The 2019 International Production & Processing Expo (IPPE) surpassed 600,000 square feet of exhibit space and broke records with 33,000 registrants and 1,420 exhibitors at the Georgia World Congress Center in Atlanta Feb. 12-14.
Comprised of the three integrated 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.—IPPE is said to be the world’s largest annual feed, meat and poultry tradeshow.
This year’s expo highlighted the latest technology, equipment and services used in the production and processing of feed, meat and poultry products, and combined expertise from AFIA, NAMI and USPOULTRY to feature dynamic education programs focused on current industry issues.
Patty Paper, Inc., Plymouth, Ind., exhibited a wide variety of select grade papers that are FDA-approved for use in the meat, dairy, bakery, deli, snack and grocery industries.
Coated with a variety of waxes or wax blends, this selection of paper is used to separate foods. The converted papers include patty interleaving, cheese slice interleaving, picking paper, bulker or roll stock paper, sheeted waxed paper, butcher paper rolls and sheets and peach/pink, green and black steak paper.
Patty Paper, Inc.
ADVANCED CUTTING, FORMING & VACUUM PACKAGING TECHNOLOGIES
Hollymatic, Countryside, Ill.; Nutec Manufacturing, New Lenox, Ill.; Former Equipment, Kenosha, Wis.; and Rollstock, Kansas City, Mo., shared a booth at this year’s show to demonstrate state-of-the-art innovations in cutting, forming and vacuum packaging equipment.
Hollymatic demonstrated the latest technology in meat saws and poultry cutters with its Defender 4000 Band Saw, which debuted at PROCESS EXPO in 2017, and its Defender PC1500 Poultry Cutter, which was introduced last year. Using proprietary technology, these defender saws effectively stop the saw blade with no damage to the saw at a rate 10 times faster than the blink of an eye.
Nutec exhibited its 745E Food Forming System again, and for the first time in the United States, its 790E Depositing System. Both systems are 100% electric and use no hydraulic oil or compressed air, making for a more hygienic process. Plus, they use approximately 50% less electricity than other machines their size.
Former Equipment exhibited its SRT-2600 Servo Rapid Throughput Electric Forming Machine, which features less parts, requires less maintenance and preventive work and allows less room for error.
Rollstock introduced its RM-100 fully automatic Rollstock Vacuum Packaging Machine.
Fortress Technology revealed the Meat Pump Pipeline, a pathogen cross-contamination deterrent.
The Meat Pump Pipeline was designed to assist meat food processors inspecting high-viscosity meats to optimize hygiene standards and tackle cross contamination, without compromising metal detection sensitivity.
It can be used to inspect sausage patties, red meats, poultry, patés, broths, gravies and sauces as well as viscous pet foods. Plus, the Meat Pump Pipeline is IP69K rated and USDA-compliant, and can withstand harsh meat processing environments and high-pressurized washdowns after every product changeover.
The Meat Pump Pipeline is not fixed to the floor or ceiling, and can be maneuvered to upstream processing lines where it can be connected to vacuum fillers.
To overcome product effect caused by the highly conductive nature and iron content of meat, the
Meat Pump Pipeline applies a digital signal processing technology to distinguish the signal generated by a metal contaminant from the product being inspected.
The system also integrates Auto-balance to re-balance the coil heads within the unit, which may over time expand or contract due to changes in product temperatures passing through the pipeline.
This helps to maintain metal detection sensitivity.
Other features include sophisticated data capture and Contact Reporter Software, and traceability compliance requirements such as GFSI/SQF, BRC and HACCP.
Fortress Technology Inc.
PROCESSING & PACKAGING SOLUTIONS
GEA Group, Germany, put its new processing and packaging solutions center stage.
GEA introduced the new MultiJector 2mm, a continuous in-line injection solution developed for high quality and accuracy in the art of bacon making and poultry processing. The new equipment features unrivaled injection accuracy with a low standard deviation for excellent product quality and maximum profitability, as well as flexible needles that will not break or distort and maximum time-in-meat technique, a GEA injection precision technique based on the specific combination of stroke height and injection cycle time, both optimized for each product type. The modular design includes exchangeable manifold needle cassettes for easy cleaning and quick changeover. At the heart of the MultiJector are the unique 2mm OptiFlex needles, which combine flexibility and strength, as they are said to be four times stronger than traditional stainless steel and will flex and recover their shape, helping to prevent bent or broken needles. This helps avoid over or under-cured areas for a more consistent taste and color.
The third-generation GEA CookStar evolved into a 3-phase cooking concept, with the ability to cook any product in virtually any style. Combining the double spiral oven technology with the SuperHeatSmoke concept enables food processors with in-line production to produce and brand their products with a CleanSmoke label. SuperHeatSmoke is designed for in-line smoking of meat, poultry, seafood and meal components, and is generated using a Red Arrow-purified smoke condensate. The smoking process is conducted at temperatures above 100°C. The oven provides a controlled environment for a more consistent smoke flavor and authentic coloring, similar to a traditionally smoked product. The technology further enables taste and color variation by using smoke condensate with various colors and flavor intensities and by applying smoke in one or both oven sections.
The new freezer process control system CALLIFREEZE continuously measures the level of product frozenness at freezer outfeed and adjusts freezing time, air temperature and fan speed to achieve the exact freezing quality with minimum energy consumption. The control unit can be configured for GEA S-Tec and A-Tec spiral freezers, handling a wide range of food products, including meat, poultry, fish, ready meals, bakery and dairy products.
The GEA PowerPak PLUS thermoformers are motorized and synchronized with the machine’s advancing cycle. In combination with the innovative web tensioning system, they facilitate a controlled unwinding and a simplified and secure film path. For top and bottom films, they adjust the transverse position during operation. The axial position of the films is automatically monitored and regulated in an optimum fashion. Overall, this provides the basis for a substantially improved sealing seam quality.
The newly developed GEA hygienic decanter provides what is dubbed as the highest hygienic standard available on the market. Features include the use of FDA-approved components, modification of the surface roughness from Ra 4.0 μm to Ra 0.8 μm and design of corners and surfaces with optimal cleanability, as well as a defined arrangement of spray nozzles.
To improve decanter performance, GEA developed the GEA PerformancePlus service tool, which extends beyond routine preventive maintenance. The service tool provides maintenance, monitoring, analysis and optimization services. GEA PerformancePlus creates transparency when it comes to the actual condition and status of the equipment, increases availability, ensures optimum productivity, delivers efficiency optimization and enables sustainable equipment utilization.
+49 211 9136-1492
Linde LLC, Bridgewater, N.J., displayed its cryogenic chilling technology solutions.
For instance, the new SmartChill control system was designed to deliver a consistent flow of cryogen to all injectors at the bottom of a mixer/blender for more consistent temperatures throughout a batch. It is also designed to supply the correct ratio of carbon dioxide (CO2) or nitrogen (N2) to food product in every batch for high batch-to-batch consistency, which reduces wasted product. In addition, new bottom-injection (BI) mixer chilling systems feature hygienic LIXSHOOTER injectors, designed to eliminate nozzle clogging while dramatically reducing maintenance and inefficiency.
The company’s automated combo chiller gently layers CO2 snow onto raw meat or poultry, as pieces are automatically loaded into the combo bin from the top. This eliminates labor and the need to store and move pellet bins, and helps achieve more rapid and consistent temperature equilibration throughout the batch.
Linde’s new, patented, dual-action CRYOWAVE CWI impingement freezer delivers nearly three times the heat transfer rate of traditional cryogenic freezers, and the wave-action of the belt helps keep items separate as they freeze.
Linde North America
ALUMINUM SURFACE GEARMOTORS PROVIDE SANITARY WASHDOWN SOLUTION
NORD Gear Corp., Waunakee, Wis., exhibited its line of efficient gear units.
For example, the modular screw conveyor package boasts a high-efficiency design that eliminates the need for separate V-belt drives by providing integral gearmotors or direct-coupled motors to a NEMA C-face reducer. This also minimizes parts and eliminates the need for top motor mounts, pulleys, belts or guards, thus increasing reliability and superior drive performance.
The high-strength NSD TUPH aluminum alloy surface conversion is the company’s alternative to stainless-steel gear reducers, motors and VFDs. Ideal for poultry and meat processors, this material features the superior washdown advantages of stainless steel, but is lighter and offers has superior heat transfer properties.
The SK9055 and SK9155 overhead conveyor drives are designed with a mounting flange and output shaft that easily drop into industry-standard footprints. The gear units incorporate the standard NORD VL3 spread bearing design with a dry cavity.
NORD Gear Corp.
SANITARY OPEN FRAME DESIGN FOR ROBOTIC PACKAGING SYSTEMS
JLS Automation, York, Pa., introduced a new sanitary open frame design for its robotic packaging systems.
The new open frame is designed so that all surfaces on the machine frame, including uprights, cross members and guard doors, can be easily inspected, accessed, cleaned and maintained. The open frame is available on the JLS Talon robotic pick-and-place system and Osprey robotic case packers.
The hygienic frame is crafted from stainless-steel sheets and eliminates enclosed spaces that harbor bacteria for easy cleaning. In addition, horizontal surfaces have been minimized to prevent pooling of fluids and product, and a sloped control box for run-off ensures sanitary operation.
EGG CARTON & TRAY INNOVATIONS
Dolco Packaging, a Tekni-Plex business unit, Wayne, Pa., exhibited its latest egg carton and processor tray innovations.
Dolco also highlighted its custom-designed alternatives to help meat and poultry processors draw attention to the unique attributes of their products. Examples include compartments/dividers for sausages, deep-draw pockets for meat patties, structural indentations for easy removal and more.
Dolco also displayed various structures and configurations designed to protect eggs throughout the distribution cycle. Offerings include apple and pear trays and mushroom tills, as well as industrial and custom packaging solutions for agricultural, food and foodservice markets.
CRYOGENIC GAS SOLUTIONS FOR FOOD FREEZING & CHILLING
Praxair, Danbury, Conn., showcased its line of cryogenic freezing systems for use with either liquid nitrogen or liquid carbon dioxide. The line includes tunnel freezer systems such as the ColdFront cryosaver tunnel freezer.
CRYOGENIC TUNNEL FREEZERS
Air Products, Lehigh Valley, Pa., showcased its latest innovations in cryogenic technology and equipment for poultry and meat production, including the company's Freshline MP and Freshline IQ tunnel freezers, which offer efficiency, economy and hygiene, along with an optional remote monitoring system for troubleshooting and efficiency tracking from afar.
Also on display was the company's Freshline IS solution, a tailor-made temperature control system that uses liquid nitrogen or carbon dioxide to deliver rapid, precise temperature control to a blender or mixer/grinder, enabling food manufacturers to optimize processing speed and product quality.
Air Products also highlighted its ability to supply nitrogen and CO2 spiral freezers, which use a small footprint to provide continuous freezing or chilling of a wide variety of food products at high production rates.
SUPPLY CHAIN PLANNING & OPTIMIZATION SOFTWARE
CAT Squared, Conway, Ark., demonstrated new functionality to its TacticalOps Planning & Optimization Software, which was introduced at IPPE 2018.
Also in 2018, CAT Squared joined the CTB, Inc. family of brands. This purchase adds value to CTB, Inc., Milford, Ind., by capitalizing on the synergy between CAT Squared’s manufacturing execution software for the food industry and CTB’s hardware and equipment brands, such as Cabinplant, a Ball Count, Ga.-based manufacturer of advanced equipment for difficult-to-handle convenience foods and food products such as seafood, fruits and vegetables, meat, poultry and dairy; and Meyn, a provider of poultry processing solutions from arrival systems to final packaging and shipment of food products, based in The Netherlands.
RECYCLABLE PACKAGING SOLUTIONS
Klöckner Pentaplast, Gordonsville, Va., introduced the new Evolve S and Elite recyclable packaging solutions.
Designed for rPET or PET applications and in partnership with Proseal, UK, the new Evolve S tray and film features a peelable top film and increases packing line speeds.
The Elite protein tray and film seals through contamination, thus reducing re-work, temperature and sealing time. Plus, this protein packaging solution is made from up to 95% recycled PET content, and is a mono material, which means it is fully recyclable.
Klöckner Pentaplast of America, Inc.
NETZSCH Pumps North America, Exton, Pa., showcased its line of sanitary pumps, ideal for food and poultry applications.
For instance, the NEMO BO sanitary prime open hopper pump, ideal for raw material handling, fruits, vegetables and meat emulsions, is appropriate for clean-in-place processes when provided with optional flushing connections. The pump also meets 3A standard requirements, and can be disassembled quickly for easy cleaning. The exclusive NEMO progressing cavity modular pump design, combined with food-grade Nitrile, EPDM or Viton stators, makes it ideal for flows up to 200 gallons per minute.
Meanwhile, the NEMO BO sanitary prime open hopper pump is an FDA-compliant pump for non-free-flowing applications. It is specially designed to handle high-consistency products with a low degree of flowability. These pumps provide continuous, pressure-stable, gentle and low-pulsation conveyance with metering in proportion to rotational speed. The pump handles flows up to 880 gallons per minute. The pump housing is designed with a larger, rectangular hopper and force-feed chamber. The coupling rod is equipped with a conveyor auger that transports the product into the rotor/stator system. The auger is oversized and provides about 80% more flow to ensure improved pump efficiency. The conveyor auger is perfectly synchronized with the rotor/stator system and covers almost the entire hopper opening. The hopper opening can be customized to fit individual specifications.
HIGH-PRESSURE WASHDOWN SYSTEMS
Sundyne, Arvada, Colo., announced the SundWASH high-pressure washdown system for the food and beverage industry.
SundWASH high-pressure washdown packages are specifically designed for facilities that process chicken, beef and pork as well as other facilities that require high-pressure washdown capabilities for cleaning and sanitation, odor control, dust suppression, deboning and scale removal and more.
SundWASH systems are comprehensive turnkey packages available in single or dual pump configurations. They include motors, motor starters, a pre-programed logic controller (PLC), flow meters, flow and recirculation control valves, temperature switches and piping.
Plus, SundWASH parallel pump systems scale as needed, and feature a small footprint. The Sunflo pumps powering these systems feature a cartridge assembly that can be easily swapped out in place, in a matter of minutes, without having to disconnect the pump from pipe connections.
NON-DESTRUCTIVE LEAK DETECTION TECHNOLOGY
INFICON, Syracuse, N.Y., showcased its non-destructive leak detection technology to the North American meat and poultry market.
Designed to help meat and poultry manufacturers detect gross and fine leaks in modified atmosphere packaging (MAP) and flexible packaging, the Contura S400 is designed for a range of meat and poultry applications that include thermo-formed meal kits, flow-wrapped breakfast sandwiches, vertical form filled and sealed chicken wings, vacuum-packed bacon and more.
The system can also detect micro and gross leaks, eliminating the risk that a package with a tear or a non-welded sealed seam might be incorrectly identified as airtight.
The technology can be easily integrated into any manufacturing environment, is gas independent and its stainless-steel housing and dirt-resistant protective cap helps satisfy various hygiene requirements.
CHECKWEIGHERS, METAL DETECTORS, X-RAY & VISION INSPECTION SYSTEMS
Mettler-Toledo, Lutz, Fla., showcased the CV35 combination inspection system, which offers accurate weight measurement and high-performance label inspection in one compact machine. This system helps manufacturers and packagers ensure accurate product weight, comply with labeling guidelines and weights and minimize product re-work, retrieval and recovery. The CV35 system combines METTLER TOLEDO'S C35 checkweigher platform with the capabilities of METTLER TOLEDO machine vision technology. The CV35 can handle large package sizes, big inspection target areas and multiple product inspections. Plus, it features METTLER TOLEDO CI-Vision’s CIVCore 11 software, which offers precision analysis of high-resolution images at up to 250 ppm. The CV35 system also features an easy-to-clean open construction, with sloping surfaces and tubular framework to minimize dirt traps, and a robust stainless-steel cabinet to protect internal mechanisms from water or dust ingress.
The METTLER TOLEDO enhanced HDS (Heavy Duty Sausage) pipeline metal detector offers in-process metal detection for vacuum filler applications. The easy-to-use key panel, mobile hygienic design and wide range of optional features make this unit an ideal solution to sausage inspection requirements. The rugged, mobile, compact HDS system is designed for close integration with leading vacuum fillers and other sausage processing equipment. The intuitive, keypad interface provides easy setup and minimizes downtime during product changeovers. In addition, HDS pipeline systems are capable of detecting non-spherical contaminants such as metal clips, wire, swarf and slivers of metal introduced during grinding processes. The HDS systems incorporate “stop-on-detect” functionality, which means, when metal is detected, a signal notifies the control vacuum filler operation, purging contaminated product from the pipeline. Alternatively, a choice of robust, stainless-steel, food-quality plug or ball-type reject valves enable manufacturers to reject contaminated product without stopping the filler.
The METTLER TOLEDO Profile Advantage metal detector features multi-simultaneous frequency technology that analyzes product signal data captured across a wide spectrum of frequencies simultaneously. 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. Profile Advantage metal detectors also incorporate Condition Monitoring technology that assesses the performance and operation of key detector components and circuitry. Operators receive alerts on adverse trends or changes in performance that can potentially cause system downtime.
Also on display was the X36 Series of x-ray inspection systems, which inspect products for contamination at high production speeds (up to 300 products per minute) on both single and multi-line operations. The X36 Series uses highly sensitive x-ray detectors that require a 20-watt generator, making it what is said to be the most energy-efficient x-ray system on the market.
Ideal for inspecting small, medium and large products, the X36 Series systems detect for contaminants that include metal, glass, mineral stone, calcified bone and high-density plastic and rubber, and simultaneously offers product integrity checks such as measuring gross and zoned mass, counting components and checking the integrity of seals.
Also new is the X38 x-ray inspection system, specifically designed for pumped food products as they are moved toward final processing and packaging. Products from ground and minced meats to soups, dairy products and jams are inspected for potential contamination by glass, metal, mineral stone, calcified bone, high-density plastic and rubber compounds. The system can inspect and reject contaminated products at throughput speeds of up to 14 metric tons per hour, and comes in three standard pipe sizes—2.5-inch, 3-inch and 4-inch diameters—which can be interchanged with different sizes.
METTLER TOLEDO Product Inspection
IN-RACK FREEZING SYSTEM
Tippmann Innovation, Fort Wayne, Ind., introduced the QF+ in-rack freezing system (QFM), a modular, mobile unit designed to work with existing racking solutions.
QFM works with QF+ patented technology, which cools by pulling air through the product for more consistent and predicable freezing. Plus, it is said to freeze up to 200-400% faster than traditional blast freezers.
Features include advanced LED communication that indicates status of each pallet position, as well as automatic shutdown and smart data sensors.