Over the past four years, PROCESS EXPO has grown total attendance by an unprecedented 198%. This year, the show surpassed 300,000 net square feet in exhibit space and over 1,000 exhibitors, and continues to evolve as the nation’s leading tradeshow event for the global food and beverage equipment industry.
The Food Processing Suppliers Association (FPSA), McLean, Va., presented 2015 PROCESS EXPO, which took place Sept. 15-18 at Chicago’s McCormick Place. This global food equipment and technology show, which covered bakery, snacks, dairy, beverage, prepared foods, meat, poultry and seafood sectors, co-located with the International Dairy Show, presented by the International Dairy Foods Association (IDFA), Washington, D.C., and InterBev Process 2015, presented by NürnbergMesse, Germany.
Here’s a rundown of what new equipment, systems and solutions made their debut at this year’s Process Expo and International Dairy Show.
FOOD INDUSTRY TECHNICIANS DEVELOPMENT PROGRAM
The Food Processing Education Consortium (FPEC) created the Food Industry Technicians Development Program (FIT), what is said to be the first national certification program for service technicians in all segments of the packaging, processing and food and beverage manufacturing industry.
In the United States, there are currently 3.5 million unfilled middle-skill jobs that do not require a 4-year degree and make up the largest part of the labor market in the country. The FIT Program addresses this great need for trained service technicians that food manufacturers can hire.
The FPEC was created in August 2014 by the Foundation of the Food Processing Supplier Association, McLean, Va., with the goal of creating, developing and implementing a career path for technicians in all segments of the processing, packaging and food and beverage industries.
During the past year, the FPEC Board has been collaborating with ITT Technical Institute to create a curriculum of core courses that meet the needs of the food and beverage industry. Through a combination of new courses and existing courses that ITT currently offers, students will be able to graduate with the academic knowledge to meet the specific challenges that technicians experience in these industries.
CLICK HERE for additional information on this program.
GLOBAL FOOD SAFETY COMPLIANCE INITIATIVE
Nexcor Technologies, Buford, Ga., and Russell Associates, the Le Sueur, Minn., owner of intRAtrain training, testing, inspections and management systems solutions, created the Global Food Safety Compliance Initiative (GFSCI), designed to help food manufacturers achieve regulatory compliance, increase efficiency and bridge gaps while reducing operating costs and ensuring food safety, employee safety and customer satisfaction.
GFSCI includes compliance-related solutions designed to assist manufacturers with issues related to food safety, employee safety, maintenance, quality, sanitation, employee training, pest management and more. These solutions are delivered via a variety of tools, including:
- Kleanz, a food safety compliance and sanitation management tool designed to provide real-time information in one place. It also includes a mobile option.
- inspectiTRAC, an automated software and management system designed to automate and mobilize the collection and management of inspections, audits and observations.
- CAMS, a solution designed to help improve equipment maintenance management, while extending asset life and reducing parts inventories.
- intRAtrain, training solutions designed to improve effectiveness of learning and efficiency of training via custom, customize and off-the-shelf solutions and corresponding training management systems.
- Kleanz IPM integrated pest management, a complete monitoring solution designed to manage the ongoing process related to mitigating pest risks.
FOOD SAFETY INSPECTION EQUIPMENT
METTLER TOLEDO, Tampa, Fla., exhibited a variety of checkweighing, metal detection and s-ray inspection equipment.
Metal detection systems included gravity flow and pipeline inspection systems as well as METTLER TOLEDO’s unique Profile Advantage system, which employs multi-simultaneous frequency technology to minimize false rejects.
Checkweighing systems included the C2325 large package checkweigher and the C3572 system, which includes production monitoring technology to maximize productivity and extreme washdown conditions protection.
METTLER TOLEDO also hosted an educational center featuring experts from BRC, SQF, IFS and FSSC22000 to address a wide range of other food safety topics, including sanitary equipment design, label mix-up detection and prevention, product traceability and overall inspection system connectivity. Other presentations covered maximizing OEE in food processing operations, improving metal detection in challengingapplications and using x-ray inspection as a Critical Control Point (CCP).
The new DynaClean Vertical Z conveyor from Dynamic Conveyor, Muskegon, Mich., is an ideal solution for food processing facilities that have a need to move product to higher elevations.
Designed for ease of cleaning and sanitizing, the patented DynaClean Vertical Z is custom designed and features a variety of belt styles, including solid-surface ThermoDrive and plastic link style belting. Drive flight options include standard 75-degree and scoop flights and are selected based on product and desired throughput.
This conveyor accepts product from a vibratory feeder, can be placed as a stand-alone or attached to hoppers for bulk product feeding.
DynaClean conveyors are constructed of plastic and stainless-steel materials that meet NSF, FDA, USDA and BISCC standards.
Dynamic Conveyor Corp.
ROTARY LOBE PUMP
NETZSCH Pumps North America, Exton, Pa., highlighted its new TORNADO T2 industrial rotary lobe pump, a self-priming, valve-less, positive displacement pump that meets most process and application requirements.
Ideal for any kind of liquid, including media containing gas, solids or fibrous matter, the revolutionary design has been reengineered to maximize uptime, and features metal lobes running inside a metal housing with an elastomer liner. Only elastomer and metal component surfaces interface within the pump during the entire pumping cycle, thus eliminating the excess wear and heat generated from elastomer-to-elastomer contact found in traditional rotary lobe pumps.
The torsional strength and deflection-resistant shaft material combined with sealed-for-life, angular contact ball bearings ensure axial and radial shaft stability. This world-class stability maintains tolerances and stabilizes the pump against higher pressures.
The pump’s innovative design provides for full service in place, improving access for inspection, cleaning, service and replacing parts. Simply removing the cover plate on the TORNADO T2 allows quick and easy access to the pump chamber.
NETZSCH Pumps North America, LLC
HIGH-SENSITIVITY INSPECTION SYSTEMS
Anritsu Industrial Solutions USA Inc., Elk Grove Village, Ill., unveiled its new XR75 inspection systems.
The precision-engineered, high-sensitivity XR75 series can not only find foreign materials other systems may miss, but can also pinpoint product shape defects and check for product integrity.
The XR75 inspection system is said to provide excellent sensitivity at lower energy levels for extended life cycles. XR75 incorporates Anritsu’s all new technology for critical system components—long life and low power components, including an x-ray tube/generator and detector. The system also entails an improved sanitary design with angled surfaces for water run-off, removable curtains for easy cleaning and the company’s signature tool-less belt removal.
Anritsu also showcased many of its other advanced inspection and detection systems, including:
- High-definition (HD) and UltraHD technologies that detect the smallest contaminants in packaged products while also offering dual line inspection, mass measurement and the discovery of packaging anomalies and any underweight conditions.
- DualX x-ray technologies that analyze two different x-ray signals at once, allowing manufacturers to better distinguish between product and contaminant.
- Dual Wave metal detectors that simultaneously run two independent frequencies for optimized detection of both ferrous and non-ferrous metals.
- New proprietary process called Detection360, a 4-phase program that determines the proper points of detection and inspection within each customer’s processing environment. The four phases include discovery, mapping, integration and performance.
USDA-COMPLIANT DRUM MOTOR
Interroll, Wilmington, N.C., introduced the FDA-approved, USDA-compliant asynchronous drum motor (models 113i, 138i, 165i and 217i) for wet and high pressure washdown situations.
This drum motor is compact, easy to install and can be cleaned and disinfected regularly using high-pressure water, steam and chemicals.
Key features include:
- Configured to drive all modular belting applications.
- Complies with Part 21 CFR for US Dairy Equipment Guidelines.
- FDA-rated Vulcanized lagging.
- Leak escape feature in shaft.
- Surface finish less than 30 micro-inches on shell and shafts.
HEAT-SEALABLE TRAY LIDDING FILM
KM Packaging Services unveiled a range of heat-sealable tray lidding films, designed to extend shelf life and prevent food leakage or spoilage.
Products include multi/universal sealing films with anti-fog, high-barrier ovenable films for long shelf life, high-performance anti-fog films for foil trays and Superguard oven thermoform films.
KM’s films meet FDA and CFIA requirements for use in food packaging applications.
KM Packaging Services Ltd.
+44 (0) 1832 274944
SANITARY CENTRIFUGAL PUMP
SPX, Charlotte, N.C., offered a vast range of food processing solutions, including heat exchangers, homogenizers, pumps, valves, dryers, evaporators and separators, designed to increase process efficiency and assure the highest sanitary standards.
Examples include the APV Cavitator, which provides breakthrough performance in scale-free heating and microscopic mixing of liquids, and the latest EcoPure pump, a sanitary centrifugal pump that increases pumping efficiency through the use of high-powered drive magnets and efficient impeller design.
X-RAY INSPECTION & FAT MEASUREMENT TECHNOLOGIES
Eagle Product Inspection, Tampa, Fla., launched three new x-ray inspection and fat measurement technologies, designed to ensure product quality, provide thorough inspection and identify and remove hazardous physical contaminants such as calcified bone fragments, small glass shards, mineral stone, rubber, dense plastics and metal filings.
The newest addition to the FA3 fat analysis platform is the Eagle FA3/M, which meets the needs of manufacturers requiring multiple applications, ranging from fresh, hot-boned, chilled and frozen in loose bulk or carton and crate formats. The machine’s dual energy x-ray absorptiometry (DEXA) technology discriminates between fat and lean portions 100% of the products. Throughput is further enhanced by Eagle’s proprietary inspection software, which enables the FA3/M to inspect up to 2,400 plastic crates or frozen blocks per hour or up to 35 tons of bulk meat per hour. Recalibration of the FA3/M is simply achieved with the touch of a button with AUTOCAL, and is complete in approximately one minute.
This automatic calibration eliminates the need for handling bulky, unsanitary and potentially unsafe phantom blocks on the factory floor. Another unique feature is VALIDATE, which validates calibration and records the result in a secure electronic log. The FA3/M also allows processors to job change easily and seamlessly using PRODUCT SWITCH, which means products with different inspection requirements can run on the same line by simply scanning a barcode.
Also new is the Eagle Pipeline, an x-ray inspection system designed to create a wall of defense against physical contamination in pumped products, such as liquids, solids, slurries and even whole muscle meat, inspected prior to further processing and packaging. The Eagle Pipeline enables thorough inspection and eliminates the challenge of inspecting different densities that can occur when dealing with a round pipe. To reduce product waste while maintaining product flow, the system has the option of a ball valve reject or a unique blade reject valve designed for muscle product that removes only the contaminated area. The pipeline is available in 2.5-, 3-, 4- or 6-inch diameters.
For manufacturers of bulk foods other than meat products, Eagle launched the Eagle Bulk 540 PRO x-ray inspection system to provide accurate inspection of high-volume dry and wet loose foods such as nuts, grains, sugar, cereals and fresh and frozen fruits and vegetables. Product depth is more uniform across the belt due to the innovative cupped conveyor with raised edges that simultaneously reduces product spillage and limits wasted product. The Eagle Bulk 540 PRO’s 8-lane flap rejection mechanism, each covering one-eighth of the belt, meets rigorous hygienic standards. Hinged louvers and easy belt removal allow a single operator to disassemble the entire machine in a matter of minutes for thorough sanitation and quick reassembly.
Eagle Product Inspection
FEEDERS, SEPARATORS, BIN VIBRATORS, METAL DETECTORS
Hi-Vi electromagnetic bin vibrators from Eriez, Erie, Pa., feature 12 AC drive units that improve the flow of hard-to-handle materials deposited into bins, hoppers and chutes. These bin vibrators boast a patented enclosed magnetic drive, and applies a superior action to bin walls.The rugged 70U is the largest double impact-type vibrator, built for heavy-duty applications and up to 60-ton bin capacity. It’s ideally suited for use on large hoppers and bunkers that are constructed of heavy plate. The 60U model also operates on the “double impact” principle, producing 7,200 vibrations per minute from a 60-cycle power supply. It provides a “cushioned” impact and is ideally suited to handle sticky materials as well as fine clinging type materials up to a 30-ton bin capacity. Another model is the D55P-D55S, a heavy-duty impact model in the medium-size range with bin capacity up to 18 tons, making it an ideal fit for more difficult material moving jobs with temperatures up to 300°F.
The Model FF metal separators are designed for inspection of free-falling products, detecting all metal contamination—magnetic and non-magnetic—even when enclosed in the product. Metal contaminants, including steel, aluminum, brass and stainless steel, are rejected through the separator’s “Quick Flap” reject unit. Model FF metal separators also inspect outgoing goods, granulate, reclaim, bagging stations, dryers and packing stations. The Model FF metal separator fits easily into existing pipeline systems, and offers an array of features such as separate detection and reject unit, adjustable free fall height, pre-installed parameters for simplified operation and more.
The Eriez ProGrade line of magnetic separators includes plates, grates, traps, tubes, pneumatic magnets, suspended permanent and electro magnets, hand-held inspection magnets and magnetic pull test inspection kits. ProGrade magnetic separators come in three magnetic power levels—ceramic, rare Earth and Xtreme rare Earth.
Also new to the portfolio is the Xtreme metal detector enhanced platform (EP), which is recommended for the harshest applications. Made for light industry applications, including chemical, food processing, packaging, textiles, pharmaceuticals, tobacco, plastics and rubber, the Xtreme metal detector EP boasts a re-designed and user-friendly interface that is ETL/CSA/CE approved and certified for the harshest of washdown environments. Other highlights include easy setup, dedicated reject log and event log. Plus, multiple Xtreme metal detectors can be remotely monitored with Eriez’ 24/7 remote service platform.
Lastly, Eriez’ Xtreme liquid line metal detectors are used to detect the presence of ferrous, non-ferrous and stainless metal contaminants in viscous products such as liquids, slurries, syrups, pastes and other pumped materials. The Xtreme liquid line metal detectors can protect vital downstream equipment from metal in the product stream, thereby reducing machinery downtime and maintenance costs. When metal is detected in the product flow, a signal is sent to one of the available output relays. The output relay can be used to activate a ball valve, control a visual or audio alarm, stop the product flow or send a signal to a PLC. Complete systems can be provided in pipe sizes ranging from 1- to 4-inch diameter.
FOOD PROCESSING, SECONDARY PROCESSING EQUIPMEHNT
Chicago-based JBT Corp., Sandusky, Ohio, showcased a line of equipment for secondary processing, including brine preparation, injection, macerating and massaging, as well as equipment further down the line, such as coating, cooking, frying and freezing.
For case-ready meats, JBT constructed a line that features the Frigoscandia ADVANTEC impingement freezer, the TVI GMS 500 single-cut slicer and the DSI 844 waterjet portioning system, along with the Wolf-tec Polar Massager 2500 and Flex Carve Macerator and IMAX 620 walking beam injector.
JBT’s food and beverage division was on hand showcasing the Fresh ‘n Squeeze multi-fruit juicer, along with a vast line of filling, seaming and sterilization systems and the JayBoT automatic guided vehicle.
BLOW MOLDING MACHINES
Serac, Inc., Carol Stream, Ill., debuted two new blow molding technologies.
The Combox H2F system is the company’s SBL blow molder coupled with the H2F filler to create an integrated monoblock blow molder, filler, capper solution going from pre-form to bottle and then directly to machine filling and capping on the same machine. The 100% positive neck transfer system patented by Serac ensures that packages move along through the process without ever touching each other.
Also, the Agami vertical thermoforming blow molding machine transforms a plastic roll into bottles. The Agami machine uses an innovative tubular thermoforming technology to produce bottles from plastic rolls. The machine was originally designed for the production of yogurts in thermoformed cups. Today, the plastic rolls can also be used for producing cups or bottles, allowing manufacturers to take advantage of a single supply source. Inspired by the conventional flat thermoforming technology, the bottles are not limited to large necks and small heights, and can be made into a round design.
Beckhoff Automation, Savage, Minn., introduced the CX8091 as a new member of the CX8000 line of embedded PCs. With support of the OPC UA protocol, a 400 MHz ARM9 CPU and a wide range of connectable K-bus or E-bus I/O terminals, this embedded PC represents a universal small controller for a wide range of applications. In addition, the CX8091 is fully interoperable with power measuring terminals to serve as a compact data collector that supplies all information via OPC UA, enabling comprehensive energy management.
Beckhoff also debuted the CP32xx series of multi-touch panel PCs with multi-core power. Featuring industrial multi-touch display technology, this PC can be used in an all-in-one, high-performance automation device for HMI and control applications. The area at the rear, which is required for swiveling and tilting the connected mounting arm, is also used to accommodate the added IPC components while saving space. Another advantage is the excellent heat dissipation characteristics achieved using internal fans; this ensures even temperature distribution to all walls of the housing. This results in an operating temperature range from 0- 45°C.
EtherCAT plug-in modules offer a highly efficient I/O solution to implement platform concepts in large-scale machine production. The circuit board is an application-specific signal distribution board that transmits signals and power to individual application-specific plug connectors to connect the controller to machine modules as required. Simple, prefabricated “plug and work” cable harnesses replace often time-consuming manual wiring processes common in control cabinet construction.
Beckhoff Automation LLC
VIBRATORY CONVEYORS, FEEDERS
Meyer Industries, Inc., San Antonio, Texas, introduced new enhanced sanitary machines.
The Meyer VFII line of vibratory conveyors offers a sanitary and low-maintenance conveying solution. Available with adjustable drives and interchangeable inserts make it ideal for a variety of conveying applications, including spreading, aligning and dewatering.
The Magna Weigh is a vibratory weighing feeder line that offers truly sanitary design in continuous weighing applications. These machines can be supplied for weight control or weight monitoring, and have the ability to compensate automatically for variations in the bulk densities of products.
The sanitary design features of the sanitary belt conveyor meet the increasing needs for enhanced sanitary design in the industry. These machines are accessible for cleaning compared with more conventional designs.
The Simplex bucket elevator packaging scale feed system is designed to gently transport a wide range of free-flowing food products both horizontally and vertically. Various configurations and multiple discharge points add flexibility.
Meyer Industries, Inc.