What’s New in Food Technology Nov/Dec 2012

CEOS KNOW GLASS BUILDS POWERFUL BRANDS. “Consumers like

to see what they’re getting,” says Edson Auricchio, CEO of OLÉ Foods.

“We package quality foods, and glass demonstrates that quality, quite literally.

Seeing is believing. I would say that glass is more than packaging for us,

it’s a form of advertising.”

GlassIsLife.com

makers of strong, bold, clearly different glass packaging © Owens-Illinois, Inc.

TM

Nov10773_8

http://www.o-i.com

www.foodprocessing.com.au 3Nov/Dec 2012

November/December 2012contents

6 food for thought

27processing.29 What ‘foodies’ think about when investing in new technology

36 Applications for UV light in the food industry

38 Third-party audits and food safety

48meat & seafood.48 Meat consumption and stress reduction

50 Blast chilling methods could change meat tenderness

51 Cattle vaccine works to reduce E. coli O157:H7

52packaging.52 Resealable packages: a frustration-free alternative

10 traceability

10 Machine vision for quality assurance

14 Finding fresh food contamination sources faster

20 bulk handling, storage & logistics

16 testing and quality assurance

©iStockphoto.com/578foot

CEOS KNOW GLASS BUILDS POWERFUL BRANDS. “Consumers like

to see what they’re getting,” says Edson Auricchio, CEO of OLÉ Foods.

“We package quality foods, and glass demonstrates that quality, quite literally.

Seeing is believing. I would say that glass is more than packaging for us,

it’s a form of advertising.”

GlassIsLife.com

makers of strong, bold, clearly different glass packaging © Owens-Illinois, Inc.

TM

Nov10773_8

©iS

tock

phot

o.co

m/A

man

ita

©iS

tock

phot

o.co

m/D

mitr

y G

ool

©iS

tock

phot

o.co

m/J

ohn

M S

cott

http://www.o-i.com

www.foodprocessing.com.au4 Nov/Dec 2012

Regards

Janette Woodhouse

Chief Editor

What’s New in Food Technology & Manufacturing

www.foodprocessing.com.au

Cooking your gooseChristmas is coming, the goose is getting fat … and if you haven’t fulfilled your 2012 New Year’s resolutions you might as well concede that that goose is cooked for 2012.

What themes do you suppose will pervade the food industry in 2013?I am guessing that ‘the obesity epidemic’ will still be ubiquitous and food

processors and retailers will continue to be held responsible for everything consumers choose to eat.

In cahoots with this will be continuing drives for ‘natural’, ‘free-from’, ‘ethical’ and ‘wellness’ products. It is possible that your goose won’t fit well into this scenario, certainly your pâté de foie gras won’t.

And while the mainstream media will continue to bemoan the wantonness of the food industry in its complicity in undermining the health of the entire population by only manufacturing “processed” foods that are “full of chemicals”, no-one will look at the reality of the situation.

Take this “full of chemicals” malarkey - just tell me any physical object that isn’t made of something and every ‘something’ is a chemical even if it’s water or air. Really, every natural, free-from-any-additives foodstuff is made of a mixture of chemicals just the same as every highly processed food. The emotive association of the word ‘chemical’ with ‘bad’ is ludicrous.

And, while I’m on my high horse, let’s also mention preservatives. In environments where food contamination is likely, access to refrigeration is dodgy, access to clean water uncertain - in other words all developing countries - food preservation is one of the most important contributors to public health. Preservatives have certainly saved more lives than they have harmed.

I will be interested to watch how sugar and alcohol fare next year. Both regularly get very bad press and I sometimes wonder if wine will end up going the same way as cigarettes. My adult children watched people smoking on Mad Men with fascination. They found it hard to believe that there could ever have been a society where every living room had at least one ashtray and that an invisible wall could separate smokers from nonsmokers on aeroplanes.

In fifty years will people watch ‘period pieces’ about the early 21st century and be amazed that people drank wine with their meals, beer with their sport, cocktails for pleasure … that society accepted the consequences of drunkenness as an everyday part of life?

Ah, but that’s all in the future. Now I am just thinking about the end of 2012. In fact, wondering which wines will go best with the roast goose I am thinking of serving for Christmas.

After that? Bring on 2013 with a whole new lot of resolutions to ignore.May 2013 be the year the goose lays the golden egg for us all.

©iS

tock

phot

o.co

m/C

harle

s B

rutla

g©

iSto

ckph

oto.

com

/bla

ckre

d

Everything begins with taste

Contact details: 1800 643 165, [email protected], www.o-i.com

Food and drink served from glass tastes, looks and feels better. O-I's glass packaging preserves flavours exactly as they were intended. Our brand-building glass containers safeguard your product while adding distinction and beauty that sets your food and beverages apart on busy supermarket shelves. Honest, pure, 100% recyclable glass. What's not to love?

#GlassIsLife

makers of beautiful, safe, �avour-preserving glass packaging

10723.15 AUG


Fo dFO

R

thoughtimag

e©iS

tock

phot

o.co

m

Food processor wins 2012 Prime Minister’s Water Wise Award

Salt-reduction campaigns not affecting new product launches, Mintel findsCampaigns to reduce salt levels in processed foods have had little effect on new product launches of low/no/reduced sodium foods, Mintel says. Research from the market analyst has shown that global launches of foods with low/no/reduced sodium claims actually declined by 5% over the 2010/2011 period, with only 2% of food launches in 2011 sporting sodium claims.

“A large percentage of the global food industry remains wary of the commercial impacts of reducing salt in their products. This anxiety is well founded, with many products positioned as low sodium forced off the shelves prematurely in recent years due to poor sales,” said Chris Brockman, Global Food and Drink Analyst at Mintel.

“Manufacturers struggled to find workable salt substitutes, forcing many to rapidly pull them from the market. Efforts are being made to offer consumers alternatives to sodium. However, existing salt replacements have not caught the imagination of consumers. Consumers are concerned about salt intake, but are not willing to compromise on taste.”

Europe is said to be the most active region in terms of product innovation, with 35% of new product launches sporting low/no/reduced sodium claims in 2011. 26% of North American new product launches carried sodium claims, while in the Asia-Pacific region, only 19% of new product launches carried a low/no/reduced sodium claim.

New Zealand leads the pack in the Asia-Pacific region, with 3% of new food products carrying sodium claims, while Australia follows with 2%. Taiwan, China and Vietnam had the lowest number of sodium claims, with 0.7, 0.5 and 0.4% respectively.

Changing consumer attitudes to low-sodium products could prove difficult. Mintel found that 49% of British consumers say that taste is more important than calories and 46% of US consumers think low-sodium alternatives don’t taste as good as their higher-sodium counterparts. In the UK, only 22% of consumers say they’ve purchased low-sodium products.

“Brands will need to dispel widely held perception about low sodium or salt alternatives to be successful,” Brockman said. “Fortunately, this is possible.

“Many food brands are already introducing step-by-step salt reduction programs that gradually reduce the salt content of their products - a strategy often called ‘stealth health’, as the incremental removal of sodium can be carried out over a period of time to help the consumer to become accustomed to the changed flavour profile, without the need to flag that up prominently on-pack and thus deter consumers who may perceive ‘less taste’.

“Other brands are also steering clear of the health issue by experimenting with different flavour profiles, such as strong spices and vinegars, to enhance taste while eliminating sodium,” said Brockman.

Macleay River Meats has won the 2012 Prime Minister’s Water Wise Award. The company, which trades as Eversons Food Processors, was congratulated by Senator Don Farrell, Parliamentary Secretary for Sustainability and Urban Water, on winning the award.

Senator for Victoria Jacinta Collins presented the award on behalf of Prime Minister Julia Gillard at the savewater! awards gala dinner in Melbourne on 26 October.

The prestigious Prime Minister’s Water Wise Award showcases commercial and industrial innovation in water efficiency. It is open to all commercial and industrial water users.

Farrell said Eversons Food Processors received the award due to its strong

commitment to water efficiency and sustainability.

“I congratulate Eversons Food Processors for recognising the need to minimise its impact on the environment and for taking action to reduce both its water usage and disposal of waste to landfill,” Farrell said.

“The company has reduced its water usage by close to 95%, which is an amazing achievement.

“Eversons’ water savings were particularly commendable, given the need to use drinking-quality water in the food production process for health and safety reasons.

“A major focus of Eversons’ water-saving strategy was the construction of three on-site wastewater ponds - two aerobic and one anaerobic - and the commissioning of a wastewater treatment system.”

The other finalists in the Prime Minister’s Water Wise Award were Serco Australia - which was highly commended - Cameron’s Nursery and Sakata Rice Snacks.

©iS

tock

phot

o.co

m/B

art S

adow

ski


Water recycling in food production

Reduced-sodium cheddar successfully manufactured

Reducing salt in cheese has historically proven difficult. Recently, however, researchers from the University of Minnesota have been successful in manufacturing a cheddar-style cheese using mineral salt replacers.

The researchers claim that previous studies into reducing sodium in cheese have used mineral salt replacers at levels too low to produce equal water activity (aw) in the finished cheese, compared with a standard, full-sodium cheese. Higher aw can result in differences in cheese quality due to differences in the effective salt-to-moisture ratio, creating differences in biochemical and microbial reactions during ageing.

Hypothesising that targeting replacer concentrations to produce the same aw as full-sodium cheese would minimise changes in quality, the researchers manufactured a

range of stirred-curd, cheddar-style cheeses. The control cheese was salted with naturally reduced-sodium sea salt, while others were manufactured with blends of sea salt with KCl (potassium chloride), modified KCl, MgCl2 (magnesium chloride) or CaCl2 (calcium chloride).

Unfortunately, CaCl2 and MgCl2 produced a range of unpleasant flavours, such as bitter, metallic, unclean and soapy. However, bitterness ratings for cheese with KCl and modified KCl were not significantly different from the full-sodium control.

The researchers concluded, “Potassium chloride can be used successfully to achieve large reductions in sodium when replacing a portion of the NaCl in cheddar cheese.”

The research has been published in the Journal of Dairy Science.

Increasing the use of water recycling in food production and manufacturing is among new research being undertaken by the Australian Water Recycling Centre of Excellence.

Led by CSIRO Animal, Food and Health Sciences, the project will collaborate with industry to demonstrate higher-value water recycling opportunities that deliver economic, environmental and social benefits to the agrifood industry and community.

The research will examine opportunities for water recycling across the agrifood chain with particular focus on food manufacturing, dairy and meat industries.

Project Director Jay Sellahewa said the project will focus on current industry challenges, including regulatory and policy pressures, and the value proposition (an analysis of all factors to determine if water recycling stacks up as the best option). It will also develop strategies to increase acceptance by consumers and enhance the sustainability positioning with customers.

“The ultimate goal is to reduce the reliance of fresh water throughout the agrifood supply chain,” Sellahewa said.

“This could be achieved by increasing the amount of water used for irrigation of crops by treating effluents from food processing plants and by increasing the amount of water recycled within food manufacturing plants.

“Outcomes of this work will include the development of fit-for-purpose water recycling guidelines for industry, a tool to enable industry to make decisions on recycling water based on the value proposition and available

technologies, and communicating positive messages in consuming foods associated with recycled water to help increase consumer confidence.”

Centre CEO Dr Mark O’Donohue said the project was a good example of the multidisciplinary work being done by the centre.

“This project is using rigorous science-based research in partnership with some of the biggest and most credible industry organisations in Australia, such as Meat and Livestock Australia, Dairy Australia and the Australian Food and Grocery Council,” Dr O’Donohue said.

“As a centre focused on water security, the applications of this research for food security are very exciting.”

More than $2.3 million has been committed to this project, which has linkages with the centre’s other work in examining public attitudes to and perceptions of water recycling.

The linkages between projects were examined at a recent workshop where project leaders had the opportunity to engage and discuss common themes of their individual projects. The workshop’s focus was to ensure the centre’s research outcomes have the greatest impact on a national scale - enhancing efficiency, expansion and adoption of water recycling in Australia.

Other new research being undertaken by the centre includes the use of nanotechnology to recover phosphorous, which could in turn be used in fertiliser products, and a study into the importance of micropollutants in water, including an analysis of whether the right chemicals are currently being monitored and regulated.


Fo dFO

R

thoughtimag

e©iS

tock

phot

o.co

m

Demystifying food ingredients: new consumer resource

LycoRed receives full approval for premix operation in China

LycoRed has received full approval for its new premix plant in Changzhou, China, which is said to be one of the largest premix factories in Asia.

The new site is now fully operational and will serve processors of infant formula, beverages, baby food and other food products in

the Asia-Pacific region.“We recently received our Halal MUI certificate for our new

vitamins D3, E and K1 formulations,” said Ilan Ron, LycoRed’s Vice President of Sales & Marketing. “These vitamins are made with a proprietary spray-drying process to ensure complete

solubility of vitamins. They can be used in premixes for infant formula and baby food, as well as in dry blends for beverages.“Our formulations are manufactured under the most stringent

specifications in the market for delivering the safest premixes. We are proud to have received all necessary certifications and can ensure our customers will receive the highest quality blends possible.”

The company also recently appointed Jason Foo as Sales and Business Development Manager, covering Malaysia, Singapore, Indonesia, Vietnam and the Philippines.

Cyanocobalamin; pyridoxine hydrochloride; calcium pathothenate: consumers reading these terms on a food label could be forgiven for thinking the product is full of artificial ingredients. A new resource from the US is helping consumers interpret food labels so they can see these particular ingredients for what they are: B vitamins.

‘What’s in Our Food: Understanding Common Food Ingredients’ is a resource that aims to take the mystery out of common food ingredients by explaining why they are used in food products. Developed by the International Food Information Council (IFIC) Foundation, the guide is free to download and will be available in some nurse practitioner clinics in the US. The resource includes a quick reference guide

that outlines common food ingredients and their functions in food, as well as providing more familiar terms for ingredients and examples of food that contains these ingredients.

“Our Food & Health Survey results show that nine out of 10 consumers give thought to what’s in their food and pay attention to ingredients listed on food labels,” said Marianne Smith Edge, IFIC Foundation Senior Vice President, Nutrition and Food Safety.

“For this reason, it is important to bring clarity to those unfamiliar ‘chemical’ sounding names of ingredients that are really quite common, readily found in nature and play important roles in keeping our food safe, affordable and delicious.”

First phage for food safety approvedFood Standards Australia New Zealand (FSANZ) has approved Listex P100 as a processing aid against Listeria monocytogenes, making Listex the first phage for product safety approved in Australia and New Zealand. The phage is produced by Dutch company Micreos.

According to FSANZ’s approval report:•The safety assessment did not identify any public

health and safety concerns associated with using Listex P100 to treat food.

•It is effective at reducing levels of Listeria monocytogenes on the surface of solid RTE foods evaluated.

•There is no appreciable ongoing technological function when it is applied to the surface of various solid RTE foods, therefore it fits into the category of

processing aids. This is consistent with international approaches.

•There were no measures that would be more cost effective than Listex P100.“FSANZ’s decision marks an important step in the

acceptance and appreciation of phage technology,” said Mark Offerhaus, CEO of Micreos. “The review process was thorough, transparent and involved all stakeholders; an example of how new - and suitable - technology should be brought to market.”

Following approvals in the USA, Canada and the Netherlands, Micreos applied for approval of Listex in Australia and New Zealand. Easy to apply, Listex is sprayed onto the surface of food products during processing, killing Listeria without any sensory or other effects.

©iS

tock

phot

o.co

m/M

ark

God

dard

©iS

tock

phot

o.co

m/F

acto

ria S

ingu

lar

Dual Bulk Bag Weigh Batch Eductor conditions,discharges by weight, andblends into a liquid stream

Bulk-Bag-To-Bin WeighBatching System discharges,de-lumps and feeds materialgravimetrically

Continuous Loss-of-WeightBulk Bag Unloader allowscontinuous gravimetricdischarging

Bulk Bag Unloader forPneumatic Conveyors hassurge hopper with rotaryairlock feeder for metering

Sanitary Bulk BagDischarger with patentedUSDA-accepted flow control valve cleans rapidly

Z-1086

Now save time, money and space with BULK-OUT™multi-function dischargers

Condition, de-lump, screen, feed, weigh batch, combine with liquids, and convey as you discharge,with a custom-integrated, performance-guaranteed discharger system from Flexicon

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

©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.*Patent(s) granted and/or pending

Bulk Bag Unloader forPneumatic Conveyors hassurge hopper with non-flow-through pick-up adapter

Bulk Bag Conditioner-Unloader loosens solidifiedmaterial, then discharges, de-lumps and conveys

Half Frame Unloaders with Conveyor or Airlockrequire forklift, eliminatingcost of upper frame

Combination Bulk BagDischarger and ManualDumping Station has multi-purpose hopper interface

Split-Frame allows loading of bag frame or rigid bins onto subframe within100 mm of ceiling

Unlimited configurations:All Flexicon dischargers are available

as fully enclosed, dust-free systems withdurable industrial finishes or in stainless

steel finished to food, dairy, pharmaceuticalor industrial standards, and as weigh

batching systems complete with automatedcontrols and pneumatic or mechanical

conveying systems.

Flexicon innovations:• SPOUT-LOCK™ clamp ring*: forms high-integrity

seal between clean sides of bag and equipment• TELE-TUBE™ telescoping tube: maintains

constant downward tension on spout as bagempties/elongates, promoting complete discharge

• POWER-CINCHER™ flow control valve*: allowsretying of partially empty bags dust-free bycinching spout concentrically.

USAUK

SOUTH AFRICACHILE

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

[email protected]

1300 FLEXICON

Z-1086 NowSaveTime_Y-0805 10/11/11 2:52 PM Page 1

http://www.flexicon.com.au


TR

AC

EA

BIL

ITY

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

Machine vision (MV) is the technology and techniques used in industrial environments to provide imaging-based automatic inspection, detection and analysis. The most common uses

for machine vision are automatic inspection and industrial robot guidance, while in recent times, vision-based sensors for detection purposes have become available to replace sen-sors such as photoelectric sensors. Common MV applications include quality assurance, sorting, material handling, robot guidance and optical gauging.

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

General operationThe first step in the MV sequence of operation is acquisition of an image, typically using cameras, lenses and lighting that has been designed to provide the differentiation required by subsequent processing. For example:

•Different types of lighting (different colours or infrared for example) render different qualities of objects that may be of interest for detection or inspection.

•Strobe lighting synchronised with the rate of flow of objects past the camera allows fast snapshots to be taken of each object without motion blur.

MV software packages then employ various digital image-

processing techniques to extract the required information and often make decisions (such as pass/fail) based on the extracted information.

While conventional 2D visible light imaging is most com-monly used in MV, alternatives include imaging in various infrared bands, line scan imaging, 3D imaging of surfaces and X-ray imaging.

2D visible light imaging can be performed in monochrome or colour, and various resolutions. The use of colour and the depth of resolution affect the performance requirements of the image processing hardware and software, and therefore the cost of the solution.

The imaging device (usually a camera) can either be sepa-rate from the main image processing unit or combined with it, in which case the combination is generally called a smart camera or smart sensor. When separated, the connection may be made to intermediate hardware, such as a frame grabber, using either a standardised (Camera Link) or custom interface. There are now also digital cameras available that are capable of direct connections (without a frame grabber) to a computer via FireWire, USB or gigabit ethernet interfaces.

Processing methodsAfter an image is acquired it is processed. Machine vision image processing methods include:

•Pixel counting: Counting the number of light or dark pixels.•Thresholding: Converting an image with grey tones to

simply black and white or using separation based on a greyscale value.

•Segmentation: Partitioning a digital image into multiple segments to simplify or change the representation of an image into something that is more meaningful and easier to analyse.

•Blob discovery and manipulation: Inspecting an image for discrete blobs of connected pixels (such as a black

©iS

tock

pho

to.c

om/B

rian

Jack

son


TR

AC

EA

BILIT

Y

hole in a grey object) as image landmarks. These blobs frequently represent optical targets for machining, robotic capture or manufacturing failure.

•Pattern recognition and template matching: Finding, matching or counting specific patterns. This may include the location of an object that may be rotated, partially hidden by another object or varying in size.

•Barcode, data matrix and 2D barcode reading: Reading codes for data input or simply to check correct labelling on finished products or shipping boxes and pallets.

•Optical character recognition: The automated reading of text such as serial numbers.

•Gauging: The measurement of object dimensions (in pixels or millimetres).

•Edge detection: The finding of object edges to detect their presence and orientation.

Quality assurance applicationsThe main uses of vision systems for quality assurance are to analyse images to perform appearance inspection, character inspection, position detection and defect inspection. Some of the main applications are:

•Detecting the presence, position and formation of a code such as a date code or barcode

•Validating the presence and positioning of labels•Checking closures for tamper seals, correct caps by colour

and dimensions•Inspecting product for fill levels, product content or other

parameters•Sorting products based on marking

Advantages for quality assuranceThe major benefits of machine vision inspection solutions are:

•Cost savings due to reduced rework, more reliable product quality and less wasted product

•Automation of quality to provide more objective QA compared with manual inspection

•Greater transparency throughout the inspection process and improved process control

•Real-time quality metrics can be made available for OEE data

Examples of QA applicationsCode validationMachine vision solutions for code inspection are used to verify code presence, position and formation, and sometimes to also provide code reading and matching. Such systems can also automatically identify and reject containers or packages with missing, incorrect or unreadable codes to ensure only properly coded items are produced.

Examples of the use of code validation are the validation of date codes, batch codes, barcodes and 2D data matrix codes.

Date code verification verifies that a code is present and is completely formed in the correct location, while batch code verification checks the quality of the printed batch informa-tion, ensuring it cannot be misread, possibly resulting in product recalls.

Barcode verification checks that barcodes are readable and correct, helping to ensure correct product tracking through the supply chain. 2D data matrix validation verifies that information which is not human readable is still valid, and is properly decoded and understood by the quality system.

Label inspection and validationHigh-speed labelling of products, of all types, shapes and sizes, can result in a wide variety of possible defects. These defects can lead to label errors that can be harmful to a brand

or even present liability issues for a brand owner. Labels can be inspected for label presence, wrinkles, tears, skewed labels, double labels, flagged or missing labels, as well as incorrect label pairs on containers and packages.

Machine vision technology for label inspection can be set up to help ensure perfect product presentation and correct labelling. Packages and containers with incorrect or defective labelling can then be automatically rejected in the production line.

Label presence and pairing can be checked, both to ensure labels are present and also that front and back labels are paired correctly with each other.

Skewed and dog-eared label detection ensures that labels are applied correctly and straight, and in the correct position, while double label inspection can make sure that only one label has been applied to the same location on the package.

Overwrap alignment is another form of label inspection in which wraparound labels are checked for straightness and proper position. With appropriate MV system design, a 360-degree inspection on round bottles can be performed.

Confirming that the correct label has been applied is of-ten performed using graphical label verification (in which a unique graphical item on the label is used to confirm that the proper label has been applied) or by using 2D data ma-trix code verification where 2D dm codes are being used on the labels. Similarly, barcode verification: confirms that the proper label has been applied by verifying that the correct barcode is present.

Closure and seal validationObviously the integrity of closures and seals on bottles and other containers is important for the quality of the product and the safety of the consumer. MV systems can be used to visually check the closures and seals for integrity.

Checking the closure’s colour and dimensions verifies that the right closure has been applied to the container, while visually checking liner formation and placement ensures the product is properly sealed and protected from contamination and leakage. In the same way, tamper seals can be checked to make sure they are not broken.

Packaging and fillingMachine vision systems can inspect filled bottles, trays, pouches, cases, cartons and other packages to verify that the packaging process was completed to the specifications required.

Bottles can be inspected to ensure that they are properly filled, labelled and capped to minimise product spoilage and ensure perfect product presentation, and case quality inspec-tion can also be performed to verify that cases are properly sealed and undamaged, to allow fast and reliable palletising and packing.

MV technology can also be used to check the content of products made of discrete items, confirming that the specified contents are present, thereby demonstrating due diligence and reducing the costs associated with missing or additional components, parts or other items.

The main uses of vision systems for quality assurance

are to analyse images to perform appearance

inspection, character inspection, position detection

and defect inspection.


RFID system for production and conveyingifm efector has developed an RFID system for production

and conveying. The robust evaluation unit is equipped

with an integrated Profibus DP interface and a web

server. Parameters can be easily set via a laptop.

The unit has an IP67 rating and a large temperature

range, making it suitable for harsh industrial environments.

The RFID evaluation unit features four antenna ter-

minals or digital I/Os. The antenna concept ensures

easy and quick connection of the LF and HF anten-

nas by means of M12 connectors. Additionally, with a

memory size of up to 2 Kb, the system also offers HF

transponders with 16 Kb as a FRAM variant which can

be rewritten an unlimited number of times.

The RFID system platform is used in production for identifying tools or monitoring pro-

duction steps. Further applications include quality assurance, the automotive industry and

automation and conveying.

ifm efector pty ltd

Contact info and more items like this at wf.net.au/R547

TR

AC

EA

BIL

ITY

Handheld HACCP auditing deviceThe Comark N5001 HACCP Auditor is a

handheld instrument for logging, monitor-

ing and managing data. The Auditor has

been specifically designed for food and

pharmaceutical applications and use in

HACCP, due diligence and health and

safety systems.

The instrument can be fully programmed

using the Auditor software to suit the ap-

plication, providing the flexibility and re-

cording functions of palm-held organisers.

The Auditor software has been spe-

cially developed for the N5001 and has

broad programming capability. It enables

the collection of temperature of event

data and the management and control

of processes. This is achieved through

the logging of location/product/suppliers

and other parameters, together with pro-

grammed corrective actions for out-of-limit

temperatures and events.

The free-form flowchart programming

enables the user interface to be customised

to match the abilities of whoever oper-

ates the instrument and does not require

specialist IT skills. In selected tasks, timed

and dated reminders for actions can also

be automatically displayed.

The N5001 can be used throughout

manufacture and processing, especially

in the food and pharmaceutical industries.

Almost any type of task or check can be

programmed into the instrument, such as

checks and actions on damage, quantity,

reference numbers and sell-by dates for

incoming deliveries or the inspection of

subassemblies and finished goods on

production lines and in processing.

ECEFast


Metal detector for wet and dry productsMettler-Toledo Safeline’s Profile Select metal detector offers sensitive detection

for both wet and dry products on food production lines. The inclusion of vari-

able frequency technology offers accurate inspection regardless of the moisture

content of the product or packaging material.

Traditionally, only dry products

can be successfully inspected at

metal detectors’ maximum sensi-

tivity setting. This is because wet

or ‘conductive’ products create an

electrical signal called a ‘product

effect’ that can disguise the signal

generated by metal contaminants.

Until now, contaminant detection in

wet and dry products used metal

detectors with tuned frequency technology.

These metal detectors can be configured to have a

number of operating frequencies to address specific

products. However, this can restrict inspection flexibility in cases

where manufacturers produce a wide range of products.

The detectors have true variable frequency technology that automatically

selects the most suitable frequency for each application. The machine’s auto-

set function selects the optimum frequency for the product being inspected,

providing maximum product quality, enhanced process flexibility and optimised

equipment performance.

Prof i le Select al lows the operat ing frequency to be adjusted in

1 kHz increments, ensuring precise tuning for each application. This allows a

variety of products with differing size, moisture content and packaging material to

be inspected on the same production line without sacrificing inspection accuracy.

Profile Select rectangular detectors are designed for easy integration with

conveyorised systems to fully automate inspection processes. Manufacturers can

choose between various automatic reject mechanisms depending on the line and

pack speed, pack weight and dimensions and the nature of the packaging material.

Mettler Toledo


http://www.sick.com.au


When an outbreak occurs, epidemiologists must interview affected people to track down where foodborne exposures happened. Often those interviews take place weeks after the exposure,

leading to inaccurate or incomplete information and making it difficult to pinpoint a likely food culprit. Once the tainted food has been identified, investigators must trace up through the food distribution supply chain to locate the source of contamination.

This means that epidemiologists involved in traceback have to reconstruct the pathway the contaminated food has travelled through the distribution network well after the fact.

Even at the supply chain level, investigating how food moves through the system is daunting as supply chains vary widely from one food marketing system and agricultural sector to an-other. Some supply chain parts change frequently. Even within a single agricultural sector, some parts of the food supply chain may be characterised by enduring supplier/customer relation-ships, while others may be market based and highly transitory.

Even industry insiders may not understand the supply chain map. Many only know ‘one up and one down’ - that is, they know only their direct supplier and direct customer. Also, some information about customers and suppliers can be proprietary and therefore hard to get.

In 2011, sprouts were the focus of a serious E. coli outbreak in Europe, but tracing contaminated products to their source proved difficult.

But now, uncovering the sources of fresh food contamina-tion could become faster and easier thanks to analysis done at

Sandia National Laboratories’ National Infrastructure Simulation and Analysis Center (NISAC). A study, in the International Journal of Critical Infrastructures, demonstrates how developing a probability map of the food supply network using stochastic network representation might shorten the time it takes to track down contaminated food sources. Stochastic mapping shows what is known about how product flows through the distri-bution supply chain and provides a means to express all the uncertainties in potential supplier-customer relationships that persist due to incomplete information.

If this approach is used on a larger scale, such methods also might assess the vulnerability of food supplies to wide-scale, deliberate contamination.

Sandia researchers applied the stochastic mapping technique to test data from the fresh sprout sector in a single state in the US, using a case study of the edible seed sprout distribution system as the basis of their computational model.

The method enables effective risk analysis and the design of robust food defence strategies because stochastic network representation can incorporate and express the uncertainties using probability maps.

Future work for the team will include scaling the analysis up to the company or industry level as well as mapping com-modity flows into, out of and within a geographic region.

Ultimately, NISAC intends to work with partners in business and federal and state agencies to ascertain whether the agencies have a business case for adopting the method. If there is, the team will seek to help achieve wide acceptance of using data analysis to assess risk.

Finding fresh food contamination sources fasterTracking down the source of fresh food contaminatiotn can be difficult and time-consuming. Adequately

characterising connections and product flows among producers, distributors and suppliers can be problematic

and contribute to significant uncertainty in assessing the risk of foodborne illness. This can present a serious

problem when there is an outbreak of food poisoning in a particular region and the authorities cannot quickly

trace the source of the outbreak.

TR

AC

EA

BIL

ITY

©iS

tock

phot

o.co

m/A

rkad

iy Y

arm

olen

ko©

iSto

ckph

oto.

com

/rafe

rto


TR

AC

EA

BILIT

Y

Invisible ink ensures traceability and authenticityA leading rigid plastics packaging manufacturer is ensuring authenticity and traceability with an unusual product: invisible ink.

RPC Containers Llantrisant is using special UV-readable ink from Linx Printing Technologies on its range of bottles. The Linx Clear UV-readable ink goes on clear and is used to code both the bottles and their caps inline using Linx 4900 continuous ink jet printers. The code includes a batch number, date and time, and the line on which the bottle was produced.

“The ink produces a completely invisible code which is nevertheless very clear and easy to read under the appropriate conditions,” said Jon Bedgood, RPC Llantrisant’s manufacturing manager

In the event of any problem or quality issue, the complete pack can be traced back through the entire filling, supply and manufacturing chain using the ink code.

RPC Llantrisant manufactures bottles in eight sizes, from 25 to 200 mL. The bottles are injection blow moulded and then fed into a capping machine. Both the cap and bottle are coded simultaneously by two Linx 4900 printers.

“We have been delighted with the performance of both the Linx 4900s and the UV-readable ink,” said Bedgood.RPC selected the Linx printers based on their speed and reliability. The 4900s can easily cope with line speeds of around

3200 bottles/h. RPC operates two lines, with a third line available to meet peaks in demand. The portability of the Linx 4900 means the printer can easily be moved as required, depending on production requirements.

“The printers have been extremely reliable and we have had no issues since they were installed - we literally only have to start them up and away they go. Our operators like them and Linx provided full training, which means everyone is familiar with how they work,” Bedgood said.

Matthews Intelligent Identification Pty Ltd


©iS

tock

phot

o.co

m/D

myt

ro K

ozlo

v

http://www.accuweigh.com.au


TE

ST

ING

TE

ST

ING

Allergen test for soyAustralasian Medical and Scientific has announced that the Romer AgraStrip

for Soy is now available. Soy is a very common allergen in foods, presenting

a problem for children in particular, but also in adults. Soy can be present

in many food, beverage and pharmaceutical items due to the common

practice of using soy-based ingredients and additives.

The AgraStrip for Soy provides manufacturers and laboratories with a

fast and simple test to screen for soy in raw ingredients, finished product

and manufacturing environments. No special equipment or laboratory is

required to perform the test, and results are available in less than half an

hour, making it suitable for on-site testing.

The AgraStrip for Soy offers a high level of sensitivity, with a limit of

detection as low as 1 ppm, and has been validated with a variety of food

matrices.

Australasian Medical & Scientific Ltd


Satellite data loggerHalytech has released a low-power

solution for remote monitoring and

data logging which uses the Iridium

satellite network Short Burst Data

(SBD) service for automated data

delivery.

The microSpider satellite is suit-

able for applications such as envi-

ronmental, industrial and infrastruc-

ture monitoring where other forms of

communication are not possible. To

reduce the cost of remote site data

acquisition to an affordable level, the

company has developed a highly

compressed data format which it

claims enhances the performance

and reduces the cost of data delivery

using the Iridium SBD service.

The microSpider satellite’s con-

figurable I/O combined with Modbus

and SDI-12 compatibility provide

good flexibility for use with a range

of instruments. The satellite includes

an onboard web server which allows

the user to view and configure all

parameters without special software

or licences.

Halytech Pty Ltd


High-speed centrifugesVWR Australia has extended its VWR Collection range

with the VWR Ultra and High Speed Centrifuges.

The centrifuges are easy to use and have many

protective features. VWR’s Automatic Rotor Life Man-

agement accurately logs the actual percentage of rotor

life used. The company claims its Automatic Rotor Life

Extension will gives longer use from the rotor.

Safety features such as automatic rotor locking and

imbalance protection are included. The systems can

be adapted to a range of applications.

VWR International Pty Ltd


Listeria detection systemANSR for Listeria is the second test available for Neogen’s ANSR pathogen detection

system and provides results after 20 minutes of reaction time. In comparison, other

commercially available molecular amplification tests require up to 3 hours’ reaction time.

The test’s approval from the AOAC Research Institute is pending.

Combined with ANSR’s single enrichment step, Neogen’s pathogen detection method

for Listeria can provide definitive results in as few as 16 h from the time the sample

is taken.

Neogen’s ANSR is an isothermal amplification reaction test method that exponentially

amplifies the DNA of any bacteria present in samples to detectable levels in minutes.

According to the company, the system was designed to combine molecular-level accuracy

with a scalable low-cost instrument and a methodology that can be easily incorporated

into a testing laboratory’s existing workflow. The system’s small benchtop footprint and

simple procedure make it an easy fit in laboratory settings.

Cell Biosciences Pty Ltd


SwabSURE ListeriaP

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

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

> The sampling swabs are coloured blue for clear identification in a food processing environment

> The open matrix offered by the foam swab enhances recovery and release of sample, ensuring accurate and confident results every time

> The neutralising buffer provides inactivation of QACs, phenols, peroxides and other sanitisers, increasing the viability of the sample

> False positives are eliminated by the introduction of a chromogenic media for easy identification of results

> Simple and quick to use with no mixing of reagents or multiple steps

> Results within 24-48 hours

SwabSURE ListeriaP

Direct detection of pathogenic Listeria

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

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

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

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

For more information please email [email protected]

Swab-Sure_Advertisement.indd 1 23/08/2011 10:19:15 AM

http://www.thermofisher.com.au


TE

ST

ING

available at

MEP Instruments Pty Ltd Australia Tel 1300 720 485

New Zealand Tel 09 912 1330 www.mep.net.au

Know the

TRUE Sodium ContentNew: Direct Analysis of Sodium in

Foodstuffs by Thermometric Titra-

tion: It’s cost efficient, precise and fast.

Call or email for details and free applica-

tion note.Metrohm 859

Titrotherm

Sodium

Analysis

Laser particle countersThe Spectrex PC-2200 in-situ laser particle counter

and PC-2300 portable laser particle counter are

designed to permit thorough inspection of bottled

and flowing liquids without consuming the sample.

The sample is placed in a specialised glass bot-

tle or beaker and inserted into the instrument for

counting - eliminating sample flushing and making

handling clean and simple. Oil immersions and other

liquids can be counted by adjustments made by

SuperCount software. The PC-2200 can also count

particles inline using a flow-through cell.

Using the principle of ‘near angle light scatter’, a revolving laser beam passes through the walls

of the beaker or flow-through cell. When directed through a central ‘sensitive zone’, the particle

counters not only count the particles in suspension, but tabulate their size, from 0.5 to 100 µm in

diameter. The analog signals generated by the light pulses are routed to a computer and digitised.

In the PC-2300, a scanning laser beam automatically quantifies small particulate matter, pre-

senting the results on a digital display. A minimum size selector is provided for this measurement

and is normally set to 1 µm. The direct connection to a computer with the company’s interface

card, cable and software gives full automatic sizing and particle counts. The counter is ruggedly

constructed with all the optical members mounted on one solid aluminium base plate.

The units come with three sealed calibration standards, each containing a precise number of

NIST traceable polymer spheres of known concentration. The suspensions are sealed with inert

argon gas and have proven stability.

Novasys Group Pty Ltd

Contact info and more items like this at wf.net.au/Q824

Method for determining catechins in teaThermo Fisher Scientific has announced a quick and easy method to determine catechins in various

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

Core-Shell Columns demonstrates use of a high-performance liquid chromatography (HPLC) core-shell

column and absorbance detection to separate and detect catechins in tea.

Catechins are flavonoid phytochemical compounds found primarily in green tea and - in smaller

amounts - in grapes, black tea, chocolate and wine. Catechins are considered potent antioxidants that

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

In North America, the consumption of green tea products has increased due to the reported health

benefits. However, commercially available teas show a high variability in catechin content; therefore,

simple and rapid methods are needed to evaluate product quality.

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

Thermo Fisher Scientific


Pipette filter sleeveParticulates in a liquid sample can be a problem for several reasons,

such as clogging pipette tips, or interfering with a sample analysis.

The Nasco Pipette Filter Sleeve overcomes these problems by

fitting over a standard 10 mL pipette and extracting the sample

through a 330 µm polyethylene filter.

The sleeve is made from strong, sterile polyethylene materials

used in Whirl-Pak products.

The sleeves are arranged into bags of 25 which can be closed

after each use. The pipettes are available in boxes of 500.

Australasian Medical & Scientific Ltd


http://www.foodtechqld.com.au


BU

LK H

AN

DLI

NG

, ST

OR

AG

E &

LO

GIS

TIC

S

CHEP helps growers take a bigger bite of the export cherry

In an industry traditionally dominated by wooden crates and cardboard hat-bins, taking a chance on plastic has paid off for a cherry exporter.

The Caernarvon Cherry Co, based in Orange, NSW, made the switch after contacting CHEP for a solution. CHEP recommended the FB3 foldable plastic bins, which were designed specifically to preserve the integrity of softer fruits and vegetables. The Australian-made CHEP FB3 bin allows air TO flow through specially designed air vents and raised platforms, ensuring good air circulation even when the crates are stacked.

Prior to export, the cherries must undergo a cold disinfestation treatment for 14 days. However, the pulp temperature must be at least 1.11°C before the disinfestation process can begin. Co-owner of the Caernarvon Cherry Co Fiona Hall says using the FB3 bins means the cherries cool faster.

“The quicker the cherries cool, the longer the shelf life of the produce, the better they present in store and the sooner we can start the cold disinfestation process,” said Hall. “Ultimately, it means we can export a better quality product, sooner.”

An additional benefit of using the FB3 bins is that they can be hosed and washed out, unlike wooden crates, which has helped the Caernarvon Cherry Co achieve its Freshcare Certificate for Food Quality & Safety.

The CHEP FB3 bins are making quite an impact on the fresh produce industry, says Martin Rees, CHEP Business Development Manager.

“Made from high-quality, food-grade plastic, the FB3 lasts longer, is more durable and retains the integrity of the fruit better than wooden crates or the one-trip cardboard alternatives,” Rees said.

“As with other products in the CHEP pool, the bins provide customers with total flexibility. For example, growers have to purchase cardboard hat-bins in large quantities to be cost effective, whereas FB3 bins can be picked up on demand. This eases the uncertainty of overordering and being left with a need to store them or underordering that can cause issues down the supply chain.”

In addition, Rees says, the FB3 bins provide multiple transport efficiencies for local growers.“The FB3s have a superior stacking configuration over their wooden or cardboard

alternatives, and can be stacked up to five high in transport and 10 high in static storage,” Rees said. “This not only decreases the need for third-party storage but, in transport, substantially improves supply chain costs by reducing the number of trucks needed to move product.”

The Caernarvon Cherry Co has found the FB3 bins easier to manage compared to the wooden crates. “They have made it easier for us to streamline our processes, have saved us capital outlay and reduced our labour and handling costs,” Hall concludes.

CHEP Australia


Postgasser and heat sealer for bulk bagsTo reduce or eliminate product

deterioration and prolong the

shelf life of fat-containing dairy

powders, it is important to close

bulk bags immediately after fill-

ing to minimise exposure of the

powder to atmospheric air. His-

torically known as Bulkpak 600,

the Postgasser - Heat Sealer by

Tetra Pak is designed for powder

deaeration and replacement of

ambient air with an inert gas,

followed by hygienic closing of

the bulk bags.

The Bulkpak 600 comprises a

single station capable of handling

a wide range of plastic liners

suitable for modified atmosphere

packaging (MAP) and heat seal-

ing. To minimise exposure of the

powder surface to atmospheric

air, the heat sealer would be

usually located in the immediate

vicinity of a filling station.

The filled bulk bag is con-

veyed to the Bulkpak 600, where

the operator puts the plastic

bag liner onto the heat sealer

bars and secures both ends of

the liner with the assistance of

pneumatic bag grippers. Once

the cycle has been initiated by

the operator, postgasser probes

go down into the powder and

replace ambient air with an inert

gas, such as nitrogen.

This achieves residual oxygen

levels typically under 3% after

seven days from closing. Option-

ally, the operator can perform

selected stages of the cycle, such

as only deaeration or only heat

sealing. All stages of the cycle

are timed and automated. An

extensive range of testing and

indication features provide the

operator with comprehensive

feedback on process flow at

each step of the cycle.

Tetra Pak New Zealand Ltd


Level transmitter for non-contact measurement of solid levelsDwyer Instruments’ Series ULL Ultrasonic Level Transmitter for Liquids

is a direct-install level transmitter designed for non-contact measure-

ment of solid levels.

The ULL uses ultrasonic technology paired with automatic temperature

compensation to provide reliable and accurate measurements in most

conditions. An integrated LCD screen and four responsive push-buttons

allow for quick and easy programming on a simple menu structure.

Diagnostic capabilities and a fail-safe output signal make the ULL

a suitable choice in critical applications.

Dwyer Instruments (Aust) Pty Ltd



We are dedicated to the design, manufacture, installation and commissioning of Bulk Materials Handling and Processing Equipment.

engineered and manufactured in house.

We strive to ensure our customers receive the latest proven technology while aiming to reduce costs, improve operations and increase quality.

Visit our website to learn all about our comprehensive range ofFresco Systems designed, manufactured equipment and systems,all supported by international technologies.

PLANT WIDE SOLUTIONSFROM FRESCO SYSTEMS

www.frescosystems.com


BU

LK H

AN

DLI

NG

, ST

OR

AG

E &

LO

GIS

TIC

S

Nonmetallic rotary peristaltic pumpThe portable, nonmetallic Flex-I-Liner rotary peristaltic pump from

Vanton Pump and Equipment Corp evacuates drums and totes

containing acids, caustics, salts, chlorides and reagent-grade chemi-

cals, without corrosion of the pump or contamination of the fluid.

The self-priming design has no seals to leak or valves to clog

and can run dry for extended periods without damage. Compact

in size with an integral handle, it fits on drum lids without protrud-

ing and has sufficient lift characteristics to operate from the floor,

skid or stand.

Only two nonmetallic parts come into contact with fluid: a ther-

moplastic body block and an elastomeric flexible liner that can be

replaced in the field without special tools. The rigid body block

is of solid polypropylene, UHMW polyethylene or PTFE, and the

moulded flexible liner of natural rubber, Neoprene, Buna-N, Hypalon, Viton or Nordel elastomers, eliminating

corrosion or contamination associated with metal pumps.

The range of thermoplastics and elastomers in which these pumps is available permits their use over the

full pH range and for an extensive list of corrosive, volatile and viscous fluids.

A rotor mounted on an eccentric shaft oscillates within the flexible liner, imparting a progressive squeegee

action on the fluid trapped in the channel between the liner and the body block. Flanges on the flexible liner

are pressed to the side of the body block by concentric grooves on the bracket assembly and the cover

plate, isolating the fluid to the channel.

The pump is suitable for flows from 1.25 to 151 L/h and pressures to 310 kPa at temperatures to 121°C.

Acromet (Aust) Pty Ltd


Vacuum-mounted vibratorUsing vibrators to move product usually involves some welding to the hopper to

give the best results. Vibration Systems & Solutions has a method which eliminates

welding by using vacuum to securely attach pneumatic vibrators to the hopper wall.

The VacMount is useful when suppliers send product to the end user in their own

containers, on which no welding is allowed. This method is also useful for hoppers

and products with infrequent ‘hang-up’ problems, which may be caused by product

differences or temperature changes.

The vibrator is supplied mounted to an aluminium plate, on the other side of

which are vacuum suction cups. The size and quantity of these cups varies with

the strength of vacuum required for specific vibrators.

Vacuum generators are built into the plate, with the vacuum being generated from the same air supply

as is used for the vibrator. Linear vibrators from 14 to 8000 N can be carried on various sized VacMounts.

Vibration Systems & Solutions (Australia) Pty Ltd


http://www.rfoot.com.au


BU

LK H

AN

DLIN

G, S

TO

RA

GE

& LO

GIS

TIC

S

Heinz-Golden Circle picks single-robot depalletising solutionNew Zealand manufacturer Scott PHS Limited has come a long way since its beginnings as CBS Engineering in 1955.

At its inception, the Auckland-based company provided packaging lines primarily to the beverage industry. Scott PHS now designs, manufactures and supports an extensive range of package handling equipment including palletisers, depalletisers, conveyors, pallet handling and other associated equipment.

It services industries such as food processing, dairy, wine and beverage, handling a wide range of products including bottles, cans, cases, trays, shrink-wrapped collations, pails and bags.

Scott brought its innovative approach to a recent installation in Melbourne. Heinz-Golden Circle was looking for an economical solution to depalletise a range of empty PET bottles from two different-sized pallets simultaneously and provide bottles in single file to two separate filling lines.

The challenge for Scott was to develop a system that had the flexibility to handle the customer’s product range automatically and deliver it into a compact footprint but maintain good operator accessibility.

The conventional approach would have been to have two independent layer-style depalletisers, each dedicated to its own filling line. The Scott PHS solution, however, involved a single ABB IRB 660 180 kg robot picking layers from two pallet stations and delivering each of the layers to separate mass flow conveyors.

Each product is then placed on a pressureless single filler directly into each filling line. The robot also stacks layer boards, top frames and empty pallets automatically.

Scott Package Handling Systems


http://www.albanydoors.com


BU

LK H

AN

DLI

NG

, ST

OR

AG

E &

LO

GIS

TIC

S

Low-maintenance wrapped wedge beltOptibelt has introduced Red Power 3 belts, which, once

installed to manufacturer’s recommendations, are claimed

to require no maintenance or re-tensioning throughout

their lifetime.

Constructed of high-quality raw

materials, the wrapped wedge

belts are claimed to produce

up to 97% efficiency with up to

50% higher power ratings when

compared to Optibelt’s standard

V-belt. The belts are available in

lengths from 1200 to 12,065 mm

in a range of V-belt and Kraftband

profiles.

A high power rating can also

mean fewer belts on a drive,

resulting in narrower pulleys

with significant space and cost

savings. In addition, they require no matched set coding.

The belts have been developed for applications such as

compressors, pumps, presses, fans and heavy-duty drives

for industries such as mining, timber, quarrying and recycling.

They are less sensitive to shock loads and are able to

operate successfully in heavily contaminated environments.

All belts in the range are heat resistant to 100°C, oil re-

sistant and antistatic in accordance with ISO 1813. They are

compatible with ATEX and come dust protected as standard.

Optibelt Australia Pty Ltd


Beef City gets a lift from Toyota Materials HandlingOne of the largest feedlots in Australia is getting a lift thanks to Toyota Material Handling Australia (TMHA). Beef City feedlot, owned by JBS Australia, recently commissioned 18 new pieces from TMHA’s forklift range on long-term hire from the company’s Brisbane branch.

With a staff of 950, a feedlot, meat processing facilities for 260,000 head per year, a farm and more than 26,000 cattle in the feedlot at any one time, Beef City definitely has a need for quality materials handling machinery.

The handover of 18 new pieces of Toyota Material Handling equipment at Beef City.

The new complement of forklifts includes three Toyota internal combustion forklifts, one Toyota electric three-wheel forklift, two Toyota electric reach trucks, two Raymond reach trucks, three BT hand-pallet jacks and six Raymond pallet trucks, both walkie and ride-on.

Beef City General Manager Justin McCormick said the company selected Toyota as it is the best brand available to suit its business needs.

“They are the best forklifts on the market and the service from Toyota’s Brisbane office has been first class,” McCormick said.

“The relationship with Toyota has grown with support from TMHA Queensland Major Accounts Manager Martin Gross and the Brisbane office being on hand 24/7 when required.”

The internal combustion Toyota forklifts are used in the Beef City feedlot main yard, rendering section and maintenance lifts. Four of the battery electric machines are used for cold-room operations and are set up to service-racking profiles.

Toyota Material Handling Australia Pty Ltd


http://www.vaughans.com.au


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

avoiding mechanical wear. It also prevents wear by transmitting data on uneven belt loads and belt drift.

A laser scanner mounted above the conveyor belt uses laser pulses to continuously detect the height

profile of the bulk materials passing by. The laser beam is eye safe and corresponds to Laser Class 1.

The two-dimensional height profile obtained is combined with supplementary information, such as

the third dimension of belt speed or density information, and the sensor autonomously determines the

transported volume or mass per time unit. At the

same time, the height distribution can be used to

reliably detect tilting or any one-sided loading so

that a warning signal can be transmitted.

The Bulkscan uses multiecho technology, whereby

the software algorithm can reliably determine the

correct signal from among the various reflected laser

pulses and dependably suppress the measurement

of interfering echoes caused by mist or rain.

Rapidly moving transport belts with speeds of

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

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

fast response times.

For the further processing of signals, the Bulkscan

system offers six switching outputs that can be indi-

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

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

which also has two inputs. No supplementary measurement value computer is required.

Sick Pty Ltd


now available online!

NEW White Papers

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

Automate your way to lean manufacturing eBookCompanies that are best at managing in a competitive and

changing market are those that are innovative. One of the most

productive ways to make your manufacturing processes more

competitive is through automation. Real-time quality control and

system automation is now readily and inexpensively available.

Find out more here!

BU

LK H

AN

DLIN

G, S

TO

RA

GE

& LO

GIS

TIC

S

Portable splice pressFlexco’s Novitool Aero portable splice

press allows users to splice a con-

veyor belt in 7 to 12 min.

It is easy to operate and offers

good splice repeatability, as well as

temperature control and integrated

air cooling.

The all-in-one unit has no external

components and requires no hoses,

couplings, air pumps, control boxes or

water tanks. A flight case is included

with the splice press.

The splice press is available in

five sizes, from 300 to 1500 mm. It

is available with a range of power

cables, both 1- and 3-phase, from

230 to 460 V.

A workshop stand is available

for use with the 900, 1200 and

1500 mm models.

Flexco (Aust) Pty Ltd


http://www.vibrationsystems.com.au


BU

LK H

AN

DLI

NG

, ST

OR

AG

E &

LO

GIS

TIC

S

Compact industrial robotABB has expanded its robot technology range with the release of

the IRB120T, a variant of the IRB120. Like the IRB120, the IRB120T

is compact, agile and lightweight, but the six-axis IRB120T variant

delivers an increase in the maximum speeds of axis 4, 5 and 6,

which ABB claims results in cycle

time improvements of up to 25%.

The faster variant is suitable

for pick and place applications,

particularly in the food and bever-

age packing industries. ABB says

it may also be suitable for as-

sembly applications for electrical

and electronics and automotive

parts manufacturers.

The IRB120T has a repeat-

ability of 0.01 mm. It can also

be mounted at any angle, either

in a cell, on top of a machine

or close to other robots on the

manufacturing line.

The robot comes with the ABB IRC5 Compact control, including

good path motion, user-friendly FlexPendant programming, Robot-

Studio offline programming, flexible RAPID language and strong

communication capabilities.

ABB Australia Pty Ltd


Bulk bag conditioner for loosening solidified materialFlexicon’s Block-Buster

Bulk Bag Conditioner has

a hydraulically-actuated,

variable-height turntable

for automated in-frame

bag rotation and con-

ditioning of bulk bags

at varying heights. The

number and pressure of

hydraulic ram actuations,

the height of the turntable

and the degree of rotation are user-programmable.

Two hydraulic rams with specially-contoured end plates press

opposing sides and corners of bulk bags, loosening material

that has solidified during storage and shipment, enabling bulk

bag unloaders to discharge it through bag spouts.

A cantilevered I-beam with motorised hoist and trolley allows

loading and unloading of bulk bags without the need for a forklift.

The system controller and hydraulic pump can be mounted

on the exterior of the safety cage or remotely. The conditioner is

fully enclosed on all four sides for operator safety and includes

full-height doors that are interlocked to prevent operation of the

system when the doors are open.

The conditioner is recommended for bulk bags containing

hygroscopic chemicals, certain spice blends, heat-sensitive

products and other materials prone to solidifying to the point

at which pneumatically-actuated flow promotion accessories

integral to bulk bag dischargers can be inefficient or ineffective.

The conditioner is also offered without a variable-height turn-

table, in which case the bag is raised and lowered using the

motorised hoist and rotated manually for conditioning of the bag

at any height and any degree of rotation.

The conditioner is offered as a standalone unit or integrated

with the company’s Bulk-Out bulk bag discharging systems.

Flexicon Corporation (Australia) Pty Limited


Motor seriesSwiss company LinMot has released a motor series that can be run from most

three-phase brushless servo drives. The P10-70 series of motors can provide peak

forces up to 2500 N, velocities up to 8 m/s, accelerations up to 90 g and provide

long wear free of force, velocity or position control.

LinMot stators are nickel-plated iron, while the slider surface is stainless steel

for longer life and corrosion protection. The series has a stator body diameter of

70 mm, with available strokes from 180 to 500 mm. The motors use non-contact,

integral position feedback using 1 Vpp sin/cos signals. This enables 10 µm resolu-

tion, ±20 micron repeatability and good linearity.

Options include mounting flanges and cooling mounting flanges, and blower

kits to extend motor performance. LinMot motor systems can be retrofitted into

existing applications.

Motion Technologies Pty Ltd


http://www.veederline.com.au

http://www.ifmefector.com


PR

OC

ES

SIN

G

It is good to know that the food industry still

considers quality improvements and new

product development to be the main objectives

when investing in new technology.

A recent Leatherhead Food Research survey in the UK asked the food and beverage industry what objectives are currently the most important when considering investment in new technology. And,

despite big moves within the industry to improve sustain-ability and resource efficiency, 55% of respondents said the primary technology innovations needed remain focused on the product - either to deliver better quality or new products.

‘Health and wellness’ was considered as less of a priority, maybe indicating a tide of change in the focus of development teams for the coming years. This also suggests that ‘health and wellness’ is no longer the domain of the innovators but is a mainstream trend that is considered the core of any de-velopment activity since it is a still a priority agenda item across the industry.

However, when asked to consider a range of issues or themes and whether an emerging technology was the only way of achieving a step change in that area, an interesting picture emerges. When asked “which of these objectives are currently the most important when considering investment in new technology?”, “product innovation” was the clear winner. Some distance behind, in second place, was “product quality” followed by “energy and resource efficiency”.

Necessity is the mother of invention so it is important to identify where emerging technologies could be most effec-tively implemented to achieve that all important step change.

Two main themes emerged – ‘efficiency, productivity and sustainability’ and ‘salt and fat reduction’ (Figure 2). These groupings suggest that it is generally believed that ‘green’ agendas cannot be met by the current manufacturing platforms and that the reductions in salt and fat that are possible by existing strategies are at their maximum. This echoes research conducted by Leatherhead Food Research earlier in 2012 that suggested that maximum salt reductions had been achieved within the current landscape. With ever-challenging targets such as salt reduction, it is possible that the industry will have to look at alternatives, such as nanoparticles, to achieve new levels of functionality and delivery.

The implementation of new and emerging technology is not thought to be key in further improvements to taste texture and market share - the product-centred and market-driven innovations. Yet product-centred objectives were at the heart of investment policy.

Around 60% felt that new and emerging technology would be key in the successful delivery of strategic objectives com-pared to existing technology; only 4% felt this would not be the case. Putting it into context of whether the greatest financial gains would be made from renovation or innova-tion, the population was evenly split with only 2% differ-ence reflected between the opinions, interestingly falling in favour of renovation. It could be considered that the reasons behind this reflect the need for speed to market and return

What ‘foodies’ think about when investing in new technology

©iS

tock

phot

o.co

m/D

mitr

y G

ool


on investments; two-thirds requiring a product to market within two years and 87% needing to launch within three years. The return on investment would need to be realised within three years by 62%.

To achieve success with a fledgling technology, less than 10% considered that their exclusive use was important with 36% rating sole rights as very or extremely important.

In summary, the survey showed that ‘product’ centred innovations outweighed ‘greener’ agendas for investment in emerging technology, yet the same population conceded that new technology was more important in achieving the step change required on those issues. While emerging technolo-gies were seen as being key to meeting strategic objectives - often the greener agenda - opinions were generally split as to whether greatest commercial gains would be from new or existing technologies; and with an expectation of product launches and return on investment coming within two to three years, it is easy to see why renovation is seen as the easier option.

Extending beyond the scope of the survey a little and considering the wider context of the questions, it may be

fair to suggest that key issues such as fat and salt reduction are at the limit of the capability when considering existing technology. Health and wellness is being seen as a lower priority in terms of new technology, or that legislation has stifled the appetite for innovation in these areas. It is more likely, however, that salt and fat reduction are actually no longer considered part of the ‘health and wellness’ agenda but more of a more generic continuous improvement activ-ity. Wider objectives such as ‘sustainability’ and energy ef-ficiency may also be considered ‘out of scope’ for many NPD and R&D teams, possibly even unattainable even though the need is recognised to achieve the shift into next-generation ‘greener’ technology.

The markets (and marketing investment) are still driven by product innovation and quality, which is achievable through incremental improvement and renovation of existing technol-ogy. Such investment is much lower risk, and can achieve the required product launch and ROI expectations. With the need for exclusivity also being considered of importance to retain competitive advantage, this allows for progress and its associated knowledge to be retained in-house.

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

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

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

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

diesel generator and an Automatic Transfer Switch (ATS) packaged

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

A UPS system protects computers, data centres, telecommunica-

tions equipment and other electricals where an unexpected power

disruption could cause serious business disruption or data loss.

The product is designed to provide seamless continuous power

in a simple and complete package, delivering constant power

protection against surges, sags and power interruptions that can

halt operations or cause loss of data or system capacity.

The Caterpillar CPM uses robust digital components and is

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

UPS systems. Its ability to operate at higher temperatures may

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

the product.

Caterpillar of Australia Ltd


Stainless steel electric motorsLafert Electric Motors has released the

Third Generation range of Scorpion

Stainless Steel electric motors.

The motors are a solution

for problem areas, from

wet areas in food pro-

cessing factories to en-

vironments with corrosive

gases. According to Lafert,

the stainless steel motors outlast

conventional motors, saving downtime and increasing productivity.

The motors have been upgraded with improved sealing and an IP67

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

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

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

Lafert Electric Motors


PR

OC

ES

SIN

G

©iStockphoto.com/Dmitry Gool

http://www.airaudit.com.au


Vision sensorSick has launched an addition to its Inspector family of

vision sensors. The Inspector P150 allows users to easily

build their own interfaces, as well as operate the sensor

from any computer or operator panel that contains a

standard web browser.

The P150 is suitable for applications such as positioning

control in commercial goods production and integrated

quality control in packaging machines.

The integrated web server means any user can oper-

ate the P150 from a computer or operator’s panel that

contains a standard web browser. Advanced users can

completely build their own operator’s interface with the

sensor’s flexible web API. The API provides commands

to design customised functions.

The PI50 contains an expanded toolbox for object

location and positioning based on a taught-in pattern,

free-form and line/polygon object shapes. In addition to

the positioning tools, it provides tools for quality inspection

such as blob, pattern, edge and pixel-counting inspection.

The sensor supports extended results and control

handling over EtherNet/IP and TCP/IP. This enables

easy communication with dedicated PLCs, or simply a

PC host using value-based results for machine control

and customised trend design, image triggering, external

teach and reference object selection for centralised de-

vice control and parameter modification for customised

configuration handling.

The calibration feature supports image translations

to ensure results are exactly aligned with the external

machine environment. It also provides reliable images

even in tight and tilted set-ups where the image could

otherwise be distorted.

The PI50 is available in a white or IR ring light op-

tion. Both are designed with the company’s easy ‘Flex’

housing - providing a fast method to exchange lenses,

filters and Dome accessory for different optical needs.

Sick Pty Ltd

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

Cogeneration system fires up Geelong breweryThe soon-to-be-completed Little Creatures Brewery in Geelong will feature a 1200 kWe natural gas fired cogeneration system, which will significantly reduce the brewery’s energy use and carbon emissions. Simons Green Energy has been awarded the contract to supply and install the system.

The system’s heat waste will provide hot water for the brewery’s process heating applications. The units will be configured to run parallel to the grid, so the brewery will only purchase energy over and above what the engines can supply, which is expected to be very little.

The system will provide up to 1200 kWe of electrical power and 1282 kWt of thermal power.

“The cogeneration system to be installed at the Little Creatures Brewery will be a great platform for other breweries and food and beverage manufacturers to follow,” said Simons Green Energy CEO Derek Simons. “The system is technologically advanced and very efficient at about 85% conversion efficiency, compared with 30% efficiency for conventional grid-supplied electricity.”

The Simons Green Energy cogeneration plant comprises two off-sized units, which allow for greater modulation of output. They consist of an 800 and 400 kWe system with reciprocating gas engines from MWM. The system is supplied as complete factory-tested packaged units made up of engine and generator sets housed inside purpose-built containers.

“We knew that we wanted to do something special for this project, in particular implement an environmental technology that would be a step change for us,” said Alex Troncoso, Head of Brewing Development for Little Creatures. “Cogeneration seemed to be a natural fit as breweries have a high thermal energy demand - we knew that we could use the waste heat effectively for a number of applications.”

Other energy-efficient equipment will also be installed, such as energy recovery systems in the brewhouse, as wel l as automated cleaning regimes and variable speed drives on motors.

Brewery owners Little Creatures, plant suppliers Krones AG and Simons Green Energy’s engineering team are working together to ensure a smooth installation. Brewery production is due to commence mid-2013.

Simons Green Energy


PR

OC

ES

SIN

G


Total food safety confidence with NEVASTANE

Get

ty Im

ages

The right choice in lubricants

TOTAL NevAsTANe food grade lubricantsFor food safety and dedicated services.

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

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

All NevAsTANe Lubricants

are NsF H1 registered.


PR

OC

ES

SIN

G

Waterproof IP69K stainless steel fanless waterproof panel PCThe APC-3792P Stainless Steel Fanless Waterproof

Panel PC is totally sealed to IP69K specifications on

all sides. IP69K is required for applications where

high-pressure, high-temperature washdown is used

to sanitise equipment.

The APC-3792P combines an embedded PC and a

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

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

uses an Intel Atom N455 1.66 GHz processor and

supports up to 2 GB of 800 MHz DDR3 memory.

The 17″ LCD provides a maximum resolution of

1280 x 1024 pixels and is supplied with a protective

capacitive touch screen. Rear panel waterproof sealed

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

ports, one RJ45 LAN port and DC input power.

The APC-3792P provides a long-term reliable

computing solution for industrial process control, food

processing and marine environments.

Interworld Electronics&Computer Ind


Simplot gets an ‘A’ with IBPSimplot Australia manufactures some of Australia’s most iconic food brands, including Chiko, Birds Eye and John West. A wholly owned subsidiary of US company JR Simplot, the company has a turnover of more than $1.5 billion and employs over 3000 people in Australia and New Zealand.

Simplot recently rolled out Oliver Wight Integrated Business Planning (IBP) across the business to help it stay ahead of the pack.

The company has been recertified as Oliver Wight Class A standard for Capable Planning & Control using the Sixth Edition Checklist and has also received Class A accreditation for Capable Integrated Business Planning.

Having rolled out Integrated Business Planning across its organisation, Simplot’s service levels are now up at 98% and inventory has been significantly cut.

“Our service levels are so good because IBP allows us to forecast the business two years out and we now have a much better process of identifying risks and opportunities,” said Deahnne Spencer, Simplot’s Strategic IBP Manager.

“With weather conditions affecting the levels of raw material, controlling inventory levels has been a constant challenge, but we are now much better equipped to manage these volatile market conditions.”

The company has also improved its product portfolio management. “We have a really good forum for prioritising projects; readdressing every month if we’re on track and if not, why not, and where we can put our efforts to drive innovation and profitability,” Spencer said.

Simplot is ranked as one of the top food companies in Australia, Spencer says, and plans to keep it that way. “The Class A journey is part of a continual commitment to become a world-class company, provide excellent customer service, drive innovation and retain competitive advantage,” she concludes.

Oliver Wight Asia Pacific


Brewhouse for small and mid-tier breweries

To enable brewers to concentrate solely on their

brewing process, Krones supplies

breweries with complete systems

for the beer production process,

from raw-materials reception

on to the brewhouse, then the

fermentation and storage cellars and

the bottling hall, as well as packaging,

intralogistics and full-coverage automation.

With the CombiCube F for the filter cellar, Krones

says it has progressed the modularised concept of the

CombiCube series for another section of the brewing process:

the CombiCube F is also a TFS filter.

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

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

filter can also be used in the lower output range.

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

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

mid-tier breweries.

Krones (Thailand) Co Ltd


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

We make ideas flow

The Bel Cheese ‘Mini Babybel’ plant

www.burkert.com.au | 1300 888 868

Innovative valve automation

WNIFT Ad 201211 FP.indd 1 7/11/2012 5:04:41 PM

http://www.burkert.com.au


Applications for UV light in the food industry

UV light has been shown to be effective on most bacterial microorganisms, as well as viruses and moulds. Ultraviolet light at wavelengths of 254 nm destroys the DNA of all microorganisms so

viruses, bacteria, yeasts and fungi are disabled in seconds.

For a whole series of microorganisms, the lethal dose of UV radiation is known: this is the dose after which the cells can no longer maintain their metabolism and can also no longer multiply. Because of the cell structure, the lethal dose for different pathogens varies. Consequently, bacteria such as Salmonella, Listeria and E. coli, which have a comparatively thin cell wall and can thus only slightly block the UV radia-tion, are extremely vulnerable and are very easily destroyed. On the other hand, mould spores protect themselves against UV radiation with a thick cell wall, which can even be pig-mented. To kill these, a UV dose which is 10 to 100 times higher than that required for bacteria is needed.

On surfaces such as conveyor belts, particularly in the meat and meat processing areas, UV light can be used to provide continuous decontamination in the form of a module de-signed to expose the belt to UV as it passes. The module is completely watertight and can be incorporated into CIP best practices. The intense germicidal action of UV light acts on microorganisms on the belt surface, rendering them inactive. This treatment can reduce the number of complete washdowns required during processing, thereby saving resources such as water and energy costs.

In the dairy industry, UV disinfection is used especially for the packaging of fresh milk products, such as yoghurt, cream

cheese and dips, which are kept in the cool chain, in order to improve shelf life. This means that the dairy processor has significantly fewer returns of spoiled product.

In baking, mould spores in the processing environment contribute to significant wastage, reducing shelf life and costing money. In most cases, the installation of a UV tunnel over the production line can provide an effective solution.

In addition, pre-packaged fresh vegetables and fruits can be treated and the packaging exposed to UV light to decrease the incidence of spoiling.

An assessment of the possible sources of mould spores in the processing environment usually indicates a build-up of material in the air supply. In order to treat the incoming air, a simple, economical and effective step is the installation of UV light in the air duct. Installing UV light at the cooling coils keeps the coil fins free from ‘bio-film’ build-up, which is the breeding ground for contaminants that are then circulated through the processing environment. Not only can UV light in the ducting contribute to a reduction in spoilage, the HVAC system needs manual cleaning less often and can be shown to work more efficiently, thereby saving on maintenance and energy costs.

UV light at 185 nm facilitates the creation of ozone, which is used to destroy odours and grease deposits associated with cooking and food processing. In the meat processing and rendering industry, ozone lamps can be used to effectively control odours that would otherwise disperse into the sur-rounding area causing concern to local residents.

Heraeus Amba Australia Pty Ltd


PR

OC

ES

SIN

G

UV light is used for a large variety of applications in the food industry. With high-performance UV light

sources and equipment, water, air and surfaces can be reliably disinfected, cleaned and treated. The use of

chemicals can be reduced or even avoided in an economical and environmentally friendly way.

©2012 Schneider Electric. All Rights Reserved. Schneider Electric, PlantStruxure and Make the most of your energy are trademarks owned by Schneider Electric Industries SAS or its affiliated companies. www.schneider-electric.com.au

Finally, your plant can perform at its full potential

Introducing PlantStruxure architecture, the collaborative process automation solution that improves efficiency with plant wide visibility.

Is your processing plant operating at its full potential? If you don’t have a collaborative architecture for monitoring and control, this question may be difficult to answer. And yet, quick access to precise information is exactly what you need to achieve optimised business performance.

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

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

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

PlantStruxure is a collaborative solution that allows manufacturing facilities to meet their automation needs whilst simultaneously addressing growing energy management requirements.

The integration of software, hardware, networking and communication forms the backbone for information transparency from field to enterprise.

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

Hardware From Modicon controllers to RTUs, drives and motor starters, our hardware is flexible, reliable, and highly efficient.

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

Learn more about PlantStruxure architecture! Download our PlantStruxure Solutions brochure today. Visit www.SEreply.com Key Code 52808K

CLIPCOM25395


PR

OC

ES

SIN

G

Martin Bucknavage, member of the Department of Food Science at Pennsylvania State Univer-sity, reviewed two of the audits conducted at the Georgia Peanut Factory plant (see Part 1).

His findings included:•Manufacturers need to be more critical of audits, including

determining “What are the credentials of the auditor?” and•“Are they familiar with the type of processing operation they

are auditing?” and finally•“Did they evaluate all of the risks associated with that type

of operation and the type of product they make in perform-ing the audit?”

The integrity of the audits and the integrity of the certificate are of the utmost importance. As Cor Groenveld, Global Product Manager Food Services at LRQA, recently commented; “Firstly, I truly believe that these can only be delivered by a trained auditor who knows audit skills but also who knows the sector. I think that this is often a weak spot and we have seen too often with other companies in other certification bodies that auditors do not have enough knowledge of the sector they are auditing, so making sure that the auditor has that knowledge is crucial - that is a starting point.”

The second thing that is really important is that an auditor has to ensure that he really looks in depth at the corporate objec-tives and strategies and understands the vision of the company. From there the auditor needs to find out what are the real risks in the organisation and the processes and try to focus on these risks. It has to be a risk-based approach, which is the only way that an auditor can do an effective audit. Essentially an effective auditor needs to be ‘bilingual’ - they need to be able to speak the language of the shop floor as well as that of the board room to achieve a complete understand of an organisation.

Thirdly, the certification process has to be linked to driving improvement. Again, the technical expertise of the auditor and the certification has to support the company to drive continuous improvement. An auditor can challenge the organisation, without being a consultant of course, and support the organisation by doing a robust and in-depth audit.

Finally, and with criticism being levied at the auditing process that sparked the cantaloupe Listeria outbreak last year, the point needs to be made that what happened at Jensen Farms was a second-party audit. There is widespread lack of understanding on the difference between a second-party and a third-party audit. The official definition according to the International Register of Certified Auditors (IRCA) is that a 2nd Party Audit relates to audits of contractors/suppliers undertaken by or on behalf of a purchasing organisation. IRCA goes on to define 3rd Party Audits as audits of organisations undertaken by an independent certification body or registrar or similar third-party organisation.

What happened at Jensen Farms was not a third-party assess-ment but a second-party audit because it was done to a Primus standard, not a certification standard or scheme.

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

Third-party audits and food safetyPart III: The role of the auditor and the difference between certification and accreditationA thorough and probing certification process can only be led by auditors with in-depth knowledge and sector-

specific expertise, and who are able to help organisations minimise risks, improve systems and processes

and deliver confidence for stakeholders throughout the food supply chain.

©iS

tock

phot

o.co

m/S

hery

l Grif

fin


PR

OC

ES

SIN

G

we are continuing to invest in recruiting new assessors to ensure that we can meet the ‘stakeholder demands of tomorrow’.

But who governs the certification industry? Well, ISO/IEC 17021: 2011 - the standard for certification bodies - ensures that the regional or country-specific accreditation bodies assess the certification industry against a consistent standard.

It has also extended the competence requirements to en-compass all staff engaged in the certification process. ISO/ IEC 17021 has clear benefits for certification bodies that are looking to set themselves apart through their transparency, expertise and independence. For these reasons ISO/IEC 17021 offers tangible, consistent benefits that translate into increased trust and confi-dence for all stakeholder groups.

In parallel, there are many legislative controls in countries throughout the world that add another layer of protection for consumers in terms of regulating the food supply chain. Yuri Cosco, from LRQA, explained further: “In Belgium, we have a system which is called Self Checking Guides, which is government regulated. The different food sectors can set up guidelines that have to be used as a basis for the Food Safety Management System of the companies in the sector. The government then authorises Certification Bodies (CBs) (after accreditation and the necessary paperwork) to audit the compa-nies with the specific guide as a basis. There are several advantages for the companies:

•Financial incentive•Fewer government audits•For some sectors, it facilitates export“This approach means that the government then can focus

on companies that are not assessed by CBs and that are thus considered as higher risk.

“The government has already done studies that point out that companies having a certified system have fewer nonconformities from the government during official inspections.”

Influential organisations in food are helping to position food safety management systems firmly on the corporate and regula-tory agenda. LRQA’s key alliances with organisations such as the GFSI and the Foundation for Food Safety will deliver added value to clients through technical insight and enable us, along with other major certification bodies, to extend their sphere of influence. Referring to the calls by the FDA for reforms to third-party auditing, Vel Pillay, Food Safety Programme Manager LRQA Americas, made an insightful remark: “There is a general lack of understanding in the difference between certification and accreditation. If we take the FDA as an example: initially, the FDA indicated that they wanted to become a certification body to grant certification to third-party auditors or audit body. They since have changed their statement to becoming an accreditation body to certify third-party auditors and audit bodies. Fortunately, there is a group of very powerful people from the industry cur-rently working with FDA to educate them on the role of audit bodies and, as the FDA does not have the resources to inspect all food manufacturing institutions, this may be a way of getting more resources from the government akin to the Belgium model.” Commenting further on the calls for reform, Cor Groenveld, said:

“Using GSFI recognised certification delivered by licensed and accredited certification bodies is the way forward.

“Although certification will never be a guarantee things will not go wrong, the controls put in place by using GFSI and ac-creditation enlarges the level of integrity of the audits themselves and in turn the certification.”

ConclusionAt LRQA, we believe that the auditing processes, which were essentially checklist driven, coupled with the alleged lack of relevant experience of the auditor, were complicit in producing a less than effective report. This approach contributed indirectly to both the 2009 Peanut Factory crisis, as well as the 2011 Jensen Farms crisis. The systems and processes of both organisations were clearly ineffective. A robust assessment approach, one that looked at their systems and processes, embedded continual improvement as a fundamental component and featured a risk-based methodology, would certainly have mitigated the risks to all of the stakeholders of both organisations to a greater extent,

including, most importantly, the consumers whose lives and health were put at risk.

LRQA have proactively worked with food safety stakeholders, in-cluding manufacturers, retailers, suppliers and industry experts, to move the food sector away from a checklist-based approach to au-

diting towards a process-based management systems approach. This approach looks at the underlying systems and processes that organisations have in place rather than the ability of that plant or factory to convince an auditor on a given day that they comply with a series of items on a checklist. It is not enough to have a strong standard or scheme, organisations need registrars or certification bodies that:

•offer auditors that have extensive experience and proven competence in the sectors they are auditing in,

•can provide a robust process-based management systems approach to auditing,

•stand up to the client when nonconformities are found, and finally,

•help the organisations being audited to reduce risks, improve food safety performance and link their food safety manage-ment systems objectives to their overall corporate objectives.

What is clear is that organisations across the food supply chain, including some of the world’s leading manufacturers and retailers, are increasingly recognising the benefits of independ-ent assessment and certification, not only in terms of the cost savings, but also in terms of the benefits and value it brings. Those organisations that are prioritising potential auditor CVs and certification body methodologies and credentials, rather than focusing on price, have clearly understood what is at stake. This approach is helping to drive consumer and other key stakeholder confidence as well as ultimately helping to safeguard the lives of people around the world. On the road to food safety, this can only be seen as a positive step.

Lloyd's Register Quality AssuranceContact info and more items like this at wf.net.au/Q413

Certification bodies have a vital role to play in bringing

confidence to the stakeholders of assessment

and certification.

This is the third part of a three-part article. See also Part I and Part II.


PR

OC

ES

SIN

G

Siphon-fed atomising spray nozzlesExair’s siphon-fed spray nozzles atomise fluids in a

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

nozzles require no liquid pressure and can be used

with gravity-fed liquids or lift liquids from siphon heights

up to 91 cm. They combine liquid and compressed

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

adjusted to meet the needs of particular applications.

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

paint a variety of products using compressed air and

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

water, atomising nozzles are an efficient way to evenly

cool hot items in an automated process.

The stainless steel construction of the nozzles adds

to their durability and corrosion resistance. All Exair

atomising nozzles are adjustable and are available in

a variety of flow patterns and rates to meet a range

of requirements. Internal and external mix atomising

nozzles are also available.

Compressed Air Australia Pty Ltd


Process automation technologySchneider Electric’s PlantStruxure process automation technology allows industrial

and infrastructure companies to transparently connect field, process and enterprise

levels within their business - creating time, decreasing cost and driving energy

efficiencies.

PlantStruxure is a key building block of Schneider’s energy management portfolio,

EcoStruxure, focused on the process automation domain. EcoStruxure connects

five domains of business expertise - power, data centres, process and machines,

building control and physical security - within an open and flexible tech-

nology architecture that delivers up to 30% savings in energy efficiency.

Schneider says its PlantStruxure system is based on tested, validated

and documented architectures for process and energy management, and

offers complete solutions from field to enterprise.

It offers energy management solutions to help achieve energy optimisation,

from device level to enterprise level. Operating and monitoring solutions

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

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

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

servers, controllers and networks. Safety process solutions ensure that

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

as defined in the IEC 61511 standard.

Networking solutions, based on ethernet, allow transparent communica-

tion among field, process, plant and enterprise. Network technologies and

web services ensure the efficient sharing and distribution of information

between sensors, instrumentation, devices, controllers, operator work

stations and other third-party systems.

Modernisation solutions to migrate to PlantStruxure are easy and customisable.

Schneider Electric (Aust) Pty Ltd


http://www.symetec.com


PR

OC

ES

SIN

G

Process calibratorFluke Calibration has introduced the 7526A

Precision Process Calibrator, which is a single

benchtop process calibrator.

The 7526A simplifies calibration of temperature

and pressure process instrumentation by incorpo-

rating an isolated measurement channel, letting

users source and measure simultaneously. With

the calibrator, users can easily calibrate RTD and

thermocouple readouts, pressure gauges, tem-

perature and pressure transmitters, digital process

simulators, data loggers, multimeters and more.

In today’s competitive global markets, precise

pressure and temperature process control is re-

quired to maintain product quality, reduce waste,

cut manufacturing costs and ensure compliance

to regulatory standards. Fluke says the 7526A

puts all the necessary tools for regular process

instrumentation calibration into one box.

The calibrator simulates and measures nine

RTD and 13 thermocouple types, accurately

measures pressure to within 0.008% of reading

when combined with Fluke 525A-P Series Pressure

Modules, sources and measures DC voltage from

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

DC current from 0 to 100 mA, accurately measures

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

supplies 24 VDC loop power.

Fluke Australia Pty Ltd


Larger-size valve rangeBürkert’s Element range of valves has been extended into larger-format valves and drives,

with orifices up to DN50 and actuators to 130 mm. This expands the application area of the

valve types, enabling their use at higher process pressures and larger flow rates.

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

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

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

flow, level and analysis chemistry sensors.

The expanded Element line of larger-size valves and drives encompasses on/off Types

2100 angle-seat and 2101 globe valves, the corresponding proportional control Types 2300

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

valve family. All valves are available with

50 to 130 mm actuators, with orifice sizes

DN8 to DN50.

The valves control fluids, steam, caustic

solutions and chemicals, as well as abrasive

or high-purity substances in many applica-

tions and process environments. A robust

IP65/67 construction suits the range to

arduous conditions, from hygienic process

caustic washdown areas (FDA and EHEDG

certification) to high-dust mineral process-

ing areas. Element on/off and proportional

control heads offer network interfaces, push-

button commissioning, super-bright LED

status indicators and numerous feedbacks

and options.

The drive design facilitates integration

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

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

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

Burkert Fluid Control Systems


http://www.symetec.com


Air handling units for food processing applicationsHurll Nu-Way has expanded its HVAC range with the Phoenix Hygienic Air Handlers, which are

designed for critical process applications such as food processing facilities, including meat,

poultry, seafood, fruit and vegetables, juice, nuts, dairy, eggs and frozen and prepared food.

Used in food processing plants, hygienic air handlers supply fresh, filtered, humidified

and cooled or temperature-controlled air to pressurise food processing rooms. Room pres-

surisation can inhibit airborne contaminants from entering the processing space from other

areas. Controlling humidity is crucial to reducing free moisture and condensation, which

fosters the growth and spread of bacteria.

Roof- or indoor-mounted hygienic handlers are used instead of air cooling units that are

mounted inside the processing rooms. By eliminating in-room equipment and mounting

hygienic air units outside the processing room, washing and disinfecting the process rooms

is faster and easier with fewer growth surfaces for bacteria.

The air handlers are suitable for a range of applications, including: meat processing; dairy

processing; fruit, vegetable and nut processing; and ready-to-eat and frozen food production.

Hurll Nu-Way Pty Ltd


PR

OC

ES

SIN

G

RFID controllerBalluff’s BIS-V RFID controller is a compact evaluation unit that enables simultaneous

connection of up to four read/write heads.

Both HF 13.56 MHz (in accordance with ISO 15693 and ISO 14443) and LF

125 kHz read heads can be connected on the front with plug connectors and are

automatically detected. The controller also allows IO-Link capable sensors or actuators

to be directly connected.

W i th an IP67 ra t ing and meta l hous ing, the cont ro l le r i s indust ry- ready.

It is equipped with Profibus interface and with USB as the service interface to the PC. There are many typi-

cal application areas for the combination of RFID controllers and sensors. For identification tasks for material flow control in

production systems, the user may benefit from the low hardware usage and low installation costs. The controller is suitable for

areas like conveyor systems in mechanical engineering, assembly lines, electric suspension systems and the intralogistics field.

Balluff-Leuze Pty Ltd


http://www.amkcoaustralia.com.au


PR

OC

ES

SIN

G

Integrated pneumatic

actuator rangeNorgren has launched a high-performance

range of cylinders designed to reduce energy usage

and operating costs for OEMs and end users in a range of process-

ing applications.

Conventional pneumatic control involves an arrangement of valves

or valve islands, actuators, flow controls and sensors, along with

connectors and accessories. In typical applications, up to 13 dif-

ferent components can be required for each actuator function. This

complexity presents some intrinsic disadvantages and performance

constraints. Norgren has developed IVAC (integrated valve and actuator

control) - an integrated unit which combines the valve, flow controls,

cushioning and sensors in a single actuator package.

IVAC is a weight- and space-optimised actuator, suitable for a

range of bore sizes from 40 to 80 mm, with an integrated valve and

magnetically operated switches for complete actuator control. Able

to be retrofitted or integrated within new systems, each unit requires

only one pneumatic and one electrical connection, eliminating the

need for multiple valve islands, components, tubing and accessories.

A number of options and varieties are available including cleanline

versions for industrial cylinders, industrial slave cylinders and easy

washdown, helping OEMs comply more easily and cost effectively with

hygiene regulations. The design of the integrated actuator is based

on modularity to allow all components to be easily assembled and

disassembled. The IVAC’s modular concept includes a special pilot

module which is placed directly at the end of the actuator

barrel, and the integration of a pneumatic interface, position sensing,

display for status and electrical connection.

Norgren Pty Ltd


Optical distance sensorEven with extraneous light of up to 100,000

lux the ifm efector O1D series optical distance

sensor provides reliable performance.

The sensor detects all distances, even in

direct sunlight, irrespective of whether the

target is fully exposed to the light or only the

sensor, or both. Even reflective and shiny polished

metal surfaces of stainless steel or aluminium are

claimed to be reliably detected. The company claims

the sensor is insensitive to reflective surfaces such as reflective strips

on safety vests or reflectors and can be used in outdoor applications

for position monitoring such as portal lifters on loading stations. As well

as the optical distance detection of up to 10 m range, this product has

two switching outputs, one of which can be set as an analog output.

The detection zone is scalable and has a window function. The sensor

can also be used in applications with background suppression.

ifm efector pty ltd


http://www.heatandcontrol.com


PR

OC

ES

SIN

G

Hotels, Clubs, Nursing Homes, Deli’s,

Hospitals, Sports Facilities, Restaurants,

Bars, Conference Centres, Correctional

Facilities, Retail Outlets, Butchery,

Bakery, Seafood and all Safety Surfaces.

1800 769 738Phone: (02) 9988 4822

Fax: (02) 9988 4833www.roxset.com.au

1800 ROXSETHEALTH AND SAFETY FLOORING

SLIP RESISTANT • ULTRA CLEAN • IMPERVIOUS

TM

Do you need flooring for your

Food Facility?

Customisable vibratory conveyorsHeat and Control’s customisable vibratory conveyors

have been designed specifically for the food industry. The

conveyors can be customised for multiple applications,

such as grading, alignment, dewatering, spreading and

bidirectional distribution.

The rugged conveyors are low-maintenance and their

construction makes sanitation easy. One-piece stainless

steel pans with large-radius corners are easily cleaned.

Open support frames and columns facilitate cleaning of

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

tions and accessories are available.

Variable-speed electromagnetic drive conveyors handle

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

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

Direct drive conveyors are suitable for fixed-speed sort-

ing, grading and bidirectional conveying. The direct drive

conveyors are suspended from a floor-mounted frame or

the ceiling.

Fixed-speed indirect drive conveyors provide efficient

transfer, dewatering, spreading, laning and fines removal

for a single product type. The underslung design saves

floor space.

For operators wanting to convey in two directions, the

conveyors can be customised to instantly alternate the

conveying direction for product distribution or accumulation

using one space-saving direct drive conveyor.

Heat and Control Pty Ltd


Two-wire magnetic flowmeterYokogawa Australia has released an upgraded version of the

ADMAG AXR two-wire magnetic flowmeter.

According to the company, the two-wire flowmeter exhibits

a level of performance comparable to that of the ADMAG AXF

four-wire magnetic flowmeter in terms of measurement accuracy

and low noise characteristics.

The ADMAG AXR has been certified for use in SIL2 applica-

tions typically encountered in the oil, petrochemical, chemical

and other industries, and can be installed in areas that require

functional safety. By pairing two ADMAG AXR flowmeters, SIL3

applications can be supported.

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

HART protocol, eliminating the need for converters to connect

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

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

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

The flowmeter uses the dual frequency excitation method, with

low-frequency excitation that ensures stable measurement of flow

rates and high-frequency excitation

that delivers high noise resistance,

realising stable measurement in

a wide range of fluid conditions.

The device can be used in

both monitoring and control

applications. Its installation and

maintenance costs are lower

because two-wire magnetic

flowmeters do not require

a dedicated power supply

unit and use only a single

pair of cables. The low

power consumption also

reduces running costs.

Explosion-proof types suit-

able for installation in hazardous

areas are now available for the entire product range, covering

bore diameters from 25 to 200 mm.

Yokogawa Australia Pty Ltd



[email protected] 0800 55 77 33

our recipe compliments yours...

make us part of your process

Heat, Mix, Separate, Aurora

AA

FT20110930

MAGNATTACKMagnetic Contaminant Separators

DIMPLEFLOTubular Heat Exchangers

ALFA LAVALPlate Heat Exchangers

MIXQUIPFluid Mixing Equipment

SPINCLEARHydrocyclone Separators

Flash steam recovery delivers large energy savingsAffco NZ has been producing prime meat products since 1904. At its Wairoa site, a large rendering addition was made to avoid trucking offsite. During the design phase, and with energy conservation in mind, one of the key components was to ensure condensate was recycled to the boiler house.

The site’s existing 11.3 MW coal-fired boiler had sufficient capacity to supply the new rendering process equipment. The majority (12,000 kg/h) is used for two rotary driers, drying meat and bonemeal from approximately 70% to 10% moisture for end use as dry chicken feed or dog biscuits.

At differential pressures (between steam use in process and the backpressure of the condensate) higher than 4 bar, a conventional condensate pump return system is not very effective, wreaking more than 6% flash steam energy in the condensate lines and often boiling the boiler feedtank water.

“I’ve worked with another operation where we couldn’t control the flash steam - it just went to waste,” said Plant Engineer Paul Sullivan. “We worked with Spirax Sarco to ensure that we had minimal wasted energy in the steam and condensate loop.”

The solution has paid off in just over a year and, according to Sullivan, “The project achieved all of our expectations, plus more.”

After several site visits and a review, Spirax Sarco put forward a proposal. Spirax suggested splitting condensate into high- and low-pressure systems and utilising energy from the dryer condensate at high pressure by installing a flash vessel. In addition, flash steam energy would be recovered and used

for a new ‘on-demand’ hot water system comprising two heat exchangers in series using low-pressure condensate for preheating and high-pressure flash steam. This was ideal as the existing hot water system was due for an upgrade.

Excess flash steam beyond hot water demand was used to heat the make-up water storage tank, while all spent condensate was returned to the vented receiver and pumped back to the boiler.

“Dropping the pressure and temperature of the condensate to 80°C was ideal. All the flash steam is run through the main heat exchanger and serves almost the entire washdown hot water requirements,” Sullivan said. “The only time we use direct boiler steam for hot water is at start-up from 6.00 to 9.00 am and it is minimal as the storage tank is preheated to about 65°C from the prior day from excess flash steam.”

Controlling the condensate return temperature at 80°C (subcooling) ensures maximum energy recovery. All spent condensate is returned to the condensate receiver and pumped to the boiler feedtank, enabling a reduction in boiler chemicals and make-up water required.

Spirax’s solution combined Affco’s need for condensate return and a hot water system upgrade into a large energy-savings project. Sullivan is enthusiastic about the project’s success: “We are not wasting energy; we are saving in the order of $100K per year and could not have asked for a better turnout.”

Spirax Sarco NZ


PR

OC

ES

SIN

G

http://www.aurora-nz.com


PR

OC

ES

SIN

G

Germ-free packaging and conveyors with Fast and

Effective UV disinfection. Less waste, improved quality,

reduced risk of re-contamination.

www.heraeus-noblelight.com/au

Clean Cover UV tunnel - Steribelt - Bluelight UV module

Phone: 03 9874 7455Email: [email protected]

Inspired by seeing an Optyx sorter in action at an Ocean Spray plant, L&S Cranberry installed its own Optyx sorter - and has increased its production from one shift a day to two, six days a week. With help from Key Technology, the cranberry grower says it has maximised productivity while maintaining the highest product quality and food safety.

“Prior to having our own packing plant, we shipped our fresh cranberries to an Ocean Spray packing plant, which had Optyx sorters,” said L&S Cranberry General Manager Kevin Connolly. “In 2008, we decided that we had grown large enough to justify having our own packing plant. We installed an Optyx sorter because we saw how successful it was at Ocean Spray.”

Using a combination of colour cameras and lasers, the Optyx 6000 series sorters inspect up to 5400 kg of fresh cranberries per hour. The cameras analyse size, shape and colour, while the lasers detect differences in structural properties, identifying and removing foreign material, defects and soft berries called ‘poppers’ that spoil quickly.

“In 2011, we went from operating one shift per day to two shifts per day, six days a week,” said Connolly. “At that time, we added RemoteMD to allow us to monitor and access the sorter remotely.” RemoteMD is a real-time monitoring and diagnostics tool for the Optyx sorter.

L&S Cranberry farms and packs about 3.6 million kg of fresh cranberries each year during the four-month season, making it one of the largest growers supplying Ocean Spray. But even for such a busy company, high staff turnover is a common problem.

“We usually begin every year with new people,” Connolly said. “Optyx reduces our reliance on labour because it automates sorting, and RemoteMD helps us maintain the highest product quality and line productivity even if the most fully trained person isn’t in the plant.”

With high staff turnover comes increased staff training. Fortunately for L&S Cranberry, Key’s PROliance protection plan includes access to Key’s online training program - a self-paced, interactive curriculum that covers hardware, software and user interface topics.

“Key’s online training program frees me up from having to train everybody myself. When employees are better trained, they lean on me less to get involved in the operation,” Connolly said. “With online training, we’ve trained more people, which is a good thing, and we didn’t have to spend thousands of dollars to bring in technicians to do the training. Online training is available any time, on-demand, which is especially valuable given our high turnover.

“At L&S Cranberry, we’re focused on producing the highest quality fresh cranberries. Given how short our season is, it’s important that we achieve perfect accuracy from the moment we start up in September,” concludes Connolly.

“Optyx helps us achieve our high-quality standards. Online training helps us be prepared and RemoteMD is like having an insurance policy.”

Key Technology Australia Pty Ltd


Optyx is the Key to quality for cranberry producer

Mechatronic flow sensor seriesifm efector’s SBT series mechatronic flow sensors can be used for

flow ranges from 0.3 to 25 L/min at pressure ranges of up to 15 bar.

The sensors function on the principle of the spring-supported pis-

ton: the piston, located in the valve seat in the housing, is lifted by

the flowing medium against the spring resistance. The mechatronic

measuring principle enables response times of less than 10 ms.

At the same time, the spring resistance forces the piston to return

to its original position with decreasing flow. This ensures position-

independent installation of the flow sensor, preventing backflow.

Due to the temperature decoupling of the transducer from the

electronics, some versions of the sensor are suitable for media in

high-temperature applications of up to 180°C.

The sensors can be set intuitively and provide an analog output signal.

ifm efector pty ltd



PR

OC

ES

SIN

G

Brolton Group Pty Ltd69 Princes St, Riverstone, NSW, 2765, Australia

Sydney Ph: +61 2 98381311 Perth Ph: +61 8 6263 4426 Fax: +61 2 9838 3113 E: [email protected] www.brolton.com.au www.sanddryer.com.au

Silos ~ Hoppers ~ Conveyors ~ Pneumatic Conveying ~ Bag Stations ~ Weigh Feeders ~ Mixers Belt Dryers ~ Flash Dryers ~ Fluid Bed Dryers ~ Coolers ~ Steam Sterilization ~ Packaging

Materials Handling Solutions

Upgraded hygiene monitoring system software3M Food Safety has announced software enhancements to its 3M Clean-Trace Hygiene Moni-

toring System, a family of products that helps food and beverage processors easily track and

monitor cleaning and sanitation within their manufacturing environments.

3M Clean-Trace Data Trending Software Version 5.03 allows easy identification of cleanli-

ness and continuous improvement in sanitation programs after samples are taken from the

production line. The updated software is available in 20 languages and includes: newly for-

matted, audit-ready reports; customisable trend analytics and a sophisticated graph wizard;

and tools for development and implementation of company-specific sample plans and master

sanitation schedules.

For food and beverage manufacturers and processors, the software improvements are

claimed to go beyond the ability to conveniently store data that has been collected. By us-

ing the full capabilities of the software to transform data into robust trend analytics, hygiene

managers can track cleaning effectiveness, bring about improved sanitation processes and

standards as well as address audit requests that originate internally or externally.

The system consists of a sampling medium and easy-to-use hardware and software.

The sampling medium - 3M Clean-Trace ATP Test Swabs - is wiped on suspect surface ar-

eas to collect residues that may contain adenosine triphosphate (ATP), an energy molecule

prevalent in organic materials.

The 3M Clean-Trace NG Luminometer rapidly evaluates the sample and determines the

presence and magnitude of potential contamination. The handheld luminometer, which delivers

a result in mere seconds, allows users to pre-select their own ‘pass, caution or fail’ levels.

Once the sample data is downloaded to the software, users gain full trend analysis capabili-

ties, allowing them to quickly make business decisions and comply with audit requirements.

3M Safety Products


Tamper-proof safety switchesEuchner’s CES and CET series safety switches

have been designed for use on decentralised

machine systems.

The safety switches from both series are based

on transponder technology and are claimed to

offer maximum protection against tampering.

They are suited for protecting safety doors, even

in harsh industrial environments.

The switches also feature mechanical guard

locking, allowing them to be used safely on ma-

chines with over-travelling machine movements.

Treotham Automation Pty Ltd



ME

AT

& S

EA

FO

OD

Consuming greater amounts of choline - a nutrient found in meat and eggs - during pregnancy may lower an

infant’s vulnerability to stress-related illnesses, such as mental health disturbances, and chronic conditions,

like hypertension, later in life.

In an early study in The FASEB Journal, nutrition scientists and obstetricians at Cornell University and the University of Rochester Medical Center found that higher-than-normal amounts of choline in the diet dur-

ing pregnancy changed epigenetic markers - modifications on our DNA that tell our genes to switch on or off, to go gangbusters or keep a low profile - in the foetus. While epigenetic markers don’t change our genes, they make a permanent imprint by dictating their fate: if a gene is not expressed - turned on - it’s as if it didn’t exist.

The finding became particularly exciting when research-ers discovered that the affected markers were those that regulated the hypothalamic-pituitary-adrenal or HPA axis, which controls virtually all hormone activity in the body, including the production of the hormone cortisol that re-flects our response to stress and regulates our metabolism, among other things.

More choline in the mother’s diet led to a more stable HPA axis and consequently less cortisol in the foetus.

As with many aspects of our health, stability is a very good thing: past research has shown that early exposure to high levels of cortisol, often a result of a mother’s anxiety or depression, can increase a baby’s lifelong risk of stress-related and metabolic disorders.

“The study is important because it shows that a relatively simple nutrient can have significant effects in prenatal life, and that these effects are likely continue to have a long-lasting influence on adult life,” said Eva K Pressman, MD, study author and director of the high-risk pregnancy program at the University of Rochester Medical Center. “While our results won’t change practice at this point, the idea that maternal choline intake could essentially change foetal genetic expression into adulthood is quite novel.”

Pressman, who advises pregnant women every day, says choline isn’t something people think a lot about because it is already present in many things we eat and there is usually no concern of choline deficiency. Though much more research has focused on folate - functionally very

Meat consumption and stress reduction


similar to choline and used to decrease the risk of neural tube defects like spina bifida - a few very compelling studies sparked her interest, including animal studies on the role of choline in mitigating foetal alcohol syndrome and changing outcomes in Down syndrome.

A long-time collaborator with researchers at Cornell, Pressman joined a team led by Marie Caudill, PhD, RD, professor in the Division of Nu-tritional Sciences at Cornell, in studying 26 pregnant women in their third trimester who were assigned to take 480 mg per day, an amount slightly above the standard recommendation of 450 mg per day, or about double that amount, 930 mg per day. The choline was derived from the diet and from supplements and was consumed up until delivery.

The team found that higher maternal choline intake led to a greater amount of DNA methylation, a process in which methyl groups - one carbon atom linked to three hydrogen atoms - are added to our DNA. Choline is one of a handful of nutrients that provides methyl groups for this process. The addition of a single methyl group is all it takes to change an individual’s epigenome.

Measurements of cord blood and samples from the placenta showed that increased choline, via the addition of methyl groups, altered epigenetic markers that govern

cortisol-regulating genes. Higher choline lessened the expres-sion of these genes, leading to 33% lower cortisol in the blood of babies whose mothers consumed 930 mg per day.

Study authors say the findings raise the exciting pos-sibility that choline may be used

therapeutically in cases where excess maternal stress from anxiety, depression or other prenatal conditions might make the foetal HPA axis more reac-tive and more likely to release greater-than-expected amounts of cortisol.

While more research is needed, Caudill says that her message to pregnant women would be to consume a diet that includes choline-rich foods such as eggs, lean meat and beans, and cruciferous vegetables like broccoli. For women who limit their consumption of animal products, which are richer sources of choline than plant foods, she adds that supplemental choline may be warranted as cho-line is generally absent in prenatal vitamin supplements.

“One day we might prescribe choline in the same way we prescribe folate to all pregnant women,” notes Press-man, the James R Woods Professor in the Department of Obstetrics and Gynecology. “It is cheap and has virtually no side effects at the doses provided in this study. In the future, we could use choline to do even more good than we are doing right now.”

ME

AT

& S

EA

FO

OD

... a relatively simple nutrient can have significant

effects in prenatal life, and that these effects are likely

continue to have a long-lasting influence on adult life.

http://www.amsl.com.au


A recent study looked at the tenderness and other meat quality traits of pork longissimus muscle, comparing

different stunning methods and carcass chilling rates at slaughter facilities.

The pigs used in this study came from one barn on a commercial finishing operation. Pigs were taken to one of three slaughter facilities. Plant A used CO2 stunning and conventional spray chilling;

Plant B used CO2 stunning and blast chilling; and Plant C used electrical stunning and blast chilling.

“Blast chilling is a rapid cooling of the muscles for at least 45 minutes at less than -23°C,” said Steven Shackelford of US Meat Animal Research Center (USMARC).

Blast-chilling systems are used to increase packing plant throughput, enhance food safety and improve meat quality, particularly water-holding ca-pacity of muscles from stress-susceptible pigs.

After slaughter, carcasses were cooled by blast chilling or conventional spray chilling. The researchers used a loin from the left side of the carcass for evaluation. They sent the loins to the USMARC, where the loins were refriger-ated and weighed for purge loss. Purge loss is the loss of fluid from meat.

At 15 days post mortem, the meat was cooked and the researchers measure the longissimus muscle slice shear force. Slice shear force is a measurement of meat tender-ness. The higher the shear force, the tougher the meat. They also tested the meat samples for marbling, muscle fibre length, moisture content, colour, the breakdown of proteins and intramuscular fat content.

The researchers found no loin quality advantages from blast chilling. They did find a 13-fold increase in excessively tough samples from blast chilling. This research shows that differences in chilling systems among pork packing plants can have a strong influence on loin chop tenderness.

“This study showed that blast chilling can have a very substantial negative impact on tenderness. So there are trade-offs that must be considered,” said Shackelford.

The findings are surprising because past literature sug-gests that blast chilling had lit-tle importance. The researchers believe this is due to changes in genetics and production systems, which can affect chill-ing rate. The researchers also found that regardless of chilling

method, CO2 stunning resulted in darker longissimus muscle lean colour and greater longissimus muscle water-holding capacity than electrical stunning.

For the future, the researchers would like to see studies that determine whether differences exist consistently across conventional and blast-chill plants over multiple seasons of the year and multiple production systems.

“Given the real and perceived advantages of blast chilling, we think that more research is needed to determine optimal blast-chilling conditions for a balance of all meat quality traits and other economical issues,” said Shackelford.

They did find a 13-fold increase in excessively tough

samples from blast chilling.

This research has been published in the Journal of Animal Science.

Blast chilling methods could change meat tenderness

ME

AT

& S

EA

FO

OD


ME

AT

& S

EA

FO

OD

A commercial vaccine for cattle can effectively reduce levels of E. coli by more than 50%

according to a Kansas State University study. The vaccine is also effective using two doses

instead of the recommended three doses, which can help cut costs for the beef industry.

David Renter, associate professor of epidemiology, is the principal investigator on a project that researched the effectiveness of products used to prevent the shedding of E. coli O157:H7 in cattle. The research appears

in an online version of the journal Vaccine and helps improve current preventative methods for addressing food safety concerns.

While E. coli O157:H7 does not affect cattle, it causes foodborne disease in humans. Vaccines and other products may be given to cattle to help prevent the spread of the bacteria.

“We wanted to test how well these products work to control E. coli O157:H7 in a commercial feedlot with a large population of cattle that were fed in the summer and may be expected to have a high level of E. coli O157:H7,” Renter said.

Using a commercial feedlot setting, the researchers studied more than 17,000 cattle during an 85-day period. They studied two products: a vaccine and a low-dose, direct-fed microbial.

“What's unique about this study is the number of animals we used, the research setting and that we used commercial products in the way that any cattle producer could use them,” Renter said.

“We didn't want it to be any different than the way somebody would use the products in a commercial feedlot.”

The researchers found that the vaccine reduced the number of cattle that were shedding E. coli O157:H7 in faeces by more than 50%. E. coli shedding was reduced by more than 75% among cattle that were high shedders of E. coli. While the vaccine label suggests that it is given in three doses, the researchers found that two doses of the vaccine significantly reduced E. coli.

“Showing that level of efficacy with two doses is really impor-tant because a shift to two doses from three could significantly cut costs for the beef industry,” Renter said.

The researchers also discovered that the low-dose, direct-fed microbial product did not work as well as the vaccine. Renter said while the study used a lower dose of the direct-fed microbial and could find no evidence that it reduced E. coli shredding, it is possible that the direct-fed microbial product is more effective at a higher dose. “This vaccine is an option for reducing E. coli,” Renter said. “We have shown that this vaccine works and that it is a tool that could be adopted in the industry.”

Cattle vaccine reducesE. coli O157:H7

http://www.mosca.com


Surveys over the years have found a significant and growing number of consumers have trouble opening packages, with many requiring assistance and oth-ers injuring themselves in the process. Inevitably,

consumers are left feeling helpless and frustrated.This experience has been termed ‘package rage’ and refers

to the anger and frustration experienced by consumers result-ing from their inability to successfully remove contents from a hard-to-open package. Coffee packaged in metal containers, shrink-wrapped cheese and cereal bags are amongst common complaints.

The trend of consumers shying away from hard-to-open packages suggests they are turning to competitor products that feature better openability and accessibility instead. Brands take note: packaging is an important marketing tool and should be

As everyday consumers, we are all too familiar with the frustration that accompanies a hard-to-open

package. Clamshell packaging is notoriously difficult to open, but other formats like candy packets or

frozen meat products can be equally challenging.

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

Besides the ageing demographic, Australia is also con-cerned with providing accessible packaging for consumers with disabilities. It has been found that one in three healthy Australians over the age of 50 struggles with packaging, in

PA

CK

AG

ING

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

a frustration-free alternative

©iS

tock

phot

o.co

m/J

ohn

M S

cott


addition to the 6.4 million Australians living with arthritis or disability. The Ease-of-Use program was established by Ar-thritis Australia and Arthritis New Zealand back in 2009 in a bid to promote user-friendly products. Since then, Nestlé has also joined the program to evaluate the packaging of many of its major products and has invested in designing packaging that is easy to open for various demographic groups. This move shows that companies like Nestlé are starting to hear the voices and demands of their consumers, and innovation is a necessary investment for companies that seek to retain consumer loyalty and win new consumers.

Increased convenience is always appreciated by those with arthritis or disability, as these consumers may not be able to as easily open and use packages. When manufacturers consider this group, they should think about creating a universal pack-age design that can be opened by consumers of all ages, from children to the elderly. This will ensure convenience in terms of portability, easy storage, opening and closing.

The rise of snack cultureIncreased income levels across the Asia-Pacific region have cre-ated a greater demand for food products that are convenient, particularly in the snack category. Products consumed out of home have become a major area of growth because modern consumers are spending less time at home and more time on the go. Research has also found increased snacking in the workplace in both developing and developed economies around the region. With spending on these convenience foods rising, manufacturers must accurately identify and address consumer needs in order to remain competitive with other brands in the market.

Packaging should be a key consideration for snack brands. Manufacturers need to make sure the package matches the product: if the product is supposed to be easy to consume, the packaging should also be easy to open. Resealable pack-ages, in particular, address the need for portability and convenience. Consumers appreciate packages with resealable

options because, in addition to portability, these packages enable them to conveniently store unconsumed contents. Resealable packaging also provides portion control options and lets shoppers indulge in their favourite snacks without fear of overconsumption.

Battle of the food packagesToday, conservative estimates suggest that 70 to 75% of all purchasing decisions are made at the point of purchase - con-sumers decide between the brands in front of them at the store itself. This means that packaging should attract and engage the often overwhelmed consumer’s attention in the space of a few seconds. Shelf impact is especially important in Asian marketplaces as these are crowded and competitive landscapes with brands increasingly investing heavily in graphics and innovative technology for their packaging. In order to stand

out, manufacturers must offer something unique to consumers in order to encourage them to select the product.

The best way for a package to stand out is through improved functionality - packaging that is functional and intuitive tends

to fare better in the competitive shelf landscape. Contrary to popular belief that packaging should be fanciful and intricate to attract the consumer, simplicity is frequently preferred. Ideally, food packaging should be simple and still able to fulfil the basic function expected of any food package: to keep contents fresh even after opening. However, good packaging accomplishes this and simultaneously responds to the trends and demands of consumers while prompting sales. The best packaging keeps contents fresh but also addresses openability, portability and convenient storage options.

Enhancing your brandMany brands have found that a simple packaging modifica-tion can revive a product. Value-added resealable closures are proven and effective ways to refresh existing packaging and maintain the current market share. At the same time, the

PA

CK

AG

ING

Brands take note: packaging is an important

marketing tool and should be a key consideration

during product development.


obvious convenience afforded by such packaging also attracts new consumers to purchase the product. In spite of the obvious benefits of resealable packaging, however, many manufacturers are still unsure about how to integrate zippers into their packaging.

It is a common belief that easy-open and other value-added features can add extra costs to packaging. However,

flexible packaging holds an overall total cost of ownership advantage in terms of reduced shipping and material costs, lowering production costs in the long run. In fact, it has been estimated that one truckload of flexible film equates to 20 truckloads of rigid containers. Likewise, studies conducted by Purple Research and commissioned by Zip-Pak have found that consumers are willing to pay more for convenient packaging with a press-to-close or slider zipper.

The cost associated with implementing resealable technol-ogy depends largely on manufacturer needs and requirements. There is a wide range of resealable products and value-added features that have been developed to suit almost any appli-cation. It is important to match the need with the zipper, as powdered products, frozen applications, bulk goods or high-temperature applications like retort and microwave require very different solutions.

Avoid cutting corners: how to adopt resealable technologyAlmost any flexible package can benefit from a resealable closure, whether or not incorporating a zipper was part of the initial packaging design. There are two ways to make the switch. Manufacturers can either invest in new machinery or opt for the more popular option of retrofitting existing pack-aging lines with zipper applicator equipment. To achieve the best results, it is important to work with a provider who can consult on machinery, materials and package design to allow for the seamless integration of resealable technology.

The biggest problems with adding closures lie in working with inexperienced operators and implementing faulty pack-age designs. Many consumers also experience frustration with value-added resealable closures that fail to work after even a single use. Most often, this is due to machinery that is not properly set up to apply the zipper. Further, for a closure to work effectively over the life of the product, the package must be designed specifically to accommodate the feature. As the only zipper supplier with an in-house equipment division, Zip-Pak is equipped to work directly with manufacturers

to ensure machinery is properly installed and operators are adequately trained. Further, the company employs experts in package design to assist food brands in producing a package with a premium zipper that works once consumers bring it into their homes.

For businesses looking to make a successful transition, here are a few tips on what to consider:

•Keep it simple: Don’t crowd your package with marketing messages - minimalistic packaging can effectively indicate quality. Highlight the convenience of your package with an instantly recognisable resealable closure.

• Match the zipper to the application: Zippers behave dif-ferently with various films and the products they package. Make sure you are choosing the right closure for your product.

• Understand your packaging system: Additional training and knowledge is required for operators on zipper-capable packaging systems. While operators are generally reliable and knowledgeable, they may lack the expertise to cor-rect closure application issues. Make sure your supplier is also a specialist who can work with and consult your operators to ensure smooth operations.

• If you are producing a premium product, make sure you back that up with premium packaging with value-added features that work every time.

• Employ universal design: If your package can be opened and resealed by children and the elderly, it will be easily accessed by everyone else in between.

Simplicity is keyToday’s consumers live in a world of convenience and choice. For any given product, they are faced with a variety of op-tions and differentiation is largely attributed to branding and packaging. Brands must realise that consumer satisfac-tion goes far beyond product. Difficult packaging threatens brand loyalty because package rage may lead consumers to competing easy-open brands. Packaging innovations can sig-nificantly improve consumer experiences, and with today’s advancements in technology, there really is no reason why consumers should experience such frustration. After all, no one has ever complained that a package kept food too fresh or was too easy to open.

Blue Sky Packaging Ltd


PA

CK

AG

ING

Difficult packaging threatens brand loyalty because

package rage may lead consumers to competing

easy-open brands.

www.foodprocessing.com.au

http://www.matthews.com.au


Conscience-free Canadian coffeeCanadian coffee drinkers can now enjoy their morning brew with a clear conscience. Pistol & Burnes, a Canadian coffee roasting company, has introduced a fully compostable pack for its Farmer First brand which incorporates cellulose-based NatureFlex from Innovia Films.

The Fair Trade organic coffee is packed in a paper bag laminated with transparent NatureFlex film. The film begins life as a natural product - wood - and breaks down in a home compost bin or industrial compost environment in a matter of weeks. It is also confirmed as suitable for emerging ‘waste-to-energy’ techniques such as anaerobic digestion.

“Most roasted coffee sold in the world is packaged in either foil bags (coated in plastic) or paper bags (with a plastic liner),” said Roy M Hardy, President of Pistol & Burnes.

“These usually end up going straight to landfill as they can prove difficult to recycle. However, our enviro-friendly coffee bag can be organically recycled (composted), which means it breaks down in a home compost bin.”

NatureFlex films are certified to meet the American ASTM D6400, European EN13432 and Australian AS4736 standards for compostable packaging. The wood pulp is sourced from managed plantations. The renewable biobased content of NatureFlex films is typically 95% by weight of material according to ASTM D6866.

Genpak, a Canadian converter, developed the bags for Pistol & Burnes. “We recommended NatureFlex to Pistol & Burnes for several reasons,” said Billy Reilly, Technical Manager for Genpak.

“First and foremost, the film performs well technically, having high barrier properties and good seal integrity that enhance shelf life, keeping oxygen out and aroma in - very important for packaging coffee. Secondly, NatureFlex is perfectly aligned with the ethos of their Fair Trade, organic Farmer First brand.”

“Continued success with partners such as Genpak and Pistol & Burnes means that our NatureFlex films are well positioned to provide solutions to converters and brand owners, especially those seeking to meet consumer demand for packaging made from renewable resources,” said Joe Piccione, President of Innovia Films Americas.

Innovia Films Pty Ltd


Automatic strapping machines with ultrasonic technologyMOSCA’s range of Stainless Steel Automatic Strapping Machines

use ultrasonic technology for sealing that allows immediate

use of machine on start-up, gives high seal strength and

increases strapping speed by up to 50%. No fumes or smells

are produced and the dangers of hot surfaces are eliminated.

These corrosion-resistant machines are constructed of

stainless steel or non-oxidating materials and have a sealed

splash-proof control cabinet and operation panel rated at IP56.

The machines offer fully automatic strap threading, automatic

strap loop ejection and strap end detection with ejection of

remaining strap.

The IP56 washdown machines are built around MOSCA’s

series 3 sealing head and brushless DC direct drive technology.

Able to be integrated into most production lines, the machines

have PLC control and an operator panel that allows quick set-

up of operating methods,

strapping positions and

strap tension.

Mosca


PA

CK

AG

ING


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

Call us today to discuss a trial sample of our new peelable PET Antifog Dual Ovenable Lidding �lm.

DFC Packaging Vic. 20 Summit RdNoble Park , 317403 9701 [email protected]

DFC Packaging NSW. 21/197 Power StGlendenning, 276102 9625 [email protected]

CIP sensor system

The Wenglor InoxSens System

is designed for the high hygienic

demands of the food, chemicals,

packaging, pharmaceutical and

similar industries. The Wenglor

InoxSens products come as a modular clean in place

(CIP) system of sensors.

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

easy cleaning. There are no edges to attract contamination.

On the outside, the system is constructed entirely of

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

stainless steel exterior is resistant to cleaning agents and

with its IP68 and IP69K rating it is waterproof, allowing

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

also provides mechanical protection for all cable types.

In accordance with EHEDG directives, the system has

an inspectable seal.

Treotham Automation Pty Ltd


Reseal, reclose and easy-open packaging systemsPackaging formats that are difficult to open or not used for

anything more than the trip home from the retailer reduce the

interaction consumers have with a brand. This has prompted

many FMCG companies to look at introducing reseal, reclose

or easy-open systems.

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

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

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

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

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

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

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

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

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

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

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

friendly feature.

Result Packaging Pty Ltd


PA

CK

AG

ING

http://www.dfc.com.au


>>>

Shelf friendly packaging - is there a problem here?

While shelf friendly packaging (SFP) has been part of the Australian retail landscape for nearly 10 years, it is a process and a function that few understand.

The core of SFP is waste and cost reduction; topics familiar to many of us. The Australian supply chain for FMCG goods is long and many hands touch the carton or pack. One of SFP’s key targets is minimising labour at each work station. For secondary packages, the accepted task of safe transport has not changed. It is just more challenging when it needs to look good on the shelf, attract a buyer and complement the primary pack.

The big three retailers are driving SFP. The shared presentation at the AIP National Conference by Rod Evenden (Woolworths) and Matt Swindells (Coles) clearly demonstrated common goals, which are summarised in the mantra of ‘five easies of SFP’: easy to identify; easy to open; easy to replenish; easy to shop; and easy to dispose.There are three elements to find the optimal SFP solution:

Size, shape and format of the secondary packaging. The question asked of brand managers and packaging professionals is “what is the item’s rate of sale?” If 24 items per week are sold in each store, a carton of 24 can be adapted. However, if the weekly rate of sale is six, the value of continuing with a slow-moving product must be analysed.

Structural. Secondary shippers are becoming smaller. Corrugated board C flute is outdated, with E and the newly-developed R as alternatives. Folded board packs are finding a niche with their exceptional printing qualities. Regular-slotted and wraparound carton formats are no longer the only choice. Tray and shrink are generally chosen for rigid cans and glass.

Communication. Having transported the primary packs successfully to the shelf, the shipper must now be point-of-sale material and communicate directly to the shopper. The choice of message and how it is printed is vital to success.

As was the case with introduction of barcodes on shippers many years ago, SFP is part of doing business today and is not going away. No-one would

consider removing barcodes; in time, SFP will be as important as barcoding.If you look you will find problems, but if you are committed you will find solutions.

Ralph Moyle MAIP National President Australian Institute of [email protected] www.aipack.com.au

Continuous ink jet printerMatthews Australasia has released the Linx CJ400

continuous ink jet (CIJ) printer.

The CJ400 prints up to three lines of information

such as lot codes, dates, times, text and symbols

onto most surfaces. With a special print-head, it

can print four to five lines, dependent on font size.

The printed code can be quickly changed without

lengthy set-up procedures. The CJ400 can print

characters from 2 to 20 mm high, making it suitable

for both product and carton printing.

The printer’s Easi-Change Service Module can be

changed within minutes using on-screen prompts,

allowing scheduled maintenance to be completed

without the need for a trained technician. On-screen

troubleshooting can solve most operating issues

without having to consult manuals or engineers.

The Easi-Change is designed so that all serviceable

parts are housed in an easily removable box, with

no wires or pipes to disconnect and reconnect, and

no need to expose other critical printer components

during servicing. There are no electronic components

to replace when the module is changed, reducing

cost and waste.

Extended print-head cleaning intervals (typically

three months) further reduce maintenance require-

ments. The Linx CJ400’s autoflush process means

there is no need for printer or conduit flushing for

shutdowns of up to four weeks, so fluids aren’t

wasted and start-up is easy after extended shut-

down periods.

Weighing 13.5 kg complete with fluids, the CJ400

can be easily moved around a factory, which may

increase productivity and reduce coding costs.

It can store settings for up to four production lines

and 1000 typical messages.

Set-up can be completed by following simple

prompts on an easy-to-use touch screen. The system

offers step-by-step message creation and editing.

Matthews Intelligent Identification Pty Ltd


PA

CK

AG

ING


Bosch modifies its Elematic case

packer to handle jarsBosch Packaging Technology has developed a new

application for its Elematic 3000 S case packer. Designed by Bosch for Rapunzel Naturkost, the German manufacturer and supplier of

organic products, this version of the machine is engineered to handle and place glass jars into tray and hood secondary packaging.

Any machine parts that come into contact with product are constructed of plastic to protect glass jars and reduce the risk of downtime. The Elematic’s wraparound technology ensures jars are gently but tightly packed, which minimises the risk of product damage during transport.

It can handle a range of jar sizes, including 250, 400, 500 and 750 g jars.The case packer can be adjusted to match the preceding filling machine’s speed without affecting efficiency

on the production line. Jars are transported from the filling machine to the Elematic via two lanes, with each lane carrying up to 95 jars per minute. A special grouping system includes an accumulation area to help regulate delivery of product to the machine and ensure consistent product flow.

Combining a packaging tray with lid and a full wraparound system, the Elematic’s modular design enables the operator to quickly switch between the two formats, speeding up changeovers. A transparent design means operators can quickly identify issues if they arise. All parts of the machine are reachable, making repair work easier. In addition, the MIS (maintenance information system) alerts the operator to pending maintenance jobs.

Nupac Industries Pty Ltd


PA

CK

AG

ING

http://www.tronics.com.au


September 2012 total CAB audited circulation (Aust + NZ): 5889 readers (90% personally requested)

Printed and bound by Webstar +61 2 9748 0020Print Post Approved PP247345/00010ISSN No. 1039-8414

NOTICE:All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.

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

Head Office

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

Chief Editor: Janette Woodhouse [email protected]

Publisher: Geoff Hird

Art Director/Production Manager: Julie Wright

Art/Production: Tanya Scarselletti, Colleen Sam, Jeanette Teuma

Packaging Section Editor: Alice Richard

Assistant Editor: Alice Richard

Circulation Manager: Sue Lavery [email protected]

Copy Control: Mitchie Mullins [email protected]

Advertising Sales

NSW, QLD - Kerrie Robinson Ph: 0400 886 311 [email protected]

VIC, SA, WA - Sandra Romanin Ph: 0414 558 464 [email protected]

NZ - Gemma Burr Ph: 0800 44 2529 Fax: +61 2 9489 1265 [email protected]

USA - Huson International Media East Coast Ph: +1 212 268 3344 West Coast Ph: +1 408 879 6666 [email protected]

UK - Huson International Media Ph: +44 1932 56 4999 [email protected]

Germany, Austria, Switzerland - Eisenacher Medien Ph: +49 228 249860 [email protected]

Asia - Lachlan Rainey Ph: +61 (0) 402 157 167 [email protected]

If you have any queries regarding our privacy policy please email [email protected]

Subscriptions for unregistered readers - price on application

Earthbound Farm automates clamshell packaging with ClamPACEarthbound Farm is America’s largest grower, packer and shipper of organic produce and is widely regarded as an innovative industry leader.

When looking to change its clamshell packaging presentation to a more environmentally friendly version, Earthbound also decided to automate its clamshell case packing operation, which had previously been manual. The system needed to be gentle enough to handle its new packaging format while increasing efficiency.

In April 2012, the company installed four Adept ClamPAC robotic systems from Adept Technology to case pack clamshells.

“We explored several suppliers offering robotic systems. Adept was the only one we found that had a product that could withstand our rigorous sanitation routine,” said Joe Torquato, Director of Engineering at Earthbound Farm. “Our new robotic packaging systems improve the consistency of our throughput, which helps position us for continued growth.

“The technology is gentle and accurate; it reduces product damage and enhances the presentation of our clamshells in the case,” Torquato said. “It helps improve our work environment by eliminating a highly repetitive task.”

Adept says the ClamPAC is the first fully integrated robotic solution in the world to be pre-engineered to case pack clamshells. Adept’s packaging solutions group modifies each standardised modular system to specific client needs before delivery. The company says this reduces the client’s total cost of ownership by minimising integration complexity and deployment time while providing the flexibility, dexterity and speed of a world-class robotic solution.

“Food processors like to find a single source supplier that handles the entire process,” said Torquato. “Adept took on that accountability.

“They handled everything including our empty boxes. They learned all our SKUs and became very intimate with our process. They set the systems up to handle our clamshells and each case packing configuration. They integrated their systems with our plant control network so we can control the operation remotely and gather data for reporting purposes. The integration went very smoothly.”

Torquato says the ClamPAC handles the clamshells more gently than the labourers ever did and much more gently than Earthbound’s old drop door case packers. The new clamshell lids are sonically welded to the tub and feature an easy-open perforation. The ClamPAC is gentle enough to lift the clamshell by its lid and not break the easy-open perforation.

This is due, in part, to the machine’s SoftPIC grippers. The grippers are selected specifically to suit each client’s product range and are made of soft silicon that conforms to the shape of the clamshell and provides a direct vacuum path to the product.

“The ClamPAC systems nest the flanges of the clamshells during case packing. This keeps the clamshells in a better position so they are less prone to damage during transportation. It also allows us to put the same number of clamshells into a smaller box, which reduces packaging materials,” explained Torquato.

The first four ClamPAC systems at Earthbound Farm are case packing 5 oz clamshells filled with an assortment of washed lettuces into six- and eight-count cases.

“The Adept ClamPAC systems have been very successful,” concluded Torquato. “We wanted an integrated, turnkey system that would be easy to start up. We wanted the systems to be easy for our technicians to operate. And we wanted to achieve significant speeds and experience exceptional uptime. The Adept systems have delivered.”

Adept Technology International Ltd


PA

CK

AG

ING

List (A) Job Function

1 Management - Corporate/General2 Management - Manufacturing/ Engineering/Specialist3 Engineer - Electrical4 Engineer - Electronics5 Engineer - Process6 Engineer - Project7 Purchasing/Procurement8 Technician - Maintenance/Service9 Technician - IT10 Technical Officer11 Scientific Officer - R&D12 Scientific Officer - QA13 Consultant14 Contractor/Tradesperson15 OHS/EHS16 Education/Training17 Student-Undergraduate/Apprentice18 Analyst19 Sales/Marketing

List (B) Industry

1 Agriculture/Rural 2 Building/Construction 3 Chemicals/Allied Products 4 Communications Systems 5 Defence/Military 6 Education 7 Emergency Services/Law Enforcement/Security 8 Engineering Services 9 Environmental Services 10 Finance/Banking/Insurance/Legal 11 Food Industry - Bakery12 Food Industry - Beverages13 Food Industry - Confectionery14 Food Industry - Dairy15 Food Industry - Fruit & Vegetables16 Food Industry - Meat 17 Government - Federal18 Government - State19 Government - Local20 Health/Hospital 21 Instrumentalities (eg CSIRO) 22 IT - Networking23 IT - Security24 IT - Storage25 IT - Wireless26 Laboratory - Analytical27 Laboratory - Clinical/Medical28 Laboratory - Life Sciences29 Logistics/Transport/Warehouse 30 Manufacturing 31 Mining32 Oil/Gas/Coal33 Packaging34 Processing35 Retail/Wholesale/Hire36 Service/Maintenance37 Telecommunication38 Testing/Certification (eg NATA)39 Utilities

FILLER FOR PALLET JACK BAG REMOVALLow profile version of patented TWIN-CENTREPOST™ filler allows removal of filled bags using a pallet jack, eliminating the need for a forklift or roller conveyor. Low cost standard models offered with many performance options.

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

FILLERS WITH AUTOMATED FEEDING SYSTEMSEvery Flexicon filler is offered with pneumatic (shown) or mechanical (bottom right) feeding/weighingsystems, as well as inlet adapters

to interface with optional overhead storage vessels.

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

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

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

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

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

Z-1085

Fill one bulk bag per week or 20 per hourat the lowest cost per bag

Flexicon’s extra-broad model range, patented innovations and performance enhancements let you exact-match a filler to your specific cost and capacity requirements

[email protected]

1 300 FLEXICON

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

©2011 Flexicon Corporation. Flexicon Corporation has registrations and pending applications for the trademark FLEXICON throughout the world.

USAUK

SOUTH AFRICACHILE

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

Z-1085 FillOneBulk_Z-1021 10/11/11 2:00 PM Page 1

http://www.flexicon.com.au

What’s New in Food Technology Nov/Dec 2012

Documents

Transcript of What’s New in Food Technology Nov/Dec 2012