October 2020
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PACK EXPO CONNECTS PREVIEW: DELIVERING NEW TECHNOLOGY TO YOUR DEVICE OR DESKTOP THE DRIVE TO ZERO DOWNTIME GET MORE FROM EXISTING ASSETS TECH TODAY: INSPECTION SYSTEMS
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Reduce and Distance Plant Personnel while Boosting Output and Preventing Contamination with automated, enclosed bulk equipment and systems from Flexicon
Automated, sealed BULK-OUT® Discharger-Conveyor Systems replace multiple workers dumping hand-held bags manually, while preventing contamination.
Enclosed Bulk Bag Weigh Batch Systems feed a central weigh hopper mechanically, and remove weighed batches pneumatically, requiring labor only to attach/detach bulk bags.
Bulk Bag Discharging Systems can loosen solidified material and meter it into liquid streams (shown), screeners, size reduction equipment and continuous blenders—automatically.
Dual SWING-DOWN® Bulk Bag Fillers fed by weigh hoppers fill up to 40 bags per hour with only one operator connecting empty bags and one forklift removing full bags.
Flexicon Bulk Bag Filling Lines automatically dispense pallets, fill bulk bags, and disconnect/accumulate filled bags, minimizing operator involvement.
TIP-TITE® Drum/Box Dumpers seal, tip and mate a discharge cone to a gasketed hopper lid, open a slide gate and feed downstream processes— automatically and dust-free.
Flexicon automated equipment and systems can move your bulk materials at higher capacities with fewer personnel, cutting costs while distancing operators from one another. UK AUSTRALIA SOUTH AFRICA CHILE SPAIN FRANCE GERMANY SINGAPORE INDONESIA
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October 2020
CONTENTS
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From the Editor
Advanced automation tools may be just the panacea our industry needs to improve operations and keep workers safe during the COVID-19 era.
In the News
PACK EXPO Connects is a new virtual trade show that will feature comprehensive educational programming from industry experts on packaging and processing trends.
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Packaging Technology
The SeaWell packaging system extends shelf life and improves food safety of seafood by separating the product from the excess liquid it releases.
COVER STORY
In the wake of the COVID-19 pandemic, many processors in ProFood World’s Global 250 Food and Beverage Manufacturers list are pivoting their operations to boost growth of their iconic legacy brands and retail channels. PACK EXPO Connects Preview
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Complete with live chats, product demos, and educational opportunities, PACK EXPO Connects is a new virtual event that will let attendees get an upclose look at the latest industry advancements and access the top suppliers and solutions they need.
Get More From Existing Asserts
Visibility tools, remote diagnostics, and the care and feeding of your essential human assets can push throughput in the right direction.
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Tech Today: Inspection Systems
Food producers are taking advantage of data and processing capabilities to not only improve food safety, but also to work toward improved traceability.
Dry Processing Solutions
To keep up with skyrocketing demand for its collagen powders, Vital Proteins turns to a rotary filler that boosts throughput and improves safety. Bulk and dry processing equipment solutions follow this lead story.
Plant Floor New Products
An inside look at the latest machinery and technologies for production facilities.
Case Study: Blender Upgrade Boosts Entire Soda Filling Operation
By adopting Bevcorp’s new MicrO2 system, Admiral Beverage simplifies deaeration, optimizes blending, and speeds up both filling and changeovers.
Case Study: Integrated Milk Processing System Delivers Sustainable Savings
An Irish milk processor reduces its carbon footprint and boosts capacity with a modular configuration of refrigeration, heat pumps, and a pasteurizer that works seamlessly together.
OpX Intel: The Drive to Zero Downtime
Building reliability into systems and equipment can help food and beverage manufacturers to fulfill safety, quality, delivery, and cost objectives.
www.profoodworld.com
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Simply the best vacuum conveyor
ProFood World ISSN 2476-0676
EDITORIAL
EDITOR - IN - CHIEF JOYCE FASSL
Connect with us
Mobile: 610/547-9814 jfassl@pmmimediagroup.com MANAGING EDITOR MAYA NORRIS
312/205-7898 mnorris@pmmimediagroup.com NEW PRODUCTS EDITOR MORGAN SMITH
@ProFoodWorld @ProFoodWorld www.linkedin. com/showcase/ profoodworld
msmith@pmmimediagroup.com EDITOR AT LARGE AARON HAND
ahand@pmmimediagroup.com CONTRIBUTING EDITORS
JEFFREY BARACH , CHRIS DARLING , MELISSA GRIFFEN , DANIEL LORUSSO, STEPHEN M . PERRY, STEPHEN SCHLEGEL , DAN SILEO
B U S I N E S S S TA F F PUBLISHER PATRICK YOUNG
610/251-2579 pyoung@pmmimediagroup.com DIRECTOR , BUSINESS DEVELOPMENT CAROLYN DRESS
312/205-7912 cdress@pmmimediagroup.com
BRAND OPERATIONS MANAGER CLAUDIA SMITH
312/222-1345 csmith@pmmimediagroup.com ART
ADVE R TI S I N G SALE S
CREATIVE DIRECTOR DAVID BACHO
PUBLISHER PATRICK YOUNG
ASSOCIATE ART DIRECTOR KATHY TRAVIS
AU DIE NCE AN D TECH NOLOGY
SENIOR VICE PRESIDENT, DIGITAL AND DATA DAVID NEWCORN SENIOR DIRECTOR , DIGITAL AND DATA ELIZABETH KACHORIS
• Lean, dense phase, plug-flow
• • • • •
DIRECTOR , WEBSITE PRODUCT MANAGEMENT JEN KREPELKA
conveying of powders & small particles Gentle - segregation & damage free Conveying rates up to 10,000 lbs/hr Safe, explosion free Quiet, hygienic, reliable No tools assembly
SENIOR DATA ANALYST LAUREN SANZ
PUBLISHING PRESIDENT JOSEPH ANGEL PUBLISHER PATRICK YOUNG
DIRECTOR , BUSINESS DEVELOPMENT CAROLYN DRESS VICE PRESIDENT, CONTENT AND BRAND STRATEGY
JIM CHRZAN CONTENT STRATEGIST, ALIGNMENT KIM OVERSTREET DIRECTOR , MARKETING SUE DAMARIO SENIOR MARKETING MANAGER AMBER MILLER EXECUTIVE ADMINISTRATOR JANET FABIANO
ADVE R TI S I N G PRODUCTION MANAGER GEORGE SHURTLEFF
SENIOR DIRECTOR , CLIENT SUCCESS
AND MEDIA OPERATIONS KELLY GREEBY
DIRECTOR , MEDIA INNOVATION SARAH LOEFFLER
SENIOR MANAGER , PRODUCT AND REVENUE STRATEGY ALICIA PETTIGREW
pyoung@pmmimediagroup.com • 610/251-2579 DIRECTOR , BUSINESS DEVELOPMENT CAROLYN DRESS
cdress@pmmimediagroup.com • 312/205-7912
REGIONAL SALES MANAGER BRIAN J . GRONOWSKI
bgronowski@pmmimediagroup.com • 440/564-5920 VICE PRESIDENT, SALES WENDY SAWTELL
wsawtell@pmmimediagroup.com • 847/784-0520 REGIONAL MANAGER RICKY ANGEL
rangel@pmmimediagroup.com • 630/805-3892 REGIONAL MANAGER LEO GUENTHER
guenther@packworld.com • 904/377-7865 REGIONAL MANAGER JIM POWERS
jpowers@automationworld.com • 312/925-7793 REGIONAL MANAGER CHRISTINE J . SMALLWOOD
csmallwood@pmmimediagroup.com 770/664-4600
PUBLISHER , AUTOMATION WORLD KURT BELISLE
kbelisle@pmmimediagroup.com • 815/549-1034 PUBLISHER , HEALTHCARE PACKAGING LIZ TIERNEY
tierney@packworld.com • 815/861-2992 PUBLISHER , OEM MAGAZINE JIM CHRZAN
jchrzan@pmmimediagroup.com • 847/830-2915
ProFood World • PMMI Media Group 401 N. Michigan Ave., Suite 300, Chicago, IL 60611 Phone: 312/222-1010 • Fax: 312/222-1310 Email: info@pmmimediagroup.com • Web: www.profoodworld.com
PUT US TO THE TEST 609-265-0101 www.volkmannUSA.com 1020_Masthead.indd 4
PMMI, The Association for Packaging and Processing Technologies 12930 Worldgate Drive, Suite 200, Herndon, VA 20170 Phone: 571/612-3200 • Fax: 703/243-8556 • Web: www.pmmi.org Staff at PMMI Media Group can be contacted at info@pmmimediagroup.com.
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FROM THE EDITOR
Advanced Automation Tools May Be Just the Panacea Our Industry Needs Industry stakeholders work toward operational improvements and worker safety, while labor unions fight for workers’ rights during this unparalleled era. But automation remains a key aspect of a winning outcome.
I
n the COVID-19 era, many question what is being done to keep the food supply chain intact and ensure food workers are safe. FDA and the Occupational Safety and Health Administration (OSHA) have provided a checklist for FDA-regulated human and animal food operations to use when assessing operations during the pandemic, especially when restarting operations after a shutdown or when reassessing operations because of changes due to COVID-19. In addition, the North American Meat Institute (NAMI) and OSHA signed a two-year alliance to provide NAMI members, the public, and other stakeholders with information, guidance, and access to training resources that will help protect workers. But labor issues continue to be a challenge. Meatpacker unions in several states sued meat processors because of failure to protect workers from getting sick and not giving them enough compensation for jobs that were deemed essential. In some states, OSHA fined meat processors $15,000 for failure to protect employees, but unions were disconcerted by what they felt were nominal sums. California, which has its own OSHA program, fined one meat company more than $200,000. Media outlets reported that meat companies and trade organizations tried to hinder federal orders to shut down affected plants. However, some food companies and trade groups said OSHA stepped up too late to help them protect workers. Back on the plant floor, some food manufacturers are still not allowing visits from outside vendors that normally assist with production issues. This issue of ProFood World emphasizes the challenges processors around the globe face during the pandemic with our cover story on the Global 250 food and beverage companies, as well as our emphasis this month on asset reliability and utilization, and the increased usage of remote diagnostics tools. While advanced automation will increase productivity, let’s not lose sight of the essential human factor in manufacturing. Here’s hoping the increased use of advanced automation tools attracts workers to the food industry by creating an environment of excitement, education, and engagement. PFW
PROFOOD WORLD EDITORIAL ADVISORY BOARD CHRISTINE BENSE CHIEF OPERATING OFFICER Ventura Coastal
HENDRIK EYSELEE DIRECTOR OF ENGINEERING, CHEESE AND DAIRY The Kraft Heinz Company
GREG FLICKINGER SENIOR VP, OPERATIONS Green Thumb Industries Inc.
BILL GILL ASSISTANT VP, ENVIRONMENTAL AFFAIRS
Smithfield Foods
JOHN HILKER DIRECTOR OF MANUFACTURING Blommer Chocolate Company
VINCE NASTI VP, OPERATIONS
Nation Pizza & Foods
JIM PRUNESTI VP, ENGINEERING Conagra Brands
LISA RATHBURN VP, ENGINEERING
T. Marzetti
MARK SHAYE VP, ENGINEERING Ken’s Foods
TONY VANDENOEVER DIRECTOR, SUPPLY CHAIN ENGINEERING PepsiCo
DIANE WOLF FORMER VP OF ENGINEERING AND OPERATIONS Kraft Foods
JOYCE FASSL EDITOR-IN-CHIEF jfassl@pmmimediagroup.com 6
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JOE ZEMBAS DIRECTOR, ENGINEERING AND TECHNICAL SERVICES
The J.M. Smucker Company
www.profoodworld.com
10/1/20 8:19 AM
PROGRESS COMES WITH CLARITY Key Technology shares your vision for progress. We share your vision to avoid waste, to ensure safety standards and to maximize yield, profits and efficiency. Bringing together the world’s leading sorting and conveying systems along with cutting-edge data and intelligence, our industry experts can help you move from complex or disparate technologies to a synchronized and easy-to-operate platform. Maximize uptime and gain peace of mind with a single, proactive long-term partner. Start your progress at Key.net SORTING
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NEWS
IN THE
Grow Your Expertise at PACK EXPO Connects
W
HILE MORE THAN 600 EXHIBITORS have already signed up for PACK EXPO Connects coming Nov. 9-13, the new virtual show also includes expanded educational content featuring leading experts on packaging and processing trends. (Learn more about exhibitor virtual showrooms and product demos in this issue on Pages 38-39.) Comprehensive educational content will feature sessions from industry experts on today’s trends. Information gleaned from these sessions will enhance attendee knowledge as they head PACK EXPO Connects will include a special into PACK EXPO Connects virtual showrooms for presentation with Jan Tharp, president and CEO of Bumble Bee Foods. Photo courtesy specific solutions. of PMMI Media Group. Innovation Stages — Daily presentations Monday through Thursday will inform with sessions on the exhibitors’ latest innovations. Tune in for 30-minute sessions to hear from exhibitors and industry experts on the latest breakthroughs and trends in sustainability, food and beverage, and more. Presenters will be available during their scheduled sessions for live chat Q&As. If you miss the live scheduled sessions, video links will be available for future viewing. The Solution Room — Friday features interactive sessions led by thought leaders and partner organizations, discussing packaging and processing challenges. Collaborate to find solutions with industry gurus from the Institute of Packaging Professionals, The Association for Contract Packagers & Manufacturers, the OpX Leadership Network, and OMAC - The Organization for Machine Automation and Control. Daily Jumpstart Sessions — Start each day of the show with the morning Jumpstart sessions. The daily kick-off presentations are highly engaging and fast paced, featuring multiple subject matter experts in addition to reporting from PMMI Media Group editors. The topics include: • Monday – Sustainable Packaging and Processing • Tuesday – Workforce Development and a special Packaging & Processing Women’s Leadership Network (PPWLN) education session with Jan Tharp, president and CEO at Bumble Bee Foods. PPWLN events connect the audience through valuable insights on women in the industry. • Wednesday – The Robot Revolution • Thursday – All Things Remote • Friday – E-Commerce, Emerging Brands, Healthcare Packaging Trends, and Contract Packaging Trend Chats will feature a brief conversation, Monday through Thursday, between prominent industry experts and PMMI Media Group editors, including: • Monday – Cannabis Packaging • Tuesday – Food Production and Manufacturing Innovation • Wednesday – Traceability and Temperature Control for Pharma and Food • Thursday – Digital Printing Daily Download — Wrap up each day, Monday through Friday, hearing from PMMI Media Group editors as they recap can’t-miss showcases and the latest innovations. Registration is free for attendees at www.packexpoconnects.com. PFW
PepsiCo Appoints New Senior Leadership
PepsiCo, Inc. named Athina Kanioura as executive vice president, and chief strategy and transformation officer. Prior to joining PepsiCo, Kanioura was at Accenture for 15 years, most recently serving as its chief analytics officer and global head of applied intelligence.
Tyson’s Poultry Business Has New President Donnie King is now president of Tyson Foods’ poultry business. King first joined Tyson in 1982 and, since then, has held a variety of executive leadership positions.
Kraft Heinz Selling Huge Chunk of Cheese Business Kraft Heinz is selling its Breakstone’s, Polly-O, Athenos, Hoffman’s, Knudsen, and Cracker Barrel cheese businesses, as well as the licensing of the Kraft cheese brand, to Lactalis in a $3.2 billion deal. The transaction is expected to close next year.
Gray Acquires Anderson Dahlen Gray, Inc. acquired Anderson Dahlen, a family-operated specialty equipment manufacturer and custom stainless-steel fabricator for the food and beverage, pharmaceutical, industrial, and vacuum technology markets. Anderson Dahlen will continue operations under its current leadership. In addition to the acquisition, Gray named Tyler Cundiff as president of Gray, Inc. food and beverage market.
www.profoodworld.com
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IN THE NEWS
Robotics Solutions Future Looks Bright
R
The pandemic has accelerated the growth of robots and cobots usage in food manufacturing.
OBOTS HAVE TRADITIONALLY been implemented in end-of-line manufacturing, and data shows that many manufacturers have difficulty envisioning robotics applications outside of secondary packaging and palletizing tasks. But technology has advanced, according to Automation Timeline: The Drive Toward 4.0 Connectivity in Packaging and Processing, whereby “robots, including cobots, are more than capable of branching out beyond end-of-line applications.” One of fastest growth areas for robot usage in manufacturing is cobots. Cobot applications grew significantly before the pandemic with both revenue and units installed up in 2019. Because they are designed to work alongside employees, cobots alleviate some of the requirements placed on humans
and make production more efficient. Versatility allows cobots to be used in a variety of applications with minimal reprogramming, which makes them an important alternative when considering “new operational realities,” such as labor fluctuations and production schedule shifts due to COVID-19. In the meat packing industry, which has been hard hit by COVID-19, many large companies have been pushed to reevaluate their automation options. While several of the largest players were already developing robotic processing systems over the last five years, many companies have now announced accelerated plans for robotic processing systems to address urgent labor needs. Learn more at www.pmmi.org/ business-intelligence. PFW — Kim Overstreet, Content Strategist
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• Built-in predictive and preventative maintenance program with valve cycle count and pump runtime analysis. • One to four tank configurations with single or dual supply. • Process parameters deliver a more accurate and repeatable process than a time-based approach, and enables users to manage chemical, water, and other resource consumption. • Allows authorized in-house users to make and track all changes. • Automated record-keeping verification occurs after each cycle, designed to comply with regulatory standards CFR21 and S88.
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10/1/20 10:49 AM
PACKAGING TECHNOLOGY
Staying Above Sea Level The SeaWell packaging system extends shelf life and improves food safety of seafood by separating the product from the excess liquid it releases. MAYA NORRIS MANAGING EDITOR
A
PTAR FOOD + BEVERAGE intends to enhance the freshness of packaged seafood from sea to table with its latest active packaging system. The Crystal Lake, Ill.-based company developed SeaWell, packaging designed to separate seafood from excess liquid in order to mitigate microbial growth, prevent breakdown of the product, and extend shelf life. SeaWell features integrated technology that absorbs excess liquid that would otherwise accumulate around the seafood. The packaging consists of a tray made out of recyclable PP with cavities at the bottom. A proprietary blend of direct food-contactsafe powder is placed in the cavities and secured with a nonwoven fabric heat-sealed over the cavities. The powder, which is GRAS (generally recognized as safe) certified by FDA, absorbs excess liquid that the seafood releases and traps the liquid in the wells of the tray, keeping the liquid away from the seafood. The company also makes a pouch version of SeaWell, in which pillow pockets in the back of the pouch contain the powder. They are typically used to package oddshaped seafood, such as crab legs or whole fish. The packaging is available in a variety of sizes for retail and foodservice.
Reeling in results Because SeaWell prevents the seafood product from sitting in excess liquid, the packaging reduces the rate of microbial growth and chemical degradation. According to the studies Aptar has conducted, SeaWell averages a 1-log (90%) reduction in bacteria. In addition to absorbing odor and maintaining the product’s visual appeal, SeaWell also extends the shelf life of the seafood product compared to foam trays with diaper pads and plastic overwraps, bucket packaging, net bags, and other traditional seafood packaging. For example, Aptar says SeaWell packaging can increase the shelf life of mussels by 15% and oysters by 70%. SeaWell can also extend the shelf life of lobster meat by four days and fish roe by 5 days, according to the company. “Between the liquid absorption and the patented tray design, the food product itself is kept up and away, completely separated from the purge [of liquid],” says Christa Biggs, manager of business devel-
opment at Aptar. “So whether it’s a fresh food product that naturally sits in a pool of its own liquid or a frozen product that you thaw in the tray, the design and absorption keeps the product up and away from that liquid. So you get product integrity, freshness extension, shelf life extension.” SeaWell offers a range of other benefits as the packaged seafood product makes its way from manufacturer to retailer to consumer. The technology enables seafood processors to pack frozen for distribution and thaw in the same package, allowing them to reach further geographic markets and decrease food waste. The extended shelf life also means retailers can increase sales and reduce shrink. And by trapping the excess liquid in the wells of the packaging, consumers don’t have to deal with messy leaking packages and possible cross-contamination in the kitchen when preparing meals. A national retail chain is using SeaWell in more than 4,000 stores, but Aptar declined to mention the name of the retailer. According to Aptar, the retailer chose to package its seafood products in SeaWell to help cultivate a high-quality seafood brand. “Their goal was to improve their seafood category,” Biggs says. “They were not previously known as a place to shop for fresh and quality seafood, and they’re trying to change that image. And it’s working.” PFW Aptar Food + Beverage www.aptar.com/food-beverage www.profoodworld.com
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SeaWell prevents excess liquid from accumulating around the seafood by using a proprietary blend of direct food-contact-safe powder placed in the cavities at the bottom of the tray that absorbs the liquid the product releases and traps it there. Photo courtesy of Aptar Food + Beverage.
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PACKAGING TECHNOLOGY
Sustainable Package Reformatting on the Rise
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RAND OWNERS AND RETAILERS are hungry for new sustainable format packaging solutions, but implementing eco-friendly packaging is easier said than done, according to Packaging Sustainability: A Changing Landscape 2020, a new report from PMMI, The Association for Packaging and Processing Technologies. About 56% of consumer packaged goods (CPG) companies are switching to or considering new packaging formats to improve recycling, the report says. But while reducing packaging’s impact on the environment can build brand loyalty and connect with customers, changing a product’s packaging format—particularly novel and/ or highly functional changes—can add challenges when testing and formatting new materials. Also, CPGs are looking for even greater machine flexibility to handle variances in recycled materials. Some of the package format changes that CPGs are implementing include using more stand-up pouches than
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bags; moving from PVC to PET, or from PET to aluminum; changing from rigid to flexible, or returning to paper from plastic; eliminating bags and filling directly into paperboard cartons; migrating from 100% virgin plastic to 100% PCR plastic; and using more sustainable labels. Respondents in the study said they are exploring materials innovations, such as recyclable barrier layers, renewable plant-based materials, or 100% recyclable monomaterial with barrier properties. While biodegradable and compostable materials are becoming more popular, other exciting innovations like edible membranes are emerging. These changes create machine challenges. Conveying lighter gauge materials can cause jams, and sealing and closing during filling can be a problem with thinner film. Machinery also requires highly reliable data collection from sensor feedback to measure sustainability goals accurately. To learn more, visit www.pmmi.org/report/packagingsustainability-changing-landscape. PFW
10/1/20 8:16 AM
WHAT IF…
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10/1/20 10:50 AM 5/28/19 10:53 AM
The Great Global
RESET
As consumers shift their buying and consumption habits in the wake of the COVID-19 pandemic, many of the manufacturers in ProFood World’s Global 250 Food and Beverage Manufacturers list are taking this unprecedented moment as a window of opportunity to boost growth of their iconic legacy brands and retail channels. MAYA NORRIS MANAGING EDITOR
T
HE COVID-19 CRISIS HAS upended the food and beverage manufacturing industry. However, unlike other sectors of the economy that have been decimated by the pandemic, most processors are not only surviving, but thriving during this unprecedented public health crisis. Many of the manufacturers in ProFood World’s Global 250 Food and Beverage Manufacturers list are nimbly navigating the coronavirus pandemic with flexibility and resilience as they pivot their operations to focus on their legacy products and retail channels. Consumers have changed their purchasing and eating habits in the wake of the worldwide COVID-19 outbreak. As businesses shut down, more people work from home, and countries around the world issue stay-at-home mandates, consumers are foregoing restaurant visits and limiting their shopping trips in an effort to avoid contracting the virus, prompting significantly more people to load up their grocery store baskets and eat at home more often.
Home sweet home At the height of the outbreak in the spring, food flew off supermarket shelves as consumers stockpiled pantry and 16
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refrigerator staples in preparation for extended stays at home. According to the Eating Occasions Compass research from the Hartman Group, a food and beverage research firm, at-home eating in the U.S. accounted for 88% of all eating and drinking occasions in spring 2020, an increase of 12% from 2019. Awayfrom-home eating occasions were cut in half this year, dropping to 12% in 2020 from 24% in 2019. Although panic buying has abated as many countries have eased their lockdown restrictions and businesses have reopened, consumers will continue to pad their pantries at least for the length of the pandemic. According to a study of more than 1,600 U.S. consumers from PwC, a multinational professional services firm, 64% of respondents said they will continue to maintain their current rate of pantry loading for the foreseeable future. The survey found that 42% of respondents won’t stop pantry loading until the COVID-19 crisis is fully resolved, while 24% said they will continue to load their pantries until grocery stores are consistently restocked. About 18% said they won’t stop stockpiling. COVID-19 will also continue to impact the foodservice industry, which includes restaurants, school and work cafeterias, and
www.profoodworld.com
10/1/20 8:09 AM
TOP 250 FOOD AND BEVERAGE MANUFACTURERS GLOBAL RETAIL SALES 2019 rank
2018 rank
1
1
2
Ranking change 2018/2019 -
Company
Headquarters
The Coca-Cola Co.
United States
3
PepsiCo Inc.
United States
3
2
Nestlé SA
Switzerland
4 5 6 7 8 9 10 11
4 5 6 7 8 9 10 13
Mondelēz International Inc. Groupe Danone Unilever Group Kraft Heinz Co. Mars Inc. Groupe Lactalis Ferrero Group Inner Mongolia Yili Industrial Group Co. Ltd.
United States France United Kingdom United States United States France Italy China
12
11
General Mills Inc.
United States
13
12
Kellogg Co.
United States
14 15 16 17 18 19 20
15 14 16 17 18 24 22
Grupo Bimbo SAB de CV China Mengniu Dairy Co. Ltd. Suntory Holdings Ltd. Campbell Soup Co. Keurig Dr Pepper Inc. Conagra Brands Inc. Red Bull GmbH
Mexico China Japan United States United States United States Austria
21
19
Ting Hsin International Group
Taiwan
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
23 21 20 26 25 27 28 29 30 31 34 32 35 37 33 36 38 41 39 40 43
Wilmar International Ltd. The Hershey Co. Royal FrieslandCampina NV Monster Beverage Corp. Jacobs Douwe Egberts Asahi Group Holdings Ltd. Lotte Group Arla Foods Amba Kirin Holdings Co. Ltd. Meiji Holdings Co. Ltd. Uni-President Enterprises Corp. Barilla Holding SpA WH Group Yakult Honsha Co. Ltd. Reckitt Benckiser Group Plc (RB) Tyson Foods Inc. Chocoladefabriken Lindt & Sprüngli AG Abbott Laboratories Inc. Perfetti Van Melle Group Yamazaki Baking Co. Ltd. Ajinomoto Co. Inc.
Singapore United States Netherlands United States Netherlands Japan South Korea Denmark Japan Japan China Italy China Japan United Kingdom United States Switzerland United States Netherlands Japan Japan
43
46
Nissin Foods Holdings Co. Ltd.
Japan
44
45
ITO EN Ltd.
Japan
45 46
42 57
Bright Food (Group) Co. Ltd. Froneri Ltd.
China United Kingdom
47
44
Groupe Bel
France
-
-
-
-
48
47
McCormick & Co. Inc.
United States
49
48
The J. M. Smucker Company
United States
50
51
Savencia Fromage & Dairy
France
Major industries
Major brands
Carbonates, Bottled Water, Juices, Iced Tea Coca-Cola, Diet Coke, Sprite, Fanta Carbonates, Sport Drinks, Sweet and Pepsi, Gatorade, Lay’s, 7UP Savory Snacks, Iced Tea Dairy Products, Bottled Water, Breakfast Nescafé, Nestlé, Maggi, Nespresso, Nestea Cereals, Coffee, Confectionery Confectionery, Biscuits Oreo, Belvita, Cadbury Dairy Products, Bottled Water, Baby Food Aptamil, Activia, Danone, Evian Ready Meals, Sauces, Tea Knorr, Magnum, Lipton, Hellmann’s Sauces, Ready Meals, Concentrates Kraft, Oscar Mayer, Heinz, Philadelphia, Kool-Aid Confectionery, Biscuits, Pet Food M&Ms, Extra/Orbit, Snickers, Mars Dairy Products, Ready Meals President, Galbani, Rondelé Confectionery Kinder, Ferrero Rocher, Nutella Dairy Products, Ready Meals Yili, Ambrosial, Satine Dairy Products, Ready Meals, Yoplait, Häagen-Dazs, Annie’s Breakfast Cereals Breakfast Cereals, Sweet and Savory Corn Flakes, Pringles, All-Bran Snacks, Snack Bars Baked Products Bimbo, PlusVita, Sara Lee Dairy Products Mengiu, Deluxe, Jun Le Bao Bottled Water, Tea, Spirits Boss, Suntory Tennensui, Iyemon, Green Dakara Sauces, Ready Meals, Concentrates Campbell’s, Pepperidge Farm, Arnott’s, V8 Carbonates, Sport Drinks, Juices Dr Pepper, Canada Dry, Snapple Sauces, Ready Meals Rotel, Hunts, Frontera Energy Drinks Red Bull Vegetable Oils, Ready Meals, Sauces, Master Kong, Wei Chuan, High Quality Soft Drinks Vegetable Oils Arawana, Gold Ingots, Olivoila Confectionery, Snack Bars Hershey’s, Reese’s, Kit Kat Dairy Products, Ingredients Hollandia, Campina, Dutch Lady Energy Drinks, Carbonates Monster, NOS, Burn Coffee, Tea Jacobs, Tassimo, Bravo, Senseo, L’Or Espresso Bottled Water, Tea, Confectionery Wonda, Mitsuya, Calpis Water Confectionery, Ready Meals, Ice Cream Lotteria, Pepero, Natur Dairy Products, Ingredients, Ready Meals Arla, Lurpak, Yoggi Tea, Health Products Kirin Gogono-kocha, Namacha, Kirin Fire Dairy Products, Baby Food, Confectionery Meiji Oishii Gyunyu, Meiji Bulgaria Yogurt, Savas Dairy Products, Tea, Ready Meals Uni-President, Uni Milk Tea Baked Products, Ingredients Barilla, Mulino Bianco, Voiello Meats Shineway, Farmland, Armour, John Morrell Dairy Products, Ready Meals Yakult, Doshirak Baby Food Enfamil, Nutramigen, Sustagen Ready Meals, Sauces Tyson, Jimmy Dean, Hillshire Farm, Ball Park Confectionery Lindt, Ghirardelli, Whitman’s Baby Food Similac, PediaSure, Ensure Confectionery Mentos, Chupa Chups, Alpenliebe Baked Products, Confectionery Yamakazi, Hear, Peko Ready Meals, Ingredients, Sauces Blendy, Maxim, Calpis Water Ready Meals, Dairy Products, Nissin, Cup Noodles, UFO, Crisp Choco Confectionery Oi Ocha, Kenko Mineral Mugicha, Ito En Tennen Tea, Coffee, Bottled Water Mineral Mugi Cha Confectionery, Ready Meals, Ingredients Bright, Momchilovtsi, Sunbeam, Tnuva Frozen Food, Ice Cream Peters, Froneri Leerdammer, GoGo squeeZ, La Vache Dairy Products Qui Rit, Boursin Sauces, Ingredients, Ready Meals McCormick, Kamis, Vahine, Giotti Ready Meals, Ingredients, Ice Cream, Folgers, Dunkin’ Donuts Juices, Coffee Dairy Products Elle & Vire, Caprice des Dieux, Géramont
Global retail Number of global food and beverage manufacturing sales (U.S. MM) plants 116,586 413 102,363
285
100,193
403
43,454 39,582 38,311 33,770 28,449 22,506 19,326 17,785
126 202 258 82 74 250 18
17,625
51
16,547
40
15,785 13,821 13,082 12,802 12,757 12,158 10,979
194 33 67 32 32 51 2
10,267 10,237 10,175 9,672 9,590 9,074 7,160 7,038 6,950 6,572 6,474 6,255 6,238 6,114 5,938 5,837 5,754 5,727 5,675 5,675 5,559 5,341
450 9 14 1 38 95
5,089
25
5,060
2
3 12 44 30 13 15 9 241 8 11 32
4,950 4,934
11
4,903
30
4,829
27
4,806
26
4,636
9
Data Source: Euromonitor
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2019 rank
2018 rank
51
59
52
Ranking change 2018/2019
Headquarters India
Dairy Products, Ice Cream
Amul, Mithai Mate, Kool Koko
4,624
18
73
Gujarat Co-operative Milk Marketing Federation Ltd. Saputo Inc.
Canada
Saputo, Alexis de Portneuf, Armstrong, Baxter
4,608
58
53
49
Orkla Group
Norway
Hamé, Fun Light, Stabburet, Toro, Grandiosa
4,437
79
54
53
Hormel Foods Corp.
United States
Hormel, Spam, Skippy, Valley Fresh
4,425
75
55
67
Indofood Sukses Makmur Tbk PT
Indonesia
Indomie, Supermi, Indomilk, Tiga Sapi
4,419
56
61
TC Pharmaceutical Industry Co. Ltd.
Thailand
Red Bull, Kratingdaeng, Sponsor Active
4411
57
54
Netherlands
Dairy Products, Ingredients Ready Meals, Sauces, Confectionery, Snack Bars, Ingredients Sauces, Ready Meals, Concentrates, Frozen Food, Vegetable Oils Ready Meals, Dairy Products, Ingredients, Tea Energy Drinks, Carbonates, Snack Bars, Sport Drinks Margarines, Spreads
Flora, Stork, I Can’t Believe It’s Not Butter
4,229
58
60
China
Vegetable Oils, Ingredients
Fortune, Xiangxue Flour, Sundry, Le Conte
4,116
United Kingdom
Confectionery, Biscuits Confectionery, Ready Meals, Juices, Biscuits Breakfast Cereals, Ready Meals, Vegetable Oils, Tea Dairy Products Rice Health Products
59
56
Upfield Holdings BV China National Cereals, Oils & Foodstuffs Imp & Exp Corp. (COFCO) Pladis Ltd.
60
50
Arcor SAIC
Argentina
61
58
Associated British Foods Plc
United Kingdom
62 63 64
55 62 80
Fonterra Cooperative Group Ltd. JA Group (Japan Agricultural Cooperatives) Yangshengtang Co. Ltd.
65
52
Nomad Foods Ltd.
New Zealand Japan China British Virgin Islands
66
65
Fujian Dali Food Co. Ltd.
China
Major industries
Major brands
Global retail Number of global food and beverage manufacturing sales (U.S. MM) plants
Company
17
Godiva, McVitie’s, Ulker
4,112
10
Arcor, La Campagnola, bon o bon, Cofler
4,100
40
Twinings, Ovaltine, Jordans
4,031
46
Anchor, Mainland, Perfect Italiano N/A Nongfu Spring, Tea Pai, Nongfu Orchard
3,965 3,833 3,823
14 47 2
Iglo, Findus, Lutosa
3,790
17
Baked Products, Ready Meals, Sweet and Savory Snacks, Tea
Hi-tiger, Heqizheng
3,761 3,718
100
Frozen Food
67
66
Want Want Holdings Ltd.
Taiwan
Biscuits, Snack Bars, Dairy
Wang Zai, Want Want, Toshitaka-Kun Shuzawa, Mum-Mum
68
63
Oetker-Gruppe
Germany
Dr. Oekter, Backin, Paula, Wölkchen
3,711
5
69 70 71 72 73 74
64 105 unranked 71 70 68
Grupo Lala SAB de CV Feihe International Inc. Shijiazhuang Junlebao Milk Co. Ltd. Otsuka Holdings Co. Ltd. Intersnack Group GmbH & Co. KG Hangzhou Wahaha Group Co. Ltd.
Mexico China China Japan Germany China
Lala, Yomi Lala, MiLeche Firmus, Opo Jun Le Bao Pocari Sweat, Oronamin, Crystal Geyser Chio, Curly, Monster Munch, Soletti Wahaha, Nutrition Express, Maoyuan
3,636 3,559 3,473 3,438 3,408 3,241
9 27 16 13 32 60
75
95
CJ Corp.
South Korea
Snow White, The Healthier, Go Back
3,130
15
76 77
74 76
Megmilk Snow Brand Co. Ltd. Ebro Foods SA
Japan Spain
Hokkaido, Snow Brand, A1 Panzani, Brillante, La Cigala, Sundari
3,125 3,072
18 38
78
93
Strauss Group Ltd.
Israel
Frozen Food, Ingredients, Dairy Products Beer Dairy Products Milk, Soy Milk, Baby Food, Cereals Dairy Products Bottled Water, Soft Drinks Sweet and Savory Snacks Coffee, Carbonates, Tea Ingredients, Health Functional Foods, Desserts, Snacks Dairy Products, Baby Food Sauces, Ready Meals Dairy Products, Coffee, Juices, Confectionery, Biscuits Dairy Products, Ready Meals, Frozen Food Breakfast Cereals, Sweet and Savory Snacks, Frozen Food, Snack Bars Dairy Products Ice Cream, Confectionery, Baby Food, Sweet and Savory Snacks Ingredients, Vegetable Oils Confectionery, Meats, Frozen Food, Coffee, Ice Cream, Ingredients Ready Meals, Frozen Food Coffee, Tea, Bottled Water Dairy Products, Ingredients, Nondairy Drinks Breakfast Cereals Confectionery Tea Dairy Products, Baked Products, Poultry, Baby Food, Juices Juices, Processed Fruit and Vegetables, Sauces Sweet and Savory Snacks, Frozen Food Sweet and Savory Snacks, Ready Meals, Bottled Water Health Drinks Sauces, Ready Meals, Nondairy Drinks Sweet and Savory Snacks, Frozen Food
Sabra, Elite, Doncafé, Pedro’s, Frisco
3,066
20
NA
79
77
Sigma Alimentos SA de CV
Mexico
80
78
Post Holdings Inc.
United States
81
75
Dean Foods Co.
United States
82
81
Ezaki Glico Co. Ltd.
Japan
83
79
Bunge Ltd.
United States
84
72
Grupo Nutresa SA
Colombia
85 86
88 82
Toyo Suisan Kaisha Ltd. Starbucks Corp.
Japan United States
87
87
Morinaga Milk Industry Co. Ltd.
Japan
88 89 90
83 90 69
Cereal Partners Worldwide SA Haribo GmbH & Co. KG JDB Group
Switzerland Germany China
91
86
Almarai Co. Ltd.
Saudi Arabia
92
91
Del Monte Pacific Ltd.
Singapore
93
94
McCain Foods Ltd.
Canada
-
94
101
Nong Shim Co. Ltd.
South Korea
95 96 97
106 92 114
Guangzhou Pharmaceutical Holding Ltd. Kikkoman Corp. Calbee Foods Co. Ltd.
China Japan Japan
Fud, Noche Buena, San Rafael, Fud, La Villita
3,042
31
Post, Malt-O-Meal, Uncle Sam
3,020
32
Dairy Pure, TruMoo, Dean’s, Silk
2,974
70
Pocky, Papico, Bifix, Cratz
2,967
10
Espiga, Primor, Nutra-Clear NT
2,920
166
Zenú, Pozuelo, Zuko, Café Sello
2,892
46
Maruchan, Sanshoku Yakisoba, Sanshoku Udon Starbucks, Seattle’s Best Coffee, Teavana
2,879 2,825
11 9
Parm, Creap, Morinaga Oshii, Piknik
2,806
20
Fitness, Uncle Tobys, Cheerios, Nesquik Haribo Jiaduobao, Kunlun Mountain
2,775 2,739 2,650
14 15
Almarai, L’Usine
2,545
9
Del Monte, S&W, Contadina
2,526
12
McCain, Healthy Choice
2,482
47
Shin Ramyun, Baeksansoo, Jeju Samdasoo
2,475
11
Wong Lo Ckat, Wang Lao Ji Kikkoman, Del Monte Calbee, Calbee, Harvest Snaps, Yushoi
2,473 2,472 2,453
3 15
Data Source: Euromonitor 18
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hotels, as consumers remain cautious about eating out. A white paper from foodservice consultancy Technomic found that 3 in 10 consumers said they plan on leaving the house less often, not go to restaurants, or not order food or beverages from awayfrom-home venues.
Taking center stage The reduction in foodservice demand combined with consumers continuing to stockpile food have been a boon to Big Food. While the world’s largest food and beverage manufacturers are experiencing a sharp drop in foodservice sales, they have been able to offset those losses with a surge in retail sales. Companies with established center-store brands have been reporting better-than-average results, including Nestlé, The J. M. Smucker Company, Kraft Heinz, Mondelēz International, and B&G Foods. Center-store sales have seen a resurgence, driven by consumers stockpiling frozen food and shelf-stable packaged foods as items that offer convenience and a longer shelf life take on renewed importance during the COVID-19 era. In addition, consumers are reaching for familiar nostalgic brands in this time of uncertainty. After years of seeing consumers flock to healthy, fresh, artisanal, and other trendy foods, this surge in center-store sales
has breathed new life into iconic legacy brands, including Kraft Macaroni & Cheese mix from Kraft Heinz and Conagra’s Chef Boyardee canned pastas, which experienced flat or sagging sales over the years. In addition, lifestyle changes consumers have made as a result of the COVID-19 crisis have further fueled demand for these old standbys. About 85% of consumers have changed the food they eat or how they prepare food because of the pandemic, according to the International Food Information Council’s 2020 Food and Health Survey. The survey found that the biggest change is that 60% of consumers are cooking at home more. Additional consumers are indulging in snacking as well: About 26% of respondents say they snack multiple times a day and another third snack daily. Snack food consumption has increased more than 8% during the pandemic as consumers turn to savory and sweet snacks for comfort and enjoyment, according to the Snack Food Behaviors in Challenging Times study from market research firm The NPD Group. Building on that need for comfort, analysts and experts say that consumers are reaching for these established brands from Big Food because they provide nostalgia and familiarity as consumers deal with stressors, such as work demands and financial hardships, during this time of uncertainty.
PROCESSORS ENHANCE SAFETY PROTOCOLS TO KEEP WORKERS SAFE DURING THE COVID-19 PANDEMIC
F
OOD AND BEVERAGE MANUFACTURING PLANTS have been hotbeds for COVID-19 due to the nature of the work: lack of physical distancing, hygiene standards, and the pressure to come in even when workers are sick. But some processors have successfully instituted best practices to keep their workers safe on the plant floor. Reports from the Centers for Disease Control and Prevention (CDC) highlight many of the safety measures and protocols Perdue Farms has implemented to protect their workers from the coronavirus after giving the agency tours of its poultry processing facilities in Virginia and Maryland. They include temperature checking as a requirement before entering the facility; installation of easily cleaned partitions between workers on the production line when social distancing is not possible; knee-pedal handwashing stations workers are required to use each time they enter the processing floor; and hosting virtual town-hall-style
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webinars with community leaders to stay updated about the symptoms and transmission of the virus. Tyson Foods has also sought to improve the safety of its plants after the company experienced outbreaks at several of its facilities. The processor installed more than 150 infrared walkthrough temperature scanners in four facilities: pork plants in Iowa and Indiana and poultry plants in Arkansas and Georgia. Every person is required to have their temperatures taken before entering the plant. It eventually plans to install these scanners at all of its facilities. In addition, Tyson intends to open health centers at several of its plants next year to provide on-site health services for employees. It recently created the position of chief medical officer and plans to hire almost 200 nurses and administrative support personnel for its health services team. Many processors are also offering their employees hazard pay and other benefits to prevent the spread of COVID-19. For example, Tyson employees who test positive for the virus receive paid leave and can only return to work when they satisfy health and safety criteria that Tyson and the CDC have created. McCormick & Co. continues to pay its workers an extra $2 an hour and offers full pay for up to 12 weeks if operations temporarily close. In March, PepsiCo paid employees at PepsiCo Beverages North America and PepsiCo Foods North America an incremental $100 a week through the month. In addition, employees who must quarantine or are diagnosed with the virus receive 100% of their pay during the 14-day quarantine period. Beyond the quarantine period, employees receive twothirds of their pay for up to 10 weeks.
www.profoodworld.com
10/1/20 8:10 AM
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2019 rank
2018 rank
98 99 100 101 102 103
97 104 89 117 109 108
104
107
105
99
Ranking change 2018/2019
Global retail Number of global food and beverage manufacturing sales (U.S. MM) plants 2,451 45 2,416 7 2,411 31 2,392 9 2,327 2,318 49
Company
Headquarters
Major industries
Major brands
BRF SA B&G Foods Inc. Tine SA Vietnam Dairy Products JSC (Vinamilk) Agrofert as Flowers Foods Inc. Sodiaal SA (Société de Diffusion Internationale Agro-alimentaire) Theo Müller GmbH & Co. KG
Brazil United States Norway Vietnam Czech Republic United States
Pet Food, Frozen Food, Vegetable Oils Ready Meals, Sauces Dairy Products, Juices Dairy Products, Soy Milk, Baby Food Pet Food, Frozen Food Baked Products
Sadia, Qualy, Perdigao, Bocatti Green Giant, Bear Creek, B&M, Accent, Ortega Tine, Go, Iste, Biola, Sommer Vinamilk, Dielac, Dielac Alpha Olma, Krahulik, Penam, Tatra Nature’s Own, Alpine Valley Breads, Mi Casa
France
Dairy Products, Baby Food, Ingredients
Yoplait, Candia, Entremont, Le Rustique, Viva
2,310
70
Germany
Muller, Homann, Lisner, Nadler
2,285
8
Koo, Albany, Enterprise, Oros
2,274
5
Lavazza, Carte Noire
2,242
5
Mt. Rainer, Hi-Chew, in Jelly
2,226
9
Liza, Pomarola
2,223
Orion, Choco Boy
2,194
12
Bonduelle, Cassegrain, Artic Gardens, Globus C’estbon, Afternoon, Fire Britannia, Tiger, VitaMarieGold Little Debbie, Sunbelt Bakery, Drake’s Alionka, Bon Roll, Darx Ganten
2,142 2,134 2,130 2,084 2,043 2,026
54 40 13 4 19 10
Great Taste, C2 Cool, Jack n’ Jill
2,023
Schwan’s, Red Baron, Freschetta, Tony’s biPro, Natrel, OKA
$2,018 2,006
10 27
106
84
Tiger Brands Ltd.
South Africa
107
100
Luigi Lavazza SpA
Italy
108
110
Morinaga & Co. Ltd.
Japan
109
103
Cargill Inc.
United States
110
111
Orion Group
South Korea
111 112 113 114 115 116
113 125 136 123 96 184
Bonduelle Groupe SA China Resources Holdings Co. Ltd. Britannia Industries Ltd. McKee Foods Corp. United Confectioners Shenzhen Ganten Industry Co. Ltd.
France China India United States Russia China
117
124
JG Summit Holdings Inc.
Philippines
118 119
120 127
United States Canada
120
130
The Schwan Food Co. Agropur Co-operative Agro-Alimentaire Karnataka Cooperative Milk Producers Federation Ltd.
Dairy Products, Frozen Food, Sauces Processed Fruits and Vegetables, Baby Food, Soft Drinks Coffee Confectionery, Baked Products, Health Drinks, Desserts Pet Food, Vegetable Oils, Ingredients Biscuits, Confectionery, Sweet and Savory Snacks Ready Meals, Frozen Food, Vegetables Bottled Water, Tea Baked Products, Dairy Products, Biscuits Snack Bars Biscuits, Desserts, Confectionery Bottled Water Snacks, Coffee, Ice Cream, Noodles, Confectionery, Vegetable Oils, Tea Frozen Food, Ready Meals Dairy Products
India
Dairy Products
Nandini
1,999
121
143
Parle Products Pvt Ltd.
India
Parle, Melody, 20-20
1,990
9
122
118
Kewpie Corp.
Japan
Kewpie Celestial Seasonings, Blue Print, Ella’s Kitchen, Almond Dream Kopiko, Torabika, Energen
1,964
17
1,908
37
1,851
2
Adria, Vitarella, Piraquê
1,830
15
NA
123
171
The Hain Celestial Group Inc.
United States
124
139
Indonesia
125
119
Brazil
Biscuits, Margarines, Spreads, Flour
126
161
Mayora Indah Tbk PT M Dias Branco SA Indústria & Comércio de Alimentos ITC Group
Biscuits, Confectionery, Sweet and Savory Snacks Sauces, Ingredients Tea, Grains, Ingredients, Ready Meals, Snack Bars, Juices, Sauces Coffee, Tea, Biscuits, Confectionery
127
112
Premier Foods Plc
United Kingdom
128 129 130 131 132 133 134
138 137 129 135 128 132 121
Adani Group Dole Food Co. Inc. Kagome Co. Ltd. The Wonderful Co. LLC KDV Group Valio Oy Karl Fazer Oy Ab
India United States Japan United States Russia Finland Finland
135
147
Aje Group
Peru
136 137 138 139 140 141 142 143 144 145 146 147 148 149 150
115 133 149 144 126 145 156 141 116 131 157 159 175 150 163
Hebei Yangyuan Zhihui Beverage Co. Ltd. Groupe Fleury Michon Chiquita Brands International Inc. Land O’Lakes Inc. Chobani LLC Link Snacks Inc. Maple Leaf Foods Inc. Britvic Plc August Storck KG Eckes-Granini Group GmbH Strauss/São Miguel Sargento Foods Inc. Emami Ltd. AriZona Beverage Co. LLC Ocean Spray Cranberries Inc.
China France United States United States United States United States Canada United Kingdom Germany Germany Brazil United States India United States United States
India
Noodles, Pasta, Sauces, Ingredients Sunfeast, Yipee!, Kitchens of India Ready Meals, Sweet and Savory Snacks, Ambrosia, Batchelors, Angel Delight, Mr Kipling Baked Products Vegetable Oils, Rice, Soy Products Fortune, Alpha, Raag Frozen Food, Juices Dole Dairy Products, Soft Drinks Yasai Seikatsu 100, Kagome Juices, Nuts, Bottled Water, Wines Fiji, Justin, POM, Wonderful Snacks, Baked Products, Confectionery Tri Korochki, Chipsoni, Chipsoni Gold Dairy Products, Ingredients Valio, Valsa, Eila Baked Products, Confectionery Pihlaja, Mignon, Fazer Blue Carbonates, Bottled Water, Juices, Big, Cielo, Pulp, Cifrut Sports Drinks Nondairy Drinks Yangyuan Snacks, Sauces, Ingredients, Processed Meats Fleury Michon Ready Meals, Fruits Chiquita, Fresh Express Dairy Products Land O’Lakes, Alpine Lace, Kozy Shack Dairy Products Chobani Ready Meals Jack Link’s Meats Maple Leaf, Larsen, Shopsy’s, Mitchell’s Carbonates, Sport Drinks, Juices Robinsons, DaFruta, Club Mixers, Energise Sport Confectionery Campino, Merci, Bendicks Juices, Soft Drinks, Concentrates Granini, Rynkeby, Mehukatti Coffee 3 Coracoes, Santa Clara, Pimpinela, Grao Fino Cheese Sargento Health Products, Vegetable Oils Emami Energy Drinks, Iced Tea, Juices, Bottled Water Arizona, Good Brew, Rickey’s! Juices, Fruit Snacks Ocean Spray, Craisins
1,818 1,801
10
1,798 1,796 1,794 1,794 1,790 1,788 1,783
25 7 9 15 18 22
1,742
32
1,736 1,711 1,650 1,631 1,613 1,602 1,600 1,576 1,565 1,562 1,555 1,525 1,522 1,516 1,501
15 9 2 7 12 3 10 34 4 3 1 9
Data Source: Euromonitor
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97
16
92
93
96 59
98 3
17
1 101 102 1 02
34 116 94
32 99
08 36 108 3
42 4 2
Decades of science, imagination, and commitment that help bring your best products to market Heat and Control has been on a mission to modernize equipment solutions since our founding in 1950. For 70 years, our passion for advancing the food, pharmaceutical, and other industries has guided our work. From the machinery we
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103 104
12 1 2
27
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info@heatandcontrol.com Learn more > heatandcontrol.com/alwaysinnovating
ProFood World_70yrs Anni FP_HAC_2020.indd 1 ProFood_AdTemplate.indd 1
7/23/2020 10:14:08 AM 10/1/20 10:58 AM
2019 rank
2018 rank
Ranking change 2018/2019
Company
Headquarters
Major industries
Major brands
Baked Products, Snack Bars Nondairy Drinks, Sweet and Savory Snacks, Biscuits Baked Products, Cakes, Noodles Coffee Milk, Vegetable Oils Coffee, Biscuits, Confectionery Vegetable Oils, Pasta, Confectionery, Milk, Spreads Sauces, Condiments Ingredients, Spices, Sauces Tea, Coffee, Bottled Water, Dairy Products Coffee, Bottled Water, Sports Drinks Beer, Spirits, Bottled Water Snacks, Instant Seaweed, Milk Tea, Confectionery
Shikishima Baking Kashipan, Choujuku, Pasco
151
154
Shikishima Baking Co. Ltd.
Japan
152
176
Blue Diamond Growers
United States
153 154 155 156
160 148 102 168
Fuji Baking Co. Ltd. Tchibo GmbH National Dairy Development Board Kapal Api Group.
Japan Germany India Indonesia
157
169
Alicorp SAAl
Peru
158 159 160 161 162
188 166 162 158 190
Foshan Haitian Flavouring & Food Ltd. House Foods Corp. Tata Global Beverages Ltd. Dydo Drinco Inc. Thai Beverage PCL
China Japan India Japan Thailand
163
164
Guangdong Strong (Group) Co. Ltd.
China
164
unranked
Health & Happiness (H&H) International Holdings Ltd.
Hong Kong United States
NA
Almond Breeze
1,478
4
Fuji Tchibo, Eduscho, Cafissimo Wamul, Quality Mark, Dhara ABC Susu, Kapal Api, Good Day
1,468 1,453 1,443 1,430
6
Primor, Blanca Flor, Alacena
1,427
Haitian House, Gaban, New Crown Ace Tetley, Tata Tea, Eight O’Clock DyDo, Saka, Wakagokochi, Miu Crystal, Chang, Mekhong, SangSom
1,420 1,403 1,364 1,339 1,337
20
U-loveit, Strong, Cici
1,331
3
Baby Food, Health Products
Biostime, Swisse, Healthy Times
1,308
4
Cott, RC, Star & Stripes, Vess
1,300
83
166
153
Empresas Carozzi SA
Chile
167 168 169
230 180 178
Australia Ausnutria Dairy Pty Ltd. NH Foods Ltd. Crown Confectionery Co. Ltd.
China Japan South Korea
170
173
Ottogi Foods Co. Ltd.
South Korea
171 172 173 174 175 176 177 178 179
185 167 181 183 193 197 195 182 177
Rockstar Inc. Jinmailang Food Co. Ltd. Ganaderos Productores de Leche Pura SA de CV Pandurata Alimentos Ltda People’s Food Holdings Ltd. Beijing San Yuan Foods Co. Ltd. National Grape Co-operative Association Inc. Cloetta AB Ruchi Group
United States China Mexico Brazil China China United States Sweden India
180
186
Bourbon Corp.
Japan
Carbonates, Energy Drinks, Sport Drinks, Bottled Water, Tea Confectionery, Sauces, Biscuits, Baked Products Baby Food Beef, Poultry, Fish, Dairy Products Sweet and Savory Snacks Condiments, Vegetable Oils, Ingredients, Noodles, Frozen Food Energy Drinks Noodles, Snacks, Flour, Juices Dairy Products Baked Products, Biscuits Frozen Meats, Poultry Dairy Products Juices, Wines Confectionery Vegetable Oils Sweet and Savory Snacks, Biscuits, Confectionery, Baked Products
181
192
Emmi Group
Switzerland
165
226
Cott Corp.
1,298
11
1,295 1,280 1,267
92 4
Ottogi
1,252
Rockstar Jinmailang, Want Want, Foco Alpura, Alpura Light, Alpura Kids Bauducco, Bauducco Cereale Jinyu Ilactou, Sanyuan, St Hubert Welch’s Läkerol, Cloetta, Jenkki Ruchi, Nutrela, Nutrela Soyabean
1,245 1,242 1,239 1,235 1,203 1,199 1,197 1,195 1,176
1 38 10 3
Elise, Pikkara, Potelka
1,174
8
Dairy Products, Soft Drinks
Emmi Caffé Latte, Comella, Aktifit, Benecol, Emmi
1,171
30
Antarctica, Sukita, Guaraná Antarctica Zero
1,167
156
Clif Bar, Zbar
1,164
1
Frutos del Maipo, Watt’s, Belmont, Calo, Chef
1,158
6
John West, Birds Eye, Leggo’s, Edgell La Serenísima, Yogurísimo, Danonino Chicken of the Sea, John West, Bellotta Svyatoy Istochnik, Borjomi, Morshynska, Myrgorodska Taoli Granarolo, Granlatte, Candia HelloFresh Anpan, Seoul Milk, CoffeePoly, Ampang
1,150 1,142 1,142
7 7 11
1,131
12
1,130 1,117 1,441 1,142
12 4
Sasko, Ceres, Liqui Fruit, Safari
1,113
Itoham, Yakituba, Niku Dango Seara, Swift, Friboi Hochlad, Patros, Valbrie
1,112 1,111 1,110
4 31 14
Dobry, Rich, Pulpy Dobry, Moya Semya
1,108
14
Tymbarak, Caprio, Kubus, Tiger Zaaki, Yudum, Shams Bofrost
1,108 1,104 1,101
21
165
Watt’s SA
Chile
185 186 187
unranked 155 189
NA
J R Simplot Co. Mastellone Hnos SA Thai Union Frozen Products PCL
United States Argentina Thailand
188
unranked
NA
IDS Borjomi International
Ukraine
Bottled Water
189 190 191 192
218 198 unranked 240
Shenyang Toly Bread Co. Ltd. Granlatte Societá Cooperativa Agricola arl HelloFresh SE Seoul Dairy Cooperative
China Italy Germany South Korea
193
146
Pioneer Food Group Ltd.
South Africa
194 195 196
213 191 170
Itoham Yonekyu Holdings Inc. JBS SA Hochland SE
Japan Brazil Germany
197
216
Coca-Cola Hellenic Bottling Co. SA
Switzerland
198 199 200
199 225 201
Maspex Wadowice Grupa Savola Group Bofrost Dienstleistungs GmbH & Co. KG
Poland Saudi Arabia Germany
Baked Products, Cakes Dairy Products Prepared Meals Dairy Products, Juices, Ingredients Cereals, Bakery, Biscuits, Flour, Rice, Pasta Frozen Meats, Processed Meats Frozen Meats, Poultry Dairy Products Carbonates, Juices, Iced Tea, Sport Drinks, Bottled Water Juices, Ready Meals, Sauces, Ingredients Vegetable Oils, Pasta Frozen Food, Ice Cream
Anheuser-Busch InBev NV
Belgium
183
229
Clif Bar & Co.
United States
NA
1 8 12
Carozzi, Costa, Ambrosoli
184
196
1
Ausnutria, Neolac, Allnutria NH, NH Foods, Hoko Choko Heim, Heim, Jolly Pong
Carbonates, Ready-to-drink Tea, Energy Drinks Snacks Bars, Sweet and Savory Snacks Sauces, Ready Meals, Dairy Products, Juices, Frozen Food Frozen Foods, Frozen Meats Dairy Products Fish
182
Global retail Number of global food and beverage manufacturing sales (U.S. MM) plants 1,494 15
1 7 5
Data Source: Euromonitor
24
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MORE THAN JUST A MAGNET
MORE THAN JUST A MAGNET COMPANY
• Industry leading process and product protection • Highest strength Rare Earth magnet material commercially available •
line of magnet tubes optimized for the application
• Certified food safe processing equipment • Multiple cleaning options
Gravity Feed Metal Separation Products •
Magnetic Tubes & Grates
•
Drawer-In-Housings
•
The Ox® Drawer-In-Housing
•
Large Tube Housings (LTH™)
•
The RotoDrawer™ rotary style Drawer-In-Housing
•
Magnetic Drum Separators
•
Plate Magnets & Plate-In-Chute Units
R&D LAB & TEST CENTER Simulate applications in the field and assist in choosing the right magnetic solution. Lab & Testing Features Include: • An automated testing system for both pneumatic and gravity-fed bulk materials • Industry leading IMI magnetic separators • Gauss & pull-testing equipment • Parts-per-million testing for ferrous contaminants in bulk material samples • Test result report provided with pictures, video and recommendations • Testing turn-around in as little as 7-10 business days
Pneumatic Feed Metal Separation Products
CUSTOMER SUPPORT
•
Pneumatic-Line-Housings (PLH)
• Magnetic equipment audits & testing
•
Bullet® magnets (BLM)
•
Exposed Pole Tube magnets (EPT)
• Engineering, Operations and Sales personnel certified as HACCP Managers
• Preventative Maintenance and Service programs
Testing Equipment & Certifications •
NIST traceable Pull Test Kits
•
Metal Detectable and X-Ray Inspectable Seals & Gaskets
•
Sanitary magnetic equipment accepted by the USDA AMS
•
HAACP International certified Food Safety Equipment
INDUSTRIAL MAGNETICS, INC. ProFood_AdTemplate.indd 1
231.582.3100 • 888.582.0821
WWW.MAGNETICS.COM 10/1/20 10:58 AM
To meet this sudden shift in consumer demand and keep store shelves stocked, many processors have cut back their SKUs. They have been focusing on producing top-selling, popular products in order to streamline operations and maximize efficiency in their supply chains. This is a strategy Campbell Soup Co. had already been executing pre-pandemic when it divested its international and fresh divisions in 2019 in favor of bolstering its core Meals & Beverages and Snacks divisions. The company accelerated the plan during the pandemic, refocusing production on its classic canned soups and snacks. The strategy paid off. In the third quarter of fiscal 2020, earnings before interest and tax rose 11% to $273 million, while net sales increased 15% to $2.24 billion. The company attributes the growth to a 35% increase in quarterly soup sales as well as strong gains with its Prego pasta sauces, V8 beverages, Campbell’s pasta, Pace Mexican sauces, and Swanson canned poultry. It says comfort foods like soup and Prego pasta sauces cater to “quick scratch cooking,” which allows home cooks to assemble meals quickly. “Consumers have gravitated to our brands because of the comfort they bring,” said Mark Clouse, Campbell’s president and CEO, during the company’s third-quarter earnings call with analysts. “Think of tomato soup paired with grilled cheese or family spaghetti night with Prego pasta sauce or the fun of sharing SpaghettiOs with your kids. All of them have seen significant consumption gains during the crisis.”
Net sales of snacks increased 9%, driven by strong gains in fresh bakery products, Goldfish crackers, Pepperidge Farm cookies, Kettle Brand and Cape Cod potato chips, Pop Secret popcorn, Snyder’s of Hanover pretzels, Lance Sandwich crackers, Late July Snacks, and Snack Factory Pretzel Crisps. “In this quarter, we experienced unprecedented broad-based demand across our brands as consumers sought food that delivered comfort, quality, and value,” says Clouse. “Campbell’s products were purchased by millions of new households, with total household penetration increasing over 6 percentage points in the quarter compared to the third quarter of fiscal 2019.”
Back to basics Frozen foods are also making inroads with consumers during the COVID-19 crisis, thanks to their long shelf life and ease of preparation. The Frozen Food Sales Amid COVID-19 survey from the American Frozen Food Institute found that 86% of consumers have bought frozen food items, such as pizza, vegetables, and entrees, since early March. Nestlé has benefitted from the frozen food boom with double-digit growth from its DiGiorno, Hot Pockets, Stouffer’s, Jack’s, and Tombstone brands. The J. M. Smucker Company had a strong fourth quarter, aided by strong sales of its Uncrustables products. The sales of the frozen, handheld sandwiches surged to $365 million in fiscal 2020, ended April 30, from $289 million in fiscal 2019. And Kellogg’s North
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1020_Global250.indd 26
10/1/20 8:11 AM
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INCLUDED AT NO ADDITIONAL CHARGE
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2019 rank
2018 rank
201
Ranking change 2018/2019
Global retail Number of global food and beverage manufacturing sales (U.S. MM) plants
Company
Headquarters
Major industries
Major brands
202
Americana Group
Kuwait
California Garden, Farm Frites, Koki, Americana Meat
1,099
29
202
219
India
Aavin
1,096
4
203
unranked
Tamil Nadu Cooperative Milk Producers Federation Ltd. Vital Pharmaceuticals Inc. (VPX)
United States
Bang, Redline
1,089
2
204
205
Cooperativa de Productos de Leche Dos Pinos, RL
Costa Rica
Dos Pinos, Pinito, Deligurt, Gallito
1,085
7
205
217
Conservas La Costeña SA de CV
Mexico
La Costeña
1,083
2
206
237
San Miguel Corp.
Philippines
207
194
Postobón SA
Colombia
208
209
Wonder Sun Dairy Co. Ltd.
China
Meats, Poultry, Frozen Food, Canned Food Dairy Products, Ingredients, Nondairy Drinks Energy Drinks Dairy Products, Confectionery, Juices, Carbonated Drinks Ready Meals, Sauces, Vegetable Oils, Ingredients Meats, Ingredients Juices, Carbonates, Bottled Water, Sport Drinks Dairy Products, Baby Food, Nondairy Drinks
209
151
Charoen Pokphand Group
Thailand
Ready Meals, Meats, Poultry
210
221
Jiabao Group Co.
China
Ready Meals
211
206
Gruma SAB de CV
Mexico
Ready Meals, Baked Products, Flour
212
214
Kameda Seika Co. Ltd.
Japan
Snacks
213 214
140 220
Dongwon Group Shandong Luhua Group Co. Ltd.
South Korea China
Seafood Vegetable Oils
215
228
New Hope Dairy Co. Ltd.
China
Dairy Products
216 217 218
179 134 203
Switzerland Spain Japan
Baby Food, Cereal Bars, Jams Vegetable Oils Coffee
219
211
Hero Group GmbH Deoleo SA UCC Holdings Co. Ltd. Anhui Three Squirrels Electronic Commerce Co. Ltd.
Michelina’s, Authentic Asia, Kitchen Joy, Thai Thai, Royal Umbrella Jiabao Mission, Maseca, Masa Rica, Tortimasa, Guerrero, Tortiricas KAMEDA no Kaki no Tane, Tsumami Dane, Usuyaki StarKist Luhua Sichuan Huaxi, Yangping Milk, Kunming Xuelan Milk Hero, Hero Baby, Hero Muesly Bertolli, Carbonell, Koipe, Sasso UCC, Shokunin No Coffee
China
Snacks, Tea, Fruit Products, Nuts
Clover SA (Pty) Ltd.
South Africa
China Resources Enterprise Ltd. Capri Sun Group Holding AG The Bolton Group Ace Cook Co. Ltd. Dongsuh Foods Co. Ltd. Hostess Brands LLC GlaxoSmithKline Plc.
Hong Kong Germany Italy Japan South Korea United States United Kingdom
Dairy Products, Vegetable Oils, Ingredients Rice, Meat, Frozen Foods Juices Sauces, Vinegars, Fish, Canned Meats Ready Meals, Ingredients, Sauces Coffee, Tea Baked Products Health Products
National Beverage Corp.
United States
Soft Drinks, Bottled Water, Energy Drinks
220
200
221 222 223 224 225 226 227
unranked 207 224 236 210 238 243
228
204
NA
NA
229
231
Bauli SpA
Italy
Baked Products
230 231 232 233 234 235 236 237 238 239 240 241 242
249 239 245 233 187 246 248 234 241 215 unranked 250 unranked
Shanghai Liangyou Group Co. Ltd. Johnsonville Sausage LLC Utz Quality Foods Inc. Acqua Minerale San Benedetto SpA Lantmännen ek för Shenzhen Eastroc Beverage Co. Ltd. Carlsberg A/S Groupe Bigard SA Melitta Unternehmensgruppe Bentz KG Andros SAS Yoshikei Development Co. Ltd. Maeil Dairies Co. Ltd. Ready Pac Produce Inc.
China United States United States Italy Sweden China Denmark France Germany France Japan South Korea United States
243
244
Kerry Group Plc
Ireland
244 245
unranked unranked
Harry-Brot GmbH Australasian Conference Association Ltd.
Germany Australia
246
223
Molinos Río de la Plata SA
Argentina
247 248 249 250
unranked unranked unranked unranked
Blue Bell Creameries Inc. Soummam SpA Hefei Huatai Food Co. Ltd. Amy’s Kitchen Inc.
United States Algeria China United States
Ready Meals, Vegetable Oils, Ingredients Meats, Ready Meals, Sauces Snacks Bottled Water, Juices, Carbonates Cereals, Pasta Bottled Water, Juices Carbonates, Bottled Water Meats Coffee Desserts, Soft Drinks Prepared Meals, Soft Drinks Dairy Products, Baby Food Prepared Meals Ready Meals, Ingredients, Sweet and Savory Snacks, Dairy Products Bread, Baked Products Cereal Bars, Spreads, Dairy Products Pasta, Frozen Food, Poultry, Snacks, Rice, Ingredients Ice Cream, Frozen Foods Dairy Products Edible Oils, Snacks Frozen Foods, Prepared Meals
-
NA NA NA NA NA NA NA NA
Baker’s Best, Buttercup, Cheezee, Chocolait
1,072
32
Hit, Hipinto, Sr Toronjo, Postobon, Cristal
1,066
23
WonderSun, Anlicong, Wanda
1,061
24
1,059
10
1,049
6
1,048
59
1,047
4
1,037 1,036
7 17
1,032
11
1,031 1,027 1,023
6 9
Three Squirrels
1,018
1
Clover, Aquartz, Tropica, Olive Pride
1,015
7
Ng Fung Capri Sun Rio Mare, Saupiquet, Palmera Jan Jan, Pho-ccori, King Taste, Acecook Maxim, Mocha Gold, Canoe Dolly Madison, Hostess, Twinkies, Donettes Horlicks, Lucozade, Maxi Nutrition Shasta, Faygo, Everfresh, La Croix Sparkling Water, Rip It, ClearFruit, Mr. Pure Motta, Alemagna, Tartufone Motta, Trinidad, Gran Soffice Lehui, Haishi, Xuege, Weidu Johnsonville, Giddy Up Utz, Bachman, Zapp’s, Dirty Potato Chips San Benedetto Go Green, Axa, Start! Ganten, Eastroc Super Drink Flash Up, Klebny krai, Taras Kvas Charal, Bigard Melitta, Cilia, Albal, Swirl, Glad Andros, Bonne Maman Yoshikei Baristar Rules, Maeil Milk, Absolute, Maeil Bio Ready Pac
1,015 1,012 976 969 969 963 960
14 24 12 5
950
13
5
946
4
946 945 943 943 935 927 918 914 911 909 904 903 881
20
Low Low, Cheestrings, Dairygold, Charleville
881
14
Harry, 1688 Weet-Bix, Up&Go, Sanitarium, So Good Cruz de Malta, Arlistán, Nobleza Gaucha, Granja del Sol, Exquisita Blue Bell Soummam Qia Qia Amy’s Kitchen
880 878
10 5
858
14
855 851 849 848
3 1 1 3
11 11 6 59 8 25 6 7 4
Data Source: Euromonitor 28
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10/1/20 11:00 AM 9/10/2020 2:59:53 PM
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1020_Global250.indd 30
THE GLOBAL 250 AND GLOBAL 50 LISTS ON PROFOODWORLD.COM
T
HE GLOBAL 250 Food and Beverage Manufacturers list ranks the world’s food and beverage companies by retail sales, while the Global 50 Alcoholic Beverage Manufacturers are ranked by volume produced. Compiled by Euromonitor International and com missioned by ProFood World, this exclusive research features much more data available online at www.pro foodworld.com/global-250. It includes information such as the major manufacturing locations of the Global 250 companies, statistics on U.S. sales for each company, U.S. beverage sales by company, U.S. packaged goods sales by company, global beverage sales by company, and global packaged goods sales by company. Sort and search functions are available for both the Global 250 and Global 50 lists at www.profoodworld.com/global250 and www.profoodworld.com/global-50.
American frozen foods business saw sales for its Eggo frozen waffles increase 45% in the first quarter and 26% in the second quarter of fiscal 2020. Sales for its MorningStar veggie line rose 66% in the first quarter and 31% in the second quarter. To continue to meet demand for these and other mainstay products, Kellogg chose to delay the launch of Incogmeato, a plant-based meat alternative for its MorningStar brand. With more people cooking at home to save money and avoid exposure to the coronavirus, many processors are ramping up production of products that facilitate those culinary endeavors. For example, as General Mills trimmed its SKUs to make its supply chain more agile, it focused on key high-volume products that let consumers bake at home. In its fourth quarter, General Mills’ U.S. meals and baking operating unit generated a 68% growth in sales, driven by strong gains from brands including Pillsbury refrigerated baked goods, Betty Crocker desserts, and Gold Medal flour. McCormick & Company is also capitalizing on the shift to home cooking. The seasonings and spices company posted an 8% sales increase it the second quarter of fiscal 2020 compared with the same quarter a year ago. Sales to consumers rose 26%, with high volumes in the Americas, Europe, Middle East, and Africa. But it also saw sales drop with its foodservice clients by 18%. To promote its products with consumers, McCormick plans to launch a marketing campaign that educates consumers on how to use its products in the kitchen. “Our results for the second quarter were significantly impacted by a shift in consumer demand resulting from the COVID-19 pandemic,” says Lawrence E. Kurzius, chairman, president, and CEO of McCormick. “Our exceptional consumer segment growth was driven by the substantial increase in demand as consumers were cooking more at home. In our flavor solutions segment, our results were significantly impacted by sharp declines in demand from restaurant and other foodservice customers as away-from-home dining was significantly curtailed. Taken together, these impacts demonstrate the strength and diversity of our offering.” Consumers in Latin America are mirroring the eating and buying behaviors of Americans and other consumers around the world as Latin American countries become hotspots for the pandemic. As they quarantine themselves in their homes and limit grocery store visits, Latin American consumers are also stockpiling food staples. For example, while Grupo Bimbo saw net sales rise in the second quarter to 19.9% primarily due to strong growth in North America, the multinational bakery company also increased sales in Latin American countries by 13.3%. The company 30
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TOP 50 ALCOHOLIC BEVERAGE MANUFACTURERS GLOBAL RETAIL SALES 2019 rank
2018 rank
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 10 12 11
12
Ranking change 2018/2019 -
Company
Headquarters
Major industries
Major brands
Anheuser-Busch InBev NV Heineken NV Carlsberg A/S China Resources Holdings Co. Ltd. Molson Coors Brewing Co. Tsingtao Brewery Co. Ltd. Asahi Group Holdings Ltd. Diageo PLC Beijing Yanjing Brewery Co. Ltd. Kirin Holdings Co. Ltd. Thai Beverage PCL
Belgium Netherlands Denmark China United States China Japan United Kingdom China Japan Thailand
Beer Beer Beer Beer Beer Beer Beer, Spirits Spirits, Ready-to-drink Beer Beer Beer, Spirits
13
San Miguel Corp.
Philippines
Beer
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
9 15 14 18 17 19 16 21 24 20 25 22 26 28 23 27 29 30 37 31 33 32
Constellation Brands Inc. Suntory Holdings Ltd. Castel Groupe Cervejaria Petrópolis SA Anadolu Group Pernod Ricard Groupe Oetker-Gruppe UB Group Boon Rawd Brewery Co. Ltd. Guangzhou Zhujiang Brewery Co. Ltd. Hite Jinro Co. Ltd. Grupo Mahou-San Miguel SA Cía Cervecerías Unidas SA E&J Gallo Winery Inc. Henan Jinxing Brewery Group Blue Ribbon Intermediate Holdings LLC Sapporo Holdings Ltd. Bitburger Braugruppe GmbH Beijing Shunxin Agriculture Co. Ltd. Distell Group Ltd. Cia da União de Cervejas de Angola SA Oettinger Brauerei GmbH
United States Japan France Brazil Turkey France Germany India Thailand China South Korea Spain Chile United States China United States Japan Germany China South Africa Angola Germany
Beer, Wine, Spirits Beer, Wine, Spirits Wine Beer, Spirits Beer Wine, Spirits Beer, Wine, Spirits Beer Beer Beer Beer, Wine, Spirits Beer Beer, Spirits Wine Beer Beer Beer Beer Spirits Ready-to-drink, Wine, Spirits Beer Beer
35
38
The Boston Beer Co. Inc.
United States
Beer
36 37
36 34
Bermuda Vietnam
Spirits Beer, Spirits
38
35
Germany
Beer
39 40 41 42 43
39 unranked 41 unranked 42
Bacardi & Co. Ltd. Hanoi Alcohol Beer & Beverages Corp (Habeco) Krombacher Brauerei Bhd Schadeberg GmbH & Co. KG Damm SA Mark Anthony Brands Ltd. Accolade Wines Ltd. Khmer Beverages Co. Ltd. Paulaner Brauerei GmbH & Co. KG
Budweiser, Bud Light, Scol, Corona, Harbin, Brahma Heineken, Tecate, Tiger, Nova Schin, Amstel Turborg, Carlsberg, Baltika, Kronenbourg, Wusu Snow, Blue Sword, Kingway Coors, Miller Lite, Carling, Keystone, Staropramen Tsingtao, Laoshan, Hans Asahi, Zubr, Peroni, Velkopopovicky Kozel Guiness, Smirnoff, McDowell’s, Johnnie Walker, Tanqueray Yanjing, Liquan, Huiquan Nodogoshi Nama, Kirin Ichiban Shibori, Kirin Tanrei Saigon, 333’ export, Chang Beer, Ruang Khao Red Horse Beer, San Miguel, San Miguel Light, San Miguel Cerveza Negra Modelo, Corona, Svedka, Casa Noble, Woodbridge Suntory, Kinmugi, -196°C Strong Zero, Yamazaki St George, Castel, Nocal, Maison Virginie, Aimé Roquesante Itaipava, Crystal, Nordka Efes, Bely Medved, Gold Mine Beer Imperial, Royal Stag, Absolut, Havana Club, Chivas Radeberger, Jever, Binding, Henkell Kingfisher Premium, Zingaro, UB Export Leo, Singha Beer, Singha Light Beer, Thai Beer Zhujiang, Supra Beer Chamisul, Hite, Terra, Filite San Miguel, Mahou, Mixta Shandy, Alhambra Especial Cristal, Escudo, Schenider, Royal Guard Barefoot, Carlo Rossi, Twin Valley, Peter Vella, Liberty Creek Jin Xing, Landmark Pabst, Old Milwaukee, Colt 45, Jacob Best Sapporo, Mugi To Hop Bitburger, König Pilsener, Köstritzer, Wernesgruener Niulanshan Er Guo Tou Hunter’s, Savanna, 4th Street, Bernini Cuca, Nova Cuca Oettinger Pils, Oettinger Bock, Oettinger Gold Samuel Adams, Twisted Tea, Truly Spiked & Sparkling, Angry Orchard Bacardi, Martini, Grey Goose, Havana Club Hanoi, Bia Lon, Anh Dao, Bia Ha Noi
Spain Ireland Australia Cambodia Germany
Beer Spirits Wine Beer Beer
44
46
Brown-Forman Corp.
United States
Wine, Spirits
45 46 47 48 49 50
45 43 40 48 44 unranked
The Wine Group Inc. Lotte Group Empresas Polar CA Treasury Wine Estates Ltd. Obolon PAT Allied Blenders & Distillers Pvt Ltd.
United States South Korea Venezuela Australia Ukraine India
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Wine Spirits Beer Wine Beer Spirits, Ready-to-drink Data Source: Euromonitor
Global alcoholic Number of global drinks volume manufacturing sales plants 53,527 156 22,863 165 11,740 11,447 98 8,777 31 8,077 60 6,633 95 4,723 91 3,879 37 3,316 3,186 21 3,042
100
3,008 2,610 2,575 1,639 1,579 1,560 1,530 1,442 1,297 1,272 1,232 1,197 1,090 1,048 1,019 983 848 711 638 631 629 623
44 14 24 5 61 101 17 79 8 20 6 5 23
617
7
608 591
30 25
Krombacher
586
1
Estrella Damm, Damm, Xibeca Damm, Voll Damm White Claw Hard Seltzer, Mike’s Hard Lemonade, Cayman Jack Hardys, Stanley, Berri States, Grant Burge Cambodia Beer Paulaner, Orginal Münchner, Hacker Pschorr Jack Daniel’s, Brown Brothers, New Mix, Early Times, Old Forester Franzia, Inglenook, Almaden, Benziger Choumchorum, Seoljungmae, Majuang Polar, Solera, Solera Light Beringer, Wolf Blass, Yellowglen, Penfolds Obolon, Zhigulevskoye, Zibert, Hike Premium Officer’s Choice, Sterling Reserve, Kyron
530 516 427 420 413
2
363
11
362 360 354 350 349 347
6 5 17 8 40
2 5 2 2 4
2 1 1
www.profoodworld.com
10/1/20 8:12 AM
WITH URSCHEL,
You'll Always Be on the Cutting Edge Cutting Assistance When/Where You Need It Urschel’s line of Affinity® Dicers provides additional feed assistance for input that presents challenges to some cutting methods. Cold-temperature, high-fat content products, sticky products, cheese and meat present certain issues to processors. The cutting principle teams cutting components with active feeding elements such as a feed spindle and feed drum incorporated with the slicing, circular, and crosscut stations, and ending with a stripper plate. The original Affinity accepts a large product infeed with a powerful 25 HP motor, and is available in a U.S.D.A., Dairy Division accepted version, or with a built-in conveyor feeder. In addition to the original, large Affinity, the Affinity Integra® Dicer (Integra) is a smaller version with a capable 10 HP motor. Choose which Affinity suits your production line goals. As your partner in productivity, Urschel is here to support your cutting efforts and deliver effective cutting solutions.
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Manufacturing Software to Help with the New Normal
credits volume growth to both retail and e-commerce channels, helping it to gain market share across bread, buns and rolled breakfast, sweet baked goods, and snacks categories. These gains helped to off set some of the weak volumes Grupo Bimbo experienced with its foodservice and convenience store channels due to the COVID-19 outbreak.
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Europe-based food processors are also depending on retail sales to help make up for losses in foodservice sales. For example, Unilever’s second-quarter sales dipped only slightly by 0.3%, thanks in part to consumers buying the company’s ice creams and soups during the pandemic, off setting its massive plunge in foodservice sales. Foodservice sales dropped 40%, and out-of-home ice cream sales decreased nearly 30% in the first half of the year as restaurants, hotels, cafes, theaters, and bars closed or operated in limited capacity. However, the consumer goods giant says it attained double-digit growth in its Foods & Refreshment division with an uptick in sales at retail channels. Its Knorr soups and Hellman’s mayonnaise lines proved to be strong performers with consumers in quarantine. In addition, sales of Breyers, Magnum, Klondike, and Ben & Jerry’s ice creams rose during the period to boost Unilever’s at-home ice cream sales by 15% in the first quarter and 26% in the second quarter. Despite weathering the first half of the year relatively unscathed, Unilever still faces challenges ahead. Some analysts say that the ongoing pandemic could put the company at risk. Unilever experienced a 2.4% growth in the first half of the year led by developed markets in North America and Europe. But the company relies on about 60% of its annual sales in emerging markets. As the coronavirus expands in Africa, Latin America, and other parts of Asia, Unilever’s overall revenue could take a hit. Like Unilever, Danone has been dinged by a decline in foodservice sales in the first half of the year. After posting a 3.7% increase in sales in the first quarter thanks to pantry loading and panic buying, Danone was unable to maintain the momentum. In the second-quarter, the French company was hit with a 5.7% drop in sales. The weaker second-quarter sales reflected less pantry loading by consumers and a 28% decrease in net sales in Danone’s bottled water division, which depends on foodservice and on-the-go consumption. 34
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SCHUBERT LIGHTLINE
YOUR DECISION HAS NEVER BEEN THIS EASY. The lightline Pickerline consists of compact modules that are preconfigured and ready to use for standard packaging tasks. In this way the Pickerline is attractively priced and delivered in next to no time. With its individual robotic tools you will experience the benefits of the highest degree in flexibility with the innovative Schubert-Technology. www.schubert.group LIGHTLINE PICKERLINE FOR PICKING AND PLACING PRODUCTS IN TRAYS
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Designed with a Purpose®
But Danone’s second-quarter financials did have some bright spots. The company’s Specialized Nutrition business, which includes infant and adult nutrition products, saw sales rise 2.7% in the first half of the year. Danone’s Dairy & Plant-based division posted a net sales increase of 3.1% in the first half of the year, with solid growth in North America and Europe. To ensure it can keep shelves stocked with its dairy and plant-based brands in Europe and North America, Danone is focusing on producing only top-selling SKUs and packaging them in larger formats. Building on the success of its dairy, plant-based, and nutrition products, Emanuel Faber, chairman and CEO of Danone, says the company will develop affordable, healthier versions of comfort foods, predicting that consumers will want to rebalance their diets as the pandemic continues.
Cheers to beer
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COVID-19 has taken its toll on the alcohol segment as well. Although more people are buying booze for at-home consumption compared to last year, those retail sales won’t be enough to prevent a downturn in the industry, according to research from IWSR Drinks Market Analysis. The study says that global alcohol sales will drop 12% this year because of the worldwide shutdown of bars, restaurants, travel, and live events, and predicts that the industry won’t return to pre-pandemic levels at least until 2024. To prevent sales from collapsing further, Big Alcohol is focusing on lower-cost products to help cut its production costs and meet consumer demands for less expensive alcohol products in this tightening economy. For example, AnheuserBusch InBev, the world’s largest brewer, saw revenue from its top three brands— Budweiser, Stella Artois, and Corona—drop 11%. But some of its inexpensive beers, like Lion Lager, were performing well in certain markets, like South Africa, and growing at a double-digit rate in the first quarter. Meanwhile, Asahi, Kirin, Suntory, and Sapporo Breweries—Japan’s four biggest brewers—saw their beer revenue in Japan fall in the first half of 2020 compared to a year earlier. However, sales from their lowmalt happoshu beers and so-called third-segment quasi-beers made from cheap malt alternatives grew in the same period as people drank at home while reducing their spending on alcohol. Although the beer category has taken a hit in 2020, IWSR predicts beer will recover better than the wines and spirits sector, led particularly by growth in low- or nonalcoholic beers, forecasting an 8.1% compound annual growth rate from 2019-2024. Both Heineken and Carlsberg will continue to invest in its alcohol-free beers, fueled by consumers’ heightened focus on health and well-being during the coronavirus pandemic. While Heineken saw net revenue decrease 16.4% and beer volumes fall 11.5% in the first half of 2020, the Dutch beer maker posted double-digit growth for its Heineken 0.0 alcohol-free beer brand across all regions, with strong performance in the U.S., Mexico, and South Africa. Its Danish rival, Carlsberg, has long focused on low- and no-alcohol beer as a key growth driver, citing demand from younger people focused on healthy lifestyles. Prior to the pandemic, Carlsberg was experiencing a 16% volume growth in its alcohol-free beers compared to 1% growth from its core beer products. The company launched its latest no-alcohol beer, Tuborg Zero, on May 1 in Denmark. After just one month, Tuborg Zero became the best-selling alcohol-free beer, according to Carlsberg.
Charting the course forward The COVID-19 crisis has certainly been both a boon and challenge for processors. While this unprecedented public health crisis has put strain on their supply chains, hurt foodservice sales, and set new product development on the back burner, the pandemic has also helped Big Food stage a comeback and fuel sales growth as consumers take a second look at their iconic legacy brands. As these processors look ahead, the challenge is to maintain this momentum in a post-pandemic world— whenever that will be. PFW 36
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PACK EXPO CONNECTS DELIVERS NEW TECHNOLOGY TO YOUR DESKTOP OR DEVICE The virtual event will foster connections with a wide variety of solutions providers—minimizing attendee time and effort to find the innovations they need. The latest industry advancements will be presented via 2,700 live product demonstrations, connecting attendees with exhibitors. SEAN RILEY PMMI SENIOR DIRECTOR OF COMMUNICATIONS
PACK EXPO Connects has several new features that will foster connections with a wide variety of solutions providers. Photo courtesy of PMMI Media Group.
W
ITH A WORLDWIDE PANDEMIC making supply chains and supplier and consumer packaged goods (CPG) connections complex, PMMI Media Group introduces a live, virtual event like no other: PACK EXPO Connects 2020 will take place Nov. 9-13. Now more than ever, packaging and processing professionals need solutions for a rapidly changing world, and PACK EXPO Connects offers the power of PMMI Media Group and the PACK EXPO brand to bring the industry together. Complete with live chats, product demos, and engaging educational opportunities, this virtual event
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provides attendees direct access to the top suppliers and solutions they need. PACK EXPO Connects boasts several new features that will foster connections with the widest variety of solutions providers available anywhere—minimizing attendee time and effort to find the innovations they are looking for. An easily searchable database of exhibitors and products organized by 12 major categories allows attendees to zero in on specific needs and schedule live chats and interactive product demos with technical experts. The interactive platform makes live engagement with exhibitors simple via MyConnects planner. At the same time, Outlook calendar integration allows attendees to add My Planner events to their Outlook calendars for ease of reference. PMMI Media Group brought together its digital marketing expertise, decades of industry knowledge, and months of research with leading CPGs to build an event based precisely on what the industry needs now: virtual showrooms for demos, live chats with product experts, and overarching education offerings. Approximately 2,700 live product demonstrations will connect attendees with exhibitors. These 15-minute demonstrations will allow attendees to see what’s new, ask questions, and engage with exhibitors in real
www.profoodworld.com
10/1/20 8:25 AM
VIRTUAL SHOW PREVIEW Thousands of live, new product demos will be available throughout PACK EXPO Connects. Photo courtesy of PMMI Media Group.
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time. Demos are categorized into 12 major categories: 1. Filling, Capping, and Sealing Rigid Containers or Trays 2. Bagging, Pouching, and Wrapping 3. Cartoning and Multipacking 4. Coding, Marking, Labeling, and Printing 5. End-of-Line Equipment 6. Feeding, Conveying, Accumulating, and Product Handling 7. X-ray, Vision, Inspection, Testing, and Weighing 8. Containers, Materials, and Transport Packaging 8. Controls, Software, and Machine Components 9. Plant Facilities and Infrastructure 10. Food Processing Equipment 11. Life Sciences Live one-on-one chats will allow attendees to talk directly with exhibitors during dedicated event hours. If an attendee can’t catch an exhibitor during the event hours, virtual business cards will help foster those connections even after the event’s conclusion. Comprehensive educational content will feature thought-provoking sessions from leading suppliers and industry experts on today’s trends. Information gleaned from these sessions will enhance attendee knowledge as they head back into the virtual showrooms for specific solutions. All content noted will be available both as scheduled and on-demand after the event.
Industry excitement More than 500 exhibitors committed to the show in the first three weeks of sales, filling the live showroom hours that will run Monday through Thursday from 10:00 a.m. to 3:00 p.m. CST and Friday from 10:00 a.m. to 1:00 p.m. CST. “We are excited by the level of support we’re getting from exhibitors who are eager to share their technologies through this new platform,” says Dave Newcorn, senior
vice president, digital and data, PMMI Media Group. “To ensure the greatest possible access for both exhibitors and their customers, we are expanding exhibit hours for PACK EXPO Connects.” Each day also features international demo hours to expand PACK EXPO Connects’ global reach. International demos will broadcast at 10:00 a.m. China Standard Time (9:00 p.m. CT) and 10:00 a.m. Greenwich Mean Time (4:00 a.m. CT). These time slots will enable exhibitors to demonstrate their solutions and enjoy live interaction with attendees outside the Western Hemisphere. In addition, all education sessions will be available on-demand for international attendees to watch at their convenience. Spanish language closed captioning will also be provided for specific content and interviews with industry newsmakers. “PACK EXPO Connects is shaping up to be the most innovative and engaging industry event this year,” says Jim Pittas, president and CEO, PMMI. In the months leading up to the announcement of PACK EXPO Connects, PMMI Media Group conducted extensive end user interviews with some of the world’s leading CPGs. These in-depth interviews had one goal: To ensure PACK EXPO Connects provides exactly what the packaging and processing industry wants out of a web-based event. The No. 1 request across the board was to see live technology and be able to interact with exhibitors during machine demonstrations, which PACK EXPO Connects delivers. Beyond seeing technology in action, attendees want to spend time exploring new products, rather than existing products presented as new. PMMI Media Group solicited its in-house team of editors to vet what is and isn’t new, serving as neutral industry experts. Together, they will ensure that attendees can track down the latest offerings and the virtual exhibitor showrooms presenting them. Free attendee registration is open now, giving CPGs plenty of time to prepare for preview week, scheduled for Nov. 26. During preview week, registered attendees can browse live demo descriptions, build their planners, and save items to their Outlook calendars. PACKEXPOConnects.com will remain live until March 31, 2021, offering additional opportunities for attendees to connect with companies via their virtual showrooms. PFW www.profoodworld.com
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Food Processing Equipment
CONNECTS
Focusing on Conveyors & Conveyor Belting • Dry Processing/Handling Equipment • Liquid Processing/Handling Equipment • Ovens, Dryers, Fryers & Heat Exchangers
Can’t-Miss Product Previews at PACK EXPO Connects Get ready for PACK EXPO Connects, the preeminent global virtual event of all things packaging and processing. Enjoy this sneak peek at some of the latest innovations that you and your teams can expect to see when the event goes live online November 9-13, 2020. Although the event is free and viewable from anywhere, its timing is limited. So create your game plan for each day now, and don’t forget to share your list of must-sees with colleagues. PACK EXPO Connects Game Plan brings you highlights of which exhibitors will have live demos and which key products you’ll want to chat about with exhibitors.* (And yes, PACK EXPO Connects will have lots of great education, networking opportunities with peers and all the other tried-and-true makings of a top industry event.) See technology in action, discover new solutions and plan for the future.
Set up your plan for each day at packexpoconnects.com.
Product Previews At-a-Glance Live Demo: The exhibitor will be hosting a live session showcasing this product’s performance and answering questions from end users. *This guide features a selection of participating exhibitors with relevant products as of press time. View the full exhibitor line-up and complete product listings online at packexpoconnects.com.
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PACK EXPO Connects GAME PLAN
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Food Processing Equipment
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PE.show/239
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PE.show/555
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Simplify your pumping process The Twin Screw pump is delicately robust – where high or low viscosity liquids are perfectly, reliably pumped.
Optimize packaging with manifolds Unique Mixproof valves maximize filling and packaging efficiency, while greatly minimizing CIP consumption.
Advanced valve flow and control ThinkTop® takes valve liquid filling automation to the next level – by reducing water consumption up to 90%.
Dry and Contact-free Vacuum Pumps MINK claw technology vacuum pumps combine performance, reliability and efficiency with innovation.
Optimize your Vacuum Performance From regular maintenance to the supply of spare parts – enjoy seamless service from our service network.
Flexible for Many Processes DOLPHIN vacuum pumps are robust and constructed using applicationoriented materials.
Revolutionary Rotary Vane Vacuum The R5 RD vacuum pump is the standard in providing vacuum for food packaging applications.
Economic Efficiency in Vacuum Minimize costs and reduce the environmental impact of vacuum generation. Learn how to stay ahead.
Intelligent Rotary Vane Vacuum Pump The R5 PLUS technology combines proven Busch experience with cuttingedge features all in one unit.
FAM CMD.2 High capacity industrial dicer for meat; providing precise cuts on all frozen, raw or cooked applications.
FS40 Full Line High capacity industrial cheese shredding line designed with hygiene and operator safety top of mind.
FAM Tridis 180 High capacity industrial dicer for meat; providing precise cuts on all frozen, raw or cooked applications.
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PACK EXPO Connects GAME PLAN Food Processing Equipment
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Customizable Product Mixing Precision VarioMix temperature, mixing & vacuum controls are perfect for processing complicated product combinations.
More Batches in a Shift Independent spiral drives give speed, power & directional options for shorter times within very tight specifications.
Mixing & Handling Designed with no center shaft & minimal spiral clearance, product carryover in the mixing vessel is dramatically reduced.
Flexible Filler for Drums and IBC Totes ELEMENTRA 16 - A semi-automatic liquid filler that is mobile, adaptable, and simply the best at filling.
Simple Pail and Can Filling Equipment ELEMENTRA 14 - A semi-automatic filler for pails/cans, a quick and economical solution for any application.
High-Speed Automatic Drum Filling INTEGRA 84 - For drums, nothing is faster than this inline automatic drum filler for liquids.
Ovens High performance impingement, spiral and multi-purpose oven solutions that achieve high yield and quality.
Rotary Dryer Roaster Continuous multi-zone convection system that provides optimal drying/ roasting in a gentle manner.
Fryers Frying technology that outperforms and outlasts any other frying equipment in the industry.
Iso-FloÂŽ Vibratory Conveyor The industry standard, best-selling conveyor that is reliable and sanitary with 25,000+ installations.
ImpulseÂŽ Vibratory Conveyor Precise feeding to optimize performance with quiet operation and instant start and stop.
Rotary Sizing and Grading Systems Robust, precise and consistent sizing for low maintenance and easy cleaning and quick product change over.
10/1/20 9:43 AM
PACK EXPO Connects GAME PLAN
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Food Processing Equipment
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Turnkey Distribution System Layton provides a Single Source Turnkey Solution ideal for Scale and Bagger Packaging Lines.
Layton Can Handle It! Layton Manufacturers Professionalgrade, Food Processing Equipment for Customers Worldwide.
Hex Tube Feeders and Graders The Layton Hex Tube Feeder/Spreader and Roll Graders for the Potatoes and Root Crop.
ScanTrac Allegro Wide X-ray Inspection Bulk inspection for foreign material featured in “Detect Before You Pack” Live Demo.
ScanTrac Trio X-ray Inspection System Multiple Beam X-ray of glass containers provides enhanced glass contaminant and package defect detection.
ScanTrac Solo X-ray Inspection System Provides high speed imaging without contact while integrating data for filler and seamer monitoring and control.
Air Knife Drying Systems Liquid, dust, and debris removal from products prior to labeling, packaging, or other secondary operations.
Most Efficient Centrifugal Blower RBX: Power efficiency and longevity give this robust centrifugal blower the leading edge.
Pumps & Blowers Regenerative blowers, dry-running rotary vane, oil-lubricated rotary vane, & dry-running rotary claw pumps.
Reduce Labor with Cabinet Washers Parts washing can be done efficiently and repeatable, and with less labor and utilities, using automated cabinet washers.
Cloud Based Cleaning Data Recording The new SaniTrend™ Cloud Online SaaS is used with any automated cleaning system, making data recording compliance easy.
2-in-1 Solution: Mag Trap Strainers Protecting a process from foreign debris is critical – learn how the 2-in-1 Magnetic Trap and Strainer solution can help.
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Sentinel™ Selectscan Metal Detector Maximize food safety and operational efficiency. Selectscan rapidly finds the best detection frequency: 50-1000 kHz.
Sentinel™ 3000/VersaWeigh™ Combo Five-frequency metal detector seamlessly integrates with precision checkweigher. Value-packed. Saves space.
NextGuard™ X-ray Inspection System Find metal, stone, bone, glass, and plastic foreign objects. Easy to own, use. Ideal for a wide range of food applications.
FOODesign® batch-pro 12 Atmospheric batch fryer with high-efficiency serpentine heating, innovative oil filtration system to extend oil life.
View in 3D on your mobile! Download “tna AR” app for ios/Android and point your camera here to view our atmospheric continuous chip fryer in 3D.
Scan me Yes! tna offers fryers and precision processing solutions for all kinds of chips, extrusions and other snacks.
Sprocketless Belt Conveyor Drive Cut washdown time by 50% and eliminate bacterial harborage areas for a safer, more sanitary conveyor drive solution.
One-Component Conveyor Drive Maintenance free design saves 30% in energy costs with no external moving parts, increasing safety and sanitation.
Sanitary Series Conveyor Drives With belt profiles machined directly onto the drum, this design easily integrates into any conveyor application.
Compact-Grid™ conveyor belts • Joins quickly and easily • Clean-in-place belt design • USDA Accepted
Eye-Flex® conveyor belts • Heavy-duty metal modular belt • Custom designed for your application • Extremely durable for long belt life
Ladder-Flex™ conveyors • Hygienic conveyor design • Spread, converge, or diverge product • Small conveyor footprint
10/1/20 9:43 AM
WE INSPECT TO HIGHER STANDARDS... YOUR CUSTOMERS’. Visit us at
November 9-13
SSV Series Combination Checkweigher & Metal Detector
Your customers will tell you they have more on the line than dinner. It’s why we built the checkweigher and metal detector combination system. This integrated solution protects consumers by detecting the smallest contaminants and with high accuracy weighing cuts waste while improving safety compliance. Learn more about our precise, reliable equipment with the smallest footprint in the industry at anritsu.com/infivis.
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Partner With the Product Inspection Experts For ultimate brand protection, regulatory compliance, and an improved bottom line.
Metal Detection X-ray Inspection Checkweighing Vision Inspection Track & Trace Visit us at Pack Expo Connects to See All New Products and Live Demonstrations!
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LIVE DEMO PLANNER November 9-13, 2020
et ready for the preeminent global virtual event for those in packaging and food processing! PACK EXPO Connects features 2,600 live product demos from leading suppliers. Highlighted within are just some of the demos taking place.* Be sure you and your team view the full demo line-up and create your plan for the event today. Register and create your plan at
Plant Facilities & Infrastructure
Food Processing Equipment
packexpoconnects.com *This guide features a selection of participating exhibitors with scheduled demos as of press time. View the full live demo line-up online at packexpoconnects.com.
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PACK EXPO Connects LIVE DEMO PLANNER
Plant Facilities & Infrastructure
Type in the URL below to view demo times & more!
Featured Demos Fogg Filler Co.: Microb-Blaster® Air Sanitiation: Meet Cody Peterson and learn all about the new Fogg air sanitization technology that can help you and your business prevent the spread of COVID-19.
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Interstates: How VR Technology Can Impact your Next Project: From improved safety and training to enhanced collaboration and communication, learn how VR is transforming the construction industry.
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Interstates: Why Manufacturing Matters to Project Delivery: Learn from our experts how custom UL508A listed panels and electrical prefabrication can impact your next project.
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Sullair A Hitachi Group Company: Oil Free Compressors - The Sullair Solution: Learn about key Sullair oil free compressors and how to determine the best compressor solution to help your operation run efficiently.
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Additional Demos ECoesia: our approach to sustainability by Coesia Designing and Building in Uncertain Times by ESI Group USA Project Delivery: Making Sense of Your Options by Food Plant Engineering, LLC Meet Miura: How Can Modular Boilers Innovate Your Business? by Miura America Co., Ltd Desktop Digital Label Printers in Action by NeuraLabel 5 Things To Look for in a High Speed Door by Rite-Hite Improve OEE with a platform to enable production workers to be more efficient by ServiceNow Oil Free Compressors - the Sullair Solution by Sullair A Hitachi Group Company 10 Months To A New Temperature-Controlled Facility by Tippmann Group US Headquarters Tour by Viking Masek Global Packaging Technologies
Food Processing Equipment
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Type in the URL below to view demo times & more!
Featured Demos ANRITSU INFIVIS INC: Ensure brand and consumer protection using the most advanced inspection technology: Why do you need the best performing equipment? See how the highest detection and accuracy drives down consumer complaints and product recalls.
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ANRITSU INFIVIS INC: Exceeding your HACCP inspection specifications can save you money: Raise inspection standards with detection accuracy. See why detecting smallest contaminants and going beyond regulatory requirements saves money.
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ANRITSU INFIVIS INC: You can have complete food inspection solutions in extremely tight spaces: Learn how Anritsu’s compact and high performing X-ray, Checkweighers and Metal Detectors provide complete quality control and contaminant detection.
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Apex Motion Control: Sauce depositing with a Cobot over a Horizontal Form, Fill, Seal Line: How a cobot can efficiently and safely deposit sauce and fillings over a HFFS line between human workers — options to consider for distancing and controlling cross contamination.
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Busch Vacuum Solutions: Economic Efficiency in Vacuum Generation: Minimize costs while reducing the environmental impact of vacuum generation. Learn the variables and how to stay ahead of the industry.
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Busch Vacuum Solutions: Increasing Productivity with Vacuum Automation and Centralization: Busch presents solutions for the modern-day production environment and ways to optimize your vacuum equipment’s performance.
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Don’t miss out! Attendance is free. Add demos to your event plan at packexpoconnects.com
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Food Processing Equipment
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Featured Demos Cablevey Conveyors: Blowing, Throwing or Grinding. How are you Managing Materials?: We’ll demonstrate a mechanical system approach to our time, money and material-preserving alternative to traditional conveying.
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Central States Industrial: How to Solve Your Common Process Problems in 15 Minutes. Join us Monday - Thursday @ 11:15 am (CST) as we help guide you through the most common obstacles processors face and how to fix them!
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Deville Technologies Inc.: Freeze-dried pet foods on the FAM CMD.2: A virtual walk-through of the FAM CMD2 showing its precision with frozen lamb liver and other challenges facing pet food processors.
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Deville Technologies Inc.: Full FS40 line cheese shredding demo: A cheese shredding demo on our full industrial FS40 processing line featuring an equal blend of Mozzarella and Cheddar.
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Deville Technologies Inc.: Problematic applications on the Tridis 180: A brief demonstration showing how the FAM Tridis 180 addresses challenges faced by fruit and vegetable processors.
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Deville Technologies Inc.: State-of-the-art centrifugal cheese shredding: An in-depth look at the USDA Dairy Accepted Centris 400C Hytec and its revolutionary cutting technology for better cut quality and capacity.
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Fres-co System USA, Inc.: Choosing the Right Coffee Packaging Machine: With so many options available, which one is right for your needs? Let the coffee packaging experts guide you through the decision process.
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Lyco Manufacturing Inc.: Efficient Pouch Cooling in Submerged Agitated Chilled Water.: See how Lyco’s Chill Flow™ Pouch cooler uses Hydro Flow®Technology to cool pouches 2X as fast in half the footprint of a deluge belt design.
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Lyco Manufacturing Inc.: Increase Profits with Higher Yields & Extended Run Time: We will show how the Clean-Flow® can achieve higher yields and reduce water & energy consumption using our automated Recipe control system.
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Lyco Manufacturing Inc.: Make your water Sustainability goals a reality with Lyco screens.: View Lyco’s PLC controlled Water Reuse System and see how it reduces consumption of water resources up to 15 million gallons per year.
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OPTIMA Machinery Corporation: Turnkey Solutions for the Next Level of Single-Serve Coffee Packaging: Solutions to incorporate processes from thermoforming the container, through the packaging, and to the finished pallet for your single-serve coffee products.
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R.A Jones: Chub Packaging Equipment: KartridgPak Technology: See our portfolio of chub packaging equipment, products we have experience with & watch a real chub customer project run on our shop floor.
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Republic Manufacturing: Blower and Pump Innovations to Save Money, Energy, and Downtime: Too many blower bearing failures? Tired of changing vacuum pump vanes? Want to save energy? Republic demos product innovations to tackle each of these problems.
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Republic Manufacturing: How Dry Is It? Reduce packaging waste with Republic Air Knife Systems.: Demonstration of drying capabilities and discussion of downtime and waste reduction utilizing air knife systems and centrifugal blowers.
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Republic Manufacturing: Is a regenerative blower kit the right choice for my application?: Explanation regarding items included in a regenerative blower kit and discussion of the advantages of the blower technology.
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Republic Manufacturing: Reduce Downtime and Save Energy with Claw Pumps: Learn how claw pump technology reduces downtime and saves energy.
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Scan American Corporation: Automated Freezing, Defrosting and other Solutions for Product Quality: Fully automated plate freezing systems, continuous tunnel freezing for varied box sizes, defrosting of frozen materials and much more!
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Scan American Corporation: Low Volume Aroma Recovery & Large Scale Continuous Cold Brew Processing: Introducing the NEW Mini SCC (Spinning Cone Column) Aroma Recovery System by Flavourtech and see our high capacity continuous Cold Brew solution.
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Schenck Process: Milling Dry Bulk Solids: Demonstration shows the versatile Kemutec Kek Cone Mill gently reduce the size of a bulk solid material.
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Thermo Fisher Scientific: Combination checkweigher/metal detectors for ultimate brand protection: Combos are costeffective space-saving solutions. See how easy they are to use with leading detection technology and integrated electronics.
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Don’t miss out! Attendance is free. Add demos to your event plan at packexpoconnects.com
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PACK EXPO Connects LIVE DEMO PLANNER
Food Processing Equipment
Type in the URL below to view demo times & more!
Featured Demos Thermo Fisher Scientific: Find metal, glass, plastic, stone and bone with X-ray solutions: See how the Thermo Scientific NextGuard X-ray inspection system design expands the probability of detecting foreign contaminants.
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Thermo Fisher Scientific: Maximize food safety with the Sentinel metal detector platform: See demo of Thermo Scientific metal detectors live. For improved sensitivity, higher probability of detection and operational efficiency.
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TNA North America Inc.: The importance of precision processing at every step for brand success: Precision processing at every stage is critical. Product handling, frying, cooling/freezing, coating impact success. Join us to learn more.
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VDG: Reduce Conveyor Drive Energy Costs by 30%: Proven in our side-by-side comparison of a conventional conveyor drive vs. the VDG drum motor, demonstrating the benefits of the VDG design.
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Additional Demos Advancing valve automation and flow control by Alfa Laval, Inc. Critical Factors to Consider when Selecting a Headspace MAP Gas Analyzer for Package QC by AMETEK MOCON Automatic Filling A-400 by AMS Filling Systems, Inc. Sauce depositing over a Horizontal Form, Fill, Seal Line with a Cobot by Apex Motion Control Axiflow Technologies Pump Demonstration by Axiflow Technologies, Inc. Magnetic Separation for Dry Gravity-Fed Granular and Powder Products by BUNTING Solutions by Codian Robotics by Codian Robotics DCI/VARO Horizontal Processing Tank by DCI, Inc. GEA Pumps, Valves & Cleaning Devices by GEA COVID - Disinfecting Water Sensitive Equipment with Alcohol by Goodway Technologies Plant Based Sausage Production Demo by Handtmann Inc. HEISLER Denesting System by Heisler Industries, Inc. Food Grade Feeders by Hoosier Feeder Company Advanced Sorting & Conveying Systems for Dried Fruit and Berry Processors by Key Technology, Inc. How to Spec the Right SIght Glass and Hygienic Clamps by LJ Star Inc. Continuous Cooking Systems for Maximum Process Optimization by Marlen Complete Bacon Processing Solutions by Middleby Processing & Packaging Chain-Vey Overview by Modern Process Equipment Corporation NORD DRIVESYSTEMS - Condition Monitoring for Predictive Maintenance by NORD Gear Corporation ParityFactory WMS | Live Demo by ParityFactory, LLC Up-right Dairy Cup and Snack Tray Rinsing by Paxton Products - ITW Air Management Flow Wrapper SERVO up to 150ppm by Plan IT Packaging Systems Inc. Automated Food Packaging Systems that Don’t Break the Bank! by Point Five Packaging, LLC Automated Processing Solutions by Propack Processing & Packaging Systems Inc. Eliminate the Guesswork & Automate Produce Packaging Filling by Quest Industrial Baked Pet Treat Product Demo: Featuring Continuous Mixing, Rotary Moulder, Baking & Drying by Reading Bakery Systems Balancing Sanitation & Productivity Requirements by Regal Beloit Corporation Reiser’s World of Thermoforming by REISER CIP and COP Data Recording Compliance - A Cloud Solution by Sani-Matic, Inc. Milling Dry Bulk Solid Materials by Schenck Process LLC IBC/Tote Containers for Food, Beverage, Pharmaceuticals, and Chemicals by Schoeller Allibert Aftermarket Excellence by STOCK America Inc. ADVANTA Open-Mouth Bagger by Technipes SRL Learn why sanitary Gear and Lobe pumps are perfect for accurate filling and metering by Unibloc-Pump, Inc. Fresh Market Blueberry Optical Sorting by WECO The Science of Optical Sorting Transparency and diagnostics with IO-Link for Remote stations in automation by Weidmuller, USA
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Don’t miss out! Attendance is free. Add demos to your event plan at packexpoconnects.com
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PRODUCTION IMPROVEMENT
GET MORE FROM YOUR EXISTING ASSETS Identifying why your equipment is running below its potential is the first step in boosting output. Visibility tools, remote diagnostics, and the care and feeding of your essential human assets can push throughput in the right direction. JOYCE FASSL EDITOR-IN-CHIEF
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SSET RELIABILITY is required to achieve good manufacturing health, according to Richard Larsen, FSO Institute coach, and recently retired chief facilities officer for Honeyville, Inc. In fact, Larsen says it affects nearly every aspect of effective production. “Every aspect of manufacturing from preparation to getting the product out the door and to the customer is affected by plant assets. How the assets function not only affects production results, but also those who work on and with those assets,” he explains. Food and beverage processors often talk about total cost of ownership (TCO) when thinking about their assets. Larsen says the difference between TCO and asset reliability is that TCO focuses on the capital expenditure and the due diligence needed to assure that you are getting what is expected in the way of manufacturing assets. “Asset reliability is taking the TCO baseline and adding real-world performance characteristics to the purchase decision,” states Larsen. He says it is important to ask questions such as: • How will this asset function under expected conditions? • Will performance be able to meet expected performance? • How will operations be able to maintain the asset before, during, and after operation? • What is needed for expedient return to service? The COVID-19 pandemic has changed so many things in food and beverage processing facilities. Keeping lines up and running, flexible manufacturing, and quick changeovers are nothing new, but with the current travel restrictions and vendor plant visitors rare these days, food and beverage manufacturers are pressed even harder to get the most out of their existing assets. According to Brent Robertson, customer leader for
manufacturing execution system (MES) products at Aptean, visibility is key to successful asset utilization. “Over the last six months, there has been a shift in wanting to get visibility into labor usage. Five years ago, it was really OEE (overall equipment effectiveness) centric,” he states. Most processors can find machine availability if they have the right tools, Robertson explains. “If I don’t have technology that’s showing me how am I actually doing against what I should be doing in terms of throughput, I don’t really know what my true capacity is,” he says. Robertson believes processors should use historical trending to ascertain if what they are implementing is actually making a difference. MES, track and trace, and OEE tools are available to help, but since the pandemic, the use of Internet of Things (IoT) devices have increased on the plant floor. Today, wireless sensors keep data moving from the shop floor into a solution that give processors the viswww.profoodworld.com
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Hixson designed renovations and a new line for Abbott Nutrition’s Tipp City, Ohio, plant. The facility features low-acid aseptic filling at greater than 800 bpm, segregated storage areas, state-of-theart sterilization technologies, and highly flexible production and packaging lines. Photo courtesy of Hixson.
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ibility into how assets can be better used. Whether it’s a checkweigher or a metal detector, modern tools can deliver data in a format that delivers true visibility. Food processors must know the metrics of their equipment availability, performance, and quality. And in the COVID-19 era, there are extra costs related to production. “With COVID, the labor piece is extremely critical,” Robertson says. “Processors either have trouble keeping people or finding the right people, so they’re trying to maximize the workers that they have,” he adds. Aptean’s MES solutions provide labor tracking. “We know how many people should be on the line working,” says Robertson. Employees can swipe into a machine, so management can see in real time what employees are doing, manage that labor, and factor in the cost of labor, he adds. Audit reports and business intelligence (BI) tools gather the data. The analytics layer or BI gives you that ability to drag and drop anything from the database into the way you want to see it, Robertson continues. “We’re actually showing you down to the second how everything actually performed,” he explains. “Then you start seeing actionable intelligence. For example, let’s say line one starts up in the morning, and we have a rough start for the first hour. The line gets up and running for two minutes, and then it stops for a minute, then it’s up and running for 30 seconds, and it stops for a minute.” For successful asset utilization, these micro stops must be recorded. “With that information, now I can take what was a poor first hour of production and make that smooth,” Robertson states.
OEE tells you a critical part of the story, but there are other pieces of the story that are very important, according to Robertson. “OEE doesn’t really factor in labor,” he says. If the overnight sanitation crew runs over into the morning shift, no product is being made during that part of the morning, but it affects equipment performance that does not show up on OEE. “Once I start the job, OEE is telling me what I’m producing, but it doesn’t tell me the whole picture. A full MES system will track that,” says Roberson. According to Niranjan Kulkarni, CRB’s director of operations improvement, improving asset utilization has a direct impact on equipment availability, which in turn increases the capability of the equipment to produce more. He says that improving asset utilization can also have other benefits in reducing or deferring need for adding more equipment, headcount, space/expansions, and capital investments. “Employing the right maintenance program can prolong the equipment life and improve equipment reliability,” but a one-size-fits-all maintenance approach is not useful, he says. “Selecting the right maintenance program can have a positive impact not only on equipment reliability, but also improve the overall profitability of a facility,” Kulkarni explains. “Without proper maintenance, unplanned equipment downtime or stoppages are likely to increase, impacting throughput and resulting in missed shipments.” He says several manufacturers are implementing corrective or frequency-based maintenance policies. However, he recommends processors consider moving toward a risk
SECURITY, REMOTE ACCESS, AND MANUFACTURING DATA
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walking plant aisles checking equipment N AN ERA where interest in remote on a daily basis, today those eyes aren’t equipment access and diagnostics is a there necessarily because people are hot topic, Carlos Rojas, global indusworking from home. Video solutions are a try lead for manufacturing solutions at simpler and quicker way to improve asset Cisco Systems Inc., says food and beverutilization and gain valuable business age manufacturers can achieve reliability insights at scale.” and security by using proven system Certified system integrators can also integrators. “They can build in securityconnect machines securely using Cisco based solutions for that access. I even see Secure Remote Access. legacy systems being connected in some Meraki MV is a surface-mounted camolder manufacturing operations.” era that can be placed on a ceiling or Cisco Meraki MV smart camera solution Hands-free headsets allow operators to troubleshoot machine failures or can be used wall. It can be plugged into and powered puts eyes on the ground in your physical when access is needed in remote locations. over Ethernet, or connected wirelessly environment, so that assets can be securely Photo courtesy of Cisco Systems. Inc. and powered via an AC adapter. “In a monitored and maintained remotely. Rojas manufacturing operation,” Rojas says, “you want to put it on says it’s a simpler solution than reviewing data directly from some of the most critical operations.” the machine because secure monitoring and management Johnsonville Sausage uses Cisco SD-Access so that its can be done via Meraki’s single-pane-of-glass dashboard from management and information technology (IT) executives can anywhere in the world. “Where you used to have support staff
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3-D simulations help food and beverage manufacturers visualize how to efficiently use their assets and floorplan. Image courtesy of CRB.
or condition-based maintenance strategy, or a true predictive maintenance strategy, when the current pandemic abates. “Implement data mining and machine learning techniques to predict with a higher accuracy when the next ‘perfect storm’ will occur,” Kulkarni suggests.
Calculated success PMMI’s OPX Leadership Network developed an Asset Reliability Calculator. In it, measurement tools were created to determine the value and justification of asset reliability from a dollar and performance view,
showing size of the prize results, says Larsen. In one example, he says, the asset reliability matrix used set reductions of 200 hours unplanned and 50 hours planned downtime. In this study, the economic gain was close to $4 million in annual operating costs. (See image on Page 55) “By using the calculator, the economic value led to identification, planning, and implementation to achieve reductions in unplanned downtime and planned downtime,” Larsen states. “Seeing this kind of dollar comprehension brings home the real need to pay attention
provide secure remote access over a Cisco infrastructure to only the parties that need it. Network settings can be set up in minutes for any user device. “As long as we put that user device on the network and it’s connected to a Cisco switch, we can provide secure access,” Rojas explains. Traditionally, a lot of things are not connected, Rojas continues. “Fundamentally, to get visibility into assets requires a level of secure connectivity on a network infrastructure.” For example, a laptop is connected to a Cisco network through a secure VPN connection using Cisco’s comprehensive remote access technologies to access information. With this type of infrastructure and connectivity, a user can capture key data from that machine, such as temperature, speed, cycle time, and pressure. After secure connectivity comes the visibility tool. Cisco’s Edge Intelligence allows data to be viewed by users, and Cisco’s Secure Remote Access and Identity Services, called ISE, allows secure access to that data. Rojas says processors can utilize these simple technologies to manage the entire environment. Cisco’s Edge Intelligence technology also provides management of the data as only critical information goes into the analytical data environment.
Cisco’s partner, a company called RealWear, hosts Cisco Webex Teams on a visual, hands-free headset that an operator can wear. “We use this a lot for troubleshooting, but also it can be used in providing the visual eyes on new product packaging introduction when remote locations are trying to test a new package on a production line,” explains Rojas. The hands-free solution has HD-camera-level capability and provides noiseprotected voice communications helping to eliminate communications issues in loud production environments. Cisco’s Zero Touch Deployment, particularly the Meraki solution, is cloud-based. Once you plug it in, it can be configured just by communicating to the cloud. Cisco’s other industrial switching technology has embedded sensors so that configuration can begin immediately. “We preconfigure that switch for three things: security, data management, and access before the sensor even hits the shop floor,” Rojas states. To get started in asset utilization, Rojas says a food manufacturer must have a value proposition for a particular outcome— improve quality, safety, or productivity. “A manufacturer also needs alignment across its stakeholders—quality, analytics, IT, manufacturing, etc. From there, it’s a matter of vetting the technology.”
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to giving the proper attention to plant assets.� The additional margin was attained with advancements in increased productivity and reduction in maintenance costs. Learn more about asset reliability and available OpX tools in this issue on Pages 90-92.
A pound of cure Chris Jarc, vice president and manager of project management at Hixson Architects, Engineers and Interiors, says in the past, processors would throw away decades-old equipment. Today that doesn’t happen, he states. Preventive and predictive maintenance not only extends the life of the assets, but extend the efficiency of the asset, he says. Jason Tucker, senior process engineer with CRB concurs. “One of the best things to do is to be more proactive on maintenance.� He sees some plants go for the quick fix when they can actually maintain, check, and replace seals and seats, for example. “I think there’s a lot of pressure on a bottom line for companies,� says Jarc. “Nobody wants to build a new plant anymore. They want to either renovate what they’ve got because it’s cheaper per square foot.� All of this makes equipment specification and layout more crucial. Workers must be able to safely access
equipment to maintain it. Tucker says a smaller piece of equipment might do the job that used to take a couple pieces of equipment—a huge help with plant footprints. Procuring and maintaining new or additional real estate can be a significant portion of any company’s capital and operating expenses. “Monte Carlo simulations, such as discrete event simulations (DES), can be used to assess and identify the right combination of variables to maximize the usage of footprint. DES has the capability to model uncertainty and variabilities inherent in process times and perform ‘what-if’ analysis,� Kulkarni says.
Help from IoT Since the start of the pandemic, some food and beverage processors have taken advantage of IoT technology. Jarc says if you have a plant full of equipment from overseas, you are more likely to use remote diagnostics. Hixson only recently allowed its staff to travel, but one solution they use is FaceTime, where processors walk to the equipment needing attention and show partners the problem. Jarc says processors have set up cameras to allow Hixson engineers to take a look. Learn more about secure camera solutions from Cisco in the sidebar on Page 52. Robertson says the future holds the use of biometrics for doing quality checks. “I think those will grow
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in terms of the need to touch screens less. Because anything I do in an application, it doesn’t matter if it’s ERP or MES or OEE, I have to touch a screen to input data.” He also believes COVID-19 is likely going to expedite use of technology such as retina scanning, facial recognition, augmented reality, and digital twins. The Remote Equipment Access: Options Analysis tool created by PMMI’s OpX Leadership Network provides an understanding of the pros and cons of common industry methodologies for remotely accessing equipment installed in manufacturing facilities. This OpX work product is not intended as a how-to guide; it is designed as a discussion tool to consider the approaches available to enable remote access to equipment.
Of human interest Kulkarni says food manufacturers must pay attention to all the little things that make their plants a great and safe place to work. Time spent on employee training is also essential, giving staff the opportunity to grow into supervisory roles. Lack of training or training or unclear procedures can cause operator error, he explains. Plant staff is a huge investment, according to Jarc. “If you think about somebody who’s working in a facility for 30-40 years, you’re going to put more money into that
Number Annual Days
Improvement Goal (Reduction in Hours Annually)
Actual 250.00
person than you are to Actual (standard) Units per Hour 3,600.00 Planned Hours per Day 24.00 an air compressor.” Annual MRO Costs $2,300,000.00 “Find [people] who Annual Maintenance Labor Costs $1,800,000.00 are really passionate Number of Mechanics 15.00 about working. And Operations Avg Labor Rate (loaded) 28.80 understand that you 200.00 Annualized Unplanned Downtime (hours) 1,200.00 have to make it a great 50.00 Annualized Planned Downtime (hours) 1,500.00 place for them to work,” Size of the Prize advises Jarc. “You must $3,888,000 retain them, make sure they love their jobs, and that their jobs drive them to want to come to work every The OpX Asset day,” he adds. Then, Jarc says, the number of widgets Reliability Calculator helps going out the door will take care of itself. determine If you focus on doing the things that make your the value and operation efficient, such as proper training, correct sup- justification of plies and ingredients, and performing the right preven- asset reliability from a dollar tive maintenance, your assets will be maximized, Jarc and performance concludes. PFW view. Image Aptean www.aptean.com
FSO Institute www.fsoinstitute.com
Cisco www.cisco.com
Hixson www.hixson-inc.com
CRB www.crbusa.com
OpX Leadership Network www.opxleadershipnetwork.org
courtesy of PMMI’s OpX Leadership Network.
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TECH TODAY: INSPECTION, VISION, AND DETECTION SYSTEMS
SMARTER FOOD SAFETY RELIES ON MORE DATA, COMPUTE POWER
Demand is rising for improved precision in food inspection. Food producers are taking advantage of the data and processing capabilities in their systems to not only improve food safety, but also to work toward improved traceability. AARON HAND EDITOR AT LARGE
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HEN IT COMES TO FOOD SAFETY, today’s food producers are dealing with a whole host of mounting challenges. A reduced use of pesticides—whether because of regulations or the popularity of organic farming—is giving rise to more toxic weeds within crops. Climate change is causing increasingly intense droughts and rains, which in turn causes a rise in aflatoxins, typically in nuts. Social media is a bigger headache than ever, where inspection slips can go viral instantly. Add the COVID-19 pandemic to the mix, intensifying an already difficult workforce
situation along with the challenge of having key experts work from home. Inspection technologies need to be not only more reliable and more precise than ever, but smarter as well. Last year, the U.S. Food and Drug Administration (FDA) announced its New Era of Smarter Food Safety, an initiative intended to build on the Food Safety Modernization Act (FSMA) to create a more digital, traceable food system. The FDA’s 10-year blueprint was initially planned for release in spring of 2020, but was delayed to July because of COVID-19. But the challenges that have arisen during the pandemic have www.profoodworld.com
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ProdX allows multiple facilities to be connected to a single data point. Photo courtesy of Mettler Toledo.
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TECH TODAY: INSPECTION, VISION, AND DETECTION SYSTEMS
The Interceptor metal detector combines multiple frequencies to reduce false positives in foods like meats and fresh breads. Photo courtesy of Fortress Technology.
shown just how necessary some of the actions in the blueprint are. “It’s more important today than ever before in our history to work together to create a more digital, traceable, and safer food system,” said Frank Yiannas, FDA’s deputy commissioner for food policy and response, at the release of the plan.
Track and trace Though FDA’s new program is largely focused on technologies that could be used within the supply chain rather than inside the factory, there will likely be a role for inspection to play from a traceability perspective, according to Robert Rogers, senior adviser for food safety and regulations at Mettler Toledo’s Product Inspection division. “Especially in the age that we’re living in today— the pandemic and restricted travel and restrictions of going into plants less—it’s totally essential,” he says. In this climate, regulators might look for ways to better focus on the inspections that are most needed. In other words, if a food producer can document that it’s performing required tests, getting good results, and basically handling food safety the way it should, that would help provide confidence to a regulator or auditor that their time could be better spent elsewhere. In fact, in its blueprint, FDA recommends evaluating the feasibility of using remote and/or virtual inspections of companies with a demonstrated history of compliance. Mettler Toledo is beginning to do some work in that space, Rogers says, providing customers access to the type of data needed for this and other scenarios. “We 58
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have data collection capabilities through our ProdX software that allows multiple facilities to be connected to a single data point and have all the systems from those multiple facilities provide information into this,” he says. Tomra Sorting is also putting more emphasis on its Tomra Insight, an Industry 4.0 monitoring platform designed to turn sorting machines into connected machines to keep them performing at their best, says Jeffry Steemans, product manager for digitalization at Tomra Food. In addition to helping to reduce downtime and maximize throughput on the machines, the data also helps manufacturers sort to high-quality levels to maximize profitability, he adds. And, what food processors have found particularly important during the COVID-19 pandemic, Tomra Insight enables more employees to work from home, able to log in to a website, and see the machine remotely. Food processors are challenged by guidelines to keep the number of people on-site to a minimum. “That means that when they’re running the plant, experts cannot always be on-site,” Steemans says. “But they need to have the information on hand if something goes wrong. It allows experts to see what is happening.” When it comes to making use of available data, Rogers says that perhaps the future is coming a lot sooner than people might think. Connected devices are important on many different levels within the food business already, he says, not only from reporting activities on inspection systems, but also for reducing downtime. But traceability will be an increasingly
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important use of data as the industry moves forward. “I believe that there’s benefits to using some of the models in other industries, such as serialization in the pharmaceutical industry, where they’re able to identify what blister pack is in a pallet of cases of cartons of medicine,” Rogers says. “That sort of serialization and aggregation down to the item level, moving that toward the food industry, is something that would greatly benefit the food industry and the initiatives along the lines, certainly, of traceability.” Track and trace technology that’s used heavily in the pharma industry is starting to trickle down into the food industry, says David Lamprey, senior product marketing manager at Thermo Fisher Scientific. “Food is starting to take that pathway, but it’s still in its infancy now. Part of the reason is because of the sheer cost to implement that process and do it across the entire horizon of food safety,” he says. “The food safety industry is dabbling and changing their whole approach from reaction when there’s an issue out in the field and doing things like recall to more prevention.” When one of its customers decided to move forward with a track and trace initiative, Fortress Technology worked alongside them to enable its customer to pull the data it needed from its metal detectors. “It allowed them to not only say that they have a metal detector, prove that it’s working, and show when they’ve gotten rejected, but it allowed them to give their customers visibility on a product-by-product basis of the results from the metal detector,” explains Eric Garr, regional sales manager at Fortress Technology.
Track and trace will become more prevalent because of both the push from regulators and the pull from the consumer side relative to increased levels of safety, Lamprey says. The cost and complexity are worthwhile, he contends, because of the benefits of avoiding the kinds of recalls that are common today. “It’s a massive recall because they don’t know what the scope is, so they pull everything back and it gets very costly,” he says. “If you’re able to do track and trace, you know specifically where a product is and can act immediately on a much smaller scale. So, although there’s a big investment upfront, the back end is much less expensive and the brand protection is much greater, as it’s tied to social media today.”
More data, better detection Putting aside the bells and whistles that might push the food industry into new levels of Industry 4.0 capabilities, inspection equipment suppliers are also working to improve sensitivity levels of their systems— finding smaller contaminants, distinguishing between similar contaminants, and generally discovering the issues that are giving food producers more concern about the safety of their products. Increased data capabilities and computing power have roles to play in optical inspection technologies, which are able to detect smaller and smaller objects, says Stephan Westcott, global AIS product manager at Key Technology. “We’re able to process more and more data so we can get to smaller pixel sizes, which ultimately translates to smaller defects or foreign bodwww.profoodworld.com
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Farmers are seeing more chance of toxic weeds growing among their spinach plants, increasing the need for improved inspection. Photo courtesy of Tomra.
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ies that we can go after on the detection side,” he says. Increased processing power also enables the technology to pull in additional channels of information, Westcott notes. “It used to be that you could only use just a couple of channels. And if you had a machine that had both cameras and lasers, they were often independent; they were making independent sort decisions,” he says. “With our latest
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platform, we’re actually fusing that information together so you can have both cameras and lasers and make smarter decisions about the classification of the objects you’re looking at.” Key Technology’s VERYX digital sorters use what the company calls Multi-Sensor Pixel Fusion, combining data at the pixel level. “With the combination of that information, you’re really able to go after both product defects as well as foreign bodies,” Westcott says. Hyperspectral imaging takes that to hundreds of wavelengths—hundreds of channels of information, essentially—to create a hyperspectral signature. The technology is not exactly new, but it continues to become more advanced and more accessible, Westcott says. And it’s wellsuited to finding more contrast in defects that might not be as easily distinguishable between safe and unsafe. “Take a french fry that’s got a bit of a rotten end on it that has gone through the fryer. It’s safe to eat, but the color is a bit darker, black even,” he says. “To a legacy sorting system, it’s really difficult to tell the difference between a piece of charred black fry and a piece of black rubber.” However, because potato and rubber have completely different moisture content, the hyperspectral imaging can easily distinguish between the two. Technologies like hyperspectral imaging or pixel fusion also provide additional tools for dealing with the increase in extraneous vegetable matter like datura or nightshade. “A nightshade berry might be indistinguishable from a pea to the naked eye, either in color or shape,” Westcott says. “In nuts, they have issues sometimes with aflatoxin. It’s an invisible defect. You can’t see it, but it’s dangerous.” Tomra Sorting uses its Detox laser technology to identify aflatoxin in nut-related products. It uses a special optical configuration to capture the low intensity of light reflected by the fungus to detect aflatoxin contamination. This is an alternative to blanching the nuts, which is “quite expensive and also reduces shelf life,” Steemans says. Another Tomra technology called Biometric Signature Identification heads into the near-infrared region of the spectrum to provide something akin to DNA fingerprinting of an object based on light. It is possible to identify certain chemical and molecular differences on the surface and also within the objects inspected.
A place for artificial intelligence With the kind of processing power available today, artificial intelligence (AI) is making it into 60
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all corners of the manufacturing space. Tomra has ventured into AI and neural networks with its recent launch of LUCAi. The technology—which grew out of the company’s acquisition of BBC Technologies in early 2018—is used specifically to grade blueberries. Able to process 2,400 individual images of fruit per second, the platform can better detect specific defects, and even enables variety-specific and seasonal-specific sorting. Looking to the future, Steemans sees a place for AI in food safety—to better identify the potentially toxic solanine in potatoes, for example, which is increasing with climate change. Read more about how Landing AI is combining artificial intelligence with machine vision to tackle food inspection at pfwgo.to/landing.
product conditions. The Profile Advantage introduction really got rid of that. Now you can run at the highest of sensitivities.” Thermo Fisher Scientific is tackling issues associated with product effect with its new Sentinel 1000 Selectscan metal detector. The system allows the user to choose the best frequency for its application from 50 to 1,000 kHz.
It’s clear who the hero is.
Multiple frequencies Just as important as finding contaminants is finding something that isn’t there. Not only will false rejects waste product and time, perhaps the most devastating effect is the loss of confidence in the detection system itself, Rogers says. When that mentality starts to creep in, operators might lower the sensitivity, leaving more opportunity for contaminants to pass through. Some metal detector suppliers have turned to simultaneous multifrequency technologies to help squash those false rejects that can occur, in particular, with high-conductive products, such as meats or fresh baked breads. Metal detectors can be challenged by product effect—temperature variations, or high salt, iron, or moisture content that can create signals falsely seen as contaminants. “These product characteristics with their high conductive effect and variability can limit the achievable performance,” Garr says. Fortress Technology’s Interceptor combines multiple frequencies to better understand the content of the product. “Different frequencies are going to have different strong points, so combining different frequencies, you can use that information more effectively to reduce false positives and improve sensitivity,” Garr says. Mettler Toledo’s Profile Advantage metal detector uses similar technology—which Mettler calls multisimultaneous frequency—to improve contaminant sensitivity in meats and other difficult foods. “Historically, those were challenging applications because of the wide product diversity that occurs during a normal production run— diversity in temperature, diversity in moisture, and things like that,” Rogers says. “That resulted in turning down sensitivities of the inspection device to deal with the diversity of the normal www.profoodworld.com
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TECH TODAY: INSPECTION, VISION, AND DETECTION SYSTEMS
it is to pick up components in that because it generates electricity as you’re running a charge through it,� Lamprey says. “Selectscan allows the customer to set the detection levels specifically where they want based on their manufacturing process, which ties back to an increased probability of detection, which obviously drives back to the consumer safety side and then the brand protection side.� That ability to set the application at a particular frequency also enables Selectscan to better find the metal that’s of concern—whether ferrous, nonferrous or stainless steel. “People want to really dial it in to specifically what they want to find,� Lamprey says.
Metal detection foiled The Sentinel 1000 Selectscan metal detector tackles product effect by allowing the user to choose the best frequency for its application from 50 to 1,000 kHz. Photo courtesy of Thermo Fisher Scientific.
Trying to dial in to particular product effects—is it wet, does it have salt in it, what’s the temperature—can complicate measurements for food producers. “The more you get into that side of it, the more complex
An evolution around fresh, shelf-stable, ready-to-go foods has driven a need for single-use foil packaging, Lamprey notes. This poses challenges for metal detection. “Frequency selectability is really important for foil film,� he says. “And then if you really want to make sure that you’re maximizing detection, you move that foil packaging into the X-ray technology. That’s one of the biggest changes we’re seeing in the industry right now in packaging.� There are other reasons X-ray technology might be
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needed over metal detectors—namely, contaminants in the food stream that aren’t made of metal, including rubber, plastic, stones, glass, and more. “They often find golf balls in a potato harvest because people go out in a field and hit golf balls,” Lamprey says. Chicken and fish bones can also present challenges. “The issue with that level of technology is the density of the product. So you need an X-ray that has the capability of picking those things up as they move down through the process.” Though X-ray is becoming part of the food safety strategy for food manufacturers, the price point and increased complexity have made adoption slow. “The technology is five to 10 to 15 times the cost of a metal detector,” Lamprey says, noting not only the need for lead curtains at the system’s entrance and exit, but also the complexity around detection and imaging algorithms. “It’s really the capability and the science behind how you’re creating images and how you’re differentiating between density in things like chicken with bones in it and being able to show that image differentiation.”
Holistic process Various inspection technologies have their benefits and limitations. A metal detector won’t find glass. And an X-ray system doesn’t work in gravity-fed applications.
Inspection requires a holistic process—balancing the needs with the technologies available, as well as mitigation techniques. “It’s important for companies to understand the potential risks and hazards within their products in their process and also understand the capabilities and limitations of systems as to what they might implement to help prevent or deter that from entering the product,” Rogers says. Inspection tools won’t eliminate the problems. “They’re going to notify you when the problem is there, and it’s the procedures and processes that you build around the technology that makes a big difference in preventing any future contamination concerns,” Rogers emphasizes. “Ideally, my systems never go off. That would be the goal. If every system that I put into a facility never goes off, that means everything is perfect, right?” PFW
Mettler Toledo www.mt.com
Thermo Fisher Scientific www.thermofisher.com
Tomra Sorting www.tomra.com
Fortress Technology www.fortresstechnology.com Key Technology www.key.net
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Rotary Filler Helps Keep Pace With Booming Collagen Market To keep up with skyrocketing demand for its collagen powders, Vital Proteins turns to a rotary filler that boosts throughput and improves safety and ease of operation. AARON HAND EDITOR AT LARGE
I
F YOU’RE A MAN, there’s a good chance you don’t know much if anything about collagen powders. But the women in your life probably do—80% of the collagen powder customers at Vital Proteins are women. As more people learn about the benefits of collagen powders—improved skin health, bone and joint health, digestion, and more—the market has been taking off. Vital Proteins launched its first collagen powder in 2012. With growth accelerating considerably since 2017, the Chicago-based company is in a good position to grab its share of the collagen market, which is expected to surpass $6.5 billion by 2025. It’s not too much of a surprise, then, that Vital Proteins found it impossible to keep up with customer orders with one single-head filler in its 25,000-sq-ft facility. The equipment was averaging 20 rigid plastic containers per minute, which wasn’t enough to meet the growing demand. Outgrowing its plant in 2017, Vital Proteins moved to a new 180,000-sq-ft facility, installing a new rotary filler from Spee-Dee Packaging Machinery Inc. to increase capacity of its fully automated powder packaging line. Scott Springer was brought on in 2017 as vice president of operations in part to build out the new stateof-the-art manufacturing facility. Although it made sense for the company to start small, spending significantly less money for a low-speed line that would run one shift, producing 20 cans a minute, he could immediately see the writing on the wall. “Even when I started, the plan wasn’t to put in a rotary; the plan was to put in a dual-head filler, which was only twice as fast. But that’s not fast enough if we’re going to grow this fast—and I saw it in the first month or two months I was there,” Springer says. “Like the first month I was there, in September of 2017, the single-head filler got up to two eight-hour shifts. By the end of the month, I put them on 10-hour shifts, so we were doing 20-hour days. By the end of October, I had them on six days a week. By the end of November, that line was maxed out and we were starting to comanufacture some of the stuff at other plants because
we couldn’t make it fast enough for how quick we were growing and selling.”
Custom made Ultimately, to bring production fully in-house for its 13 powder collagen products—where the producer could better control costs and quality and could pivot quicker as new demands arose—Vital Proteins opted to add Spee-Dee’s rotary filler. Though driven largely by its speed—the rotary filler can fill 100 cans a minute—it’s also easy to clean, easy to change over, easy to control, and more reliable, Springer notes. In fact, Spee-Dee started with a clean slate on this rotary filler design, re-engineering it for sanitary www.profoodworld.com
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Vital Proteins container weights range from 5 to 400 oz. Its rotary filler can run four different sized containers. Photo courtesy of SpeeDee Packaging Machinery Inc.
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design, all servo motion, easy access for maintenance, quick changeover, and simple setup and operation. Filling funnels attach to the turret with embedded magnets, enabling faster changeovers of Vital Proteins’ various container sizes. Timing screws, star wheels, and turret change parts can all be removed quickly and easily without tools. Though the single-head line makes for faster changeovers simply because it’s smaller equipment, Springer was attracted to the Spee-Dee rotary filler in large part because of its changeover ease. “One of the reasons I like Spee-Dee vs. their competitors was it was so easy to change over that machine compared to other machines we looked at,” he says. “They’ve got these cups, which fill these cans. They’re just held on by magnets, so you can literally just pop them off by hand, so you don’t have to unscrew stuff. The whole changeover on the line is tool-less. They’re hand knobs and magnets. You could probably change over the whole line in 15 minutes to 30 minutes with one person.” The tool-less changeover contributes to a safer system, as do the level of Spee-Dee’s guarding and safety interlocks, Springer says. “Everything can be moved easily around in position. You don’t have to fight with the equipment on changeovers. You don’t have to fight
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Filling funnels attach to the turret with embedded magnets, enabling faster changeovers of Vital Proteins’ various container sizes. Photo courtesy of Spee-Dee Packaging Machinery Inc.
with it on jams,” he says. “Stuff like that makes it safer than other equipment that we have.” Open access to the base, drive system, and change parts not only make changeovers easier, but also make cleaning and maintenance easier and faster. With the servo drives, all setup can be done electronically. As its sales continue to grow, Vital Proteins plans to expand operations to other parts of the world, Springer says. Though it will likely start any new production facility off with a slower line, he notes, the expectation is that the company will expand its use of rotary fillers throughout its operations in much the same way as it has at its home plant in Franklin Park, Ill. Spee-Dee Packaging Machinery Inc. www.spee-dee.com
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Point Level Switch Can Be Installed at Tank Bottom or Top The Endress+Hauser point level switch detects all types of powdered and fine-grained solids, such as grains, sugar, spices, milk powder, animal feed, and other dry materials. The Nivector FTI26 Industry 4.0-ready switch meets all hygienic requirements, including 3-A Sanitary Standards, EHEDG (European Hygienic Engineering & Design Group), and FDA, and is cleanable up to protection class IP69. It offers IO-Link communication and can be checked via LED signalization without dismounting it. Endress+Hauser us.endress.com
Lump Breakers Have Compact Footprint Built to promote the free flow of dry materials that tend to form agglomerates in storage, Palamatic Process lump breakers include two pin shafts with knives or blades that can spin at a fixed or variable rate and a stationary mesh screen below the grinding medium. The lump breakers are available with mild-, 304- or 316-steel options and a variety of components to meet the requirements of different hazardous area classifications. Palamatic Process Inc. palamaticprocess.com
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The Material Transfer discharging system features sanitary stainless-steel product contact surfaces with ground smooth, continuous welds. FDA and USDA approved for areas of direct and indirect dry food contact, the MATERIAL MASTER bulk bag discharging system has an electric chain hoist and bag lifting frame equipped with a custom debris shield. The unit includes a bulk bag massaging system, a round bag spout access chamber with gull-wing doors, a custom electropolished 304 stainless-steel discharge transition, and a pneumatic bag spout clamping system. Material Transfer materialtransfer.com
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Rotary Fillers Have Simple, Hygienic Design Spee-Dee filling machines feature a tool-less design, filling funnels with a magnetic connection that eliminates the use of fasteners, and container adapters that can be changed for varying heights and shapes. Vibrators help settle product into rigid containers, including plastic tubs and bottles, glass jars, fiberboard boxes, and metal cans. The rotary fillers can be integrated with a variety of filling systems, including Spee-Dee auger or cup fillers, or high-speed combination weighers. Spee-Dee Packaging Machinery spee-dee.com
Level Switch Reduces Food Buildup Built for bulk solid materials that have a tendency to pack or bridge, the Dynatrol level switch has a vibrating paddle design, making it suitable for potato flakes, powdered sugar, spices, and additives to bulk foods, such as almonds or frozen vegetables. The CL-10GJ CIP Teflon-coated bulk solids switch features a density range of 10 to 15 lb/ ft3 and NEMA 4X washdown capabilities. It has no moving parts and requires no field adjustments. Automation Products, Inc. – DYNATROL Division dynatrolusa.com
Conveyor Comes with Range of Screw Types and Lengths The Flexicon flexible screw conveyor includes a carbon-steel floor hopper and discharge housing, and a 4-1/2-in. O.D. fully enclosed polymer conveyor tube. The Model 1450 flexible screw conveyor has an inner screw that self-centers as it rotates. The lower end of the screw requires no bearing, while the upper end is driven beyond the point of discharge, preventing material contact with bearings or seals. Available with round, square, flat, or beveled flexible screws in lengths from 10 to 40 ft, the unit can convey virtually any free- and nonfreeflowing bulk material, including products that pack, cake, seize, smear, or break apart. Flexicon Corporation flexicon.com www.profoodworld.com
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Screener Easily Fits in LowHeadroom Food Production Areas
Making our world more productive
The Kason screener employs two imbalanced-weight gyrating motors mounted on opposing exterior sidewalls of the unit, lessening the height operators must lift heavy bags of ingredients. The FLO-THRU low-profile, high-capacity screener can be equipped with an air-lift device for disassembly, cleaning, inspection, and screen changes. Both the screener and air-lift device come in diameters from 18 to 84 in., and can be manufactured to comply with domestic and international sanitary standards, such as 3-A, FDA, and BISSC. ATEX and UL explosion-proof compliant low-profile screeners are available. Kason Corporation kason.com
Cone Mills Process Difficult-to-Grind Food Materials
Quick, In-Line Sauce Chilling The ChillStreamâ&#x201E;¢ in-line cryogenic chilling system chills liquid products WR VSHFLÃ&#x20AC;F WDUJHW WHPSHUDWXUHV TXLFNO\ IRU SDFNDJLQJ 7KLV KHOSV PDLQWDLQ SURGXFW TXDOLW\ UHGXFH SURGXFWLRQ ERWWOHQHFNV DQG ERRVW SURGXFWLYLW\ RI SDFNDJLQJ OLQHV The ChillStreamâ&#x201E;¢ V\VWHP UDSLGO\ FKLOOV FRRNHG PDULQDGHV VDXFHV VRXSV FXVWDUGV IUXLW Ã&#x20AC;OOLQJV SXUpHV DQG PRUH &RQWDFW XV DW 1-844-44LINDE or visit www.lindefood.com/chill WR OHDUQ KRZ WKH V\VWHP PD\ LPSURYH \RXU SURFHVV
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Kemutec cone mills feature a gentle, grinding action to maintain a close particle size range with minimal fines generation while reducing residence time, resulting in negligible heat generation. Constructed of 304 or 316 stainless steel, KEK cone mills feature an ultra-hygienic design and come in a variety of finishes, including bead blast, crack- and crevice-free welds, and mirror-polished surfaces. Used for fatty, heat-sensitive, sticky, moist, and other difficult-to-grind applications, the mills are available in sizes ranging from 3- to 25-in. cone diameters. Kemutec kemutecusa.com
9/24/20 4:48 PM
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performance
Maintenance managers realize more
and less downtime.
EcoStruxure™ for Food & Beverage manages up to 80% of maintenance tasks remotely. • Make business decisions based on actionable IIoT data. • Increase overall efficiency for longer equipment lifespans. • Empower workforces through simple remote management. EcoStruxure Augmented Operator Advisor #WhatsYourBoldIdea
se.com/fb
©2020 Schneider Electric. All Rights Reserved. Schneider Electric | Life Is On and EcoStruxure are trademarks and the property of Schneider Electric SE, its subsidiaries, and affiliated companies. 998-20970266_GMA-US
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BUNTING: WEâ&#x20AC;&#x2122;RE STRONG. WEâ&#x20AC;&#x2122;RE DURABLE. WE GET THE JOB DONE. Some magnetic separation OEMs boast about having higher magnetic strengths, without telling you how they achieved it. By designing equipment with a thinner metal tube, other OEMs may deliver slightly higher strength, but WKLV GHVLJQ FKRLFH VDFULÆ®FHV GXUDELOLW\ DQG decreases the life of their product.
HFS Drawer Magnet Manual Self-Cleaning
HFS Drawer Magnet Pneumatic Self-Cleaning
At BUNTING, our products are built strong with durability built in, NOT designed out.
Some magnetic separation OEMs claim a 99.98% on-time delivery. What they donâ&#x20AC;&#x2122;t tell you is that the number was based on a single one-month time-frame. We deliver high strength magnetic products that withstand the test of time. And when you order from us, you can expect our products to be delivered right on time, since BUNTING Magnetic Separation has a 12-month on-time delivery rating over 98%.
Pneumatic In-Line Magnet
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PLANT FLOOR
New Products Metal Detector Improves Safety and Operational Efficiency The Thermo Fisher Scientific metal detector system allows the selection of the ideal frequency, from 50 to 1,000 kHz, to detect ferrous, nonferrous, and stainless-steel foreign objects. The Sentinel 1000 Selectscan system also includes an autolearn function that guides users through product setup, and has an IP69K rating for manufacturing environments that require high-pressure sanitation. Thermo Fisher Scientific Inc. thermofisher.com
Pump Reduces Cleaning and Cooking Times and Energy Consumption Using steam as the motive force, the Statco-DSI Process Systems pump simultaneously heats, mixes, and pumps liquids with or without particulates. Engineered to sit within a cooking vessel or to be integrated inline for batch and continuous processing, the Steam Infusion Vaction pump can heat 2,200 lb of product from 60°F to 194°F in five minutes with no burn or particulate damage. It is suitable for a variety of food and beverage products. Statco-DSI Process Systems statco-dsi.com
The Choice is Clear. Stainless Steel Conveyors Built For: • Easy Maintenance • Fast Cleaning • Minimized Downtime • Flexible Configurations • Lower Operating Costs 262.367.7600 | www.dornerconveyors.com/pfw 1020_PlantFloorNewProducts.indd 73 Dorner_ProFoodWorld_ClearAd_920F.indd 1
10/1/20 10:01 AM 9/18/20 2:52 PM
PLANT FLOOR PRODUCTS
Skid System Mixes and Pumps Lowto Moderately Viscous Products The ROSS skid system is a custom conical vessel on a movable skid with a progressive cavity pump rated for 10 to 30 gal per min. The 400gal Model VSL-400 mixing and pumping skid system features a 5-HP inverter-duty motor that drives a flange-mounted turbine mixer equipped with two axial flow impellers, as well as a 34-in. diameter upper blade and an 18-in. diameter lower blade. Controlled from a NEMA 4 weatherproof control panel, the mixer and pump include a thermal protection system that disengages the pump motor if a set temperature is exceeded. Charles Ross & Son Company mixing.com
Checkweigher Has Requirements-based Modularity for Greater Flexibility
We look at food differently. Todayâ&#x20AC;&#x2122;s processors must adapt to a quickly changing market: Deville takes care of helping you achieve the perfect cut while designing hygienic, simple, versatile and easy to clean cutting solutions that enable processors large and small, to keep up with demand. Because we donâ&#x20AC;&#x2122;t just see food, we see the whole picture.
1.866.404.4545
www.devilletechnologies.com
Deville Technologies is the exclusive North American distributor of FAM.
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Designed for food and beverage manufacturers, the WIPOTEC checkweigher features electro-magnetic force restoration weigh cells that provide the precise weighing of packages. The HC-A checkweigher readily fits into existing packaging lines and offers a maximum throughput of 600 pieces per min. A range of options is available, including a double-track configuration and a variety of faulty product sort and reject mechanisms. WIPOTEC-OCS, Inc. wipotec-ocs.com
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Processors Integrate Mixing, Flavoring, Heating, Encapsulating, and More Featuring a co-rotating, twin-screw configuration with a flattened paddle arrangement that applies high-intensity shear over a relatively long barrel length, Readco Kurimoto continuous processors impart a choice of textures to plantbased meat products to mimic the look and feel of natural beef, pork, sausage, and other types of meat and poultry. Capable of shredding, macerating, and pulling finished products into a variety of forms, the units texturize plant-based products that use soy, whey, wheat, pea, and other proteins, while simultaneously adding flavors, seasonings, and other ingredients. They are available in USDA- and 3A-compliant designs, and are custom-engineered for each installation. Readco Kurimoto readco.com
Tanks Resist Dings and Dents Built to meet or exceed USDA sanitary standards, Koss Industrial tanks are used to clean external equipment parts, such as hoses, clamps, fittings, filling nozzles, trays, and conveyor belts. The 12-gauge 304L stainless-steel clean-out-ofplace tanks are available with a range of options, including direct injection heat, a shell and tube heat exchanger, or electric immersion heater; insulation; a self-acting brass steam valve or pneumatic steam throttling valve; center or end drain location; single-, double-, or custom-placement drain location; and integrated hoists. They come in five sizes with capacities from 117 to 276 gal. Koss Industrial, Inc. kossindustrial.com
Increased PrRGXFWLRQ (IȊFLHQF\ Rethink end-of-line palletizing with our new palletizer, combining productivity, flexibility and simplicity. The RI20 sets the new standard for end-of-line robotics. Email us at info.us@ȋexlink.com or visit us at ȋexlink.com to learn more.
flexlink.com
www.profoodworld.com
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FlexLink is part of Coesia, a group of innovation-based industrial solutions companies operating globally headquartered in Bologna, Italy. www.coesia.com
10/1/20 10:02 AM
PLANT FLOOR PRODUCTS
Decanter Centrifuge Helps Craft Brewers Boost Yields Capable of separating liquid from heavy solids concentrations, Flottweg decanter centrifuges are used to process the hop sludge from the tank bottoms that would otherwise be dumped. After fermentation is complete, beer is pumped to the centrifuge to be clarified, where it is spread out into multiple thin layers. The centrifugal force expels the solids to the edge of the bowl, and then, the separated solids are ejected and sent down the drain or to a pump for disposal. The clarified liquid flows from the disk stack to a pairing disk, where it is discharged from the centrifuge via a centripetal pump to a beer tank. Flottweg Separation Technology, Inc. flottweg.com
MATERIAL MASTERâ&#x201E;˘
Robot Has Smaller Footprint for Production Line Flexibility Designed for use in confined spaces, the ABB robot has 20 input/output ports, enabling it to be used with more sophisticated grippers or end-effectors. Capable of lifting heavy objects or loads with complex and irregular shapes, the IRB 1300 six-axis industrial robot includes a controller that can be equipped with a range of additional equipment, including fieldbus protocols, vision solutions, and force control, and offers an intuitive pendant that features a multitouch display with standard gestures, such as pinch, swipe, and tap. Built with IP40 ingress protection as standard, the robot is available with IP67 protection and can be supplied to the IPA Clean Room protection standard. ABB abb.com
MATERIAL HANDLING SOLUTIONS Container Discharger
Drum Discharger
Bulk Bag Filler
Bulk Bag Material Conditioner
Direct Lift Drum Discharger
Bulk Bag Discharger
call: 800.836.7068
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visit: www.materialtransfer.com ww.materialtransfer.com
10/1/20 11:35 AM
Refrigerant Dryer Delivers Energy Savings of 50% or More Available in sizes from 212 to 636 cfm, the Atlas Copco refrigerant dryer matches consumption to demand. The FD VSD series 100300 variable speed drive dryer allows for fluctuating air demand, made possible by an inverter that enables the refrigerant dryer compressor to match its motor speed to demand, while the heat exchanger reduces the pressure drop in the incoming air, eliminating precooling inefficiencies. Combined with an Ethernet connection and SMARTLINK remote monitoring, the dryerâ&#x20AC;&#x2122;s air-system performance and maintenance intervals can be viewed and controlled from any location. Atlas Copco Compressors LLC atlascopco.com
V E R S AT I L E & A DA P TA B L E
CAPPING SOLUTIONS Capping and Cap Handling Systems Zalkin capping solutions for screw-on, roll-on or press-in and push-on closures. Proven capping technology for all bottle sizes and closure types, delivering greater efficiencies, versatility, and dependability to production lines. Contact us to discuss your next project or application requirements. 877-549-3301
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ZalkinCapping.com
10/1/20 10:03 AM
PLANT FLOOR PRODUCTS
Flow Wrapper Is Easy to Operate, Clean, and Maintain Ideal for multiproduct applications, the Syntegon flow wrapper can wrap individual or grouped products, including bakery goods, bars, fresh and frozen products, confectionery, snacks, prepared foods, household goods, and many other items. The fully automated Pack 202 horizontal flow wrapper machine produces up to 300 pillow, gusseted, and easy-to-open packs per min at a film speed of 50 meters. It features a standard 450-mm dual back
stand, engraved splicing instructions on the deck plates, fin modules that can be tilted and adjusted at the turn of a knob, a double-spring crossseal unit, and sequentially numbered film rollers that facilitate film threading. Rockwell controls and HMI 4.0 are standard on units for the North American market. Syntegon Technology syntegon.com
Monitoring System Helps Maintain Cleaning and Sanitizing Schedules An aid to establishing scheduled workspace sanitizing as an integral part of the return-to-work process, the Banner Engineering monitoring system features bright, high-visibility IP65-rated indicators that are located at workstations to notify staff when to pause production and implement their designated cleaning procedures. The Clean Workspace monitoring system verifies the completion of cleaning events, creates a data log, and resets the status indicator until the next cleaning interval. The system does not require alteration to the workstation or area infrastructure, and resists aggressive cleaning procedures. Banner Engineering bannerengineering.com
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Rethink What’s Possible
What if?.... At Yaskawa, we help you explore what’s possible, and open new doors to opportunity. Rather than accepting the status quo, we invite you to wonder, “What if...?” And then, we make it possible. That dedication to engineering and innovation is what makes us different. So ask yourself: wouldn’t it be awesome to work with a company that can do all that?
Let’s Make Awesome Happen
Yaskawa America, Inc.
YAI_ProFoodWorld_10-2020.indd ProFood_AdTemplate.indd 1 1
Drives & Motion Division
1-800-YASKAWA
yaskawa.com
For more info: http://www.yaskawa.com/packaging
9/15/2020 10/1/204:28:43 11:12PM AM
PLANT FLOOR PRODUCTS
Systems Eliminate Errors Due to Buildup of Material on Filters and Other Parts Utilizing a three-step weighing process, Volkmann weighing and dosing systems offer loss-in-weight within +/-1% or better at the conveyor feed point and gain-in-weight at the vacuum receiver prior to discharge into the process. A controlled-release, dosing weight discharge uses a floor scale or similar device. The on-site, controlled batch weighing and dosing systems are suitable for processes such as feeding a mixer with solids according to a specified recipe, the initial weighing of delivered raw material, and unloading smaller batches from big bags. They come in one-, three-, and four-load cell configurations. Volkmann volkmannusa.com
Pressure Sensor Achieves Precision across Entire Temperature Range The Baumer pressure sensor has a digital IO-Link that simplifies parameterization, while allowing process control via the 4-20 mA analog output. The link also makes it possible to call up additional process data, such as the temperatures of the sensor and the microchip in the central processing unit. Intended for the dairy industry, the PP20H pressure sensor includes a completely sealed, condensate-resistant silicon measurement cell with a barometric pressure sensor in the back of the housing that can measure the reference pressure of the environment via an opening. Baumer Group baumer.com
The Super Tough Industrial Polymer Sheet
SUPER TOUGH POLYMER www.kingplastic.com | Made in U.S.A.
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King Hy-PactÂŽ is the smart choice for many high abuse applications. Gears, machine parts, sprockets, star wheels, wear strips and more.
10/1/20 10:18 AM
HLOP_AD
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High Heat Ovens? Switching Relays Offer Low Power Dissipation Output CARLO GAVAZZI DC switching relays feature maximum output ratings of 100A at 60 VDC, 50A at 200 VDC, and 10A at 500 VDC. RM1D Series DC switching solid-state relays have switching frequencies up to 1,000 Hz, a 4-32 VDC control voltage range, integrated overvoltage protection, and self-lifting terminals. UL, CSA, and CE certified, they are suitable for off-grid and renewable energy systems that run off batteries, as well as DC heaters, solenoids, valves, fans, and other equipment that requires DC switching. CARLO GAVAZZI Inc. gavazzionline.com
GRAPHALLOY® self-lubricating bushings keep their cool. • • • •
Withstands temperatures up to 1,000° F Self-Lubricating FDA Acceptable Perfect for use in ovens, fryers, roasters, steamers, etc. • Withstands harsh, corrosive washdowns • Reduces maintenance and downtime Yonkers, NY USA
HLOP_AD.qxp_Layout 1 9/23/20 4:51 PM Page 1
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Highest Level of Protection Against Dangerous Tramp Metals
Rare Earth
MAGNETIC SEPARATORS
Available in a range of designs to get metal out, from the global leader in magnetic separation for more than 75 years.
Purity.Eriez.com | 814.835.6000 1020_PlantFloorNewProducts.indd 81
10/1/20 10:19 AM
PLANT FLOOR PRODUCTS Converter Reduces Need for Inventory and Space The WAGO converter can be used to accommodate four signal types: PNP to NPN, NPN to PNP, PNP to PNP isolation, and NPN to NPN isolation. Able to be used as a standalone unit or to be integrated with other WAGO TOPJOB S sensor/actuator terminals, the 2000 Series PNP/NPN isolating converter includes extra terminals, allowing for sensor power rather than power from a separate device. The 7-mm converter has an operating temperature of 0°C to 40°C for a variety of applications. WAGO wago.us
Vision Systems Efficiently Detect Label Errors
AIR FOR RENT SPECIALIZING IN TEMPORARY BLOWER SOLUTIONS UNDER 50 PSIG
Silgan Equipment vision systems conduct 360-deg inspections of full-body, shrink sleeve-labeled products, as well as products with standard wraparound labels. The 51R84 vision system has four GigE cameras that inspect labels at speeds up to 800 containers per min and process the images using Windows 10 software. The 51R85 model includes a fifth camera that inspects container necks for cocked caps and damaged tamper-evident bands. The system’s vision tunnel is mounted on a stand that fits over an existing conveyor. Silgan Equipment silgancls.com
Bulk Bag Fillers Are Available with Nitrogen Purging
LET’S TALK Matt Piedmonte, Rental Director 1-844-400-2379
Aerzen Rental provides more than just equipment; we provide solutions. Now you can rent packages with Aerzen’s quality and reliability complete with all the accessories and guidance to execute a temporary blower project. From emergencies that require shipment within an hour to planned projects and rent to own, Aerzen Rental is your partner for temporary oil-free air needs under 50 PSIG. www.aerzenrentalusa.com
1020_PlantFloorNewProducts.indd 82
Rental-USA@aerzen.com
Spiroflow bulk bag fillers feature a coned densification table for fill rate and fill accuracy, as well as densification. The CTE fillers can integrate foil or plastic bag liners, which, following a nitrogen purge and heatsealing process, can extend the stored life of a variety of products. The units come standard with a pneumatic neck seal that is compatible with the lined bags. The inflation assembly consists of a stainlesssteel filling nozzle, food-grade rubber sleeve, pneumatic value, regulator, filter, gauge, and machine-mounted interface components. Spiroflow spiroflow.com 82
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FOOD SAFETY REOPENING As restaurants reopened, a team of secret shoppers was sent out to conduct research on which restaurants were complying with government mandated protocols and procedures. The resulting data was discouraging, at best. â&#x20AC;&#x153;I Hired a Team of Secret Shoppers to Find Out How Businesses Were Opening in Dallas. Itâ&#x20AC;&#x2122;s Not Good.â&#x20AC;? Š 2020 Mark Cuban blogmaverick.com. May 7, 2020.
of businesses were non-compliant across all mandatory protocols
mandated compliances were adhered to at ~ 1/3 of the locations
offered a Safe Waiting / Staging Area
PRODUCT INSPECTION, ROTATION â&#x20AC;˘
Has all food been examined for spoilage, damage, expiration, or evidence of tampering or pest activity? If needed, was such food appropriately discarded?
â&#x20AC;˘
Is food properly labeled and organized, such that receiving date and rotation is evident?
â&#x20AC;˘
Are all food, packaging, and chemicals properly stored and protected from cross-contamination?
â&#x20AC;˘
Has contact been made with suppliers in the supply chain to ensure FGNKXGTKGU CTG UEJGFWNGF CPF CDNG VQ DG HWNĆ&#x201A;NNGF! â&#x20AC;&#x153;Best Practices for Re-Opening Retail Food Establishments During the COVID-19 Pandemic â&#x20AC;&#x201C; Food Safety Checklistâ&#x20AC;? www.fda.gov. May 21, 2020.
SATO SOLUTIONS
FreshLoc2Go Labels FX3-LX
The versatile FX3-LX features an intuitive 7â&#x20AC;? touchscreen that allows for quick, 100% accurate and precise printing in a lightweight, portable format that can be used with minimal training.
Tamper-evident labels help food retailers immediately identify and remove items that may have been tampered with or damaged. â&#x20AC;˘
â&#x20AC;˘
SATOâ&#x20AC;&#x2122;s AEP (Application Enabled Printing) programming platform allows the rapid development of custom and intuitive VQWEJUETGGP RTQORVU VJCV DGUV HWNĆ&#x201A;NN [QWT WPKSWG TGSWKTGOGPVU
FreshLoc2Go tamper evident labels provide reassurance that orders remain untouched in transit from the restaurant kitchen to the customerâ&#x20AC;&#x2122;s home.
â&#x20AC;˘
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Ideal for food-prep environments, the FX3-LX is water-resistant and easy to clean with an anti-microbial casing that minimizes the risk for cross-contamination.
Permanent adhesive prevents the labels from being peeled off cleanly. When peeled, the label will separate to indicate tampering.
â&#x20AC;˘
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To learn more about how to enhance safety with robust food safety labeling solutions and printers, visit www.satoamerica.com. SATO America â&#x20AC;˘ 10350-A Nations Ford Road â&#x20AC;˘ Charlotte, NC 28273
ProFood_AdTemplate.indd 1
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We understand how you strive for constant product quality and optimized costs.
CONSISTENT &21),'(17 You are poised to meet your safety and quality requirements while optimizing resources and securing process repeatability.
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Do you want to learn more? www.us.endress.com/food-beverage
ProFood_AdTemplate.indd 1 ProFood_AdTemplate.indd 1
10/1/20 11:14 AM 4/2/20 9:46 AM
CASE STUDY
Blender Upgrade Boosts Entire Soda Filling Operation By adopting Bevcorp’s new MicrO2 system, Admiral Beverage simplifies deaeration, optimizes blending, and speeds up both filling and changeovers. MATT REYNOLDS EDITOR, PACKAGING WORLD
A
DMIRAL BEVERAGE CORP. is among the largest suppliers of carbonated soft drinks in the western United States. Opened in Wyoming in 1947, it has grown to three large facilities supplying carbonated and still beverages, bottled water, and fountain mixes to multiple distributors throughout the mountain and western states and Alaska. In 2017, Admiral contacted Bevcorp to explore updating the software in the 22-year-old, earlier model MicroBlend blenders on its PET bottle and can filling lines. In the ensuing conversations, Bevcorp introduced Admiral management to the new MicrO2 blender it had developed and suggested that Admiral might be a valuable beta site for the new technology. The system limits dissolved oxygen (DO) to reduce foaming, which in turn allows the line to run faster.
Design advantages Admiral installed two MicrO2 blenders on its filling lines. The MicrO2 design turns traditional blending/deaeration procedure on its head. Whereas traditional systems deaerate water prior to blending, MicrO2 deaerates the fully blended product prior to carbonation instead of only deaerating the water. Traditional methods introduce DO into the product mix in the syrup. This difference enables the MicrO2 to deliver blended product to the filler with lower DO levels of 0.1 ppm for carbonated sugary soft drinks and 0.3 ppm for diet soft drinks. This compares to DO levels resulting from the traditional process of 1.8 ppm. “The fact that the MicrO2 system integrates deaeration makes it not only more efficient, but also more precise,” points out Admiral’s Plant Manager Clarence Foster. “Air is driven out of the product by CO2 and nitrogen flushing rather than by pumps and valves, and is done right at the point of use rather than remotely.” In addition, to reduce the possibility of air being reintroduced at the filler, during installation of the system, the Admiral and MicroBlend teams added a purge system to the Bevcorp filler that reduces air from entering the product at the filler.
Reducing DO and N2 levels improves the stability of a beverage during packaging, whether in cans or bottles. There is less foaming at the filler, which enables higher filling speeds. Beverages can also be filled at higher product temperatures. Traditional methods attempt to compensate for higher volatility by lowering temperature. The MicrO2 process reduces volatility by eliminating non-CO2 gases, making lowering the temperature unnecessary. This then reduces refrigeration costs and improves control over net weight that increases yields. A lower DO level also lowers the volatility of the product, minimizing opportunities for gases to be reintroduced at the filler and producing greater CO2 consistency. MicrO2 is also ideal for use with cans that feature new, first-generation BPA-NI (BPA non-intent) liners that are more susceptible to DO than BPA-lined cans. This is particularly important when using cans from can makers that guarantee “no leakers” only for filled cans with DO levels less than 1.2 ppm. Perhaps most significant for the customer and retailers, lower DO levels contribute to maintaining www.profoodworld.com
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Using the same filler, MicrO2 lets Admiral increase filling speeds of its 2-L bottles by 25%. Photo courtesy of Bevcorp.
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CASE STUDY
we could fill at those higher temperatures. But they proved me wrong.â&#x20AC;?
The MicrO2 blends and deaerates product upstream of Admiralâ&#x20AC;&#x2122;s bottle filler, reducing foaming and speeding the filling operation. Photo courtesy of Bevcorp.
Higher filling speeds and changeovers
product flavor longer through the beverageâ&#x20AC;&#x2122;s shelf life and can also extend that shelf life itself. For Admiral, the payback period for the cost of installing each new system is about 1.8 years. In addition, because the new line configuration lowers power needs for the facility significantly, Rocky Mountain Power, the local power utility, provided incentives that reduced the cost of power even further. For example, the power required for refrigeration on the previous bottle and can lines totaled 500 HP; today both lines use 25% of that amount of power. On average, product temperatures at the linesâ&#x20AC;&#x2122; filling heads went from 33°F to 46°F; some of the products being filled require no refrigeration at all. â&#x20AC;&#x153;This was one of the surprises,â&#x20AC;? says Dave Willard, Admiralâ&#x20AC;&#x2122;s vice president of production. â&#x20AC;&#x153;I didnâ&#x20AC;&#x2122;t believe
Lower product foaming at the filler is what enables filling to take place more quickly. Admiralâ&#x20AC;&#x2122;s 60-valve bottle filler from Bevcorp was filling 2-L bottles in the past at 165 bottles per min; today the filling rate is 210â&#x20AC;&#x201C;a better than 25% increase. In addition to higher filling speeds, the MicrO2 system increases productivity by its operational simplicity. â&#x20AC;&#x153;Every beverage is different,â&#x20AC;? points out Foster. â&#x20AC;&#x153;The previous system required operators to make adjustments as each new product recipe was bottled. Today, most of those adjustments are made by the software in the MicrO2, and operator involvement is minimal.â&#x20AC;? Another factor that can affect productivity in a beverage filling operation is product changeovers. The MicrO2 system speeds Admiralâ&#x20AC;&#x2122;s product changeovers by compressing that time: A critical innovation in the MicrO2 system is that the filler is being washed down as the blending tanks upstream are simultaneously being filled with the next product. PFW Bevcorp www.bevcorp.com
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CASE STUDY
Integrated Milk Processing System Delivers Sustainable Savings An Irish milk processor reduces its carbon footprint and boosts capacity with a modular configuration of refrigeration, heat pumps, and a pasteurizer that works seamlessly together.
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HEN AURIVO, IRELAND’S second largest milk processor, upgraded its manufacturing plant in Killygordon in 2019, it took a holistic, sustainable approach. The company installed an integrated milk processing system designed to increase capacity and reduce its carbon footprint, energy use, and reliance on fossil-fuel-fired water boilers. Aurivo replaced its outdated, inefficient refrigeration system and pasteurizer with a modular system from GEA’s Sustainable Energy Solutions program, which enables processors to customize and integrate equipment to meet heating and cooling demands efficiently and sustainably. Aurivo’s new integrated configuration consists of refrigeration, heat pumps, and a pasteurizer from GEA. Outfitted with a skimming separator, automatic standardizing unit, and homogenizer, the pasteurizer processes 45,000 L of milk per hour and works seamlessly with the upgraded refrigeration and heat pumps. GEA’s heat pump technology reclaims and channels excess heat from the new cooling system to heat water for the milk pasteurization process. The pumps remove heat from the cooling system at a low temperature and then uses a small amount of electrical energy to raise the temperature of the heat for the pasteurization process. Thermal buffering balances the load between the cooling and heating sides of the system to further optimize performance.
A sustainable turn of events This heat recovery system helps Aurivo to reduce primary energy consumption and its dependence on fossilfuel-based heating systems like water boilers, which, in turn, cuts carbon emissions. “The new refrigeration and heat pump solutions provide us with 1,200 kW of cooling and roughly the same in heating capacity,” says Stephen Carlin, Aurivo’s engineering manager. “The GEA heat pump that collects and recycles excess energy from the chiller provides us with the remaining energy needed to take the water up to the pasteurization temperature of 78°C or even a couple of degrees higher if required. This has rendered our traditional fuel oil-burning boilers almost redundant for the pasteurization process. In fact,
we now only have to turn the boilers on for one hour a week to kick-start each process cycle.” Aurivo has reaped a slew of other benefits since it has been using GEA’s modular system of refrigeration, heat pumps, and pasteurizer. The company boosted its hourly milk processing capacity by 80%, allowing it to produce 120 million L of whole, skim, and low-fat milks a year. Because the heat pumps have cut Aurivo’s use of fossil fuels significantly, the company has reduced energy consumption by about 12% and CO2 emissions by more than 181,000 kg per year. In addition, Aurivo has yielded operational savings of about €150,000 annually. And the upgraded facility was awarded the Excellence in Energy Efficient Design Certification from the Sustainable Energy Authority of Ireland. With the GEA milk processing system in place, Aurivo is looking forward to future growth by taking advantage of the heat pump system’s untapped capacity. “At present, we are only using 50% of the heat pump capacity,” Carlin explains. “If necessary, we could double the amount of hot water produced, and, therefore, potentially double our capacity for pasteurization.” PFW GEA www.gea.com
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Aurivo’s heat pump system reclaims and channels excess heat from its cooling system to heat water for the milk pasteurization process, helping to reduce energy consumption and carbon emissions. Photo courtesy of GEA.
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AD INDEX COMPANY
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COMPANY
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PAGE
ABB Motors & Mechanical baldor.abb.com
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Hapman Hapman.com/profood
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Aerzen USA www.aerzenrentalusa.com
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Hansen-Rice www.hansen-rice.com
Anritsu www.anritsu.com/infivis
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Bunting Magnetics www.buntingmagnetics.com
COMPANY
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PAGE
ROSS Mixers www.mixers.com/web-app
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55
Schubert www.schubert.group
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Heat and Control heatandcontrol.com/alwaysinnovating
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Samuel Packaging Systems Group www.samuelpsg.com
67
72
Industrial Magnetics, Inc. www.magnetics.com
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Busch Vacuum Solutions www.buschusa.com
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IQMS www.iqms.com
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Schneider Electric www.se.com/fb
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Clayton Industries www.claytonindustries.com
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King Plastic Corporation www.kingplastic.com
Cleveland Gear Company, Inc. www.clevelandgear.com
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CSI www.csidesigns.com
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Linde www.lindefood.com/chill
Deville Technologies www.devilletechnologies.com
74
Lubriplate Lubricants www.lubriplate.com
Dorner Manufacturing www.dornerconveyors.com/pfw
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Endress + Hauser www.us.endress.com/food-beverage
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Mettler-Toledo www.mt.com/pi
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Midwestern Industries, Inc. www.midwesternind.com
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mk North America www.mkcleanmove.com/pfw
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Volkmann, Inc. www.volkmannUSA.com
4
Nercon www.nerconconveyors.com
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Paxton Products www.paxtonproducts.com
30
MECO Seals www.mecoseal.com
86
80
68, 70
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FlexLink Systems flexlink.com
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P.E. North America 63 www.PENorthAmerica.com • www.AxonCorp.com
Yaskawa America, Inc. www.yaskawa.com
79
GEA Systems North America www.gea.com
21
Petro-Canada Lubricants Lubricants.Petro-Canada.com
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Zalkin Americas ZalkinCapping. com
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Graphite Metallizing www.graphalloy.com
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PPM Technologies www.ppmtech.com
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ProFood World ® (ISSN 2476-06760, USPS 22310) is a registered trademark of PMMI, The Association for Packaging and Processing Technologies. ProFood World ® is published 6x a year (February, April, June, August, October, December) by PMMI Media Group, 401 North Michigan Avenue Suite 300, Chicago, IL 60611; 312.222.1010; Fax: 312.222.1310. Periodical postage paid at Chicago, IL, and additional mailing offices. Copyright 2020 by PMMI. All rights reserved. Materials in this publication must not be reproduced in any form without written permission of the publisher. Applications for a free subscription may be made online at www.profoodworld.com. Paid subscription rates per year are $55 in the U.S., $80 Canada and Mexico by surface mail; $130 Europe and South America. $200 in all other areas. To subscribe or manage your subscription to ProFood World, visit ProFoodWorld.com/subscribe. Free digital edition available to qualified individuals. POSTMASTER: Send address corrections to: ProFood World, 401 North Michigan Avenue, Suite 300, Chicago, IL 60611. PRINTED IN USA by Quad Graphics. The opinions expressed in articles are those of the authors and not necessarily those of PMMI. Comments, questions and letters to the editor are welcome and can be sent to: jfassl@pmmimediagroup.com. We make a portion of our mailing list available to reputable firms. If you would prefer that we don’t include your name, please write us at the Chicago, IL address. Volume 4, Number 4. www.profoodworld.com
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OPX INTEL: ASSET RELIABILITY
The Drive to Zero Downtime The time invested in building reliability initiatives can pay huge dividends in the future. Systems and equipment can become more reliable and allow food and beverage manufacturers to fulfill safety, quality, delivery, and cost objectives. CHRIS DARLING GENERAL MANAGER, GREEN THUMB INDUSTRIES DANIEL LORUSSO SYSTEM SALES DIRECTOR, BW PACKAGING SYSTEMS DAN SILEO CO-FOUNDER, PARTNER, AND CHIEF MANUFACTURING COACH, FSO INSTITUTE STEPHEN M. PERRY, PH.D. CO-FOUNDER AND COACH, FSO INSTITUTE
Case in Point: Green Thumb Industries and BW Packaging Systems and explore best practices. We know the time we invest today in building out the reliability initiatives will pay huge dividends in the future, as our systems will be reliable and allow us to fulfill our safety, quality, delivery, and cost objectives. FSO Institute: Dan, as Chris noted, GTI is in the early stages of developing their asset reliability initiative. In your experience with both emerging and mature consumer packaged goods (CPG) companies, what are Chris Darling Daniel LoRusso Dan Sileo the most significant challenges you’ve seen in asset reliability? AS A PRELUDE to the next OpX Asset Reliability document release, FSO Institute checks in with two members of the Sileo: One of the biggest challenges I’ve seen time and time OpX Asset Reliability Solutions Group—Chris Darling of Green again is getting everyone on the same page regarding the value Thumb Industries (GTI) and Daniel LoRusso of BW Packaging of assets. For example, the shop floor operators and frontline Systems—to weigh in on some of the greatest asset reliability leadership have a strong desire to deliver results and product to challenges and how the OpX guidance document could help the customer, but may not understand the long-term benefit of solve some of those challenges. Dan Sileo, chief manufacturing investing in the assets. As such, there is a tendency to shortcut, coach with the FSO Institute, weighs in as well. delay, or skip scheduled maintenance programs like autonomous maintenance or preventive to deliver the immediate need. FSO Institute: Chris, you were there from the beginning in Most manufacturers know that this can create a vicious downdeveloping the OpX Asset Reliability document and clearly ward spiral in OEE (overall equipment effectiveness). As leaders, saw the need for it. What are some of the challenges GTI faces we have an obligation to invest in these associates to explain the regarding asset reliability? “why” and demonstrate the “how” of increasing asset reliability by investing in the equipment, but are too often consumed in Darling: The priority for GTI was to start building an asset manother priorities and don’t act on this as a priority. agement system and reliability strategy. The solutions group was an opportunity to help develop and educate everyone on FSO Institute: Chris, what solutions have you put in play, and the value and need. We are in a business that is maturing, as how might this OpX asset reliability guidance document help well as we are in an emerging high-growth phase. Therefore, with those and other solutions you’re considering? these processes will help to ensure our future success. Helping to develop the OpX asset reliability document was a great way Darling: We are still very early in our journey. We are building for us to share, learn, explore, and understand the challenges teams with a proactive focus in mind, educating on the value of that are impacting other consumer packaged goods companies reliability and the processes. We are starting from the ground
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HILE THERE MAY BE as many definitions of asset reliability as there are consumer packaged goods (CPG) manufacturers to define it, most all agree that the primary goal of undertaking an asset reliability initiative is zero downtime and maximizing asset life. PMMI’s OpX Leadership Network recently commissioned the Asset Reliability Solutions Group to undertake a work product on asset reliability in order to get CPGs and original equipment manufacturers (OEM) on the same page regarding definitions, key performance indicators (KPI), calculations, and leadership guidance when developing an asset reliability initiative. The work product is nearing completion and will be available later this year.
up, collecting data focused on our most critical assets and then implementing our CMMS (computerized maintenance management system) solution for work management and materials management to drive some of the baseline KPIs highlighted in the solutions group document. Once we have established our baseline objectives, we will start building more advanced processes and KPIs. FSO Institute: Dan, of the challenges you highlight above, what are some of the solutions you’ve put in play to improve the reliability of assets in the drive to zero downtime? Sileo: In one company I worked with, we trained on the importance of planned maintenance, but then made it important by putting a process in place that if scheduled PM (preventive maintenance) time was moved, it needed plant manager approval, and if by more than 24 hours, they had to get VP approval. This put pressure in the system to hold to the scheduled maintenance, and we were then able to show a greater than 4% improvement in OEE (almost an hour a day). FSO Institute: Daniel, you also became a contributor in developing the OpX asset reliability document and clearly saw the need for it. From an OEM perspective, what challenges have you faced regarding asset reliability, especially in working with your CPG customer base? LoRusso: As an OEM, we define value to our customers in a variety of ways. It’s easy
The team discovered early on that perhaps one of the best ways to understand asset reliability is in its relationship to overall equipment effectiveness (OEE). As shown in the graphic below, asset reliability initiatives are focused on two key areas within OEE loss: planned downtime events and unplanned downtime events. These are the very events that inhibit a machine from performing its intended function or from doing what it is supposed to do, when it is supposed to do it. In this soon-to-be-released OpX work product, the focus of an asset reliability initiative to address these events is based on three categories of KPIs: 1. People KPIs – Focused on labor factors, including total production maintenance labor costs, actual fully loaded operations labor costs, overtime mainte-
Calendar production potential = 24 × 60 × 365 target throughput rate
OEE production potential = Scheduled minutes × target throughput rate Calendar production potential Lack of demand OEE production potential Initial delivery loss Planned downtime events Asset reliability focus
Unplanned downtime events Target throughput rate loss
An important factor in understanding asset reliability is in its relationship to overall equipment effectiveness (OEE). Asset reliability initiatives are focused on two key areas within OEE loss: planned downtime events and unplanned downtime events. Source: PMMI’s OpX Leadership Network OEE guidelines report.
Off-quality and rework loss Net good production
OEE loss
Capacity utilization loss
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OPX INTEL: ASSET RELIABILITY
nance costs and hours, contractor costs and hours, planned and unplanned maintenance costs, preventive maintenance costs and hours, and others. 2. Operating KPIs – Focused on operating factors, including plantwide average downtime (planned and unplanned), plantwide scheduled production hours, total plant MRO (maintenance repair operations) budget to spend, OEE, availability, uptime, stores inventory turns, mean time between failures, mean time to repair or replace, and others.
About the Case in Point Series
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N THE PAST FEW YEARS, PMMI’s OpX Leadership Network has produced more than 20 manufacturing process-improvement documents for CPGs and OEMs. The FSO Institute has facilitated the adoption and implementation of these documents, especially for food and beverage manufacturers. In this Case in Point series with the FSO Institute, ProFood World presents actual cases to show just how CPGs are using OpX documents to improve their overall manufacturing health and their collaboration with OEMs and other suppliers. Learn more at www. opxleadershipnetwork.org and www.fsoinstitute.com. ™
Case in Point continued from Page 91 to see the value of our innovation investments because machines with new technology, more intuitive operator interfaces, and quick and easy product changeovers are often well publicized as marquee improvements. However, our investment and efforts to make our machines more reliable and robust may go unnoticed by potential customers because of how difficult it is to quantify reliability back to an operation’s bottom line. Each year, BW Integrated Systems, a BW Packaging Systems company, makes significant investments in product development. I’m excited to see the development of tools that can help our customers better quantify the value of a reliable machine. I have seen too many instances where we’ve been asked to replace or modify a machine that had a cheaper price tag at the time of original purchase, but ultimately hindered our customer’s entire packaging operation. For years, our customers have been looking for a way to “see into the future of a machine,” and I’m glad they now have a tool to do just that. Hopefully, a better understanding of asset reliability paired with the [OpX] total cost of ownership tool will help guide our potential customers toward machine centers that will foundationally improve their business. FSO Institute: What solutions have you put in play and how have they been incorporated into product development at BW Packaging?
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3. Financial KPIs – Focused on financial factors, including stocked MRO material inventory value, ratio of replacement asset value (RAV) to craft wage headcount, total maintenance cost as a percent of RAV, opportunity cost due to unplanned downtime, and others. For each KPI, there is a corresponding definition, leadership guidance, and calculation (where needed) to get CPGs and OEMs speaking the same language when it comes to asset reliability. In addition, the KPIs are categorized by stage in the asset reliability journey, e.g. which KPIs are necessary at the beginner stage as well as those needed at later stages. For CPGs trying to determine the value of an asset reliability initiative—the “size of the prize”—the Asset Reliability Value Calculator can help determine the potential value of missed opportunities that could be gained by improving line reliability. The focus here is on improving the reliability of the critical asset or the main bottleneck on the line in addition to the processes involved in the entire manufacturing process. Collaboration can yield significant improvements in OEE by focusing on opportunities to reduce the impact of planned and unplanned downtime and, instead, drive to zero downtime. PFW
LoRusso: As I stated before, BW Integrated Systems has a strong and purposeful innovation plan. We invest year after year to keep our marquee products at the top of their game, and we also develop new solutions that help our client’s meet their ever-changing packaging needs. In each case, sitting with our customers and documenting their needs, likes, and frustrations are always the first steps. We interviewed dozens of clients in multiple countries who have experience with our machines, as well as our competitors. This gave us a broad understanding of what was needed. In each case, machine reliability was a key factor, but it was a factor that was difficult to quantify. One example of finding reliability through a reduction of planned downtime is a move away from compressed air and pneumatics. In our most complicated machines, we have dozens of valves and cylinders, all of which need frequent maintenance through planned downtime. By replacing these components with systems that require less maintenance, we have increased the potential uptime and put real money back in our customers’ pockets. We all understand that a machine with better uptime and limited planned/unplanned downtime is the preferred machine. Yet even as an equipment supplier, it is hard for us to financially compare what additional uptime could do to a customer’s bottom line. The example of the Asset Reliability Value Calculator is such a good tool to show the benefits of a machine or upgrade package that correlates to less downtime and more production.
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