Food Engineering

What issue about your current plant/facility keeps you up the most at night?

Thermal pasteurization techniques have been around since Louis Pasteur, and there is no question they’re effective.

In the face of coming regulations, as well as forecasts calling for increases in food production and decreases in food waste, the task at hand for food and beverage processors appears to be a monumental one.

Just-in-time manufacturing, advanced automation and process control, sustainable operations and a relentless focus on food safety and sanitary plant design are the hallmarks of Food Engineering’s most recent Plant of the Year award winners.

When most people in the food industry hear the word “antimicrobial,” they usually think about preservatives such as sodium benzoate or calcium propionate.

Announcements about new food and beverage plant construction projects, plant renovations and plant expansions.

Many chemical bactericidal washes and rinses have been tried in the poultry processing industry with varying results; Campylobacter and Salmonella still find their way to finished product.

Projecting nearly 325,000 combined net square feet of exhibit space, the co-located PROCESS EXPO, International Dairy Show and InterBev Process is shaping up to be the largest in the event’s history.

PacMoore, a food processor that specializes in mixes for home-baked goods, blends and packages the mixes into boxes for more than 40 customers nationwide at its Hammond, IN facility.

After House passage of a bill to repeal the Country of Origin Labeling (COOL) law, the Senate appears headed toward similar action.

Announcements about new hires, staff promotions, association news, awards, mergers and acquisitions.

The team at Seacore Seafood is passionate about delivering the world’s freshest, locally sourced seafood, fish and live lobsters to its customers throughout North America.

Safeway Fresh Foods is a family-owned food processor of healthy snacks and meals that go to market under the company’s Sunnyside Farms brand and customers’ private labels.

Glanbia Nutritionals in Ireland operates one of the world’s most modern production facilities, manufacturing high-quality, matured cheddar cheese.

When California seafood canning company Chicken of the Sea International saw more of its customers buying multi-packs of shelf-stable seafood, it decided it needed a new bundling machine that could shrinkwrap multiple cans into a package.

RPC Barrier Containers’ multilayer plastic pot used in Soulié Restauration’s Shake Me pasta product won the best convenience/on-the-go packaging at the World Food Innovation Awards.

Packaging designed to keep products fresh plays a crucial role in reducing some of the 1.3 million tons of food that is wasted around the world each year.

For some time, industrial manufacturing companies have been looking for ways to bring together the seemingly divergent needs of enterprise networking systems and the real-time requirements of plant floor communications systems.

According to the Environmental Protection Agency, almost half the food wasted in the US, approximately 44 percent, occurs in consumers’ homes.

When the Food and Drug Administration (FDA) issued its final determination June 16, giving the food industry three years to remove artificial trans fat from its products, the industry had already made huge advances in finding substitutes.

Engineered for conveyor applications, the Siemens SINAMICS G110M motor-mounted drive for SIMOGEAR gear motors includes USS/Modbus RTU, Profibus and Profinet/EtherNet/IP communication profiles.

The Optima DFe 4-2 filling weigher for powders, granulates and granular products uses a high-resolution load cell.

Lewellyn Technology offers combustible dust fire and explosion compliance and risk mitigation solutions where combustible particulate solids are used, processed, handled or stored.

The Coperion ZRD hygienic rotary valve is used in pneumatic conveying systems and for the discharge of powdered and pelletized materials.

Designed for a variety of foods, the Coperion ZSK Mv PLUS twin screw laboratory extruder meets hygiene requirements.

Vibra Screw heavy-duty bin dischargers for large silos combine a shallow upper section with a steeper lower cone; the compound shape eliminates bridging and packing at the discharge outlet, as well as the need for secondary baffles.

The SolidsFlow USDA feeder provides a sanitary solution for a variety of dry bulk solids.

The Ystral PiloTec processing system offers induction, mixing and dispersing equipment on a smaller scale.

The Material Transfer portable drum discharging system empties various materials from drums through a stainless steel open pour chute with an adjustable drum retention bar and an electroless nickel-plated cylinder.

Designed with an integral dust collection system, the Hapman bag dump station features a centrifugal blower that captures airborne particles as material is dumped into the hopper.

The Hörauf and Optima InlineCan machine makes, fills and closes carton cans containing powders, granules or pieces.

The Alfa Laval hybrid powder mixer combines pump and powder dissolving technologies in a single unit.

The Linde dry ingredient chilling system uses liquid carbon dioxide to cryogenically pre-chill ingredients while they are pneumatically conveyed to the mixer.

Spee-Dee Packaging Machinery’s combination filling systems use one or more fillers to fill multiple ingredients into a single container on a vertical form/fill/seal machine.

The Low Headroom Material Master bulk bag discharger has a discharge spout closure system to stop material flow for partial bag discharge, allowing the bag to be retied and removed.

The Camfil HemiPleat synthetic dust collector filter utilizes 100% polyester media to handle heavy dust loading conditions.

The Acrison Model BDF-1.5-2 volumetric feeder allows metering and hoppering over a wide feed range; it uses two independently driven metering augers with a dual agitator flow-inducing mechanism.

Used to inspect loose-flow bulk products, the Eagle Bulk 415 PRO X-ray system features a cupped conveyor that promotes uniform product depth across the belt and prevents product from spilling onto the floor.

Engineered for hazardous locations, the Material Master Powerfill bulk bag filling system positions its fill head for ergonomic bag connection; the bag hanger system rotates, allowing an operator to connect all 4 bag loops from 1 position.

The EXAIR 110-gal. heavy-duty HEPA vacuum has a high-capacity drum and operates at a 0.3 micron level with a minimum 99.97% filtration.

4B Components P800 Proxswitch proximity sensors have solid state relays for monitoring applications requiring a pulse output up to 120VAC/VDC for PLC integrations; they also can be used to detect shaft, gate or slide position, as well as object presence.

The Eaglestone troughed rod bed conveyor has a sanitary, open design; the main structure is a stainless steel tube rotated 45°.

Using digital signal processing, the Foxboro CFT51 Coriolis mass transmitter improves flow meter performance, particularly during 2-phase flow, partially empty tube conditions and batching from empty operations.

Enabling manufacturers to meet EU regulations for food information to consumers, the CSB-System Nutritional Value Management system calculates, identifies and manages all ingredients, nutritional values, allergens and genetically modified ingredients in a production process.

Fluke a3003 FC wireless DC and a3004 FC wireless DC 4 to 20mA current clamps wirelessly send measurements to Fluke Connect-enabled master units and the Fluke Connect mobile app.

Used to pull and analyze data from multiple sources, Synchrono SyncOperations version 6.0 manufacturing intelligence software includes a workflow automation engine, a data historian and the ability to connect and aggregate data from enterprise systems and machines.

The Banner Q3X laser contrast sensor detects targets within its 50mm sensing range.

The Dorner 2200 Series Precision Move pallet conveyor system has a pin tracking system that guides 160 to 480mm pallets through 90° turns; the pallets move on twin dual-strand timing belt conveyors.

The ABB LMS100 SPDT switch is mounted on a level gauge with a magnetic coupling action that eliminates process contact and the need for seals, diaphragms, springs or torque tubes; it senses high or low levels within a vessel.

The Weber Alpha compact top and bottom labeling system includes 2 mirrored label applicators (one above, one below) and a split conveyor system that allows applying multiple labels on various containers at the same time.

The FabEnCo mezzanine clear height safety gate protects workers from falls on elevated loading areas; it can accommodate tall pallets to allow more material through mezzanine entryways.

Able to measure mass flow in large ducts with hot, dirty gases, the FCI MT91 Series flow meter features a multi-point averaging thermal mass flow sensor and a no-moving parts flow element with up to 16 flow sensing points; up to 4 meters can be installed to measure air/gas in the largest stacks.

Designed for compact areas, Solenoid Solutions Wattmizer miniature solenoid valves feature operating pressures up to 1,200 psi and low wattage coils ranging from 0.65 to 9W.

Certified as HX-1 food-grade, Elevance Aria WTP 40 co-polymer synthetic base stock can be used as an ingredient in H1 lubricants, anti-rust films or release agents with incidental food contact.

Atlas Copco NGP+ plug-and-play onsite nitrogen generators include pressure swing adsorption technology that produces nitrogen with purities up to 99.999%; it can be plugged directly into an existing compressed air installation to offer an independent, flexible supply of nitrogen gas.

The Watlow F4T temperature process controller provides intuitive navigation and screen personalization, allowing channels, alarms, inputs and outputs to be programmed with user-defined specifications.

Featuring multiple product handling areas, the PMI VXL all-servo, vertical top-load cartoner singulates and orients pouches from a bulk hopper and then loads them into a built-in tilt-tray system that delivers them into the carton.

The A-B-C Model 436 all-stainless case sealer for dairies and juice plants offers hot melt sealing speeds up to 50 cases/min.

Federal Mfg. filling machines are used for shelf-stable juices and drinks in 6- to 32-oz. containers, as well as viscous foods including salad dressings, salsa and ketchup in containers from 4 oz. to 1 gal. in size.

Featuring an infrared reflected digital output technology, Clark stainless steel turbine flow meters/flow sensors provide flow monitoring and totalizing for liquids in pressures up to 363 psi.

Compatible with a range of containers including tall bottles and large canisters, the PDC steam tunnel system includes an integrated air knife blowoff system and stainless dual wall construction.

Meeting all global safety standards to protect fingers or hands/arms, the Omron F3SG-4RA IP67 washdown-rated safety light curtain is supported by 24-hr. multi-language online diagnostics.

Used for general lighting in hazardous areas, R. STAHL EXLUX 6402 LED-based linear luminaires are approved to provide type Ex nA protection; the IP66/IP67 devices can be operated at ambient temperatures ranging from -30°C to 55°C.

Used to monitor products in trucks, refrigerated compartments and warehouses, the ECCS IPlug PDF single-use temperature data logger automatically generates PDF reports that serve as proof of best practices; a built-in USB interface allows connection to a PC for downloading data.

The Endress+Hauser Liquiphant FTL33 liquid level switch includes a piezoelectric drive that causes its tuning fork to vibrate at its resonance frequency.

A standalone, fully equipped unit, the GEA Panther NS3006L high-pressure laboratory homogenizer provides continuous operation up to 1,500 bar for limited productions in pilot plants.

Antaira LNP-0802C-SFP and LNP-0802C-SFP-24 8-port industrial PoE+ gigabit unmanaged Ethernet switches have 48 to 55VDC and 12 to 36VDC low-voltage power inputs.

Providing measurements for paper, plastic films, and corrugated and board materials, the TMI 83-76 Elmendorf tear tester has a 7-in. touchscreen for the input of test parameters and the selection of instrument settings.

Based on diode array technology, the Perten DA 7440 SD NIR process sensor measures multiple parameters in all types of fried/baked snack foods; it does not require recalibration between batches and product changeovers. 

Suitable for a variety of fluid transfer applications, NewAge Clearflo Ag-47 antimicrobial PVC tubing is manufactured from a clear, flexible, phthalate-free PVC compound; it contains a silver ion additive on all the tubing surfaces to guard against microorganisms such as E. coli, Listeria, Salmonella, Legionella, MRSA, Campylobacter and Pseudomonas.

Featuring Siemens drive technology, the Kaeser SFC 22 rotary screw compressor has a flow range of 36 to 152 cfm at 125 psig.

The JVL HDCT-100 hollow core rotary actuator has a nominal output torque of 6.8 Nm (963 oz.-in.), a maximum speed of 167 or 200 rpm (motor dependent) and axial load of 150 N (33.7 lb.), while the HDCT-130 model has a 12 Nm (1,699 oz.-in.) nominal output torque, a 167 or 200 rpm (motor dependent) maximum speed and a 200 N (45-lb.) axial load.

The Shimadzu LCMS-8060 triple quadrupole mass spectrometer features an ion optical system for sensitivity in the multiple reaction monitoring and scan modes; the technology helps reduce electrode contamination and provides reliable data for the continuous analysis of potentially contaminated food samples.

The Centrifuge Processing Magnum CFC 1000 centrifuge separates a range of solids from waste, rinse and process water, industrial coolants, and juice and wine processing.

Available with a range of conveyor sizes, the METTLER TOLEDO Hi-Speed XS2 checkweighing system features electromagnetic force restoration weigh cell technology.

Capable of being integrated with horizontal vacuum formers, tray sealing lines and automatic conveyors, the Hinds-Bock model 4P-16V multi-piston depositor fills a range of pumpable products including sauces, marinades, salsa, gravy, entrée items such as macaroni and cheese, and other products with or without particulates.

Equipped with a return-to-neutral feature, UniCarriers BX series battery-powered forklifts include a standard seat-actuated operator presence system that automatically locks lifting and tilting when the operator exits the truck.

Contained in a flameproof enclosure, the Quintex EXTC 100 electronic thermostat can be fully controlled via an infrared remote control without opening or switching off the unit.

The Eriez HandyTec Model HH-10 hand-held metal detector pinpoints small pieces of ferrous contamination in shallow layers of food products.

The Rite-Hite Machine Guarding Defender automated barrier door protects employees from automated stretchwrap machines and other robotic machine movement zones; it has a non-contact safety switch configuration, control systems and interlocking capabilities.

The Yaskawa U1000 Industrial Matrix drive employs a system of 9 bidirectional switches arranged in a matrix to convert a 3-phase AC input voltage directly into a 3-phase AC output voltage; it returns regenerative energy directly back to the power supply.

EcoLine food machinery-certified, biobased, corrosion-inhibiting lubricating grease is made with renewable American-grown natural seed oil.

Designed to work with a Logix-based programmable automation controller, the Rockwell Allen-Bradley PowerFlex 527 AC drive uses a single software package to help simplify machine development and operation.

The Nook caged ball profile rail for linear guidance prevents bearings from making incidental contact.

The GF Fuseal polypropylene corrosive waste piping system handles corrosive waste streams for a variety of dairy, food processing and beverage applications where mixtures of acids, bases and solvents are drained; it does not rust, pit, scale or corrode and is unaffected by electrolysis.

The MOCON OpTech-O2 Model P test system uses a pressure needle and sensor to measure internal package pressure and calculate headspace oxygen levels.

NSF certified for installation in food processing environments, the MaxLite LED linear Vapor Tight fixture has a shatter-proof, watertight housing that can withstand daily washdowns, grease, oil, smoke, dust and steam.

The Omega AQM-103 carbon monoxide monitor measures CO concentration, humidity and air temperature.

Pfannenberg PWW water-to-water heat exchangers offer 2 isolated water circuits; the demand side includes a coolant reservoir and a circulating pump, while the process side has an electronically actuated ball valve for modulating coolant flow rate.

3-A and FDA compliant, the API Heat Transfer Sigma plate heat exchanger meets demanding processing requirements.

Designed for the heavy-duty mixing of viscous pastes and highly filled dispersions, the Ross Model PDM-200 PowerMix planetary disperser has a working capacity of 200 gal.

Baldor Reliance crusher duty motors are available in frame sizes 180T to 449T and in the 5 to 350hp power range.

Used for a range of process hot water applications up to 4 million BTUs, the Spirax EasiHeat DHW heat exchanger delivers a constant supply of hot water at a stable temperature on demand.

Available in ranges from 0/5 through 0/300 psi and vacuum, the Ashcroft G3 compact pressure transducer offers absolute pressure measurement.

Kenics heat exchangers for food processing applications are equipped with static mixer elements.

Used to clean birds with feathers on or feathers off, the Cantrell CBS-60 bird scrubber removes feces and other contaminants from the feathers or skin before processing.

Designed for fresh and salt water processing, Hyde IBS stainless steel seafood processing blades have a honed edge and smooth Ra microfinish coating to reduce friction and the adhesion of fish and waste products during cuts.

Litre Service, Inc. is ISO 9001:2008 certified for rechroming, repairing, reconditioning and rebuilding scraped surface heat exchangers.

Tolomatic servo and stepper drives can be controlled from a PLC or master controller via 24VDC digital I/O, 0 to 10VDC or 4 to 20mA analog I/O, Ethernet or Modbus RTU over RS-485 (EtherNet/IP or Modbus TCP protocols).

Nanotec SC3518 series 2-phase hybrid stepper motors have a NEMA 14 35mm frame and a 1.8° step angle; depending on motor length, torque is between 0.18 and 0.32 Nm.

Designed to prevent product from being heated in pressure conveying systems, Xchanger AA heat exchangers use an aluminum plate-fin core with alternating finned flow channels to cool the conveying air close to ambient temperature.

The Aerodyne standard GPC cyclone dust collector is designed for 10,500 ACFM and stands approximately 20-ft. tall.

The Ystral Conti-TDS system offers powder induction, wetting and dispersing of an agglomerate-free liquid.

The Acrison Model 820 bulk bag unloader uses controlled vibration to discharge the contents of bulk bags.

Boca Bearings offers full-ceramic and ceramic-hybrid bearings for the food processing, beverage and food packaging industries.

Serving as drop-in replacements for all inch-sized linear ball bearings, LM76 FDA- and USDA-compliant bearings measure from 1/4 to 1 1/2 in. in size; they are available in closed and open configurations.

Alfa Laval Unique mixproof valves can handle 2 different fluids at the same time without the risk of cross-contamination.

Used with pump and conveyor technologies, the NORD SK 180E decentralized AC vector drive features 3 digital inputs, 2 digital outputs, 2 analog inputs, an integrated 24V power supply and an onboard AS interface.

Suitable for continuous operation in high-speed rotation applications under low loads, igus iglide L500 self-lubricating plastic bearings accommodate speeds over 16 ft./sec. and perform in temperatures ranging from -148ºF to 482ºF.

Combining a LeCentric reducer with a Regal electric motor, Grove Gear preassembled GEAR+MOTOR cast iron units are torque rated from 5,974 to 18,587 lb.-in., with a maximum input of 1/3 to 40hp.

MFD Pneumatics coalescing filters protect sensitive pneumatic equipment from air line contamination, removing fine oil mist and contamination down to 0.01µ.

Constructed for applications such as CNC routers and conveyors, the Nexen Versa thermoplastic rack also can be used with a range of picking, part-marking and gantry-based automation systems.

AESSEAL modular component seals offer seal face cooling through directed barrier fluid flow systems, hydraulically balanced seal face technology and plug-in designs; standard product lines can be adapted to suit application requirements.

The HRS-R Series rotary scraped surface heat exchanger has a multi-tube design to increase capacity per module.

Engineered for the starch market, the Heinkel horizontal peeler centrifuge has a lower installation height and center of gravity.

Built for packaging machine applications, the VACON 20 AC drive includes a built-in PLC functionality.