“Meat” new people, “hatch” new ideas—that was the mantra of this year’s IPPE show.
The International Production & Processing Expo (IPPE) is said to be the world’s largest annual meat, poultry and feed industry event of its kind, and this year, it brought together more than 1,301 exhibitors, over 30,000 attendees and spanned more than 464,750 net square feet of exhibit space at the Georgia World Congress Center in Atlanta Jan. 26-28.
“This year’s tremendous exhibitor and attendance numbers are a tribute to IPPE’s unparalleled education sessions, abundant networking opportunities and distinctive exhibits. The enthusiasm and energy displayed by this year’s attendees and exhibitors will only ensure the success and growth of future IPPEs,” according to the three organizations that make up IPPE—the U.S. Poultry & Egg Association (USPOULTRY), Tucker, Ga.; American Feed Industry Association (AFIA), Arlington, Va.; and the North American Meat Institute (NAMI), Washington, D.C.
Exhibitors demonstrated the most current innovations in equipment, supplies and services used by industry firms in the production and processing of meat, poultry, eggs and feed products—from live production and processing to further processing and packaging.
The wide variety of educational programs complemented the exhibits by keeping industry management apprised on the latest issues and events. This year’s educational lineup featured 25 programs, ranging from a conference on challenges and opportunities in meat product traceability to a technical seminar on maximizing the efficiency of the poultry industry conducted entirely in Spanish, among others.
Here is a rundown of some of the latest innovations in equipment, supplies and services introduced and showcased at IPPE 2016.
CO2 & CRYOGENIC EQUIPMENT
Linde LLC, a Murray Hill, N.J.-based subsidiary of Linde North America, Inc., showcased its team of advanced proprietary cryogenic freezers and carbon dioxide (CO2) snow chilling solutions designed to replace dry ice pellets.
For example, the DRI PACK box chilling system and other automated solutions fill boxes with CO2 snow as they move along a conveyor. The ACCU-CHILL combo chiller automates loading and chilling cut poultry in combo bins. And, Linde CO2 snow horns and snow generators are engineered to efficiently chill with CO2 snow.
Meanwhile, the CRYOLINE CW (CRYOWAVE) IQF freezer uses a patented rolling-wave action on the conveyor belt to keep items separate as they are individually quick frozen (IQF). And, the Linde impingement freezer is said to freeze about 30% more than a standard tunnel freezer of similar length thanks to a proprietary process that uses high-velocity liquid nitrogen.
Linde also offers advanced ACCU-CHILL bottom-injection systems that can now chill from the bottom of mixers using liquid nitrogen.
The Linde Group
INTERNET OF THINGS SOLUTION PLANT-WIDE
Worximity Technology Inc., Canada, developed the Smart Factory, which is equipped with Tileboard smart sensors that executes Internet of Things (IoT) by connecting all of the facility’s machines, systems and software and analyzing productivity, downtime, yield, over-production and overall equipment effectiveness in real-time.
The Tileboard application lets users create smart forms, and the live dashboard features a slideshow mode, which can be used to display a plant’s performance indicators to its employees.
Worximity Technology Inc.
FLEX-STYLE METAL CONVEYOR BELT
Cambridge Engineered Solutions, Cambridge, Md., introduced DuraHinge Safety Edge, a new state-of-the-art, flex-style metal conveyor belt.
Fabricated with reinforced edge technology to prevent snagging, DuraHinge Safety Edge improves employee safety and food handling sanitation in processing environments, particularly those in the meat and poultry industries.
The belt, a new and improved model of Cambridge’s DuraHinge line, boasts a fully secured edge that allows for tight transfers in the plant. Each end loop sweeps back around to the adjacent end loop to prevent catching while maintaining enough openness for easy splicing.
Cambridge Engineered Solutions
PROPRIETARY MEAT MIXER COOLING TECHNOLOGY
Praxair, Danbury, Conn., developed a proprietary liquid nitrogen injection technology that is said to be on par with CO2 meat mixing technology in every aspect, including cryogen efficiency.
The new CryoBlend injection system for meat and poultry mixing allows the use of liquid nitrogen in place of liquid carbon dioxide, and can improve cryogen efficiency by more than 30% vs traditional nitrogen cooling systems.
Mixers with CO2 injection systems can be retrofitted with a new liquid nitrogen injection system.
FOOTWEAR HYGIENE SYSTEM
The new XFA footwear hygiene system from Meritech, Golden, Colo., features a fully automated walk-through sanitizing pan for any type of footwear.
Ideal for use in entrance areas of warehouses and production facilities, this system is easy to install, clean and operate, ensures effective sanitizer time and boasts 3-minute fill and prime. Plus, it automatically recharges every 10 minutes, maintaining PPM levels.
ROBUST X-RAY SYSTEMS
Sesotec, Bartlett, Ill., introduced Raycon W x-ray, designed for arduous applications. Using faster image processing and multiple concurrent detection algorithms, the Raycon identifies agglomerated, deformed, broken and missing items, even in metallic packaging. This machine uses the latest long-life x-ray tube and proprietary real-time software running for reliability and ease of use. The unique configuration with the x-ray source under the conveyor, called “bottom-up shoot,” rather than over the top, provides full product width inspection, even for tall products. New control and image processing software simultaneously inspects up to four product lines running in parallel at up to 600 items per minute with different products being inspected in each lane. An icon-based user interface on a 10-inch LCD touch-screen monitor simplifies setup, and non-volatile memory stores multi-product data to facilitate product changeover.
Sesotec also expanded its contaminant detection portfolio to include the new range of Rapicon metal detector conveyors, designed with modular components, standard reject systems and a full range of aperture sizes. The Rapicon’s fully welded construction with GHF or GLS metal detection technology is a food safe platform from which detection at the smallest pieces of metal is possible without adding a risk for bug traps or harbourage points into the process.
Meanwhile, the LIQUISCAN VF+ is specifically designed for the inspection of sausage meat or similar viscous product. Its compact design makes it easy to install directly at the outlet of vacuum fillers. When metal is detected, the conveying process stops, or a pneumatic reject valve automatically separates contaminated product into a reject container. A range of connectors is available to permit easy mounting to all filler and clipper systems conventionally used in the meat industry.
All Sesotec metal detection systems for the food industry are equipped with the GENIUS+ technology, which processes and evaluates data from the detection coil using digital signal processing in a multi-stage evaluation process. The GENIUS+ control unit features enhanced stainless-steel detection accuracy. Data logging and archiving is standard for compliance with GFSI, IFS and HACCP requirements, and GENIUS+ is also intuitive and easy to operate using the optional full color touch panel.
USDA-APPROVED DRUM MOTOR
Interroll, Wilmington, N.C., showcased its USDA-approved drum motor, which helps poultry processors stay away from costly recalls due to food contamination. Unlike other belt drives and drum motors, Interroll’s drum motors were designed in strict accordance with USDA, FDA and NSF guidelines, and are said to be the most hygienic belt drive on the market.
The Interroll Asynchronous Drum Motor (models 113i, 138i, 165i and 217i) is compact, easy to install and can be cleaned and disinfected regularly using high-pressure water, steam and chemicals.
Key features include:
· USDA equipment acceptance certificate (meat, poultry and dairy)
· Approved for models 113i, 138i, 165i, 216i and 217i
· Configured to drive all modular belting applications
· Complies with Part 21 CFR for U.S. Dairy Equipment Guidelines
· IP66 (IP69k available on the Synchronous Drum Motor)
· FDA-rated Vulcanized lagging
· Leak escape feature in shaft.
· Surface finish less than 30 micro-inches on shell and shafts.
SUSTAINABLE EGG CARTON SUPPLIER EXPANDS INTO U.S.
Brodrene Hartmann A/S, a Denmark-based producer of sustainable molded-fiber egg cartons, announced plans to expand into the United States with a manufacturing facility planned for Rolla, Mo. The company’s U.S. business will operate under Hartmann US.
The $30 million, 334,000-square-foot facility will be retrofitted to produce the company’s egg cartons. Hartmann’s molded-fiber cartons, made from renewable raw material paper, are carbon neutral, biodegradable and can be recycled. The Rolla facility is slated to begin operations in early 2017.
Brodrene Hartmann A/S
+45 45 97 00 00
WATER-RESISTANT PACKAGING SUPPLIER CELEBRATES 20 YEARS
International Paper, Memphis, Tenn., celebrated 20 years of innovation and sustainability with ClimaShield recyclable water-resistant packaging at this year’s IPPE show.
ClimaShield recyclable corrugated packaging uses proprietary coating technology that allows for easy recycling via existing old corrugated container (OCC) recovery system.
INLINE INSPECTION EQUIPMENT
For the first time, Eagle Product Inspection, Tampa, Fla., exhibited at IPPE, showcasing its lineup of inline inspection equipment for meat and poultry products.
The Eagle RMI3 Series, for example, is ideal for contaminant detection for those working with unpacked bulk, open crate and carton applications, with systems having been designed specifically to operate within harsh washdown environments. The RMI3/B ensures reliable inspection of unpackaged bulk products, such as chicken and raw beef, at speeds up to 37 meters per minute and a maximum throughput of 50 tons per hour.
For closed cartons or open crates of raw meat, the RMI3/C x-ray system, similar to the RMI3/B, and the addition of Eagle Product Switch allows processors to minimize downtime through automatic product changeovers without disrupting the line.
Producers of ground meat chub and other packaged meat and poultry products looking to streamline operations, the Pack 400 HC eliminates the need for multiple systems on the line, such as checkweighers, metal detectors and vision systems. With multiple inspection capabilities, the system provides superior contamination detection while simultaneously measuring mass and inspecting seal integrity.
Using dual energy x-ray absorptiometry (DEXA) technology, Eagle’s range of fat analysis systems give both slaughterhouses and meat processors the capability to inspect 100% of throughput inline and in real-time, providing fat analysis within +/- 1CL. For slaughterhouses, this capability can eliminate fat claims and help achieve combo targets without sorting/sampling. For processors, accurate fat analysis helps achieve least cost formulation, enables accurate blending targets and reduces inconsistencies in recipe operations.
Eagle’s FA3/M is a multi-application system capable of providing inline fat measurement and contaminant detection for a variety of products, such as unwrapped meat conveyed in plastic crates, frozen or tempered meat blocks and fresh, chilled, frozen and hot-boned loose bulk. It is a robust machine that has been designed to NAMI sanitary standards with fast breakdown for sanitation. There is no degradation in inspection performance at full throughput, which is 2,400 plastic crates or frozen blocks per hour, or up to 35 tons of bulk meat per hour.
The AUTOCAL automated calibration system, coupled with VALIDATE, is said to be the only machine in the industry to feature automatic calibration and validation. Operators can precisely calibrate the machine in less than one minute with a simple tap of the touchscreen and can then validate this calibration at any time. These features remove the need to use unsanitary and potentially unsafe phantom blocks on the factory floor.
Eagle Product Inspection
WASHSTATION DISPENSER FOR FOOD PROCESSING PLANTS
SCA, a Philadelphia-based producer of the Tork brand of away-from-home (AfH) professional hygiene products, launched the newTork washstation dispenser, a purpose-built dispenser designed to handle the rigors of challenging food processing environments. It provides best-in-class water resistance, hands-free dispensing and what is said to be the highest capacity refill on the market. Plus, it is HACCP certified.
This dispenser was designed to channel water off the housing and away from the refills inside. This not only avoids bacteria growth from pooling water, but also reduces waste from refills getting wet during clean up.
SCA North America
THIN FILMS FOR FRESH FOOD PACKAGING
Linpac Packaging, UK, showcased its new range of LINtop films. Designed for fresh food packaging, LINtop films offer packers complete flexibility and are said to be thinner than standard laminated films with strong sustainability credentials.
Also new is the LINtop Star PE CXO, a high-barrier, medium shrink film for outside-cut tray sealers and case-ready (MAP) formats requiring a PE sealant layer, as well as LINtop PE HB OSL, a low-shrink barrier film, offering a thin, robust solution for outside and inside-cut tray sealers and thermoforming lines.
Both films include anti-fog properties with excellent seal-through contamination performance and are suitable for both vertical and horizontal pack display. Also, both films were developed with a co-extruded structure, making them between 20-30% thinner than equivalent laminated films, resulting in a significantly lower pack carbon footprint.
LINPAC Senior Holdings Ltd.
+44(0) 1977 692 111
ALUMINUM COMPRESSED AIR DISTRIBUTION SYSTEM
Kaeser’s versatile aluminum SmartPipe is now available in a 2-inch diameter.
SmartPipe is a modular, aluminum compressed air distribution system featuring lightweight materials and simple connectors that can be installed without threading, welding or sweating, ideal for headers and branch lines all the way down to the point of use.
SmartPipe is made from smooth, calibrated aluminum, will not rust, boasts a low coefficient of friction and provides what is said to be the best possible laminar flow.SmartPipe can be easily integrated into existing steel or copper systems and modified to accommodate changing needs.
METAL DETECTION & PACKAGING EQUIPMENT
Heat and Control, Hayward, Calif., showcased a lineup of metal detection and packaging equipment.
For example,the Ishida poultry weigher, model RV-214W-1S/70 – WP, boasts a large capacity weighing of big pieces or large target weights. Features include IP69K washdown construction, consistent and precise accuracy, high packaging speeds, H4-embossed surfaces that prevent product sticking and can be disassembled without tools.
The CEIA multi-spectrum metal detector, model THS/MS21 – 650 X 150, prevents false rejects without reducing sensitivity and detects small sizes of all metal contaminants. Features include IP69K washdown, 316 stainless-steel construction, auto-learn function, which improves accuracy and reduces setup time, one-button settings reduces operator error and FDA Title 21 CFR 11 compliant for data security, integrity and traceability.
The CEIA multi-spectrum metal detector, model THS/MS21 500 x 275 with MBB 2000 X 450 conveyor and rejector, is designed to prevent false rejects and detect small sizes of all metal contaminants without reducing sensitivity. An auto-learn feature improves accuracy and reduces setup time, while a 1-button preview of settings reduces operator error. Additional functions include Bluetooth for remote calibration and service, IP69K washdown construction with conformal coated circuit boards and FDA Title 21 CFR 11 compliant for data security, integrity and traceability.
New to the host of equipment is the FastBack 260E Gen 3 hygienic washdown horizontal motion conveyor, what is said to be the first sanitary conveyor designed specifically for the rigorous requirements of the poultry industry. The hygienic washdown horizontal motion conveyor features a self-draining, water-resistant, stainless-steel cabinet with a sanitary one-piece stainless-steel pan. All electronics in a drawer simplifies maintenance, while the external motor makes for easy access and cool operation. Plus, it reduces product breakage and coating loss, maintains pre-mixed blends, boasts a quiet operation and low vibration and dynamic load for a lighter support structure. It also features the highest levels of hygiene and washdown protection, a flush stainless-steel cabinet, threadless feet and an open stainless-steel motor.
Heat and Control
SOLUTIONS FOR SECONDARY PROCESSING & FURTHER DOWN THE LINE
Chicago-based JBT Corp. debuted a solution dedicated to the production of clean label products—the new Polar Fusion high viscous brine system. This system incorporates the Polar Fusion Dissolver PDM/PDH 250, Polar Fusion Homogenizer, IMAX 620DH-HVB Injector, optional Flexcarve Macerator and Polar Massagers, as well as a variety of oven options. By utilizing the natural binding qualities of whole-muscle protein, the system can reduce or eliminate additives such as sodium and phosphates as well as deliver yield increases up to 5% across the full process.
JBT also introduced the DSI dual-blade (DB20) portioning system, which is a low-maintenance blade portioner powered by DSI software and scanning technology. The new portioning system is consistently accurate, simple to clean and easy to operate, and is suitable for a wide range of linear portioning applications, including the portioning of poultry tenders, breast meat and leg meat into strips, nuggets, steaks, shots and kakugiri. The DSI DB20 system delivers superior scanning with a single, high-performance sensor that continuously self-calibrates while detecting product shape as well as fat vs. lean. The dual-lane system can run a separate application on each lane. Weight-controlled or dimensionally controlled portions, strips or nuggets can also be combined with angled cuts.DSI Q-LINK portioning software, common to all of JBT’s DSI products, delivers sophisticated yield optimization software with an intuitive, large-format touchscreen interface and easy calibration routines. DSI Q-LINK software allows users to change applications at the touch of a button and can be easily configured to notify users when, for example, a blade becomes dull, when yields are not on target or when loading efficiency has decreased.
JBT also announced a new cooking technology that delivers significant advances for food processors and restaurants. This reduced-temperature pasteurization (RTP) system, developed by JBT engineers and food scientists, is a continuous industrial-scale cooking system based upon time-temperature process control. This patent-pending, USDA-approved, bagless technology delivers results similar to those achieved by the sous vide process. This industrial cooking method captures the benefits of low and slow cooking, significantly enhancing food taste and texture, while ensuring food safety. The treatment operates at temperatures as low as 131°F using precision controls, instruments and equipment designed and manufactured by JBT. In the RTP process, meats are steam pasteurized and frozen before shipment to restaurants, killing pathogenic bacteria without overcooking. Once at the restaurant, cook times are reduced by as much as 30%.
PRODUCTION MONITORING & CONTROL
METTLER TOLEDO, Columbus, Ohio, showcased a host of checkweighing and metal detection machinery.
For example, the C3572 checkweigher features production monitoring that maximizes inspection productivity and robust design for washdown applications. The C3000 frame meets the safety needs of high-volume food processors by incorporating sturdy stainless-steel conveyors with an open and accessible frame design. A complete library of package handling, functional and operational production monitoring and control and communication options allow for a custom-tailored solution to meet any application.
The CM3572 combichecker combines a checkweigher and a metal detector in one system that features production monitoring and control features that help optimize the inspection processes and increase production efficiencies. Ideally suited for food production areas with heavy washdown requirements, the CM3572 combichecker’s modular design provides a system that meets the highest standards for food safety in the production environment. Standard features include reliable and accurate METTLER TOLEDO EMFR (electromagnetic force restoration) weigh cell technology, a stainless-steel, easy-to-clean open frame and a conveyor support structure of four solid tubes. Optional features include infeed timing and spacing conveyors, a variety of reject mechanisms and stainless-steel locking reject bins.
Mettler Toledo Safeline and Marlen International, Riverside, Mo., joined forces to develop a superior method of bone and metal contaminant detection and rejection for the processed meat and poultry industry. The Mettler-Toledo Safeline Opti PipeChek Plus x-ray inspection system was designed specifically to meet the unique high-speed inspection needs of processors of liquid, slurry and solid products. Unlike conventional belt-style x-ray systems, Marlen's Opti PipeChek 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. During inspection, "purge" that would otherwise be lost to the floor is re-absorbed by the product, resulting in net yield recovery by weight of 1.5-3%.
METTLER TOLEDO’s new Profile Advantage metal detector uses multi-simultaneous frequency technology to reduce false rejects, possible thanks to the company’s 3S software algorithm in real time, which is said to result in a 30-50% higher sensitivity than competing technologies. In addition, Product Signal Suppression virtually eliminates the incidence of false triggering by suppressing the active and unwanted product signals often produced during inspection of high-moisture products. Profile Advantage metal detectors incorporate advanced condition monitoring technology, which assesses the performance and operation of key detector components and circuitry.
24/7 VIRTUAL REFRIGERATION OPERATOR
Frick by Johnson Controls, Waynesboro, Pa., showcased its new Quantum HD Unity system controller and energy management solution.
This 24/7 virtual refrigeration operator incorporates best refrigeration control practices with reliable, easy-to-use hardware, software and central control system for cold storage and other refrigeration processes.
The Quantum HD Unity system unifies multiple controllers into one display. Operators can easily navigate from engine room control to evaporator control to condenser or vessel control with the click of a button.
The analog and digital I/O control panel can be mounted anywhere and accessed via the internet.
Johnson Controls, Inc.