- THE MAGAZINE
From casings, packaging equipment, wastewater systems and food safety solutions to slicers, dicers and cutters, IPPE 2014 showcased everything one would need to safely and efficiently operate a meat or poultry plant.
However, you didn’t need to see the equipment up close and personal to experience the chilling temperatures. You just had to step outside. That's because this year's IPPE, which took place Jan. 29-31 in Atlanta, coincided with one of the nation's most interesting storms.
Yes, snow in Atlanta, and enough snow to shut down the town, cancel flights and prevent from even the coffee kiosks from opening for the 24,000 attendees and 1,148 exhibitors. Restaurants closed, cabs discontinued service and waiting for the MARTA train, forget it. You might as well stand in your cold storage unit without a coat on.
Yet, the show must go on, and despite the outside elements, that’s exactly what happened. The show continued on.
“It speaks to the strength of integrating these three shows together that attendance held up so well in spite of the inclement weather,” says the trade associations in charge of the show—the International Feed Expo (IFE) and American Meat Institute’s (AMI) International Meat Expo (IME).
The “largest-ever” education slate complemented the exhibits by keeping industry management informed on current issues and events. This year’s educational lineup featured 16 programs, ranging from a conference on ground poultry pathogen reduction to antibiotic use in the meat and poultry industry to a program on how to export feed and feed ingredients to the United States.
The College Student Career Program attracted approximately 500 students from 30 universities throughout the United States, while the new International Student Career Program brought in 24 students from 14 universities. The graduating students interviewed for jobs and internships with 93 human resource representatives from 28 industry and allied firms. They were also able to visit the exhibit floor to see the most current technology used in today's industry.
Other featured events included the International Poultry Scientific Forum, VIV International Pork Production Summit, Tech XChange program, Meat Me in @LANTA activities and publisher-sponsored programs, all of which made the 2014 IPPE the premiere annual protein and feed event of the western hemisphere.
In case you couldn’t make it to the show, or did but were stuck at your hotel, here’s a rundown of some of the latest innovations in equipment, supplies and services introduced and showcased at IPPE 2014.
Metal Detector/Separator for Liquids, Pasty Foods
Bunting Magnetics Co., Newton, Kan., debuted the latest in magnetic separation and metal detection.
The Bunting meatLINE is a metal detector/separator that examines liquids and pasty foods when integrated into vacuum fillers.
Features include an optional extension axle for twist-off gear, easy and fast operation through touch-screen display with self-explanatory menu structure and a reject mechanism that can easily be disassembled and cleaned without the need for tools. All reject components are secured with a loss prevention device.
The meatLINE operates even in case of pronounced product effect thanks to a powerful signal processor with a large dynamic range and precise product effect filtering. All components are made of stainless steel or food-safe plastic.
Bunting Magnetics Co.
Bottom-Injection Systems for Chilled Proteins
Linde, LLC, Murray Hill, N.J., featured its ACCU-CHILL bottom-injection systems for ground meat, poultry and seafood.
This patented bottom-injection (BI) chilling system chills proteins from the bottom of mixers/blenders with cryogenic efficiency. Temperature can be controlled within 1°F, helping to ensure consistent product quality and repeatable mixing and forming operations.
The chilling system can use either liquid carbon dioxide or liquid nitrogen, utilizing most of the refrigeration, so it is immediately available to the chilling process. The ACCU-CHILL BI system can be retrofit to existing mixers, or designed and installed as a customized chilling system when upgrading to new mixing or grinding equipment.
Linde North America
Micro Breader, Washdown Weigher, Cooking Oil Filter and Metal Detector
Apply all styles of breading in less space with Heat and Control’s new Micro Breader. Just 90 inches long, the Micro Breader uniformly applies all styles of pre-dust, crumb and flake coatings to poultry, meat, vegetables and other foods. Standard features include automatic belt tensioning that increases conveyor belt life; top coverage and breading bed density are independently adjustable; and interchangeable top hoppers and large clean-outs permit fast changeovers between free-flowing and non-free-flowing coatings. The Micro Breader can be retrofit to be a part of a complete batter-bread-fry line, including conveying, weighing and inspection equipment.
The Hayward, Calif.-based equipment manufacturer also displayed its Ishida RV weigher. Built for IP69K washdowns, these weighers are said to be able to stand up to the most aggressive sanitation. They are self-draining and feature improved product feeders and electronics, making them 15% faster than previous models. Ishida’s Auto Setup feature speeds changeovers and reduces operator error, and it automatically recommends the optimal operating settings based on only five key product and performance parameters. Wireless access is available for Android tablet computers and Smartphones, and diagnostics can be performed by wire or wireless to reduce the need for in-plant service calls.
The Micron-Pro cooking oil filter has said to pay for itself in oil savings within the first year at plants producing meatballs, batter-breaded foods and other products. Using no paper, additives or consumable filter media, Micron-Pro can filter particles down to sub-micron size at rates up to 65 gallons per minute of hot oil. Fines are quickly removed from the oil and filter to minimize burning and free fatty acid formation. Up to 98% of the oil can be recovered from filtered particles, depending on debris type. Fines are automatically discharged from the filter with no operator intervention. Micron-Pro has minimal moving parts and requires no costly centrifuge, bellows or conveyorized screens. It was designed by Filtration Automation, Inc., Alverado, Texas.
Lastly, Heat and Control displayed its CEIA MS-21 Multi-Spectrum metal detectors, designed to eliminate the waste and delay of false rejects caused by product effect, yet maintain the highest level of sensitivity to all metal contaminants. Using what is said to be the world’s only multi-spectrum technology, the CEIA MS-21 offers exceptional inspection of high product effect foods such as fresh poultry parts, ground meat and non-homogeneous products such as multi-product meal kits. The MS-21 continuously tests and readjusts its detection characteristics to ensure maximum stability and performance. This process eliminates the need for periodic calibration and ends line arrest and product waste. Standard features include a single-button preview of detection settings, such as sensitivity level and estimated detection size of the three metal types.
Heat and Control, Inc.
Compact X-Ray, Checkweighing Systems
Tampa, Fla.-based METTLER TOLEDO launched the HI-Speed Beltweigh XS I69K checkweighing system, which features a larger, 15-inch dashboard-style control display and IP69K protection that makes it suitable for harsh washdown conditions. The 2-belt Beltweigh XS is compact and requires only 23 inches of line space, making it ideal for existing production lines where space is a premium. The integrated XC control is mounted to the front of the system with a low-profile user interface. This means the operator does not reach across the conveyor—keeping the operator and your products safer—and maintenance can be performed from one side of the machine. The XS controls are easy to learn and operate. The color touch-screen user interface guides the operator quickly through product set-up and changeovers to optimize uptime and simplify training. Password-protected access for operators and supervisors ensures the security and integrity of the product. The all-welded, stainless-steel frame means only four points of contact to the floor for ease of installation and inspection. The open design gives maintenance personnel clear access to the area below the machine, making cleanup fast and effective.
The METTLER TOLEDO HI-Speed CS3600 Caseweigher is an in-motion scale for weighing large packages such as boxes, cartons, cases, bags or sacks. Its design delivers accurate and repeatable weights, while a wide variety of accessories allow it to be tailored to specific application needs. The robust frame and conveyor construction withstands the impact of heavy packages, so the system is ideal for tough environments. Combining the CS3600 with the METTLER TOLEDO HI-Speed IND469 remote terminal gives the system a high degree of IP protection and hygiene. With the network-compatible stainless-steel IND469, METTLER TOLEDO provides an ideal weighing terminal for connection to a FreeWeigh.Net system. The flat surface and materials allow simple and thorough cleaning in line with EHEDG and NSF guidelines for use in hygienically sensitive environments.
The Safeline Pipeline PRO metal detector can increase productivity, improve the competitiveness of products, reduce overall costs and support compliance with food safety standards. Safeline’s advanced detection coil technology and digital signal processing combined with new enhanced filtering techniques delivers unparalleled levels of in-process detection sensitivity to all metal types, including ferrous, non-ferrous and normally difficult-to-identify non-magnetic stainless-steel. Pipeline metal detectors are able to detect non-spherical contaminants such as wire, swarf and slithers of metal. Advanced software provides exceptional levels of in-process stability that result in reliable, on-line performance and minimal product waste due to the elimination of false triggering. The Pipeline PRO operator interface utilizes Safeline’s PowerPhase software platform accessed via a full-color touch screen. The platform’s numerous operational benefits include high-security password-protected access, continuous condition monitoring, SMS/email messaging capability, continuous waterproof controls and a user access and detection log.
Mettler Toledo Safeline and Marlen International, Riverside, Mo., joined forces to develop a bone and metal contaminant detection and rejection system for the processed meat and poultry industry. The Opti PipeChek X-Ray inspection system unites the effectiveness of the Safeline PipeChek system’s inspection capability with the superior product handling capability of the Marlen Opti vacuum system. Unlike conventional belt-style x-ray systems, the Opti PipeChek system runs product through a closed pipeline, allowing full retention of both solids and liquids during the entire inspection process. The vacuum system pumps whole muscle products at rates of 12,000-32,000 pounds per hour and was designed specifically to meet the high-speed inspection needs of processors of boneless ground and trimmed meat and poultry products. During inspection, "purged" product is re-absorbed, resulting in a net yield recovery by weight of 1.5-3%. It also features a 6-inch full color touch-screen user interface and intuitive software.
Lastly, the METTLER TOLEDO Safeline PowerChek Plus X-ray inspection system was designed specifically to meet the product contamination inspection needs of volume producers of bulk and packaged food products. PowerChek Plus combines the highest protection levels of functionality and detection sensitivity with maximum system reliability and productive uptime. Allen Bradley controls ensure reliable performance and optional AMI and 3-A elevated sanitary specifications are also available. PowerChek Plus systems can also be fully customized to fit customers’ production lines and specific needs rather than requiring the customer to re-configure a production line or adjust needs to accommodate the equipment. Using low energy x-ray technology, PowerChek Plus inspection units reliably detect and reject many contaminants, including metal, stone, glass and bone. It features a 15-inch full-color touch-screen user interface and intuitive software.
Freezer Hygiene Innovations, Reduced-Emission Fryer
JBT FoodTech, Sandusky, Ohio, unveiled new freezer hygiene innovations designed to address the needs of the modern processor.
For example, its ground-breaking high-hygiene (HH) single-piece extruded evaporator coil delivers a high heat transfer rate, which saves valuable factory-floor space. With the removal of all crevices or overlapping surfaces, the patented HH coil eliminates harboring areas and complies with 3-A Sanitary Design standards.
Additionally, the Frigoscandia GC M10 Tight Curve spiral freezer offers a Hygiene-by-Design freezing solution for long run times and short turnaround time in a small footprint. The GC M10 TC comes with a fully seam-welded stainless-steel enclosure, a stronger FRIGoBELT and allows for an optional steam-in-freezer defrost and sanitation system. As an added feature, the GC M10 TC also utilizes a self-stacking and internal clean-in-place system to make cleaning the entire spiral freezer automatic. For added uptime, JBT FoodTech optimized the design of the freezer’s fan-driven air balance tunnel to minimize the amount of moisture entering the spiral through both openings and provides an optional robust solution for sequential defrost.
JBT FoodTech also introduced its new reduced-emission, high-performance Stein TFF-V THERMoFIN fryer, which features a new hygienic open-frame structure and a proprietary new integrated exhaust scrubber that greatly reduces oil mist and particulate matter in the fryer exhaust. A more saturated and uniform blanket of steam protects the oil during cooking while sediment handling and drainage is improved, all extending oil life. Faster conveyor speeds are available, allowing more throughput in the same space as prior models. The TFF-V fryer includes the new PRoLINK control system with touch screen, recipe-driven, web-enabled controls and automated event notices and reports from the fryer via email. The new interface design supports multiple languages and units of measurement.
Meanwhile, the patent-protected DSI LaneMaster portion harvester allows processors to reduce labor while improving yield and quality. The bolt-on modular design accurately harvests portions cut by a DSI portioning system. The harvester can pick up portions and place them onto the same conveyor where the product was scanned and cut, or place them in other locations.
Longer-Lasting Conveyor Belt
Cambridge Engineered Solutions, a Cambridge, Md.-based division of Cambridge International, unveiled DURAFLEX EDGE, what is said to be the next generation of open metal conveyor belting for poultry and food manufacturers. This patent-pending product features a revolutionary clinched edge design that has proven through rigorous testing to be the strongest and most durable belt on the market.
For example, the clinched style edge reduces breakage and damage while nearly eliminating all potential for metal hits and product contamination. The patent-pending ‘EDGE’ technology bends with a true hinge in both directions, eliminating friction and metal fatigue and ensuring proper tracking.
DURAFLEX EDGE also includes a 30-second splicing time to reduce maintenance and replacement time, and is easy to clean with increased carrying capacity and tighter transfer capability. And, it doesn’t compromise belt strength and handles heavier loads than typical light?duty conveyor belts.
Cambridge Engineered Solutions
Scales for Harsh Food Processing Environments
Gainco, Inc., Gainesville, Ga., introduced a newly expanded DuraWeigh line of scales, ideal for weighing meat, poultry and other foods in harsh food processing environments. The innovative scale design is improves calibration accuracy, is durable while reducing equipment downtime and simplifies sanitation and maintenance operations.
The suspended platform design features a free-floating chain and rod system to protect load cells from damage caused by the daily use of forklifts and pallet jacks. The low-profile, diamond-plate, skid-resistant ramp provides easy-on/easy-off weighing, with the ramp guides allowing for correct aligning on the weigh deck.
Developed for general weighing, portion control and manual batching, the load cell features tension and compression overload stops that dramatically reduce load cell failure. Fast weighing response prevents production bottlenecks and improves productivity.
The Gainco Infiniti weight indicator thrives in cold work environments, hot chemical washdowns and high pressure washing, thus removing the need for double boxing or bagging during washdowns.
The heavy-gauge, stainless-steel construction features continuous seam welds that stand up to the rigors of the meat and poultry processing environment. High-and-dry overhead wiring plus a double NEMA-4X stainless-steel enclosure provides better protection from moisture and chemicals during sanitation.
Gainco, Inc., a subsidiary of Bettcher Industries
Tamper-Evident Overcapping Machine
Fill-Tech Solutions, Largo, Fla., featured its new Fill-Star IL-31 tub filling and tamper-evident overcapping machine. Set up to run IPL’s new 4- and 5-pound in-mold labeled tamper-evident square containers, a tamper-evident security system securely locks the lid to the tub, protecting the product from undesirable openings.
This machine incorporates five Allen Bradley MPS series servo axis. Other features include a stainless-steel door design with over 8,000 precision laser-cut openings in the door and guarding panels, an 11-gauge stainless-steel skin with incorporated drain channels, custom NEMA 4X overhead electrical enclosures to enhance the machine’s washdown ability and servo motors for the main drive, filler actuation, fill nozzles, lid pick and place and the out-feed tub lift assembly.
This 3-lane machine produces an excess of 23,000 pounds per product per hour.
Fill-Tech Solutions, Inc.
IQF Fluidization Tunnel Freezer
The continuous 24/7 IQF fluidization tunnel freezer from Advanced Equipment, Inc., Canada, pumps out 60,000 pounds of blueberries or 75,000 pounds of green peas an hour. This tunnel freezer, which stands at is 180 feet long x 19 feet wide, operates 24/7 for 14 days non-stop.
This tunnel freezer also features an automatic sequential defrosting mechanism with hot gas re-claiming recycled water.
Advanced Equipment, Inc.
Tunnel Freezing System
Praxair, Inc., Danbury, Conn., debuted its newest tunnel freezing system, the Praxair ColdFront Cryo-Saver Tunnel Freezer.
This new tunnel freezer system employs advanced technologies that expand the ability of processors to freeze more economically in the same footprint of a traditional cryogenic tunnel system.
The Cryo-Saver Tunnel Freezer’s entrance and exit are uniquely positioned to decrease the infiltration of room air into the freezer, which is said to result in up to 15% savings in customer operating costs, depending upon the production parameters. The freezer enclosure is also designed to meet new USDA sanitation standards and make cleanup quick and thorough, allowing the production facility to more easily maintain in-house sanitary equipment standards.
Advanced Liquid-Solid Separator
Lyco Manufacturing Inc., Columbus, Wis., introduced a Micro Drum Screen, which is an advanced liquid-solid separator.
The unique drum design allows for quick interchange of screen or mesh, and the stainless-steel construction reduces maintenance. Integrated controls allow for automated clean-in-place and motorized traveling spray adjustment. Additionally, a fine mesh screen material allows for collection of fine particles.
This screen is said to produce savings of more than 30% on sludge removal and handling and provides savings on dissolved air flotation (DAF) and municipal costs.
Lyco Manufacturing Inc.
France-based LIMA developed the new RM 900 DSP deboner, which allows reduction in the calcium level in separated pork meat while keeping an optimum yield.
This model can process up to 5.000 kilograms per hour of pork back and neck bones without any pre-crushing.
Other features include simple yield adjustment, short downtime for cleaning, no extra pre-breaking, low temperature increase and a small footprint.