The International Production & Processing Expo (IPPE) 2017 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 1,275 exhibitors and more than 7,200 international visitors from 120 countries at the Georgia World Congress Center in Atlanta Jan. 26-28.
IPPE is made up of three organizations—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.
“This year’s tremendous exhibit floor and attendee, and exhibitor numbers are a compliment to IPPE’s unmatched education programs, ample networking opportunities and diverse exhibits. The excitement and energy displayed by this year’s attendees and exhibitors will continue to safeguard the success and growth of future IPPEs,” according to USPOULTRY, AFIA and NAMI.
Here is a rundown of some of the latest innovations in equipment, supplies and services introduced and showcased at IPPE 2017.
SOLUTIONS TO HELP PROCESSORS BOOST FOOD SAFETY
Linde LLC, Bridgewater, N.J., featured two new advanced chilling solutions designed to help processors improve temperature control while meeting goals for improvements in hygiene and food safety.
The hygienically-designed LIXSHOOTER injectors for chilling mixers and blenders from the bottom with liquid nitrogen (LIN) or carbon dioxide (CO2) are patented hygienic injectors designed to seal out wet products and food particles. The self-sealing injectors mount flush with the internal surface of the mixer to eliminate or minimize areas that could harbor moisture or foodborne pathogens. These new state-of-the-art bottom injectors conform to the hygienic design principles of the North American Meat Institute, and can be used with almost any existing mixer, blender or kettle. The dual-cryogen option makes it possible to switch between LIN and CO2 in a matter of minutes, rather than hours or days.
The ACCU-CHILL automated box chiller chills food in boxes, on demand, with CO2 snow and can eliminate the use of dry ice pellets. Designed and built to meet USDA requirements, the ACCU-CHILL system chills with high process repeatability from box to box. The automated system is the ideal upgrade for operations that manually pack boxes with CO2 dry ice pellets, which can present contamination risks, and where over- or under-filling creates temperature inconsistencies.
Linde’s patented high-speed, inline MAPAX LD leak detection system is ideal for packaged meat, poultry, seafood and prepared foods packaged with tray sealers or thermoforming machines. It tests packages inline, and is said to achieve 100% sampling at speeds up to 120 packages per minute. It works by adding a small volume of hydrogen as an indicator to the modified atmosphere mixture at the package sealing stage. The MAPAX LD sensor detects for the gas after the sealed packages travel into the leak detection unit. In contrast, the MAPAX LD system offers non-destructive package testing. Because testing is inline, if a package leak exists due to a pinhole, tear or defect in the seal, a visual alarm signals, so issues can be immediately resolved or investigated. A defective item can be removed from the production line with minimal interruption to the process flow. MAPAX LD also identifies faulty settings on a machine if, for example, several leaks are found consecutively.
Linde also highlighted its in-line crust freezers that can chill with nitrogen (N2). For example, its impingement freezer can freeze 300% more than a standard cryogenic tunnel freezer of similar length.
Linde also announced plans to break ground on a new large-scale air separation unit (ASU) in Adel, Ga., announced the start-up of its new carbon dioxide (CO2) plant in Fort Worth, Texas, and announced plans to expand its Claymont, Del., industrial gases plant.
METAL MODULAR CONVEYOR BELT FOR MEAT, POULTRY PROCESSORS
Cambridge Engineered Solutions, Cambridge, Md., introduced Metal Modular, a modular-style metal conveyor belt similar in pitch, size, structure and application to plastic modular belting, but boasts a fastener-free integrated flight design to eliminate food contamination issues. During the manufacturing process, spacing can vary across the belt’s width, making the mesh denser at points of distress to add strength and rigidity where needed. In addition, three connection points reinforce the stainless-steel wires, preventing them from falling into product during processing. Further customization capabilities using exclusive rail match technology allow Cambridge to fabricate Metal Modular to easily drop into a customer’s existing conveyor support beds and insert integrated flights in exact locations. The belt design is robust in nature and can withstand the harshest of environments and sanitation treatments at up to 1,000°F. Ideal applications include both horizontal and incline conveyors for bagging, pack-outs, dip tanks, macerators and in-feeds.
Also new is the CamEDGE conveyor belt for cageless spiral systems, featuring the same edge treatment as the original design, but with an interior mesh overlay to accommodate smaller foods and soft poultry and meat parts placed directly on the belt. The CamEDGE MORE metal belt is suited for daily sanitation practices necessary to prevent Salmonella, Listeria and other bacteria. The cageless spiral belts utilize a robust, well-supported drive link on the outer edges to reduce component flexing during sprocket engagement. This results in an extended belt life and less chance of component fatigue. In addition, the stainless-steel belt’s hold-down tabs eliminate “Christmas treeing” (lifting) associated with traditional spiral designs.
Cambridge Engineered Solutions
Patty Paper, Inc. (PPI), Plymouth, Ind., exhibited a wide variety of FDA-approved papers for use in the meat, dairy, bakery, deli, snack and grocery industries. Coated with a variety of waxes or wax blends, the company's broad selection of paper is used to separate hamburger patties, cheese, poultry, pork, bakery and deli foods.
PPI's converted papers include patty interleaving, cheese slice interleaving, picking paper, bulker or roll stock paper and sheeted waxed paper or peach/pink, green and black steak paper. All sheets feature consistent feedability for uninterrupted sheeting.
Patty Paper, Inc.
MAGNETIC SPEED CONTROLLER
Interroll, Atlanta, showcased its new patented MSC 50 (magnetic speed controller), an easy-to-install, maintenance-free solution for warehousing, e-commerce, food processing and any customer that uses flow racks for heavy containers. The MSC 50 controls the speed of boxes and plastic trays traveling on gravity roller conveyors and spirals or the end sections of sorters. Suitable for handling goods weighing up to 77 pounds, this system provides customers with total control over their conveyor, and ensures lightweight packages move smoothly, while limiting the speed of heavy goods traveling along the conveyor. The MSC 50 features an eddy current brake, double shielding, which prevents magnetic emissions entirely and a bidirectional braking function. In addition, the MSC 50 speed controller is well suited for retrofitting existing gravity conveyor installations. The MSC 50 produces a maximum infeed speed of 500 fpm, maximum input up to 3,000 units per hour, comes in 8- to 55-inch roller length and is capable of withstanding ambient temperatures of 40-104°F.
The Interroll Drum Motor was designed according to USDA, FDA and NSF guidelines for meat, poultry and dairy applications.
REUSABLE PLASTIC CONTAINERS
Sæplast Americas, Canada, introduced a third size into its reusable plastic container ranges for food processing.
The Sæplast PE 750 container is ideal for supply chain handling in the poultry and meat industries. Being of a smooth wall 1-piece construction, the 750-size container sits between the 630 and 875 sizes to offer customers additional choice and flexibility in food transportation and storage. It comes in a variety of color offerings along with optional drain holes, optional lid and can be personalized with company logos. It can also incorporate tracking options such as barcode, QR code or RFID technology.
The unique ergonomic “closed cell core” design does not absorb liquid, and prevents the growth of harmful bacterial growth to deliver highly effective hygiene control.
TRAY FORMER, STREAMFEEDER
Thiele Technologies, a Minneapolis-based division of Barry-Wehmiller, showcased the SWF TF 600V Tray Former for the poultry and proteins packaging industry. The SWF TF 600V Tray Former offers speeds up to 60 trays per minute, ideal for box rooms.
Thiele also highlighted the new TF-1250 Packaging Series Streamfeeder, ideal for all non-nested product feeding requirements, including batch counting, on-demand and continuous feed, into banders, shrink wrappers, flow wrappers, cartoners, labelers and several other finishing machines.
Thiele Technologies, a Barry-Wehmiller company
Remco Products, Zionsville, Ind., showcased its line of hygienic, FDA-compliant, color-coded tools for the food industry.
New to the portfolio are color-coded, stainless-steel scrapers. Featuring a 1.5-inch-wide or 3-inch-wide blade, these scrapers are an ideal solution for removing stubborn debris from smooth surfaces. The scraper’s beveled blade loosens dried pastry dough, starches, chocolate and burnt food. Both sizes come in 9 colors.
The bottle brush, sold under the Vikan brand, entails bristles along the sides as well as in the front. It is used in areas where a wider tube cleaning action is required or where the equipment has an end point that cannot be reached with a hand brush. It works well as a drain brush, particularly in black (it comes in 6 colors).
Cleaning between and around pipes is made easier with the curved design of the hook brush. The hand grip utilizes a threaded recess on the end that allows another handle to be connected to the brush. The brush bristles are secured with non-corrosive stainless-steel wires, helping increase longevity.
The new grout brush is mounted with thread adapter that can be removed for easy cleaning of the whole product. This brush entails a 180-degree rotating neck and “arrow”-shaped bristles, making it suitable for cleaning under equipment, between equipment, getting into corners and cleaning the crevice between floors and walls.
Vikan’s new 5-gallon pail is a problem solver. Whether mixing ingredients, storing ingredients or simply moving heavy loads that other pails cannot, this durable pail boast easy-grip handles for easy transport.
Ultra Safe Technology is a new line of brooms and brushes that help improve food safety and quality, minimize food waste and increase cleaning efficiency. These new products from Vikan comply with food safety regulations and minimize the risk of contamination hazards. Choose from a soft broom, short handle brush, soft bench brush, deck scrub, medium broom, long handle broom and medium bench broom, available in 8 colors.
CLICK HERE to learn more about the many ways Remco’s color-coded tools can enhance food safety and organization in many of today’s food processing plants.
Remco Products Corp.
MOISTURE-RESISTANT COATING FOR CORRUGATED PACKAGING
International Paper, Memphis, Tenn., celebrated a 40-year milestone exhibiting at IPPE by introducing ClimaShield, a recyclable moisture-resistant coating for corrugated packaging.
ClimaShield offsets 1.7 billion pounds of landfill waste, equivalent to the annual waste of 1 million households, avoids greenhouse gas emissions equivalent to230,000 passenger cars driven for one year (122 million gallons of gasoline) and lowers energy usage equivalent to the annual consumption of nearly 100,000 homes.
ClimaShield packaging works with all existing processes and packaging systems.
The proprietary coating technology allows for easy recycling via the existing old corrugated container recovery system, making it what is said to be most recycled type of packaging in the United States, compared to plastic containers.
ONE-STOP-SHOP OF COMPLEMENTARY SOLUTIONS
From cooking and frying, freezing and chilling to portioning and sorting, weighing and grading, JBT Corp., Chicago, provides a team of solutions for food processors. And now, with the addition of TIPPER TIE from Dover, Downers Grove, Ill., and Cooling and Applied Technologies (C.A.T.), Russellville, Ark., JBT is expanding its portfolio to offer complementary packaging solutions as well as systems for secondary processing.
As part of the TIPPER TIE acquisition, JBT released the TTSealH for meat processors, featuring an automated heat-seal-and-clip system for pumpable products. TTSealH is compatible with the TIPPER TIE TT1512 and TT1815 automatic double clippers. The system runs roll stock films, including blank or printed films, as well as most types of monolayer and multi-layer flat foils such as poly, Mylar and aluminum coated films. The system’s hot-seal capacity is 30 meters per minute, producing chubs in calibers from 20-120 millimeters. Advanced touch screen controls integrate into the clipper, and the controls enable a single operator to work in any of several languages, quickly accessing and recalling hundreds of product recipes.
JBT and TIPPER TIE also introduced the TTBagS for processors wanting the premium look of shrink bags with secure clip closure. Specifically designed for the poultry market, the base model TTBagS enables manual feeding of product into shrink bags opened by sensor activated air flow. Constant bag tension is maintained by two auto take-up wheels. In this configuration, a single operator can bag up to 40 birds per minute. For higher throughput and productivity, this is an ideal set-up to support automated vacuum packaging systems such as the JBT/TIPPER TIE Rota-Matic. The TTBagS is also offered as a stand-alone bagging and clipping station with the addition of up to two hocking stations, vacuum nozzles and pump and JBT/TIPPER TIE clippers. The machine is also available with an auto-tagger and ink stamp or inkjet printers.
Thanks to the acquisition of Novus X-ray, JBT introduced XVision, which provides foreign body contamination protection for protein products, metal packaging, liquids, bulk flow foods and an array of food applications.
Under the C.A.T. acquisition, JBT released the Trident Rocker Arm Pre-Chiller, which utilizes a robust independent drive and unloader assemblies to provide hours of reliable operation. By utilizing an independent drive, the Trident gives end users the ability to tailor the rate at which it unloads whole WOGs.
The UltraCAT line of injectors and mixing equipment add innovation, flexibility, reliability and consistency thanks to JBT’s ability to tailor the equipment to fit specific processes.
CAT Scales boast high-quality, durable, cleanable construction for line feeding, packaging, yield management and quality control.
The new FreezeCAT spiral freezer brings a new twist to spiral freezing for the poultry, red meat and fish industry as well as the tray pack market. With no center drum and less material, it offers cleaner operation as well as a more efficient spiral. Eliminating the center drum takes out belt flip sensors and baffles that normally would be in place to direct air flow to the products. A more efficient, easier to clean and maintain spiral
Lastly, thanks to the acquisition of Novus X-ray, JBT will introduce XVision in order to provide foreign body contamination protection for protein products, metal packaging, liquids, bulk flow foods and an array of food applications.
JBT also introduced the Stein JSO-C Compact Jet Stream Oven, the latest in thermal process innovation featuring a hygienically superior design for a continuous process at a low throughput requirement. The new 24-inch-wide belt linear oven is designed for the most demanding applications and regulatory environments, and allows easy access to every surface, with focal points being on cleaning and inspection. JBT’s patented impingement cooking technology helps to create the most consistent and reliable cooking oven on the market, producing predictable and superior products.
PACKAGING, PRINTING, KNOWLEDGE-BASED SOLUTIONS
Sealed Air Corp., Charlotte, N.C., introduced a suite of equipment solutions for food processors that provide an automated and comprehensive approach for packaging and distributing food products.
For instance, it launched Diversey Knowledge-Based Services, a range of consulting and implementation services that enable food and beverage processors to capitalize on improved use of equipment and resources. The new range of services include AirCheck, AquaCheck, SteamCheck, Dynamic Flow Monitoring, DryFormance Conveyor Systems and the Diversey Hygiene Academy. Sealed Air acquired global cleaning and sanitation services supplier Diversey Holdings Inc., Sturtevant, Wis., in June 2011.
Sealed Air also now offers Cryovac Graphics, a total systems approach that uses state-of-the-art graphics services and flexographic printing capabilities to produce dynamic printed products. From brands, logos, color schemes and fonts to copywriting, photo shoots, physical mock-ups and 3D printing, Cryovac Graphics can be extended to any collateral material and secondary packaging for consistency across the brand.
Also on display was the Cryovac Grip & Tear family of easy-open barrier bags for further processed poultry products. Features include an easy-open tab design, superior optics for retail display, straight or curved end or side seal, improved oxygen-barrier and grease-resistant properties and reduced risk for injury and cross-contamination. Cryovac Grip & Tear is compatible with all Cryovac loading and heat sealing equipment, helps reduce offline leakers and re-wraps as a result of improved sealing capabilities. It’s available in 2-sided, 10-color process print.
Sealed Air Corp.
CHECKWEIGHERS MAXIMIZE INSPECTION PRODUCTIVITY
The METTLER TOLEDO C3572 checkweigher from METTLER TOLEDO, Columbus, Ohio, features production monitoring and control features to help optimize the checkweighing process and increase production efficiencies. 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. Ideally suited for food production areas with heavy washdown requirements, C3572 checkweigher boasts a complete library of package handling, functional and operational, production monitoring and control and communication options for a custom-tailored solution. Standard features include 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.
The HI-Speed CS3600 Caseweigher is an in-motion scale for weighing large packages such as boxes, cartons, cases, bags or sacks. It features a 100-product memory and high-contrast color touchscreen. The flat surface and materials used allow simple and thorough cleaning in line with EHEDG and NSF guidelines for hygienically sensitive environments. The caseweigher’s rugged construction of powder-coated mild steel can handle the stress of heavy packages; optional stainless-steel construction is available. The system can be supplied with a wide variety of rejecters depending on the application, including freestanding standard or heavy-duty push-off rejecters or drop-through conveyor and lift roller rejecter systems.
In 2014, METTLER TOLEDO introduced the Profile Advantage metal detector. Now, it features expanded applications with the launch of the Profile Advantage Pipeline Metal Detector, which applies the technology to inspecting piped products for metal contamination. This is processed by METTLER TOLEDO’s 3S software algorithm in real time. In addition, Product Signal Suppression technology virtually eliminates the incidence of false triggering by suppressing the active and unwanted product signals often produced by the “Product Effect”––signals produced by the products themselves, particularly high-moisture products such as meats. By suppressing those false signals, the Profile Advantage inspects products at full sensitivity, ensuring more effective inspection and maximizing product safety. Profile Advantage metal detectors also incorporate advanced Condition Monitoring technology that assesses the performance and operation of key detector components and circuitry. Operators are alerted of adverse trends or changes in performance that can potentially cause system downtime.
VERTICAL FORM-FILL-SEAL BAGGER
Triangle Packaging Machinery, Chicago, showcased its Model XY-RJ VFFS bagger, a vertical form-fill-seal (VFFS) bagging machine designed to run a variety of bag styles, including 3-sided seal, Doy, pillow, gusseted and flat bottom.
A rotateable sealing jaw allows packagers to run multiple package styles on the same machine.
Ideal for produce, individually-quick frozen products, meat, poultry and seafood, it fills up to 120 bags a minute, features a stainless-steel film cage and intuitive operator controls.
Triangle Package Machinery Co.
SPIRAL CONVEYOR BELT
Ashworth Bros., Inc., Winchester, Va., introduced the Omni-Grid 360 Weld line of grid style spiral/turn-curve conveyor belts.
The Omni-Grid 360 is said to reduce cage bar wear and downtime in demanding high-tension spiral/turn-curve applications while maintaining belt strength integrity and easy-to-clean attributes.
The increased strength comes from the revolutionary 360-degree buttonless welds utilizing a patented “zero tension” design, which allows for a higher load bearing capacity. Unlike a traditional bridge weld, the 360-degree buttonless weld is free from surface imperfections and crevices, which improve hygienic characteristics by eliminating the possibility of bacteria entrapments. The “zero tension” design permits the belt to run smoother with less wear on spiral system cage bar caps. Each link is formed with a proprietary coining process to prevent break-in wear, reducing belt elongation and increasing belt life. The 1-inch pitch and 1.5-inch pitch integral guard-edges feature a smooth rounded finish for applications where product retention is a potential concern.
Ashworth Bros., Inc.
Packers Sanitation Services Inc. (PSSI), Kieler, Wis., launched the Value-Added Services Program (VASP) to assist meat, poultry and food processors with a variety of non-production jobs.
During production shifts, VASP helps workers with:
- Dry pickup, including tracking pickup weights, so customers can identify potential sources of waste.
- Tub washing and utensil and cart cleaning.
- Trolley room operation and repair.
- Janitorial and housekeeping services.
VASP eliminates the challenges that companies often have filling these roles by utilizing the PSSI human resources platform to recruit, train and manage team members. The program aligns with PSSI’s sanitation services for plants regulated by the United States Department of Agriculture (USDA) and the Food and Drug Administration (FDA), as well as the Canadian Food Inspection Agency (CFIA).
DIRECT-STORE DELIVERY APP FOR MOBILE DEVICES
CAT Squared, Conway, Ark., released a new direct-store delivery (DSD) app for mobile devices.
This DSD app provides route accounting, inventory control, mobile point-of-sale and delivery functionality, and integrates into a company’s ERP, CRM and WMS systems, thus reconciling financial and inventory data.
DSD also provides an easy method for resolving incorrect orders or customer disputes. If a customer disputes the weight labeled on the product or needs to change the order, the driver can record variances with an explanation and process order changes along the route. As the driver scans each box of product and processes each payment, transactions can be updated in real time using GPRS, or if cellular communication is not available, the data is stored within the mobile device’s local database and reconciled when the driver completes his/her route.
Other features include:
- Digital signatures.
- Real-time route tracking.
- Ability to print invoices and pick lists.
- Can record variances and process order changes.
- Ensures product meets age-restriction requirements for each customer.
- Data can be used to create KPIs and dashboards.