well as wrapping machines
for packaging butter, margarine, etc.
IFS Applications is a pioneer in providing business software based on

actual business processes. Companies can reconfigure the software on
the fly, enabling them to adapt quickly to changing market conditions.
And because IFS Applications is component-based, customers need only
deploy the functionality they require and implement it step by step, adding
new components as their business changes or expands. IFS Applications is
based on an open design using industry standards, so integration with other
enterprise software is simple and seamless, eliminating technology lock-in.
IFS Applications puts the user back in the drivers seat by offering an
interface that can be adapted to individual needs. With Google-like search
functionality and no-nonsense navigation, it leads to increased productivity
and efficiencyand a healthier bottom line.
IFS is a public company (XSTO: IFS) founded in 1983 and currently has over
2,700 employees. IFS supports more than 2,400 customers worldwide from
its network of local offices and through a growing ecosystem of partners.
For more information visit: www.ifsworld.com.
IMA Dairy & Food

USA also offers
aseptic vertical form,
fill and seal machines
for stick packs/
pouches, as well as
FS and FFS machines
for packaging single
portions of coffee,
honey, jam, etc.
Recent Developments
IMA has introduced the Hassia FFS Machine P300, a form-fill-seal
platform for the production of portion packs. Ideal for manufacturing
and filling small to medium-sized cups, the P300 FFS Machine produces
up to 63,000 portion cups/hr and comes equipped with an integrated
case packing system. The P300 is the first in a new line of cost-effective
FFS machines combining compactness and low operational and repair
costs with high availability and more than 1,000 types of cup sizes and
configurations, including oval, round, square and honeycomb.
IMAs Erca EF Series of Form-Fill-Seal Machines allow food
manufacturers to create proprietary shapes for cups and bottles at nearly
the same cost as standard molds. Known as Open Mold, the system
can shape unique-to-brand containers for food products including
yogurt, cream spreads, jellies/jams, juices, water, butter, margarine,
sauces and fruit salads. On EF FFS Series machines, manufacturers
utilizing Open Mold can produce up to 18,000 product-filled portion
cups, or 16,800 product-filled bottles, per hour.
Contact:
Laura Stockhausen
Address: 300 Park Boulevard, Ste 555,
Itasca, IL 60143
Phone: 888-437-4968
Email: request@ifsworld.com
URL: www.ifsworld.com
Contact:
IMA Dairy & Food USA
523 Raritan Center Parkway
Raritan Center Edison, NJ 08837 / USA
Tel: +1 732 343 7600
Email: sales-usa.dairyfood@ima.it
Website: www.imadairyfood.com
141

SHOW PREVIEWS
Ingersoll Rand
Peco InspX
Peco Controls Corporation and InspX Corporation are leading providers
of advanced technology inspection solutions for the food and beverage
industries. With headquarters in Fremont, CA, the company serves
customers around the world and inspects over 1 Billion food and beverage
containers daily. The company specializes in accurate high speed package
inspection in machines that are easy to use with a low cost of ownership.
At Peco InspX
were obsessive
at ensuring that
we deliver a high
quality machine
that is seamlessly
integrated into your
operation. Our
applications experts
work closely with you to make our equipment more productive and efficient
so your operations can be more profitable.
Managing Compressed Air Contamination Risk

With growing concerns over food safety, its critical to have a compressed air
partner you can depend on for a full range of solutions that deliver cost and
energy savings without sacrificing quality. For more than 140 years, Ingersoll
Rand has remained passionate about the reliability and efficiency of the
solutions we provide, including:
Our allegiance to customer service goes beyond traditional post-sale

service. At Peco InspX we partner with our customers in ways that facilitate
their success. Using our extensive applications engineering expertise,
we seek to design the best possible inspection equipment to exceed
our customers requirements. With Real-Time Machine Monitoring and
Remote Support over 95% of customer issues are resolved remotely. We
demonstrate our commitment in serving customers large and small whose
facilities span 6 continents.
Oil-Free and Oil-Injected Air Compressor Systems

Dryers, Filters, Lubricants
Controls & Automation
Air Audits & Leak Assessments
Rentals & Remanufacturing
Maintenance & Risk Transfer Agreements
Well help you assess the risk of contamination, determine air quality
standards to support your HACCP, and choose the appropriate equipment
for your individual processing and packaging applications. For every air
need, you can depend on our solutions to help avoid compressed air
contaminationso you can Stress Elsewhere.
Contact:
Ingersoll Rand
800-D Beaty Street
Davidson, NC 28036
(800) 483-4981
IngersollRand.com/StressElsewhere
142
Contact:
rich.cisek@peco-inspx.com
Phone number: (510) 226-6686

SHOW PREVIEWS
Intralox, L.L.C.
Paxton Products
Paxton Products manufactures
high efficiency centrifugal blowers
and custom-engineered air
delivery devices, used for drying,
blow off, and air rinsing of food
and beverage products during
processing or packaging.
Centrifugal Blowers by Paxton Products are highly efficient, providing

150 1150 cfm of air at pressures of 30 100 inches of water. Available in
sizes from 3 20 hp, all Paxton blowers carry a full three year warranty.
Intralox, L.L.C. is a global provider

of conveying solutions, offering
direct service in more than 40
countries. We specialize in three
innovative technology platforms:
Activated Roller Belt (ARB)
equipment, ThermoDrive Belting,
and Modular Plastic Conveyor
Belting, which includes our
DirectDrive spiral system. With
the strongest guarantees for
belt performance and on-time
shipping and significant expertise
in the industries we serve, Intralox
has become a world leader by
consistently delivering where it
matters most.
Over the last four decades, Intralox has developed a worldwide
reputation for ethical and responsible business practices, and maintained
our founders commitment to treating employees, customers, and
suppliers with honesty, fairness, and respect. Our growth and sustained
success is the result of a diligent focus on continuous improvement,
a core belief that self-managed people are our greatest asset, and a
commitment to ideas, teamwork, and effort.
The Intralox Strategy integrates premium products with a powerful
blend of engineering expertise, services, global support and delivery, all
backed by the strongest, written performance and delivery guarantees,
for the pursuit of continuous, long-term profitability for our customers.
Contact:
Intralox, L.L.C.
301 Plantation Road, Harahan, LA
1 800 535 8848
customerservice@intralox.com
See us at PACK EXPO Booth: C-3336
Air Delivery Devices are customengineered to maximize drying and blow

off of products or surfaces. From an air
knife design to manifolds to halos that
encircle the product to individual nozzles,
well configure whats needed for your
application.
PowerDry System is a pre-configured drying system, originally designed
for date coding applications, and now setting the standard for a complete
Air System that can be used for drying and blow off for a wide variety of
cans, bottles and jars.
Ionized Air System dissipates the
static that causes particulates, dust and
contaminants to adhere to products
and surfaces, then uses high velocity air
from Paxtons high efficiency blowers
and air delivery system to remove the
contaminants. The Ionized Air System is
used in a wide variety of applications:
Bottle Rinsing for glass or PET bottles and jars, high speed and low
speed lines, including the hard to clean narrow mouth 2 liter PET bottle
Can Rinsing, for both high and low speed lines
Cleaning of the outside of bottles or packages after packaging of
powdery or dusty materials
Contact:
Rick Immell, International Sales Manager
Paxton Products, an ITW Company
10125 Carver Road, Cincinnati, OH 45242
800-441-7475
sales@paxtonproducts.com
www.paxtonproducts.com
143
PACK EXPO SHOW PORTRAITS

INTL PRODUCTION AND PROCESSING EXPO SHOW PREVIEWS
PROFILES
2014 | CORPORATE PROFIL

SHOW PREVIEWS

SPECIAL ADVERTISING SUPPLEMENT
Kagetec
Key Technology
Kagetec provides chemical resistant, hygienic, industrial flooring systems,

consisting of slip resistant ceramic tile and integrated stainless steel drains.
We have specialized in the installation of flooring in wet process areas for
We specialize
custom
thirty
years, andinoffer
a tenvisionyear warranty.
guided floors
roboticare
solutions
for in their sanitary/safety qualities, and
Kagetec
unsurpassed
high sanitary food packagingloading capabilities.
mechanical/thermal/chemical
environments.
Our in
history,
Kagetec
takes pride
maintaining the highest quality floors by performing
experience
and
application
the installations ourselves. Our employee craftsmen install over 1 million
knowledge
the backbone
square
feet ofisfloor
tile annually worldwide.
of our Design for Agility
philosophy,
focuses
onsolutions depending on your project requireKagetec
offerswhich
several
flooring
offering
simple,
user-friendly
ments. The Kagetec BS (basic system) has been used since our inception to
solutions
to complex
packaging
challenges.
provide
a chemical
resistant
floor that
withstands the daily rigors of industrial
Key Technology offers food processors the single most complete source of
high performance digital sorting, conveying, and process automation systems
from a single supplier.
Key Technology
JLS Automation
issed
on
orth
eriof
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olof
Mill
Key Technology offers food processors the single most complete source
of high performance digital sorting, conveying, and process automation
systems.
use, and is still widely used today.

Our robotic solutions include:
Are you repurposing a warehouse into wet production? The Kagetec GFK
creates
Ospreya sloped
Case Packers
Chub Loading
Systems
system
mortar bed,&minimizing
the amount
of concrete to be
Talon
Pick
&
Place
Systems
removed. Is installation time a critical factor? The Kagetec AR system provides
Heron
Tray Loaders
the fastest
installation/cure
time. Kagetec also installs static dissipative floors for
sensitive production areas, our AS (anti-static) system eliminates static buildup.
Benefits of our robotic primary and secondary packaging solutions:
on
stry
Laser / camera sorting systems, Cayman, Manta, Optyx, Python, Spyder,

Taurys, and Tegra remove defects and foreign material (FM) to improve
product quality, optimize yield, reduce labor and improve process control to
Laser / camera sorting systems remove defects and foreign material (FM) to
enhance plant efficiencies.
improve product quality, optimize yield, reduce labor, and improve process
control to enhance plant efficiencies.
These sorters are complemented by Keys other processing systems IsoFlo vibratory conveyors; Horizon horizontal motion conveyors; Impulse
These sorters are
complemented
by Keys
other grading,
processing
Isoelectromagnetic
conveyors;
equipment
for sizing,
andsystems
separating;
conveyors;
Horizon
motion conveyors;
Impulse
Flo vibratory
systems
for blanching,
air cooling,
airhorizontal
cleaning, washing,
and feeding.
electromagnetic conveyors; equipment for sizing, grading, and separating;
systems for blanching, air cooling, air cleaning, washing, and feeding.
Our line of customizable trench and area drains are available in 304 and 316
Flexible
Design with
Footprint
can easily
integrate
into existing
stainless
steel. Kagetec
offersSmall
heavy
duty sanitary
drains
that incorporate
lines
double box tubing reinforcement in our trench design and fully welded
Rapid
Changeover
few adjustments
and
no tweaking
bar grate
covers.
The sizes with
and design
are custom
tailored
to your specific
USDA-Approved
design
for sanitary,
wash-down
environments
water volumes
and product
use. Our
craftsmen
typically install
the drains to
proper
Patented
and Proprietary
End-Of-Arm
Tooling
handle:
ensure
elevation
and orientation.
Of course,
all designed
our drainstocan
also be
Meat,
poultry
and
dairy
products
installed by your plumber in non-tiled areas as well.
Frozen and prepared foods
Bakery products
as tortillas,a flat
snack
cakes
Safety - The Kagetec
vitrified tilesuch
incorporates
slip bread,
resistant
surface
into its
High
reliability
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by
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design that is matched to the production area it is being used in. This helps
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ackon
food
s.
to significantly reduce slip and fall accidents while maintaining the highest
OurofPIVT
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level
cleanability.
UnlikeIntegrity
other products, the slip resistant surface of the
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tile does not wear off or becomeSystem
dislodged over time creating harbors for
is a collection
bacterial
growth.of technologies that
utilizes vacuum, vision and other
technologies
to control
detect seal
Insensor
addition
to our quality
plan, Kagetec has a full written safety plan
leaksJobsite
and pinholes
incontamination,
place for our staff.
safety isthat
first priority on our projects.
lead to the loss of package integrity.
detect leaks
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If PIVT
you arecan
dissatisfied
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quality of your flooring, and would like to have
speeds
and
is
ideal
for
packages
that contain
or juice such
as hot
a product that does not require frequent
renewala brine
or replacement.
Kagetec
dogs,
sliced
luncheon
meats,
and
sausages.
This
enabling
technology
allows
would like to talk to you. We would like to know what floor systems you nora robot
identify
a leakycan
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speeds of
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min, and reject it.
Contact:
24631
Benedict
Rdof PMMI, FPSA, BEMA and the Wisconsin Cheese
WereSaint
active
members
Jordan,
MN
55352
Makers Association as well as a long time Strategic Partner for ABB Robotics.
m: 612.298.8838
p:Contact:
612.435.7642
f: 612.435.7643
Craig A. Souser President / CEO
e: 3495
sha@kagetecusa.com
Industrial Blvd, York, PA 17402
w:717-505-3800
www.kagetecusa.com
Sales@jlsautomation.com
Www.jlsautomation.com
See us at PACK EXPO Our booth number is C-4703
144
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Keys global support includes application testing, line integration, installation
Keys global support includes application testing, line integration, installation
and start-up, training, customizable service packages for maintenance and
and start-up, training, customizable service packages for maintenance and
repairs, and more.
repairs, and more.
106
Contact:
Key Technology, Inc.
Email: product.info@key.net
Contact:
Tel: 509 529 2161
Key Technology, Inc.
www.key.net
Email: product.info@key.net
Tel: 509 529 2161
www.key.net
Contac
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July 2014 | Food Engineering | www.foodengineeringmag.com

See
us at PACK EXPO Las Vegas booth #S-7222
www.foodengineeringmag.com | Food Engineering | January 2015

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SHOW PREVIEWS
Lubriplate Lubricants Company
METTLER TOLEDO
Trust the Product Inspection Industry Leaders

Lubriplate offers a complete line of high-performance, NSF H-1
Registered, Food Machinery Grade Lubricants. Manufactured under
strict NSF/ ISO 21469 Certified and ISO 9001 Registered quality
control standards, these lubricants are formulated to deliver a number
of significant, cost effective advantages, including; extended lube and
fluid change intervals, multiple application capability, lubricant inventory
consolidation and improved performance.
All Lubriplate H-1 Lubricants are manufactured with ingredients that
comply with FDA regulation 21 CFR 178.3570 for lubricants with
incidental food contact. They meet USDA H-1 safety standards and are
authorized for use in federally inspected meat and poultry plants. Clean,
safe and non-toxic, their use can eliminate lubrication as a critical control
point in HACCP programs.
All Lubriplate Lubricants come with the exclusive Lubriplate ESP Extra
Services Package at no-charge. Services include; a complimentary plant
lubrication survey by a factory direct representative, lubrication scheduling
software, color coded machinery lubrication tags and follow-up lubricant
analysis.
Offering a full line of innovative product inspection and connectivity

solutions, METTLER TOLEDO helps manufacturers ensure product quality,
increase productivity, and protect their customers and brand.
METTLER TOLEDO will showcase a variety of metal detectors,
checkweighers, vision and x-ray inspection systems, and track and trace
equipment designed for all types of food and pharmaceutical applications.
From economical systems to sophisticated, state-of-the-art systems with
customized material handling solutions, our systems can ensure perfect
product presentation, mark and verify packages and label integrity, ensure
weight range compliance, detect physical contaminants and inspect
contents inside the closed package
Our inspection systems are offered with a variety of interfaces including
Ethernet TCP/IP, EtherNet/IP, Modbus TCP, USB, Serial, and our ProdX
software for a complete off the shelf solution. OMAC compliant PackML
data is displayed locally and available over a variety of interfaces. We will
demonstrate real-time data collection and monitoring of all of the equipment
in both booths.
All systems are supported with comprehensive engineering solutions,
product testing, training, and 24/7 customer support with nationwide field
service.
Contact:
Lubriplate Lubricants Company
Newark, NJ 07105 / Toledo, OH 43605
Phone: 800-733-4755
E-Mail: LubeXpert@lubriplate.com
www.lubriplate.com
Contact:
METTLER TOLEDO
6005 Benjamin Road
Tampa FL 33634
(813) 889-9500
FAX: (813) 881-0840
www.mt.com/pi
pi.marketing@mt.com
See us at PACK EXPO Booth #C1814 and #N607
145

SHOW PREVIEWS
MEYER INDUSTRIES, INC.
Mitsubishi Electric
Mitsubishi Electric Automation,
among the top three automation
suppliers globally, offers
American manufacturers, system
integrators, and OEMs the most
advanced and reliable factory
automation solutions for improving
performance, enhancing quality,
and furthering competitiveness.
Mitsubishi Electric Automation is a major global manufacturer as well as
an automation systems supplier. Mitsubishi Electric Automation faces
all the same issues of performance, cost, and quality as its customers.
Because they are living the reality of manufacturing every day, the people
at Mitsubishi Electric Automation understand the energy, performance, and
sustainability trends that are shaping manufacturing for decades to come.
For over half a century Meyer has been one of the leading innovators
of bulk material handling and food processing equipment. As one of the
most respected names in the industry, Meyer prides itself on being a
totally integrated manufacturer offering standardized equipment as well as
complete custom distribution systems. The company has a full engineering
staff with decades of experience capable of taking a project from initial
concept through installation.
Vibratory Conveyors
Bucket Elevators
Belt Conveyors
Hopper-Feeders
Mix-Blend Systems
Distribution Systems
Vibratory Feeders
Continuous Weighing Conveyors
Integrated Systems
Washers
Blanchers
Chillers
Recognizing our customers specific requirements and providing a
customized solution is what makes Meyer stand out above the rest.
Contact:
Meyer Industries, Inc.
San Antonio, TX
(210) 736-1811
sales@meyer-industies.com
www.meyerindustries.com
146
Mitsubishi Electric Automation is known for its leadership in motion

control/servo solutions as well as integrated control platforms. In terms of
components, the company is recognized for the innovation, reliability, and
performance of its programmable logic controllers, human machine interface
devices, variable frequency drives, computer numerical controls, and robots.
Mitsubishi Electric Automation customers know that the company is

dedicated to their success because of the superior technical and logistical
support they receive. Every North American manufacturer, system integrator,
and OEM looking for a solution for improving performance and reliability
while lowering total cost of ownership will benefit from a supplier/customer
relationship with Mitsubishi Electric Automation. Mitsubishi Electric
Automation U.S. operations are headquartered in Vernon Hills, Illinois
30 minutes from OHare International Airport. The companys website is
us.mitsubishielectric.com/fa/en.
Contact:
Mitsubishi Electric Automation, Inc.
500 Corporate Woods Pkwy
Vernon Hills, IL - 60061 - US
Tel: (847) 478-2100
us.mitsubishielectric.com/fa/en/

SHOW PREVIEWS
Nercon
Pentair Food & Beverage
Learn All About Nercons Spirex Conveyor

At Pack Expo Booth #C-4200
Process Solutions from Sdmo, Keystone Sanitary & Haffmans

For industries that demand uncompromising standards of safety, sanitation,
and performance, Pentair is at the forefront of innovation. Pentairs process
valve, component, and quality control equipment meets stringent industry
requirements and successfully blends safety, quality and innovation.
Neenah, WI Nercons
Spirex Spiral Conveyor
provides a compact
solution to elevate
or lower a variety of
products in a production
line. The system gently
carries products
between floors or
machines or over aisles,
taking up minimal floor
space. Designed with a uniform slope and a continuously moving tabletop
chain, the Spirex Conveyor ensures smooth operation without disturbing the
product.
This makes
it ideal for
fragile products like pies and other food items
2014
PACK
EXPO
INTL
that cannot handle impact or gripping. The Nercon Spirex is engineered to
Show
Previews
convey trays, cartons, boxes, pouches, plastic containers, bottles and bundles
ADVERTISEMENT
for the food & beverage packaging, household product packaging,
and light
industrial packaging industries.
Nercon
With attractive pricing, a robust design, and such versatility in packaging
LER TOLEDO is your single source for product inspection and conapplications, Nercons Spirex Conveyor is an ideal choice for new projects
ity solutions. As the worlds largest manufacturer of metal detectors,
inspection systems, checkweighers,
machine vision systems,
or line and
modifications
that we
require elevation changes. The bi-directional Spirex
a solution for virtually every application. From economical systems to
can be
inhandling
a variety of in-feed and discharge height combinations,
sticated, state-of-the-art systems
withconfigured
customized material
ons, our systems can ensure perfect product presentation, verify
along with high and low speed applications. Operating speeds up to 150 feet
ge and label integrity, ensure weight range compliance, detect physintaminants and inspect contents
inside the closed
package.
per minute
are attainable
depending upon the height change and product
size
and
weight.
Safeline Metal DetectionFor wash-down environments requiring stainless steel
METTLER TOLEDO Safeline metal detection
construction, the Spirex is the smart choice. It is also available in painted steel
systems prevent costly recalls by ensuring
your
products are free ofAdaptable
ferrous, non-ferrous
construction.
to customer requirements, multiple lanes, slope and
and stainless steel contaminants which can
Packaging
the Fast Track
widths
are available rangingNercons
fromRapid-Rail
3 toPuts15.
Theonin-feed
and discharge
bechain
introduced
during processing
Neenah,
new patent-pending
will the
be introduced
location is also variable depending
on WI
the Nercons
application.
It evenRapid-Rail
features
Safeline X-ray Inspection
at the Pack Expo Show in November Booth #N5345. Engineered to
METTLER
TOLEDO
Safeline
x-ray
inspecsimplify
changeovers
on
the
packaging
line,
Rapid-Rail
offers
a
single
flexibility for three different case sizes
to be conveyed without any changeover.
point, easy-to-use hand adjustment of guide rails to accommodate multiple
ETTLER TOLEDO
tion systems can detect ferrous, non-ferrous,

stainless steel, glass and stone contaminants,
detect mass and check for missing or damaged product inside closed packages.
package sizes on the same piece of equipment. Now several points along
the conveyor, over a long distance, can be controlled from one location on
Nercon is a leading manufacturertheofline.standard and specially designed conveyor

value to packaging customers is multi-fold. Time savings with Nercons
systems. Their systems work withThe
aluminum,
tin, paperboard, cardboard,
Rapid-Rail is HUGE! On a long carton conveyor line with numerous guard
Hi-Speed Checkweighing
rail brackets, it could take several hours for rail adjustments to changeover to
METTLER
Hi-Speed
dynamiccontainers. All conveyors are designed to maximize line
paper,TOLEDO
plastic
or glass
different size cartons. With Rapid-Rail, all adjustments are made from only a
checkweighing systems ensure 100% quality
few locations and affect all points along the line. Change from 32 oz. bottles
efficiencies
and
reduce
changeover
times.
control,
minimize costly
giveaway
and give
to 16 oz.
bottles in a minute with Rapid-Rail. The equipment works equally
you total peace of mind.
well with any type of grocery packaged product.

Nercon employs a simplified, more economical design on Rapid-Rail that
Pentairs Food & Beverage Process Solutions provide advanced technology

for todays production plants. Sdmo and Keystone Sanitarys valve and
component range includes stainless steel mix proof, single seat, butterfly,
and specialty valves that meet the highest hygienic and aseptic standards.
Haffmans specializes in quality control equipment
for measuring carbon dioxide, oxygen, air,
alcohol/extract, and turbidity, as well as carbon
dioxide recovery.
Backed by service
Operating a state-of-the-art production plant
requires a just-in-time manufacturing system,
minimized production losses and compliance
with tough quality regulations. This is why it is so
important to have scheduled service intervals,
trained service personnel and an adequate supply
of original spare parts. Pentair offers tailored
service plans to help you achieve maximum
plant efficiency.
Complete Solutions
Pentair offers end-to-end solutions for the
food and beverage industries. For Pentairs
customers, this means more time and resources
directed where they should bemaking the
food and beverages to nourish a rapidly growing
planet.
Keystone Butterfly Valve
Haffmans OGM In-line O2
Pentairs proven products lead from a

technology point-of-view and include:
Mix Proof / Aseptic / Butterfly Valves
Valve Manifolds
Product Recovery Systems
CO2 / O2 Quality Control Equipment
For more information on their Spirex

Spiral
any
othersystem,
systems,
visit
limits the
numberConveyor
of moving parts.or
With
a repeatable
its easy to
fine-tune the path as products go through the turn. The new design also
them at Pack Expo Booth #C-4200.
(844)293-2814
www.nercon.com
enables operators
to add a motor and control
any adjustments right from a
CI-Vision Machine Vision

METTLER TOLEDO CI-Vision inspection
systems ensure that products consistently
meet manufacturers quality standards and
specifications resulting in perfect product
presentation every time.
conventional control system.
TLER TOLEDO Connectivity Solutions

nspection systems are offered with a variety of interfaces including
net TCP/IP, EtherNet/IP, Modbus TCP, USB, Serial, and our ProdX
are for a complete off the shelf solution. OMAC compliant PackML
s displayed locally and available over a variety of interfaces.
Contact:
Nercon
600 S. Commercial St.
Neenah, WI 54956
sanklam@nercon.com
act:
LER TOLEDO
Benjamin Road
a, FL 33634
See us at PACK EXPO
89-9500
rketing@mt.com
mt.com/pi
us at PACK EXPO International booth # 1706 & 776
ber 2014 | Food Engineering | www.foodengineeringmag.com
Sdmo Mix Proof Aseptic

Secure
To learn more, visit Nercon at Booth #N5345 at Pack Expo or

call (844)293-2814. www.nercon.com
Contact:
Nercon
600 S. Commercial St.
Neenah, WI 54956
Booth # C-4200
sanklam@nercon.com
Contact:
Pentair Food & Beverage North America
293 Wright Street
Delavan, WI 53115
Phone: 262.725.9026
Fax: 866.673.4621
snasales@pentair.com
www.sudmona.com
sschiedemeyer@nercon.com
147

SHOW PREVIEWS
Precision PMD
Precision PMDs mission is to design
and manufacture reliable yet affordable
machines for the packaging industry. The
impact on your bottom line is not only
affected by the purchase price of the
machinery, but the up-time and life-span of
the machinery itself.
Designed to be versatile
and maintenance friendly,
Precision PMD machines are
manufactured for use in 24HR
operations in USDA and FDA
packaging facilities.
Precision PMD Complete Packaging
Systems:
We design and manufacture everything from
container D-Nesters, Conveyors, Piston Fillers,
Volumetric Pocket Fillers, Container Sealers and Lid
Applicators.
Our D-Nesters and Fillers can
be added to your existing
system or we can design and
manufacture a Complete
Packaging System tailored to
your specific needs.
Contact Precision PMD to discuss
how we can partner with your TEAM
to provide you with packaging
machinery that you can rely on today
and in the future.
Cup & Tray Application Expertise:
Cereal, Oatmeal, Nuts, Candy, Mac & Cheese
Soup, Salsa, Humus, Pudding, Fruit Cocktail, Applesauce
Fresh Salad including Spinach, Spring Mix (Complete Salad Tub
Packaging Systems)
Macaroni Salad, Cole Slaw
Family Meals, Frozen Entrees, IQF Vegetables and more
Contact:
Precision PMD, LLC.
9009 Freeway Drive, Unit 7
Macedonia, OH 44056
P: 330-908-0410
Toll free: 877-567-PPMD(7763)
sales@precisionpmd.com
www.precisionpmd.com
See us at PACK EXPO Las Vegas Booth # S-6125
148

A leading food industry machinery
supplier, Rovema North America
manufactures and supplies
equipment for dosing, vertical
form-fill-seal pouching, cartoning,
and final packaging operations,
primarily for the bakery, cereal,
confectionary, coffee, dry powder,
snack and frozen foods sectors.
At Pack Expo Las Vegas, Rovema
NA will showcase two advanced
BVC Series Vertical Form-FillSeal (VFFS) Machines: The BVC 400 for the IQF/Frozen Food market, and
the BVC 260, which will be displayed running a Ropack standup bag. The
BVC 400 VFFS Bagging Machine is a continuous motion, dual axis servo,
vertical form-fill-seal machine offering broad flexibility in product sizes and
shapes demanded by the frozen food sector. The BVC 260 VFFS Bagging
Machine, also a continous motion, dual-axis servo packaging machine,
is capable of running up to 210 cycles per minute at a maximum forming
width of 260mm. Demonstrations of each machine will take place regularly
throughout the show.
The BVC Series incorporates
a patented Sense and Seal
quality control solution that
determines, for example, if
product is present in the cross
seal area and, if so, discharges
the bag without the application
of sealing pressure. The BVC
260 is equipped with Rovemas
innovative Premium-Seal
system. Premium-Seal offers
the option to pre-heat and then
compress multilayered seal seam
packing material for optimum
tightness.
Contact:
Pack Expo Booth C-4942
4366 Shackleford Road, Suite A
Norcross, GA 30093
Tel: (404) 640-5310
E-Mail: info@rovema-na.com
Website: www.rovema.com

SHOW PREVIEWS
Sesotec Inc.
Silverson Machines
Food and agricultural product producers need consistent high quality output
with minimal waste and downtime at an affordable price. Our sorters are
designed to meet this need.
The ASM VISION color sorter is
designed for reliability and performance
using the latest technologies. Distinctive
European engineering has attracted
hundreds of customers worldwide with
over 600 food sorting units installed.
The new software features a userfriendly and intuitive touchscreen. The
LED lighting system increases the
contrast on the finest contaminants and provides a constant light quality. A
special chute design can process a higher throughput than conventional
sorting machines with the same operating width. The latest generation
of air-valves further reduce the loss of good material and offers a longer
service life.
The VISION INOX is full stainless steel for applications with this requirement,
such as salt.
The VISION sorter is available in 5 different sizes.
Our world-class lean manufacturing facility enables affordable pricing for
topnotch quality.
Our North American
headquarters and service center
is located outside Chicago to
provide local support.
____
The Labseed sorter helps
industry leaders in the seed
industry. It is designed for quick
batch changes in laboratories
and research institutes and
focuses on sorting accuracy and
smaller quantities.
Contact:
Sesotec Inc
Eli Cannell
North American Sales Manager
224-279-5554
Eli.cannell@sesotec.us
Revolutionary powder/liquid mixing

At PACK EXPO International in November, Silverson Machines will debut
its latest Flashmix powder/liquid mixer. The Silverson Flashmix is now two
times faster. Powder is incorporated into liquid at a rate of 500lbs/min. The
Flashmix incorporates breakthrough technology, allowing it to bring the
benefits of high shear mixing to new applications. It can be used with higher
viscosity mixes and at higher temperatures than was previously possible.
Unlike most powder/liquid mixers, which use vacuum to pull in powders, the
Flashmix literally forces powder into the liquid stream - theres no venturi,
no vacuum. When the powder and liquid components are introduced
directly into the high shear zone of the mixer, they are subjected to intense
mechanical and hydraulic shear, which instantaneously combines them,
producing a homogeneous product without agglomerates. Stop by booth
7038 to learn more about the Flashmix and other Silverson high shear
mixers. Silverson High Shear mixers are available in laboratory to production
size models and are engineered precisely to enable seamless scale up.
If you cant wait until November to see the new Flashmix, please watch one
in action at Silverson.com or contact a Silverson representative to arrange for
a free trial at (413) 525-4825 or sales@silverson.com
Contact:
Silverson Machines
East Longmeadow, Mass.
(413) 525-4825
www.silverson.com
149

SHOW PREVIEWS
Stainless Steel Flooring Products

SlipNOT slip resistant stainless steel
products increase productivity for
food and beverage processing plants.
SlipNOTs stainless steel products are
registered by NSF International, chemical
and corrosion resistant and provide
a hygienic solution for slippery areas.
Stainless steel products also withstand
the extreme heat of cookers or extreme
cold of cryogenics. In facilities where
chemicals, water and other vicious liquids are present, a slip resistant
surface is necessary to keep workers safe. SlipNOT manufactures a
variety of versatile products such as floor
plate, grating, ladder rungs and covers,
stair treads, nosings, drain covers and
many other products. SlipNOT products
are utilized for catwalks, crossovers,
walkways, platforms, trench covers, drain
covers and numerous other applications.
SlipNOT products are custom fabricated
to detailed specifications or can be
provided in stock lengths and widths.
SlipNOT recommends fabrication prior to SlipNOT coating, however,
SlipNOT products can be fabricated in the field. Customers can also
send in existing material to be coated methodically so there is no
downtime at the plant.
SlipNOT is a permanent solution; it will
not chip or wear quickly like traditional
methods of slip resistance. SlipNOT
products require little maintenance and are
cleaned by power washing or using a stiff
bristle brush. Stainless steel products will
not contaminate the end product and are
resilient to caustic cleaning agents.
Contact:
Christina Molnar Metrose, Vice President
SlipNOT Metal Safety Flooring
2545 Beaufait Street
Detroit, MI 48207
P: 313-923-0400
F: 313-923-4555
info@slipnot.com
www.slipnot.com
150
TD Sawvel
Since 1976, T.D. Sawvel
has been providing creative
automated packaging
solutions for denesting, filling,
sealing and capping a wide
range of packaging shapes
and sizes from 1 ounce to 6
gallons.
T.D. Sawvel Company is
excited to announce the
continued expansion of our
Triple-A line of automated packaging equipment. Designed to meet or
exceed 3A, FSMA, and USDA standards, the following new models are
now available: Model 135PF-AAA Rotary Piston Filler for cups from 4 to 80
ounce, Model 119-AAA Lid Press for pails from 2 to 6 gallon sizes, Model
135TF-AAA Rotary Time Filler for cup sizes from 4 to 64 ounce, Model
1000-PLC-AAA Semi-Automatic Ice Cream Filler for pint to 3 gallon sizes.
We have many more Triple-A models in the pipe line so stay tuned.
If your equipment needs
do not require -AAA The
following New Models
may be of interest: Model
81-SRVO High Speed Dual
Lane Volumetric Filler for
cup sizes 6 to 64
ounce, Model 1000-6 Dual
Head Table Top Time Filler
designed for dosing cups from small continuous freezers.
Here at T.D. Sawvel we are continually improving and expanding our product
line. Whether it is more -AAA models or an All New high speed filling
line, there is always something on the drawing board. If you have not
checked out T.D. Sawvel Company lately, please do so. Thank you! Troy
Sawvel, President
Contact:
Troy Sawvel
T.D. Sawvel Co., Inc.
5775 Hwy 12 W
Maple Plain, MN 55359
troy.sawvel@emailtdsawvel.com
877-488-1816 toll free
763-479-5460
763-479-3517 fax
www.tdsawvel.com

SHOW PREVIEWS
The Austin Company
Triangle Package Machinery
Design-Build Leaders for Food &

Beverage Facilities
The Austin Company is an international
design-build firm offering a
comprehensive portfolio of in-house
architectural, engineering, construction
management and consulting services.
In addition, Austin offers value-added
strategic planning services such as site
location, transportation and distribution
consulting, and facility and process audits.
Austins building solutions are more
than just shade and shelter for your
operations they are facility solutions
developed and implemented to make
your operations better. We have been
recognized as an innovative leader
in the food and beverage industry
since the early 1900s. Our Food &
Beverage Group is an experienced
and dedicated in-house team specializing in planning, designing and
implementing safe, efficient and economical food and beverage facilities. From
new construction to renovations and expansions, Austin offers advanced
solutions for your facility needs.
Our services include:
Architecture/Engineering
Planning
Construction Management
Economic Analysis
Site Location
Packaging Systems Services
Design-Build
Installation & Start-Up
Process Engineering
With a diverse product line that includes vertical form fill seal (VFFS)
baggers, combination weighers / scales, depositors, and horizontal
cartoners, Triangle is your source for quality packaging machinery. As one
of the first companies in the world to manufacture VFFS bag machines,
Triangle helped set an unparalleled standard of excellence in the industry.
Family-owned and operated since 1923, today the familys third generation
continues a tradition of superior engineering, world-class manufacturing,
and unparalleled customer support.
Our global experience includes facilities for baking and snack foods,
beverages, condiments, confectionery, diary, frozen foods, grains, fish,
produce, and specialty items.
We have successfully implemented projects including:
Manufacturing and Production Facilities
Bottling Plants
Formulation and Packaging Plants
Research Laboratories
Bulk Storage Warehouses
Automated Distribution Centers
New for 2015: At Pack Expo 2015, Triangle is introducing an enhanced

version of Model XYT15 VFFS Bagger designed to run PrimaPak
packages. PrimaPak is an innovative stackable and reclosable package
style designed to replace rigid, pre-made containers or trays. In addition,
we are also introducing our Model XYT15-RJ VFFS Bagger, which can run
3-sided seal (Doy) bags, as well as pillow and gusseted bags, all on the
same machine!
VFFS Baggers: Available in intermittent or constant motion and 3 levels of
sanitation, including stainless steel, stainless steel washdown, and USDA/3A
models. Optional features include zipper applicators, ability to run quadseal stand-up bags, and Ultrasonic welding. Ultrasonic welding is a cold
sealing technology that provides multiple benefits to refrigerated and frozen
food packagers, including: material, energy, and labor savings; reduced or
eliminated leakers; and improved production and OEE.
Belt-Fed or In-Line Combination Weighers: Triangle Combination
Weighers provide expert product handling, superior sanitation, and nonproprietary (AB) controls. Pair with a Triangle bagging machine for a
complete integrated system with a single HMI.
Tray Loading / Depositing Systems: Designed to deposit product into
a predetermined space in preformed bowls or in sectioned trays, Triangles
Tray Loading / Depositing System is ideal for small IQF products, fresh cut
produce, and more.
The Austin Company was founded in Cleveland, Ohio, in 1878. The firm
became a wholly-owned subsidiary of Kajima USA in 2005 and is a proud
member of the Kajima family of companies. Kajima Corporation is one of the
leading engineering and construction contractors in the world.
Contact:
Matt Eddleman
Sr. Vice President, Sales & Marketing
404.564.3962
Matt.Eddleman@theaustin.com
www.theaustin.com
Contact:
Triangle Package Machinery Company
6655 W. Diversey Ave.
Chicago, IL 60707
Phone: (773) 889-0200
Fax: (773) 889-4221
Email: info@trianglepackage.com
Web: www.trianglepackage.com
151

SHOW PREVIEWS
Triple/S Dynamics
Triple/S Dynamics introduced
the Slipstick Horizontal
Motion Conveyor to the food
processing industry in 1982.
Today, with thousands of
conveyors installed around
the world, the Slipstick
Conveyor and other accessory
components set the standard
of performance and sanitation
in food processing.
Processors have many hot button issues including product breakage or
degradation, sanitation and minimizing downtime. The Slipstick conveyor
addresses all of these issues.
The Slipstick is an oscillating mechanical conveyor driven with a slow-speed,
horizontal differential motion and requires no fiberglass springs or base
frame. The motion is a slow-advance and quick-return cycle that glides
product along the length of the conveyor. This motion does not impact
the product so breakage is greatly reduced or eliminated. The product is
conveyed gently, intact retaining any added seasonings or coatings.
This horizontal motion also provides sanitary conveying as the gliding of the
product along the seamless one-piece formed conveyor pan discourages
build-up of materials on the surface. The continuous sliding action on the
conveyors surface typically
scours the pan clean so theres
less downtime.
In addition to the Slipstick, the
Triple/S Dynamics Tex-Flex
Vibratory Conveyor, equipped
with a screening section, can
remove overs and/or fines
that enter the product stream
before cartoning.
Food processors can rely on Triple/S Dynamics lineup of conveying
equipment to solve their processing challenges.
Contact:
Triple/S Dynamics, Inc.
P.O. Box 151027
Dallas, TX 75315-1027
214.828.8600
800.527.2116
Fax: 214.828.8688
Email: sales@sssdynamics.com
www.sssdynamics.com
152
URSCHEL DISPLAYS THE

LATEST IN FOOD CUTTING AT
PACK EXPO IN LAS VEGAS
September 28-30, 2015 Visit Urschel booth #S-7233 to view the latest in
food cutting technology including the newly-released Sprint 2 Dicer. Other
machines featured include the Affinity Dicer, E TranSlicer Cutter, and the
M6 Dicer.
The latest addition to the Urschel line of dicers, the Sprint 2 builds on
the technology of the DiversaCut Sprint Dicer and is inspired by the
longstanding Model G. Accepting an infeed product up to 6.5 (165.1
mm) in any dimension, the dicer offers a stainless steel sanitary design
throughout with the food zone completely isolated from the mechanical
zone. The new Sprint 2 offers an alternative to the Models G, G-A, GK-A, H,
or H-A Dicers with increased horsepower and benefits.
The Affinity Dicer, the largest dicer Urschel manufactures, specializes in
the cutting of cheese and difficult-to-cut products such as meats with high
fat content. The U.S.D.A., Dairy Division accepted machine accepts a large
in-feed product size of up to 10. Driven by a 25 HP gear motor with heavyduty gears and belts and equipped with a 5 HP VFD (variable frequency
drive) motor on the crosscut, the Affinity excels at delivering maximum
capacities.
Urschel has recently moved into a newly-constructed manufacturing/global
headquarters in Chesterton, Indiana, U.S.A. The 350,000+ square foot
state-of-the-art facility situated on 160-acres will allow for future growth of
the company. Founded in 1910, Urschel remains the global leader in food
cutting technology and continues to partner with food processors around
the world to develop and offer the latest in cutting machinery.
Contact:
Urschel
1200 Cutting Edge Drive
Chesterton, Indiana 46304
Toll-free: 1-844-URSCHEL(877-2435)
info@urschel.com
www.urschel.com
See us at PACK EXPO Booth #S-7233

SHOW PREVIEWS
Volkmann, Inc.,
Wenger
Pneumatic Conveying, Bulk Material Handling Solutions
WENGER EXTRUDERS AND DRYERS
Volkmann manufactures a range of high

quality, high performance vacuum-based
pneumatic conveying systems for the
transport of fine food powders, chemicals,
granules, pellets, tablets and other small
components. Volkmann conveyors are
driven by the patented Multijector
multi-stage pump, which uses a series of
precision Venturi nozzles to increase both
the generated airflow from a given air supply
and to achieve a greater level of vacuum
thereby making it possible to convey in lean,
dense or plug flow conditions and do so
without segregation or damage. Conveying
distances can range up to 260 ft. as well as
heights of up to 115 ft., with custom systems
being built at times to accommodate higher
distances. In most applications; however,
the horizontal distances run to 150 ft. and
heights extend to 65 ft. Densities are most
frequently in a range between 6 to 150 lbs/
ft3. Volkmann vacuum conveyors have been
used for materials in such low ranges of
approx. 3 lbs/ft3 (e.g., fluidized pyrogenic
silica) to a high of 806 lbs/ft3 (e.g. uranium
Volkmann No-Tip Unloader
compounds). It is even possible to have
with Enhanced Features
custom conveying solutions for such
critical materials as wet, oily, adhesive,
bridging, hygroscopic, poor-flowing and
explosive materials. Even nanoparticles have been successfully transported
pneumatically by vacuum.
Wenger Thermal Twin Screw

Extruders are unlike any
extruder on the market today,
with significant advantages
in design, capabilities and
efficiency. Higher levels of
thermal energy allow a more
gentle cooking process
than high-shear cook, and
therefore offer new opportunities in extruded foods. Products high in corn or
rice content can be processed without the stickiness typically encountered
in conventional extrusion systems. Ingredients may be fully cooked without
damage to the starch or protein matrix.
Suitable for the food, pharmaceutical, nutraceutical, and chemical industries,

Volkmann conveyors feature such standard features as No-Tools
disassembly and easy cleaning, all stainless steel contact parts, as well as
designs conforming to cGMP standards. The Volkmann series of vacuum
conveyors is industry leading with the additional benefit of ATEX certification
for explosion-proof applications.
Wenger Dryers are

customized to exact needs,
including the optimum
dehydration of fruits and
vegetables. A dual plenum,
continuous conveyor
dehydrator provides high
volume, low-cost-per-ton
output, removing moisture
slowly, under controllable
conditions, to assure correct
final product moisture, color, taste and aroma. Humidity controls and variable
speed product conveyors regulate drying for proper product finishing. Multiple
pass conveyor configurations give great flexibility to process requirements as
well as plant design and layout. Heated airflow direction (up or down) may be
changed within each drying zone to meet varying product airflow demands.
Wengers experts will help you plan projects, develop product prototypes,
provide extrusion and drying demonstrations, perform laboratory analysis and
create processes for your new products.
See us at Booth #58447
In addition to their VS Series of vacuum conveyors, Volkmann will showcase

their new No-Tip Unloader, Post Hoist and High Containment Rip and Tip
Unloader at Pack Expo Las Vegas.
Contact:
Volkmann, Inc.,
609-265-0101
www.VolkmannUSA.com;
Contact:
Doug Baldwin, Director of Business Development
dbaldwin@wenger.com
785-284-2133
153
2014
PACK
EXPO
INTL
OW
2014
PACK2015
EXPOPACK
INTLEXPO LAS VEGAS
OW PORTRAITS
PORTRAITS
TION
AND
PROCESSING
EXPO
SHOW
TION AND PROCESSING
EXPO
SHOW PREVIEWS
PREVIEWS
Show
Previews
SHOW
PREVIEWS
Show
Previews
Wire
Wire Belt
Belt
Zeppelin
Wire Belt, the leading developer of open
Wire Belt, the leading developer of open
mesh stainless steel conveyor belts, has
mesh stainless steel conveyor belts, has
been keeping your lines running for
been keeping your lines running for
over 85 years. Our conveyor belts are
over 85 years. Our conveyor belts are
extensively used for breading, battering,
extensively used for breading, battering,
frying, blanching, cooking, coating,
frying, blanching, cooking, coating,
dusting, and cooling. Wire Belt is a
dusting, and cooling. Wire Belt is a
fourth-generation family owned company,
fourth-generation family owned company,
dedicated to serving our customer base
dedicated to serving our customer base
and remaining the industry leader in
and remaining the industry leader in
stainless steel conveyor belt innovations
stainless steel conveyor belt innovations
Screw
Screw
y
y
today,
today,
ages
ages
nd
nd
of
of
more
more
and
and
orn or
orn or
ered
ered
hout
hout
Zeppelin Systems is a world leader in

the design, manufacture, and supply of
automated material handling systems
for powder and liquid ingredients. Our
systems are installed in world class
food and beverage companies around
the globe. Zeppelin Systems provides
engineered solutions customized to
the specific needs of our clients. We
emphasize the integration of dry and
liquid material systems into the rest of
the clients manufacturing environment.
Wire Belts entire line of belting products are accepted by the USDA NSF/
Wire Belts entire line of belting products are accepted by the USDA NSF/
ANSI/3-A hygiene standards. This is the only acceptance that can assure you
ANSI/3-A hygiene standards. This is the only acceptance that can assure you
that you have the cleanest, safest conveyor belt available.
that you have the cleanest, safest conveyor belt available.
needs,
needs,
m
m
and
and
enum,
enum,
high
high
-ton
-ton
sture
sture
able
able
correct
correct
ariable
ariable
Multiple
Multiple
nts as
nts as
may be
may be
ands.
ands.
es,
es,
sis and
sis and
g.com
g.com
Competence and tradition are an

advantage for our customers. Zeppelin
Systems has been a source for complete solutions in process engineering and
CONVEYOR BELTS
CONVEYOR BELTS
Wire Belts Versa-Link conveyor
Wire Belts Versa-Link conveyor
belt is perfect for poultry
belt is perfect for poultry
processors. Versa-Link is one of
processors. Versa-Link is one of
the most durable and open metal
the most durable and open metal
belts available for light to mediumbelts available for light to mediumduty applications. Versa-Links
duty applications. Versa-Links
unique spacing is designed to outperform competitive style belts especially in
unique spacing is designed to outperform competitive style belts especially in
bread crumb and flour applications, where typical belts are greatly stressed
bread crumb and flour applications, where typical belts are greatly stressed
and damaged during this process.
and damaged during this process.
material handling for more than 120 years.
CONVEYORS
CONVEYORS
Wire Belt also offers CarrySmart conveyors, its unique made to order line of
Wire Belt also offers CarrySmart conveyors, its unique made to order line of
sanitary conveyors. The CarrySmart line includes Flex-Turn, Straight,
sanitary conveyors. The CarrySmart line includes Flex-Turn, Straight,
and Spreader or Converger conveyors. CarrySmart conveyors are custom
and Spreader or Converger conveyors. CarrySmart conveyors are custom
designed to accommodate your specific processing application. Other
designed to accommodate your specific processing application. Other
advantages include open construction that is easy-to-clean, gentle product
advantages include open construction that is easy-to-clean, gentle product
handling, and one of the tightest transfer and smallest turning radius available.
handling, and one of the tightest transfer and smallest turning radius available.
Continuous mixing system (CODOSSystem)
To learn more about Wire Belts complete line of products, including our
To learn more about Wire Belts complete line of products, including our
CarrySmart conveyors, please visit us at www.wirebelt.com.
CarrySmart conveyors, please visit us at www.wirebelt.com.
Overall solutions from one source:
Our areas of expertise include, but are not limited to, the following:
Bulk ingredients unloading (railcar, truck, containers, bags)
Bulk silos/tanks for dry and liquid ingredients
Pneumatic conveying (dilute and dense phase; vacuum and pressure)
Mechanical conveying (screws, trays, bucket elevators, belts)
Liquids unloading, storage, transfer and metering systems
Minor and micro ingredient systems
Pneumatic blending
Mechanical mixing
Continuous and batch fermentation systems
Sugar handling and grinding systems
Process automation and controls
System software (PRISMA, production resource information systems
management applications)
Rockwell Automation Solution Provider
Equipment and components

Process technology
Automation and controls
Project management
Service and support
Contact:
Stephen Marquardt - Sales Director Food,
North & South America
E-mail: stephen.marquardt@zeppelin-usa.com
Zeppelin Systems USA
13330 Byrd Drive, Odessa Fl. 33556
Tel.: +1 813 920 7434
Fax: +1 813 920 3864
www.zeppelin-systems.com
Contact:
Contact:
Wire Belt Company of America
154 Harvey Road
154 Harvey Road
Londonderry NH 03053
Londonderry NH 03053
(603) 644-2500
(603) 644-2500
sales@wirebelt.com
sales@wirebelt.com
www.wirebelt.com
www.wirebelt.com
See us at the IPPE Show Booth #7023
See us
usat
atthe
PACK
8302
See
IPPEEXPO
ShowBooth
Booth##7023
154
| Food
Engineering | October 2014
| www.foodengineeringmag.com
September
2015 | Food Engineering
| Food
Engineering | October 2014
ZEPPELIN TECHNOLOGY FOR

LIQUID SPONGE AND SOURDOUGH
PRODUCTION When using liquid sponge
a natural improver develops, ensuring
better tasting baked goods that stay fresh
longer. The process can be carried out in
batches or by using a CODOS continuous
mixing system. Zeppelins systems deliver
consistently superior products.
153
153
CLASSIFIEDMARKETPLACE
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157
AD INDEX
COMPANY
PHONE NUMBER PAGE
www.3-a.org
86
A&B Process
888-258-2789
41
ADI Systems, Inc.
800-561-2831
84
Admix
www.admix.com
37
Alfa Laval
www.alfalaval.com/gphe-us
39
ALLPAX
888-893-9277
108
A.M. King
704-365-3160
71
Ampco Pumps Co.
800-737-8671
83
Archon Industries Inc.
800-554-1394
90
Atlas Copco
866-688-9611
69
Austin Co., The
www.theaustin.com
92
APEC
616-374-1000
31
Beckhoff
www.beckhoffautomation.com 111
Belt Technologies Inc.
413-786-9922
96
BETE Fog Nozzle, Inc.
www.bete.com
81
Big D Construction
www.-big-d.com
BC
Bimba Manufacturing
708-534-8544
14
Bradman Lake Group
www.bradmanlake.com
50
Breddo Likwifier
800-669-4092
IBC
Bhler Inc.
763-847-9900
116
Bunting Magnetics
800-835-2526
28
Caloris Engineering LLC
410-822-6900
89
CDM Smith
www.cdmsmith.com
88
Clarion Lubricants www.clarionfoodsafety.com
cover
Complete Water Services, LLC
678-355-9270
90
Cone Drive
888-994-2663
6
Cubic Designs
800-826-7061
129
Dorner Manufacturing
800-397-8664
18
Douglas Machines
800-331-6870
52
Dow Water & Process Solutions www.dowwaterandprocess.com 87
Dur-A-Flex
860-528-9838
91
Dynamic Conveyor
800-640-6850
53
Eriez Magnetics
888-300-ERIEZ
34-35
Festo Corp.
800-GO-FESTO
12
Flexicon Coporation
888-353-9426
2, 19
Flowtrend
www.flowtrend.com
54
FAM Conference www.foodautomationconference.com 99
FE Webinars www.foodengineeringmag.com
79
Fortress Technology
www.fortresstechnology.com 22
Fristam Pumps
800-841-5001
7
Gamajet
www.gamajet.com
82
GE Software
www.gesoftware.com
109
GEA Group
www.gea.com
97
Goodway
888-364-3432
6
GreCon
503-641-7731
130
Hapman
800-427-6260
120
Harpak Ulma
800-813-6644
125
Haskell
904-791-4500
55
Heat and Control
800-227-5980
67
Heatec
423-821-5200
94
Hinds-Bock
425-885-1183
38
Hixson, Inc.
513-241-1230
1
Hixson Webinar
webinars.foodengineering.com 85
Hoosier Energy
812-876-0294
76
HR Green
800-728-7805
57
IFS
www.ifsworld.com
46
IMA Dairy & Food
732-343-7600
20
Industrial Magnetics
888-582-0821
36
Ingersoll Rand
www.ingersollrand.com/stresselsewhere
65
COMPANY
PHONE NUMBER PAGE
Intralox
www.intralox.com
23
JAX
800-782-8850
110
JLS Automation
717-505-3800
70
Kent Elastomer Products, Inc.
888-239-3940
58
Key Technology
509-529-2161
115
Kollmorgen
540-633-3545
113
Leatherhead Food Research
www.leatherhead.com
56
Lubriplate Lubricants co.
800-733-4755
26
Marchant Schmidt Inc.
920-921-4760
16, 17
Marion Process Solutions
800-397-6371
57
Masosine Pumps
800-282-8823
100
Master Bond
201-343-8983
49
Material Transfer & Storage
800-836-7068
112
McCloud Services
800-332-7805
59
Mettler Toledo
www.mt.com/pi
42
Meyer Industries, Inc.
210-736-1811
43
Mitsubishi Electric
www.mitsubishirobotics.com
107
Multi-Fill
801-280-1570
127
Nelson Jameson
800-826-8302
59
Nercon
844-293-2814
60
Pack Expo Las Vegas www.packexpolasvegas.com 119
Paxton Proudcts
800-441-7475
47
Peco-InspX
877-722-6875
25
Pentair
www.sudmona.com
117
Polyguard
214-515-5000
53
Polytron
855-754-7659
30
Precision PMD
877-567-PPMD
24
Pure Bioscience
www.purebio.com
95
Rovema
404-640-5310
73
Ross, Charles & Son Co.
800-243-ROSS 13, 131
Schenck Accurate
800-558-0184
4
Sesotec
224-208-1900
72
Sigma
800-578-5060
48
Silverson
413-525-4825
29
SlipNOT
800-754-7668
98
Specialty Equipment
713-467-1818
105
Spiroflow Systems, Inc.
888-909-7674
5
Spraying Systems Co.
800-95-SPRAY
11
SPX
800-252-5200
IFC
STOCK America
262-375-4100
114
Sudmo Pentair
www.sudmona.com
117
Summit Industrial Products
800-749-5823
40
T.D. Sawvel Co. Inc.
877-488-1816
32
Tekleen Automatic Filters Inc.
800-336-1942
33
Terlet USA
800-965-6065
10
Tetra Pak Webinar www.webinars.foodengineeringmag.com
93
Therm Omega Tech
877-379-8258
74
Tomra Sorting Solutions
www.tomra.com/food
33
Triangle Package Machinery Co.
800-621-4170
44
Triple S Dynamics, Inc.
877-542-8010
9
True Clean
www.trueclean.us
51
Unifiller
888-733-8444
123
Urschel Laboratories
219-464-4811
103
Volkmann, Inc.
609-265-0101
118
Weitz
www.weitz.com
45
Wenger
www.wenger.com
128
603-644-2500
75
York Saw & Knife
800-233-1969
61
Zeppelin Systems
813-920-7434
49
Further information on these companies can be found in the 2014-2015 FOOD MASTER CATALOG. This index is published as a convenience. No liability is assumed for errors or omissions.
158
ENGINEERING R&D
Wayne Labs, Senior Technical Editor
Lubrication keeps wheels turning

in flash freezing applications
For the meat packing industry, lubrication for conveyors must

maintain adequate lubricity in freezing cold areas, provide
corrosion resistance and be safe to use.
Pork processing, like any live protein processing, is not a nice environment for humans or
machines. Humans, however, can dress properly or take breaks, but that isnt the case for
machinery, especially gambrels and rail surfaces on overhead conveyor systems. This machinery
must run in hostile, cold environmentsand keep on running.
Unfortunately, finding lubrication that survives a pork processing environment, especially blast
freezers, hasnt been easy. But now, Birko Corporation is offering a product line for pork processing applications including hog scalding, defoamer agents, pathogen reduction treatments and
chemistries for gambrel cleaning and oiling.
The lubrication solution, known as Frostlube, is designed for the gambrels and rails in
blast freezing applications. It received a US patent (8716205) last year. We caught up with
Dr. Jeremy Adler, Birkos director of technology and innovation, and asked him for some specifics
about the product.
Dr. Jeremy Adler,

Birko director of
technology and
innovation
FE: The patent attributes Terry L. McAninch of

Birko as the inventor. Can you tell us a little
about his background?
Dr. Jeremy Adler: Terry is the current vice presi-
dent of research and development at Birko. He

has worked for Birko for 41 years, during which
he has authored or co-authored 11 issued patents.
He is truly the foundation of Birkos R&D efforts
and an industry expert in cleaning, sanitation and
lubrication.
FE: How did you come to develop this
lubrication?
Adler: A majority of our R&D projects come direct-
ly from identifying customer problems and trying to

solve them. In this instance, we had a customer that
was losing significant trim yield on hog carcasses
because black specs had to be trimmed from the
carcasses. Upon investigation, we realized the black
specs were iron particles from the gambrels that
spalled [chipped or flaked] onto carcasses after passing through the blast freezer. This spalling is caused
when water adheres to a gambrel and freezes solid
during blast freezing. The freezing of the water spalls
iron flakes off the gambrel and onto the carcasses.
FE: What special lubrication problems needed

to be solved?
Adler: Gambrels in a hog plant are cleaned and
lubricated between uses. For the lubrication step,

oil is floated on top of a water bath. Floating the oil
on the water bath decreases the amount of oil needed
for lubrication, saving the plant money. During the
lubrication process, the gambrel is dipped into the
tank passing through the oil layer and into the water.
The gambrel is then passed through the oil layer again
as it is raised out of the tank. It is then blow-dried to
remove excess oil. Any water from the lower layer of
the lubricating bath that is not displaced by the oil
remains on the gambrel. This residual, or undisplaced
water, can lead to gambrel spalling. Our goal was
to find an oil mixture that would displace the water
on the gambrel to minimize the amount of spalling.
After several trials in the lab, we formulated Frostlube,
which contains the precise amount of silicon oil to
preferentially adhere to metal to displace water.
FE: How do you balance real-world lubrication

needs with food safety requirements?
Adler: When formulating oils for lubrication, we
use only products approved for incidental food
159
ENGINEERING R&D
ever, silicon oils tend to have a viscosity that is less affected by
temperature to the point where they are almost temperature
independent in the range of temperatures found in processing
environments. Simply put, silicon oils stay fluid during pork
processing at 180F and even during blast freezing at -28F.
FE: How do you keep the lubrication from dripping onto
the carcass immediately below it?
Adler: The key is to develop a lubricant that does not thin
out and drip. To inhibit dripping, we have incorporated an oil

thickener into the formula of Frostlube. Additionally, we formulated the lubricant so it is thick and unlikely to drip at pork
processing temperatures. For the oil to be applied quickly and
uniformly, it must be applied hot. The lubricant application
tank I previously described is around 180F. After application,
the oils temperature drops, and it forms a gel on the gambrel.
FE: How do you create a formula safe for incidental

contact with meat?
Adler: We use only products approved by FDA and USDA
The patent for Birko Frostlube describes an improved
lubricant for use with a conveyor in a meat packing plant
meeting the requirements of adequate lubricity, drip resistance,
safety, rust resistance, economy of manufacture and use, and
the ability to be removed by cleaning methods. Source: US PTO.
contact. Given this, from a chemistry standpoint, there are

really no food safety issues, as long at the product is applied
as directed. Ultimately, Frostlube decreases the amount of
trimming during the visual inspection of a carcass, increasing
carcass yields.
FE: What level of viscosity should a lubrication
treatment have for gambrel/rail applications?
Adler: We tend to define our gambrel and trolley lubricants
by their lubricity and load-bearing properties. Lubricity is the

lubricants ability to reduce friction, thus making it easier to
move the loaded gambrel along the rail. The friction can be
between the rail and the gambrel wheel or the gambrel wheel
and central axis pin as the gambrel travels along the rail. The
load-bearing capacity is the lubricants ability to adhere and
remain on the surface to hold, or separate, the gambrel weight
from the rail. Therefore, a lubricants load-bearing capacity is
directly proportional to the viscosity. We design our lubricants
to have the necessary load-bearing capacity and lubricity for
the carcass weights and range of temperatures found in the
processing environment.
FE: How does a lubricants viscosity change depending
on environmental temperatures?
Adler: In general, the viscosity of fatty acid and mineral oils,
which are [used in] the most common type of food industry
lubricants, increases as the temperature is lowered. How160
for incidental contact with food, specifically, in this case, pork.

If our lubricants come in contact with an edible product, that
product is still safe to consume. Nonetheless, when a lubricant
does come into contact with an edible product, USDA inspection procedures dictate that the product must be trimmed to
remove the lubricant. FDA and USDA approval makes choosing the lubricant components easy: Either they are OK or not
OK to use. However, it also limits the choice and possible functionality of the lubricant.
FE: When its time for washdown, does the lubricant

stay put, or does it need to be reapplied?
Adler: Gambrels are cleaned and oiled between uses. The
cleaning process is dependent on the gambrel metal composition and usually includes a cleaning agent applied at a high
temperature. These cleaning processes, whether the plant is
using steel or aluminum gambrels, clean the gambrels including the lubrication. Then, the gambrels are oiled before they
are used again.
FE: Would this lubrication technology be suitable
for gambrel/rail conveyor systems in other food
applications?
Adler: Yes, Frostlube can be used in poultry and beef process-
ing plants. But, since these plants do not use blast freezers and,
for the most part, dont have spalling issues, they would not
experience the technical benefit of the lubrication.
FE: Are there any similar products on the market?
Adler: Frostlube was designed specifically for a pork proces-
sor that uses a blast freezer before cooling carcasses. We are

unaware of any similar products in the poultry, beef and pork
markets. It is patented technology, so we can protect this product for several years.
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