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September/ October 2012
Food for thought
Foodtech Packtech packaging 10 Come and see the latest in food
© iStockphoto.com/Richard Clark
fruit & vegetables
Sustainable production 39 Fruit juice used to halve and packaging benefits the fat in chocolate both manufacturers 42 Spray-on coating delays and consumers banana ripening 44 Testing
48 55 86 89
Automation, sensing & robotics .
57 48 Food and water safety provide new 64 challenges for today’s sensors 68
Slippery coating evicts biofilms Third-party audits and food safety
86 Combating antimicrobial resistance
Lower pasteurisation temperature may limit spore germination
78 Upscaling the production of ethnic ready meals
Bulk handling, storage & logistics 91 The six guidelines you need to specify a bulk bag filler 96 Intelligent cargo for more efficient, greener logistics 102 New racking standard brings Australia up to date 106 Chocoholics rejoice
What’s with all the cows?
We all trot off to work each day and, no matter how much we enjoy what we do, there is always a repetitive factor. Some of us have fairly low tolerance to repetition and boredom so we invent ways of keeps ourselves entertained. In many ways my job is the antithesis of boredom as I am tasked with finding out “what’s new” - but converting this into text and images for the web and magazine is repetitive. So, many years ago, simply as private entertainment, I decided to include an image of a cow in every issue of the magazine. This went well for a while but then it escalated … I moved on from single cows to multiple cows - rather than using conventional ‘stops’ at the end of every article I used cows. Cows were proliferating. Then the art team became involved - for a while we contented ourselves with all sorts of different ‘stops’ but the need for cows was still simmering on the backburner. My private entertainment had become public and people started giving me cow-related gifts. Now I am in bovine overkill. At Foodtech Packtech, What’s New in Food Technology & Manufacturing has a stand. It’s a great opportunity for me to actually meet the magazine and website readers and I always come away from such meetings both enriched and humbled by the knowledge, interest and professionalism of the readers I meet. In return I would like to portray a professional persona as befits the editor of the magazine and website. But what has happened? Cows! Our Events team procured little giveaways to entice potential new subscribers to our stand - cow stress balls - and I have succumbed to temptation and put an illustration of a cow reclining in a sun chair on the front cover. If you are in Australia rather than New Zealand you won’t get this cover because the publisher has placed a moratorium on my cow - declaring that we are a reputable business and cutesy cows do not align with our image. I have to say he is right. What’s New in Food Technology & Manufacturing is not cutesy and you can help in ensuring it stays that way. When you or your company does something newsworthy in the food and beverage industry, let me know. Send me a press release and a picture so I can publish some serious Australian and New Zealand content about how you are meeting and beating the challenges of manufacturing foods and beverages. And from now on, I am limiting my cows (but I am developing an alternative keep your eyes peeled in coming issues and let me know if you see a subtle theme). Regards Janette Woodhouse Chief Editor
What’s New in Food Technology & Manufacturing www.foodprocessing.com.au
No health claims allowed on sugary, salty and fatty foods, forum decides The Legislative and Governance Forum on Food Regulation met on Friday 20 July to discuss general level health claims in the draft Standard for Nutrition, Health and Related Claims. The forum, composed of ministers responsible for food regulation in Australia and New Zealand, reached agreement on a preferred approach for a system regulating general level health claims. The approach includes pre-approved food-health relationships and the option for food producers to self-substantiate new claims that comply with detailed criteria set out in the standard. The ministers confirmed their support for a nutrient profiling scoring criteria (NPSC) that would ensure only healthy foods carry health claims. Foods high in sugar, fat and salt would be precluded from claiming health benefits. The review period for the standard has been extended until 31 October 2012.
Fo d FOR
Microwaving retains RPO’s carotene content, study finds
Microwave heating of red palm oil (RPO) retains a higher carotene content than RPO that has been conventionally heated, researchers at Universiti Teknologi MARA in Malaysia have found. The researchers conducted a study to evaluate carotene and the antibacterial effects of microwave heated and conventionally heated RPO. They found that heating RPO decreased its carotene levels, but microwave heated RPO retained higher carotene content. The study also found that neither fresh nor heated RPO exhibited inhibitory effects on Escherichia coli bacterial growth. As a result of the study, the researchers recommend conventional heating be replaced with microwave heating as part of a health red palm oil diet. The research paper was presented at the 2012 IEEE Symposium on Humanities, Science and Engineering Research in Kuala Lumpur.
GS1 announces global product recall standard ©iStockphoto.com/ Alexander Chernyakov
Following nearly three years of industry-driven work, GS1 has announced the ratification of a new global product recall standard, as well as an implementation guide for multijurisdictional recall notifications. GS1 Australia said the new standard ‘connects’ all the recall portals being developed across the globe, enabling the exchange of data between portals. GS1 says the standard will enable supply chain stakeholders to implement more effective product recall processes and notifications. “The standard defines, standardises and harmonises the critical attributes to be captured and shared among trading parties and regulators during a product recall alerting and
messaging process,” GS1 said in a media release. “Effective product recall is complex, multijurisdictional and typically involves multiple stakeholders in extended supply chains,” said a Woolworths Australia spokesperson. “Having a standardised process globally will enable us to run more timely and targeted recalls. Ultimately, consumer safety will benefit.” The standard identifies the key principles of traceability and demonstrates how to apply them for effective product recall. Accompanying the standard is an implementation guide that is dedicated to multijurisdictional requirements as a product recall alert is issued and executed. “The GS1 Product Recall Standard will enable manufacturers, retailers and suppliers to work more closely together,” said Procter & Gamble’s Marketing Logistics Leader Daniel Triot. “By leveraging a system of global supply chain standards that we all know and use today, product recall will become a function that is embedded into all our global supply chain. Critical mass adoption and interoperability of the notification tools will accelerate the implementation of the standard.” The standard is incorporated into the GS1 Recallnet platform in Australia. GS1 Australia’s COO Mark Fuller says this is part of GS1 Australia’s long-term plan for making GS1 Recallnet a more global solution for brand owners and consumers.
Lactose-free dairy products:
not an oxymoron, but a growth area While ‘lactose-free dairy products’ might sound like an oxymoron, apparently it’s a huge growth area. Innova Market Insights has reported that global launch numbers for lactosefree dairy products more than tripled in the five years leading to 2012. In 2007, lactose-free dairy products accounted for less than 2.5% of total dairy introductions; by 2012, they made up 4.5% of total dairy introductions. Interest in lactose-free dairy products has been highest in the USA and western Europe, with 10% and 6% respectively of total dairy launches in the past 12 months being marketed as lactose-free. Lu Ann Williams, Research Manager for Innova Market Insights, puts the growth down to several factors: interest in dairy alternatives, improved labelling, growing awareness of the potential problems associated with lactose intolerance and technological developments allowing the
production of better-tasting products. Rather than just being focused on the specialist dietetic market, lactosefree products are now moving into the mainstream. Large companies have extended their brands with lactosefree alternatives: Danone’s Activia now comes in a lactose-free option, Yoplait has four lactose-free variants and New Zealand’s Anchor dairy brand has released two Zero Lacto lactose-free alternatives. Already established dairy alternative sectors have the highest share of lactose-free ranges, particularly beverages, with over 30% of products marketed as lactosefree. Creamers accounted for over 9% of introductions in the beverages subsector. Williams says the increasing presence of lactose-free options in mainstream dairy markets will drive both the dairy sector and the food and drinks market forward.
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CSIRO forms new division
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CSIRO has announced a new research addition: a Division of Animal, Food and Health Sciences. The new division is an amalgamation of the former divisions of Livestock Industries and Food and Nutritional Sciences. In the months leading up to the official 1 July formation of the new division, staff from the two former divisions have been working together to ensure a smooth transition. CSIRO says all projects and agreements will continue and staff contacts for partners and clients will remain the same. Leading the new division is Dr Martin Cole, Chief of Food and Nutritional Sciences and an internationally recognised microbiologist. Cole says the 568 staff from the former divisions will form one of the most comprehensive cross-disciplinary life science capabilities in the world and maintain CSIRO’s unique position in the whole of food-value-chain research. “Just as the last century has seen a revolution in computing, biology is experiencing a major wave of technical innovation
flowing from the significant advances made in the life and computational sciences. Our capacity to understand complex processes in a highly targeted manner is vital to our capitalising on opportunities in the food, health and life science industries,” Dr Cole said. “This new understanding will have profound impacts on animal production and health, human nutrition, and prevention of infectious and lifestyle diseases. The new division will allow us to capture these opportunities. It will connect primary production to food processing and manufacturing and consumer needs. “This is something more than a merger. This is about creating a division that affords new science approaches that more effectively provide our clients and research partners with the greatest benefits,” Dr Cole said.
Guideline changes mean dollar-for-dollar grants for manufacturers gas emissions and face a direct carbon price liability under the $1 billion Clean Technology Investment Programs. Greg Combet, Minister for Industry and Innovation, announced the update to the program guidelines yesterday. He said the new funding ration would increase support for manufacturers to invest in equipment and technology to reduce their power bills and emissions. “The change in the Clean Technology Investment Programs’ grant ratio has been made after detailed consultations with industry. It will ensure manufacturers who are directly liable under the carbon price are able to apply for significant assistance under the Clean Technology Investment programs,” Combet said. “Capital investment in low-emission and energyefficient technologies throughout manufacturing
facilities will help these Australian businesses to become more competitive and sustainable.” The changes to the guidelines mean that manufacturers with a facility that emits between 25,000 and 100,000 tonnes of greenhouse gas emissions in the full financial year prior to lodging their application now only have to match the government grants on a dollar-for-dollar basis. For businesses that meet the criteria and have already lodged an application under the Clean Technology Investment Programs, the new funding ratio will be available retrospectively. Existing grant funding ratios will continue to apply to businesses not liable under the carbon pricing mechanism. Manufacturers with a turnover of less than $100 million applying for grants under $500,000 will continue to receive a dollar-for-dollar grant ratio. The Clean Technology Investment Program and the Clean Technology Food and Foundries Investment Program are open for applications. For more information, visit the AusIndustry website.
Supermarket private labels will keep growing, says IBISWorld Private-label products will increase to cover 30% of the market in the next five years, IBISWorld predicts. The market research group forecasts that private-label products will increase from just over one quarter to over 30% of total supermarket sales by 2017-18. Karen Dobie, IBISWorld General Manager (Australia), says private-label products have been one of the fastest-growing segments in the supermarket industry in the past decade. The rising cost of living, compounded by the carbon tax, will see more Australians opt for private-label products, Dobie predicts. “In 2007-08, private labels accounted for just 13.5% of total supermarket sales - meaning the segment has grown by more than 85% over the past five years,” Dobie said. Of the $85.9 billion Australians are expected to spend on groceries in 2012-13, IBISWorld predicts $21.6 billion will be spent on private-label products. Ths is up from $9.96 billion five years ago and $19.7 billion in 2011-12. By 2017-18, Dobie expects this will reach $31.8 billion - a growth of nearly 50% in five years.
“The recessive economic climate has been a strong driver of private-label growth,” Dobie said. “Households have been reining in spending, paying off debt and increasing savings. This, coupled with an increase in the range of private-label products available, has led many consumers to make the shift to home brands.” Within the private-label segment, dry grocery items and chilled packaged food categories have shown the strongest growth. Alcohol has also worked well for Woolworths and Coles, Dobie said. “Products with a high degree of homogeneity that are staples of grocery baskets have shown the strongest private-label growth. These include private-label butter, which accounts for 68% of total butter sales; private-label sugar, accounting for 67% of total sales; bread at 56%; and fresh milk at 55%,” Dobie said. The consumer trend towards free-range eggs has seen privatelabel egg sales decrease from 61% to 50% of market share in the past ten years. Consumer preference for trusted brands in chocolate, confectionery, soft drinks, cosmetics and sanitary products means these categories have not performed well. Dobie also commented on the supermarket price wars, saying that consumers will benefit from cost savings in the short term, but may be faced with less choice longer term as supermarkets increase their private label ranges. “All of this discounting means that someone is paying the cost of purchasing $1 litres of milk and $2 loaves of bread,” Dobie said. “More often than not, farmer and producer margins are being squeezed as supermarkets discount heavily to increase store traffic.” Heavy discounting strategies, such as Coles’ flybuys program, are often detrimental to suppliers. “In the long term, this trend will primarily benefit the supermarket giants and those producers that are contracted to manufacture private-label products,” Dobie concluded.
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What: Foodtech Packtech When: 25-27 September 2012 Where: ASB Showgrounds, Auckland Online registration for free entry: www.foodtechpacktech.co.nz Foodtech Packtech is a must-attend event!
ew Zealand’s biennial Foodtech Packtech exhibition gives food sector professionals the opportunity to come face to face with the experts behind the key innovations entering the New Zealand and Australian markets. The event will showcase the freshest ideas, latest technologies and the newest developments entering the food technology and packaging technology market from more than 180 prominent suppliers. A series of development and business seminars will also run, and Foodtech Packtech 2012 is endorsed and supported by the Packaging Council of New Zealand, the New Zealand Institute of Food Science and Technology, and Plastics New Zealand. Many exhibitors are keeping secret for now what visitors will see, but some are prepared to offer a teaser or two into the products and services they’ll have on their stands. You can rest assured that there will be plenty of extra-tempting show specials on some of these, too. No matter your business or interest, there will be something to pique your interest at Foodtech Packtech 2012. D&L Packaging’s Digby Morton says visitors to their stand will see a few interesting technologies. “We are offering the latest in shelf life boosting (SLB) technology, including vacuum packaging, tray sealing/ packing, skin packing and thermoforming, and the latest tray lidding barrier films. These technologies greatly extend shelf life to most fresh food products, while maintaining the quality and freshness of the food and all without the need of additives. Clearly there are great advantages for both food producers and consumers. “Odour control technology is another area of huge interest to the sector and many others. We have a brand new, never seen before range of products for odour control. This product is an odour absorber unlike anything else on the market. Our product actually absorbs the odour and does not simply mask the odour by creating clouds of perfumed mist. This product can be used in virtually any building,
vehicle, rubbish bin or enclosed area where foul odour is a problem and it will not just mask the odour, but absorb it and eliminate it.” Spain’s Hiperbaric will present its complete range of integrated high-pressure equipment for the first time at Foodtech Packtech 2012. “Hiperbaric is a benchmarking and leading global supplier of high-pressure processing (HPP) equipment for the food industry, and is presenting its fully integrated range of machinery at Foodtech Packtech together with its regional partner Scanz Technologies Ltd,” says Tony Rumbold of Scanz. “Hiperbaric is currently the only manufacturer of highpressure processing machines offering a whole range of integrated equipment. Hiperbaric will also introduce its latest developments and improvements in HPP wear part and spare part design, which are allowing a consistent decrease in cycle and production costs together with a maximisation of the availability of HPP units and diminishing down times.” Another exhibitor, Intralox, understands just how critical reliable conveyance is to food processors, says Tomoko Sacks. “Our innovative conveying solutions for improving food safety, increasing package handling capabilities and increasing productivity have made radical improvements to our customers’ operations. Intralox’s comprehensive approach to food-safe conveyance includes the right choice of belt and components including ThermoDrive and SeamFree beltings that offer the most time-efficient and cost-effective means of ensuring hygienic conveyance solutions: the Intralox FoodSafe Team’s food safety consulting service; hygienic conveyance design guidelines; and thorough cleaning process management support.” Foodtech Packtech is a trade-only event with free entry for those who register online at www. foodtechpacktech.co.nz. XPO Exhibitions Contact info and more items like this at wf.net.au/Q666
Come and see the latest in food
Fully sanitary stainless steel highspeed vertical bagging machine Reactive Engineering NZ will exhibit its Flow fully sanitary stainless steel high-speed vertical bagging machine at Foodtech Packtech 2012. The machine is fully servo driven, both on the film transport as well as on the sealing systems. Flow is designed for packaging processes with a medium to high capacity
for a wide variety of products and film types. The machine is available in both heat seal (PP and laminated films) as well as in impulse sealing. At the heart of this new machine concept is an AB PLC with a user interface via an AB PanelView Plus, which has an interface modelled on the simplicity of the iPad. The new machine offers users an IP67/69K hygienic design: there are no trap points, no flat horizontal surfaces and the entire machine frame, parts and panels are made from stainless steel - but clever design keeps the overall weight down. All of the modules that are usually on the outside of traditional VFFS machines are enclosed, including the electrical cabinet and film rollers. Complete internal and external washdown is also possible. The bag length is determined by an encoder on the film which ensures a high degree of accuracy. The maximum film width is 740 mm. Reactive Engineering NZ Ltd Contact info and more items like this at wf.net.au/Q799
Checkweigher range JL Lennard is exhibiting Thermoâ€™s family of Versa checkweighers at Foodtech Packtech 2012. Versa models are designed for use with the lightest products through to packages of 25 kg. Checkweighers are usually positioned at the end of the packaging line to do a final check of the weight of an individual product or package. But the Versa range can also be used in the production process to control dosage such as flour and sugar, or any product that is volumetrically dosed. Versa checkweighers can also be integrated with the APEX metal detector, offering a complete system for metal check and weighing. The checkweighers are easy to use, featuring: Microsoft Windows XP operating system; a large, easy-to-read, colour touch screen; configurable security access levels; advanced automatic set-up, which reduces the need for formal training; and contextual help screens to guide operation. The durable checkweighers have full stainless steel frames, electronics enclosures and conveyor beds, and high-torque sealed brushless DC motors. Advanced statistics and graphs give detailed views of production line performance including product giveaway. Users can save up to 100 standard product memories, which are expandable and searchable by product or name.
AIP exhibiting at Foodtech Packtech 2012 The Australian Institute of Packaging (AIP) is heading to New Zealand for the third time to exhibit at Foodtech Packtech 2012 and is excited to catch up with its NZ members and meet potential new members. The AIP stand will have information about the AIP Diploma in Packaging Technology, Certificate in Packaging and half-day training courses that are all available in New Zealand. The AIP is an educational institute designed to provide professional and personal development
JL Lennard Limited
for individuals within the packaging industry.
Contact info and more items like this at wf.net.au/Q796
Australian Institute of Packaging Contact info and more items like this at wf.net.au/Q789
Biopolymer derived from renewable plant resources NatureWorksâ€™ Ingeo biopolymer is derived from an abundant 100% annually renewable plant resource. Carbon is captured in these plant resources, sequestered from the atmosphere during plant photosynthesis, and stored in the starch found in the grain of the plant. This starch is then converted into natural sugars. NatureWorks uses this plant sugar, dextrose, from a simple existing supply stream as Ingeoâ€™s fundamental building block. Through a process of fermentation, separation and polymerisation, the carbon and other elements in these natural sugars are transformed into Ingeo biopolymer. According to NatureWorks, Ingeo resins and fibres are a significant step towards a better future. Replacing petroleum with an annually renewable resource for the production of plastics and fibres reduces fossil fuel dependency and is a positive step towards carbon-neutral manufacturing and more sustainable processes and products. The production of Ingeo uses significantly less non-renewable energy and generates significantly lower CO2 emissions when compared with all traditional oil-based polymers. Compared to PET, for example, Ingeo reduces fossil fuel usage by 47% and greenhouse gas emissions by 59%. Ingeo biopolymer is used to create a full and diverse range of finished consumer lifestyle goods from clothing to housewares to personal care products as well as food packaging, appliances, auto parts, consumer electronics and durable goods. NatureWorks will showcase its Ingeo biopolymer at Foodtech Packtech 2012. NatureWorks LLC www.natureworksllc.com
Air-operated diaphragm pump range Matrix Process Solutions provides a comprehensive portfolio of liquid processing equipment, engineering and installation expertise to the food and beverage industry. The company has recently added to its portfolio the Australian-manufactured range of air-operated diaphragm pumps designed and built by Pumps 2000 in Newcastle. The range includes pumps manufactured with flame-resistant antistatic (FRAS), polyethylene and noryl, with available diaphragm combinations in santoprene, hytrel and polyurethane. Applications include explosive environments, chemical, wastewater slurries, high solids media and food contact applications, with pump sizes ranging from 15 to 75 mm. The pumps are self-priming, have low air consumption and are lightweight, making them suitable for portable applications. Flow rates of up to 500 L/min are achievable with the pump range, with discharge head pressures of up to 7 bar also possible. The air-operated pump portfolio is completed with the highly polished Murzan stainless steel range, capable of pumping complete chicken breasts, whole fruits and even soft-boiled eggs without causing damage to the food items. Matrix Process Solutions will showcase its range of pumps at Foodtech Packtech 2012. Matrix Process Solutions Pty Ltd Contact info and more items like this at wf.net.au/Q932
Hach Pacific to exhibit new products Hach Pacific will showcase its new products at Foodtech Packtech 2012. New products include: DR3900; Hach Orbisphere 3100; Hach Orbisphere 3658; Hach Orbisphere 410 with M1100; TSS inline with SC200; Sension+ benchtop + pH + COND; Hach H-Series H135 pH meter and calibration set; Tinytag logger; Vaisala HMP300 series with RH probe. The company offers lab and process water analytics as well as other products such as leak detection and pipe and cable location equipment, which can be easily bundled with water quality analytics. Hach Pacific Pty Ltd Contact info and more items like this at wf.net.au/Q784
Multihead weigher range Selpak will showcase machinery from the weighers as well as the premium Sigma F1
Range of natural flavours
Series at Foodtech Packtech 2012.
Creating just the right flavour re-
Alpha Series Value line of Yamato multihead
The company says the Alpha Series Value
quires more than science: it also
line represents good value for money in terms
takes the flair, creativity and instinct
of flexibility, precision and speed across a range
of expert flavourists. In response to the market demand for high-quality, inexpensive
and dried fruits, fresh produce, IQF products, tea, cof-
and â€˜true-to-flavourâ€™ natural flavours,
of applications, including snacks, confectionery, granulated products, pasta, cereal, pet food, nuts
Ungerer Australia has developed
fee and herbs. The Sigma F1 Plus offers maximised sealing clearance, versatility in packaging pattern and a 10% higher operational speed, as well as higher accuracy.
a unique range suitable for most applications.
The Yamato multihead weighers include springless buckets, stepper motors, digital filters,
Ungerer will sample a selection
modular actuator units, self-diagnostics and LCD touch screens for ease of use. The weighers
of some of its flavours in confec-
are easy to use, accurate, cost-effective and easy to clean.
tionery and beverages at Foodtech
The colour touch screen has intuitive graphics to make troubleshooting and recovery easy
to learn and simple to use. Selpak claims the weighers offer maximum return on investment,
maximum uptime, easy operation and good hygiene.
Contact info and more items like this at wf.net.au/Q787
The Selpak team is also available to discuss process or packaging solutions across their range, including Bepex, Hassia, Oystar, Pamasol, Rommelag, TAM, Techgen, Techne and Volpak. Selpak Automation Pty Ltd Contact info and more items like this at wf.net.au/Q809
Chemical delivery system for water treatment Ashland Water Technologies has launched a solid chemical delivery system designed to provide food and beverage producers with more sustainable and environmentally friendly chemical water treatment solutions. The Ultra-Serv Solid uses an easy-to-install solid chemical delivery system that replaces liquid water treatment chemistries with a 100% active solid product. The dissolver system is loaded with 3.5 kg solid chemical discs that are sprayed with water
to dissolve the chemical into a small volume of liquid, ready for application through the existing chemical dosing and control system. The dissolver system overcomes the problems associated with other solid chemical systems and the company claims the system has proved highly reliable in the 200plus applications currently in place. By using solid product, the volumes of chemical that need to be shipped and managed are typically reduced by between 50 and 90%, depending on the application. This large reduction in chemical volume lowers freight requirements, and reduces fuel consumption and CO2 emissions. This, in addition with the elimination of plastic pails and drums, can assist food and beverage companies in improving their carbon footprint and supporting their sustainability goals. Ultra-Serv Solid has been demonstrated to reduce environmental and health and safety risks by eliminating potentially hazardous liquid spills and eliminating the need for workers to handle heavy containers. Inventory management is also streamlined as less chemical storage space is required and the handling of solid product is much easier and reduced compared to handling pails and drums. Ashland Water Technologies will exhibit the Ultra-Serv Solid at Foodtech Packtech 2012. Ashland Water Technologies Contact info and more items like this at wf.net.au/Q807
Labelling systems Apex Printing & Packaging Engineering designs and manufactures
Eccentric disc pumps Eccentric disc pumps by Mouvex, supplied by NuWay Energy NZ, are selfpriming, with clean-inplace capability and low shear for sensitive liquids. Mouvex pumps are used for pumping of sheer-sensitive thick liquids or food products with entrained solids, glucose pumping, wine filtration, bottling and packaging and other applications. The disc pumps have a seal-less design that ensures leak-free transfer of product and low-impact wear parts that are claimed to offer industryleading mean time between repair (MTBR). Designed for hygienic markets, the pumps have EHEDG and 3A certifications and are CIP and SIP capable. The pumps have the ability to pump low- and high-viscosity products, and combine low-shear with high-volume efficiency. The C-series pumps can be cleaned and flushed without disassembling. Nu Way Energy (NZ) Ltd
designs and equipment to suit each application. The companyâ€™s equipment is made from high-grade stainless steel and has the capability to be handed either left to right or vice versa. The electrics, bearings, sensors and other parts are readily available throughout New Zealand, which can minimise machinery downtime as parts do not need to be delivered from overseas. Apexâ€™s new range of automatic labelling equipment has been developed to ensure speed, accuracy, reliability, ease of use, fast changeover times and minimal waste. Apex Printing & Packaging Engineering will showcase its equipment at Foodtech Packtech 2012. Apex Printing & Packaging Engineering www.apexpp.co.nz
Contact info and more items like this at wf.net.au/Q791
complete labelling systems, creating
Metal detector Dynamic Inspection Limited will be showcasing its new STEALTH metal detector at Foodtech Packtech 2012. The STEALTH unit offers powerful digital signal processing (DSP) technology which provides high-speed precision detection, while ultra-sensitivity levels detect the smallest metal contaminants. Automatic testing and calibration allow for simple operation and the true auto-balance enables recovery
Gripping and handling systems for use on robots and gantries Romheld Automation will exhibit gripping and handling systems for
from large metal contaminants to avoid detector ‘blindness’. Dual power/frequency facilitates automatic compensation for extreme product characteristics (excluding metallised and nonmetallised packaging).
use on robots and gantries at Foodtech Packtech 2012.
The STEALTH’s product
The Romheld range includes Unigripper self-sealing intelligent
library stores individual
vacuum grippers, Goudsmit magnetic grippers, SAS pneumatic grip-
settings which can
pers and Schunk servo electric grippers commonly used for filling
be recalled instantly
cartons, palletising and depalletising of cans, bottles, shrink-wrapped
to simplify product
product, punnets, cartons, bags, rolls, pallet handling and more.
For maximum flexibility, ATI fully automatic robotic toolchangers
provide fast, safe unattended changes of tooling, including all
testing on samples
pneumatic, electric, vacuum, hydraulic and other services.
can be initiated on
Other equipment on display will include WEH quick connectors
demand or by time
and check valves. The connectors are used for filling, testing and
interval; and the unique
evacuating most liquid or gaseous media, including refrigerants.
software filtering system
Simply push on or flick a lever and a safe, pressure- or vacuum-tight connection is made to almost any interface - straight tubes, male or female threads, flares, barbed tails and pin index valves, from vacuum to 1000 bar. WEH check valves with very low crack pressures are made from brass, steel or stainless steel and are available for a wide range of gaseous and liquid media. Romheld will also show Goudsmit magnetic separators for catching ferrous particles in your product stream, and Heypac high-pressure, airoperated pumps capable of handling water, most oils, emulsions, esters
while minimising false rejects. In addition, password configuration permits security protection for critical parameters and proprietary product information. The STEALTH’s optional USB port enables easy metal detector updates and access to QA reports, while the sleek modular design has a user friendly, multi-language control panel interface. Dynamic Inspection Ltd
and even grease.
Contact info and more items like this at wf.net.au/Q773
Romheld Automation Pty Ltd Contact info and more items like this at wf.net.au/Q788
Hot topics in food packaging
FSANZ announces decision on country-oforigin labelling for unpackaged meat Unpackaged beef, sheep and chicken meat could soon be required to have country of origin labelling. Food Standards Australia New Zealand (FSANZ) has approved a proposal to extend country of origin labelling to some unpackaged meats. Food regulation ministers have been notified of the decision and have 60 days to seek a review. If no ministers seek a review, the decision will become law in Australian states and territories. There will be a six-month implementation period once the change is gazetted. The Australian Government asked FSANZ to address an inconsistency in country of origin labelling requirements for unpackaged meat after the rules for beef imports were changed in 2010, said FSANZ CEO Steve McCutcheon. FSANZ was also asked by food regulation ministers to continue this work following the recommendations of an independent review of food labelling headed by Dr Neal Blewett. “Research indicates country of origin information is important to consumers and is valued more in fresh food products such as fresh meat than other food categories,” McCutcheon said. “Mandating additional country of origin labelling requirements will ensure consumers are provided with access to this information consistently across the retail sector.” Many retailers already label products voluntarily, McCutcheon said, so the cost to industry as a result of the change is unlikely to be large.
Compostable biopolymer trials show extended brassica shelf life Cantankerous cauliflower could soon be a thing of the past. A new film for packaging fresh produce has performed well in trials with brassicas, which tend to deteriorate after just one day on the shelf. In the trials, Sirane’s Sira-Flex Resolve was used to package cauliflower and broccoli. The produce was found to be in good condition five days after packaging with the film. Cabbages, leeks and carrots gained two days of shelf life with the packaging. In Australia, where long transport distances and high temperatures can shorten shelf life, Sira-Flex Resolve trials showed a shelf life extension of more than 20 days, Sirane’s Managing Director, Simon Balderson, said. “Initial tests using the film showed the produce had a remarkable shelf life extension when compared with existing products. We await further trials with interest,” said Balderson. The film is a fully compostable biopolymer. According to the company, it has been developed to give the optimum balance between humidity control and O2 and CO2 permeability. The film’s permeability to humidity, O2 and CO2 is apparently different in each case, being affected by storage conditions and other variables. “The unique structure means we are getting some varied results on shelf life extension,” Balderson said. “Because the results are very specific to the conditions, we are finding it difficult to advise on just what the shelf life extension potential is. “Where one person might get two days, another might get 10 days, as it depends so heavily on the various factors at play in relation to storage conditions and other variables.” Sirane is encouraging people to run their own trials to assess how the film will benefit their operations. The film could reduce food waste and costs, Balderson said, making it more likely that the consumer will receive the produce in good condition. Balderson says Sira-Flex has broken new ground, delivering packaging that will keep food from drying out, eliminate ‘fogging’ within the pack and ensure no mould or bacteria growth on the produce.
The Food Technology Association of Australia (FTAA) is hosting a one-day seminar focusing on hot topics in food packaging. • Tuesday, 23 October 2012 • Hemisphere Conference Centre, Moorabbin, Melbourne Food packaging is an important part in the food safety chain and recent global experiences have indicated that more work needs to be undertaken to ensure safety of food packaging, particularly with recycling being a global priority. This one-day seminar will include packaging innovation, safety and marketing, and will be of interest to policy makers, product developers, consultants, packaging marketers, QA managers and retailers. Presentations will include: • Materials innovation for packaging • Packaging application for high-pressure processing • Acrylamide, BOP and dioxin - an Australian perspective • Food-grade packaging - a legislative overview • Safety of packaging - an Australian survey • No surprises in closure technology • Innovation in printing • Marketing innovative food packaging The full program and registration form are available in the Events section on the FTAA website (www.ftaaus.com.au) or email firstname.lastname@example.org for more information. Special pricing is available for FTAA and AIP members, CSIRO and DIAA.
Sustainable benefits and It’s a fact: consumers prefer minimal packaging ©iStockphoto.com/Michael Bodmann
A 17,000-person survey covering 17 nations, the 2010 Greendex research study from National Geographic and GlobeScan found 40% of consumers avoid excessively packaged goods “all” or “most of the time”. Another survey, the Natural Marketing Institute’s 2011 LOHAS Consumer Trends Study, found 75% of Americans believe many consumer products are overpackaged.
long with minimal packaging consumers like recyclable packaging, environmentally friendly packaging materials and to support consumer packaged goods companies (CPGs) that bring sustainability to the production floor with improvements to reduce energy usage or air and water waste. Following, some of the exhibitors at the upcoming PACK EXPO International in Chicago share some of their environmentally-friendly materials and innovations which can improve productivity while reducing carbon footprints.
Sustainable process improvements In many instances, changes in the design and layout of a manufacturing facility can make a difference in a company’s sustainability goals. “Environmentally sensitive design and manufacturing improves efficiency and reduces the costs of processing, inspection and packaging machinery,” says Brian Barr, Packaging Systems Sales Manager, Heat and Control. “Precision laser and water-jet cutting of materials and unitised equipment designs reduce waste, air pollution and the number of parts required
to build each machine. Modular machinery cuts the time, labour and floor space required for installation. We now also offer equipment that recovers energy from cooker exhaust and conveyor drives that can be re-used with different pans - not scrapped - when line layouts change.” QuikWater offers a sustainable direct-contact water system for heating sanitation and process water for the food manufacturing industry. “Our patented clean-burn technology outperforms traditional boiler systems on virtually every level - from improving worker safety to being more energy efficient,” says Tammy Collins, Sales Manager at QuikWater. “Whether you need as little as 20 L of hot water per minute or as much as 8500 L/min up to 93°C, there’s a system that’s right for your application. “The system is non-pressurised, so no boiler codes are required, and there is no need for special operators or AMSE stamps,” adds Collins. “It is also up to 40% more fuel efficient than typical steam-to-hot-water systems, which means less fuel and less energy are required. This lowers overall operating costs. And with a 20 to 40% reduction in carbon dioxide emissions, the system reduces a company’s carbon footprint.”
Centrifugal blowers and air delivery devices from Paxton Products, an ITW company, provide clean dry air and reduce energy usage during packaging and labelling by as much as 80%, as compared to compressed air systems. “Each Paxton system is custom engineered for drying based on the size and shape of the target product and the line configuration,” says Barbara Stefl, General Manager at Paxton. “The devices can be configured either to deliver a curtain of air, to dry the top and sides, or with the new Air Halo, to deliver a 360° halo of air to dry top, bottom and sides at once.” Stäubli Robotics now offers the TP80 fast picker, a new series of high-speed pickers that deliver greater speeds (up to 200 picks per minute) and more flexibility at a lower cost to the packaging market. This robot is more agile and lighter weight, has extremely fast cycle time and maintains high, repeatable precision throughout the entire work envelope. A simple base or wall mounting eliminates the need for a large gantry, further enhancing cost effectiveness and ease of integration.
Hidden green opportunities Even small changes to packaging machinery can impact a CPG’s sustainability efforts. Tom Miller, Bearings Unit Manager-North America, igus, points out, for example, the benefit of switching from metal bearings to dry-running plastic bushings, which do not require lubrication and require less energy to produce. “These days, many companies are working hard to reduce their carbon footprint on the environment, but this does not happen overnight,” says Miller. “It is usually a culmination of changes that take place over time, in a number of different areas. Even small changes to the design of a packaging machine can make a difference. “We offer an FDA-compliant bushing material that is blue in colour for easier detection,” says Miller. “The iglide A350 plastic bushings are highly wear resistant and can handle long-term temperatures up to 180°C. They are suitable for applications in the food, packaging and bottle-filling industries. They deliver low coefficients of friction and are resistant to a variety of chemicals and other liquids. “They are also extremely lightweight, which helps reduce fuel consumption and carbon dioxide output,” he adds. “And they do not require environmentally harmful galvanising baths to achieve chemical resistance, unlike metals that often have to be coated using an environmentally unfriendly, high-energy zinc galvanising bath to achieve this effect.”
Tom Duffy, National Sales Manager, Badger Plug, says, “The scope of package sustainability should include recycling and the re-use of packaging components as part of the need to reduce waste and save money. Today, manufacturers and converters of film, paper, metals, textiles, etc consume large amounts of packaging that can often be recycled. Roll protection products such as core plugs and suspension packaging need to be part of the sustainable discussion. “An experienced provider of recycled packaging can help avoid the pitfalls that can occur when dealing with recycled/ used packaging,” adds Duffy. “Low-cost packaging components such as single-core plugs are generally difficult to re-use due to freight costs, damage and cleanliness. More expensive suspension components such as end boards, sleeve plugs, pallets and channels/clips are readily recycled. Everyone in the business transaction can find value in this recycling process. Plus, the impact on our environment is greatly reduced.”
Eco-friendly, food-specific package modifications An increasing number of shoppers are seeking out coffee products produced and harvested in a sustainable manner - including beans grown in a manner that is kind to the environment and its people. Coffee marketers who want to take this to the next level also want sustainable packaging options, such as the Flexis Air valve from Avery Dennison Designed and Engineered Solutions. “Flexis technology allows for up to a 30% increase in application throughput and a 30 to 50% product purchase advantage over hard valves,” claims Nick Greco, Business Development Manager at Avery Dennison. “Plus, they offer exceptional performance characteristics. Tests conducted by a major university show that the valve maintains less than 2% residual oxygen for 24 months, equalling the reliability of hard button valves.” The Flexis Air valve employs about 90% less plastic than injection-moulded plastic degassing valves, creating another opportunity to reduce carbon footprints and non-recyclable waste. The valves are also pre-oiled with a precise amount of food-grade silicone oil at the necessary valve location to protect against oxygen ingress. The pre-oiled feature can save time and reduce scrap and clean-up by eliminating the need to oil valves during the packaging process. Sustainable advancements in can packaging of ground coffee, milk powders such as infant formula and other dry, powdered products include technologies that reduce the use of typical gases required for a modified-atmosphere environment. For
production and packaging both manufacturers consumers
The Cognex In-Sight 7000 series vision systems are used to improve product quality, drive down costs and comply with product and package safety requirements such as traceability and label verification on food and pharmaceuticals. example, the INDOSA Can Process Center (CPC) 127-10 ProVac from Grabher INDOSA AG uses proprietary vacuum technology. “The high efficiency is guaranteed by 10 stationary workstations, which are in use more than 90% of the process time,” says Michael Grabher, Vice President of Grabher INDOSA. “The system includes evacuating, gassing and seaming, and allows the customer to vary the end pressure inside the can. With this technology, it is not necessary to use carbon dioxide, as the underpressure of each can is adjustable and less than 0.5% oxygen content can be achieved.” He adds that nitrogen consumption is reduced to a minimum, because each can is gassed in a separate stationary chamber only slightly larger than the can - improvements in efficiency and gas use that reduce a canner’s carbon footprint. For baggers of milk powders or other dried ingredients such as bakery mixes, flour, soy protein, starch, spices, sugar, etc, Premier Tech Chronos has recently developed the BFW Series Open-Mouth Bagger with Bottom-Up Filler, a sustainable solution for the bagging of powdery materials. This innovative system is the combination of a hygienic vertical main feeder (meets 3A standards), FANUC Robot(s) and a bottom-up filling system. “It is certainly the best hygienic approach in the industry and has a very high accuracy on weight (up to ±15 g),” says Yan Gagné, Engineering Supervisor at Premier Tech Chronos. “It can produce airtight bags for long-term storage and is equipped with a large bag magazine that provides long-production runs, very few modules and a great floor clearance. “Furthermore, the BFW Series provides both versatility and speed since it can handle paper, polyethylene, laminated polywoven and Cap-Sac (a PE bag within a paper bag) bags at up to 12 bags/min, depending on products, bag sizes and applications,” says Gagné. “Complete control on side-gusseted pinch top bags is achieved; no gusset realignment device is required.” As the EPA tightens rules and regulations on conventional aerosol hydrocarbon propellants, the bag-on-valve package (BOV) is a growing trend in the aerosol industry. “A rolled up aluminium bag is welded or attached to an aerosol valve,” says Jim McBride, owner of MBC Aerosol. “Compressed air is charged into the can and an aerosol valve with the bag attached is crimped onto the container. The product is forced through the aerosol valve stem to fill the bag. When the spray button is pressed, the product is squeezed out of the bag by the compressed air, which creates the aerosol spray via the spray button orifice. “The major benefit of this package is the lack of volatile organic compounds,” McBride says. “The other benefit is that 24
Ultrasonic sealing technologies from Herrmann Ultrasonic reduce the amount of material being used for packaging, as well as reduce power consumption and improve overall equipment efficiency. it is completely recyclable. Plus, about 99% of the product is squeezed out so the only thing left is aluminium and 30 to 40 psi of compressed air. A variety of foods are making their way into this package, including olive oils and salad dressing.”
Getting green through package processing modifications Sometimes a modification to a current packaging process can assist with saving money, materials and energy. Vacuum Barrier now offers Nitrodose Liquid Nitrogen Dosing Systems, which allow manufacturers to use the most lightweight PET and aluminium can packaging by providing the most precise liquid nitrogen dosing at the highest discrete dosing speeds. “This eliminates liquid nitrogen waste and reduces consumption by having a very low LN2 delivery pressure along with both speed and dose compensation,” says Edward Hanlon Jr, Vice President Sales at Vacuum Barrier. “It also allows for a reduction in packaging materials.” Induction heating is a method of providing fast, constant heat for electrically conductive materials. Although the basic principles of induction are well known, modern advances in technology have made induction heating a remarkably simple, cost-effective heating method. Formost Fuji has adapted this technology to sealing film on its horizontal wrapping machine. This technology has reduced the cost of maintenance, increased the reliability and stability of the heater system, reduced energy usage and greatly extended the useful life of the parts. In addition, through the reduction of moving parts, the component is much less complicated, which all adds up to a better system. In a bid to reduce the amount of material used to seal plastic packages, ultrasonic sealing technology, which has been around for more than 50 years, is now being used more frequently in packaging. New and innovative solutions reduce the amount of material being used for packaging and ultrasonic sealing reduces power consumption while improving overall equipment efficiency (OEE). Installed applications include bagged salad, beverage, coffee, dairy, pasta, readycooked meals and powdered products. “For vertical form-fill-seal (VFFS) machines, ultrasonic allows welding through contamination on the cross seal this results in less headspace for the package and reduced sealing width,” says Uwe Peregi, Executive Vice President and General Manager, Herrmann Ultrasonics. “Thanks to the feedback on the ultrasonic technology, each seal is validated
with modern generators, which allows statistical process control monitoring. Further, the molecular weld process starts from the inside layer, which results in reduced sealing time and less abrasion of the film.”
Ensuring label accuracy Due to miniaturisation and advances in the power of digital signal processors, imaging sensors and decoding algorithms, traceability applications such as ID code reading, text verification, mark quality assessment and label inspection can now be accomplished more economically using the latest generation of smart camera vision systems. “The most advanced of these smart camera vision systems now offer advanced networking, communication capabilities and powerful factory integration tools,” says John Lewis, Market Development Manager, Cognex. “And with a standard operator interface for a common look and feel across all packaging lines and inspection points, many packagers and materials suppliers now consider smart camera vision systems indispensable in their efforts to build strategic information architecture in line with corporate sustainability goals.” Such vision systems help reduce defects and eliminate scrap, he adds. “It’s really better for the environment to use machine vision, but it’s also better for the manufacturer because it
reduces production costs by increasing manufacturing yields to help them achieve their corporate sustainability goals.” For example, label, material and container suppliers use a lot of vision systems and image-based barcode readers. Suppliers of pre-printed labels, injection-moulded bottles, flexible films and carton-board containers use vision to eliminate misprints and mix-ups. Packaging materials including onserts and inserts are often furnished pre-printed with barcodes and characters that must be verified. Label-converting companies use vision and image-based barcode readers to ensure code quality and data integrity on their serialised labels. Mistakes on any of these items can result in costly FDA-mandated recalls.
PACK EXPO International 2012 is organised by PMMI, a trade association of more than 600 member companies that manufacture packaging, processing and related converting machinery in the United States or Canada, machinery components and packaging containers and materials.
Heat and Control specialises in environmentally sensitive design and manufacturing to improve efficiency and reduce the costs of processing, inspection and packaging machinery.
Smoothwall aluminium trays, wrinkle wall trays and tray lidding films Nicholl Food Packaging has appointed DFC Packaging as the Australia and New Zealand distributor for its range of smoothwall aluminium trays, wrinkle wall trays and tray lidding films. Smoothwall aluminium tray use has been a growth market in the UK and Europe, with many manufacturers and supermarkets preferring packaging that can be used in the microwave as well as in a conventional oven over plastic products that cannot tolerate higher conventional oven temperatures. Nicholl also offers a range of coated smoothwall trays that are suitable for products such as lasagne and high-pH sauces that would ordinarily eat through a standard aluminium tray. Smoothwall trays offer a long shelf life due to metal being a high oxygen barrier material. Along with the Nicholl tray range, DFC also offers a range of lidding films suitable for both coated and uncoated smoothwall aluminium
trays and a range of films suitable for various plastic trays such as PET, PP, PS and PVC. The PET film is peelable and antifog, and can be used in a microwave or conventional oven. DFC Packaging Group Contact info and more items like this at wf.net.au/R008
Compostable coffee packaging solution Innovia Films’ compostable, cellulose-based material NatureFlex is helping a New Zealand coffee roaster meet its commitment to being socially and environmentally responsible. Caffe Prima, based in Christchurch, has chosen to use Econic coffee bags. The bags were specifically developed by New Zealand converter Convex Plastics, using NatureFlex renewable and compostable films in their construction. “Coffee is a very demanding product to package because maintaining freshness and taste is absolutely paramount. Packs have to be puncture and impact resistant and offer high barrier and good seal integrity to keep oxygen out and aroma in. Coupled with this, Caffe Prima was looking for a solution that was kind to the environment. NatureFlex ticked all the boxes as far as we were concerned,” said Andrew Sheerin, Technical Manager, Convex Plastics. A laminate construction was produced using three flexible films that are certified compostable and renewable - reverse printed clear NatureFlex, high-barrier metallised NatureFlex and starch-based biopolymer. NatureFlex films are certified to meet the American ASTM D6400, European EN13432 and Australian AS4736 standards for compostable packaging. The wood pulp is sourced from managed plantations from referenced suppliers operating Good Forestry principals (FSC or equivalent). The renewable bio-based content of the films is typically 95% by weight of material according to ASTM D6866. It has been confirmed as suitable for emerging ‘waste to energy’ techniques such as anaerobic digestion. NatureFlex was a good solution for this application as the film begins life as a natural product - wood - and breaks down at the end of its life cycle in a home compost bin or industrial compost environment within weeks. Innovia Films Pty Ltd Contact info and more items like this at wf.net.au/Q964
VFFS machine for polyethylene packaging tna is releasing the tna robagFXIS 3ci series vertical form fill and seal (VFFS) machine for polyethylene (PE) packaging. The machine features what is claimed to be the world’s first rotary impulse sealing jaws system for efficiently packaging fresh or frozen vegetables, salads, ready-to-eat fruit and pre-wrapped candies. tna’s product-in-seal-detection (PISD) software monitors product in the seal and jaw area and adjust the bagger’s speed accordingly to optimise speed and reduce waste. The robagFXIS can be added to existing packaging lines and fully integrated with tna weighers, metal detectors, date coders and conveyors. TNA Australia Pty Ltd Contact info and more items like this at wf.net.au/R131
A tried&true way to LEAN your labelling and coding operations.
Domino introduces iTech: Common parts, software and control pads for all coding technologies. Todayâ€™s business is about LEAN operations, process improvement and achieving 100% quality. The new Domino iTech range allows users to control multiple technologies from a single touch point, and provides maintenance staff access to common parts for all equipment. Achieving LEANER operations, Dominoâ€™s iTech range allows the use of common parts, software and control pads for continuous ink jet, laser, thermal ink jet, thermal transfer overprint and print and apply technology.
Contact us to find out more about the Domino iTech range.
Phone: 1300 467 446
Allen Coding Systems designs and manufactures a range of
Shrink labelling system
online thermal transfer printers suitable for the food, pharma-
Avery Dennison and Tronics have
ceutical, chemical and cosmetics industries.
collaborated on a labeller for the
Thermal transfer printer range
The company manufactures products from 2â€ł entry-level
Avery Dennison Shrink PS packag-
thermal transfer coders to high-end printers with multiple
ing material that enables late-stage
programming options, as well as a large-format 8â€? machine
decorating of vacuum-shrink bags.
and multi-lane variable information printers featuring up to
The labeller applies the pressure-
14 printheads, each capable of printing a different image
sensitive label to the shrinkable
bags offline or inline prior to filling
Large-format thermal transfer coding systems in the NG Series
and vacuum sealing. The system
are available with 160 or 213 mm wide printheads (NG8). The
is suitable for the meat and dairy
NG8 is capable of printing 1 m-long prints in a continuous
printing mode with a simple and quick ribbon change system.
Tronicsâ€™ Shrink Labelling System
The TP 4000 is available with 52 or 106 mm printheads and
enables Shrink PS labels to be applied quickly to shrink bags. Easy to use, the
operating speeds of up to 600 units/min. Multiple printheads
labeller enables quick roll changes, label reel to shrink reel labelling or single
with auto code sensors mean faster operation and less chance
bag tear-away for easy label and fill manufacturing.
of operator error, the company claims. Its prints dry quickly and
The system has a heavy-duty stainless steel frame and an easy-to-use LCD
give higher resolution images with no hot stamp characters.
that allows quick adjustments. Electromagnetic clutches maintain constant
It can print barcodes, 2D codes and logos.
tension throughout the roll of bags.
The single modular unit can be integrated with all types of intermittent-motion packaging equipment, including horizontal
The labelling system allows for bags to be labelled singularly using a food control system that can be torn off at the nip/pinch roller assembly.
form fill and seal, overwrapping, bagging, thermoforming and
Both the bag feeder and label head are motion controlled, stepper driven
blister pack lines, and offers fast message changes, easy
and capable of speeds up to 30 m/min. Linear speeds up to 30 m/min deliver
set-up and low maintenance.
up to 60 bags/min for 500 mm bags.
Result Packaging Pty Ltd
Tronics Pty Ltd
Contact info and more items like this at wf.net.au/N707
Contact info and more items like this at wf.net.au/N879
High-Speed Offline and Inline Strapping Systems
Machines for liquid food filling
Lightweight hot-fill PET bottle
Bosch Packaging Technology has
the SIPA SFR rotary blow moulding machine. The SFR is a good choice of
released two products for liquid
PET blow moulding machinery for beverage manufacturers as it can produce
food filling: the SurePouch clean-fill
high-quality containers in standard, multilayer and lightweight hot-fill PET
(SPC) machine and a thermoform-
formats. The range has a production speed of up to 1800 b/h per cavity.
ing clean-fill (TFC) machine.
The SIPA Bottless range of 500 mL hot-fill PET bottles is manufactured on
SIPA engineers designed the range to reduce the effects that PET con-
The SPC machine is a roll-fed
tainers have on the environment. While the bottles weigh only 13.1 g, the
vertical form, fill and seal (VFFS)
functionality and the aesthetic appeal of the bottles has been maintained.
machine that produces the Sure-
The bottles are available in different neck finishes, according to user
Pouch, a line of reclosable, flexible
requirements. A 28 mm collar weighs 3.8 g, while the 33 and 38 mm
stand-up pouches with multiple
versions weigh 6.5 g.
shape and fitment options. The
HBM Packaging Technologies
SPC can create four pouch formats,
Contact info and more items like this at wf.net.au/Q869
including the stand-up EZPouch, EZGable and EZSquare formats. The pouch formats range in filling volume sizes from 100 mm to 5 L. Bosch claims the machine achieves hygiene standards up to ultra clean-fill. The pouch packs are fitted with reclosable spouts that are ultrasonically welded to the exterior of the pouch. As the product is filled directly into the pouch and not through the spout, they offer better hygiene, claims Bosch. The closure only comes into contact with the product when the package is opened. The TFC machine clean-fills fresh products and foods requiring a cooling chain, such as yoghurts and desserts, and single-serve portions of butter, margarine, condiments, microwavable convenience foods and pet foods, in a variety of sizes. The production of multiple cup and label heights without tool changes means the machine can be adapted to different production and market needs. The machine has an operational height of 1 m. The cylindrical thermoforming mould can be adjusted by the user and is then synchronised with the labelling system. The wraparound labelling system has a central cutting blade, allowing the operator to adjust sizes by changing the label reel. The system positions the labels so the front is always facing the outside of a multipack. Nupac Industries Pty Ltd Contact info and more items like this at wf.net.au/N705 www.foodprocessing.com.au
Vertical form, fill and seal machine Accolade Packaging is showing the Penta 2200 vertical form, fill and seal machine for the first time in New Zealand at Foodtech Packtech 2012. The Penta 2200 has a small footprint and its 1.3 m height makes adding a multihead weigher or linear weighers possible without having to create a special-height room. It can form bag lengths of 60 to 500 mm through a simple PLC
touch-screen interface, making it a suitable option for liquids, powders or granular foodstuffs. Manufactured in stainless steel with an IP68 rating, this unit can run simplex films or laminated structures with or without euroslot, bag gusseting or block bottom 4-sided-seal stand-up stabilo packs. The predecessor to this machine, the Penta 2100, has been widely in use in New Zealand since 1995. Where the Penta 2200 improves on the past is through the use of brushless servo drive motors to increase speed and bag length accuracy, which provides laminated bag speeds of up to 90/min with or without print registration. The machine offers quick changeover of forming tubes and is capable of bag widths 60 to 290 mm wide. With a simple change of the forming tube collar apex, the Penta 2200 can run an overlap seal or fin seal depending on the presentation required. Also available are the larger Penta 3100 and Penta 4200 models, which can run greater bag widths and lengths. Built to the highest Italian standards, Accolade can add inline coders, labellers and gas flush units to suit production requirements. The company maintains the complete array of spare parts on the shelf in New Zealand. Accolade Packaging Limited Contact info and more items like this at wf.net.au/Q806
Labelling solutions range Hally Labels will showcase its range of labelling solu-
Adhesive technology products Henkel will showcase several of its adhesive technology products at Foodtech Packtech 2012. Technomelt Supra is claimed to offer higher productivity and substantial savings. This adhesive is more efficient than conventional hotmelts and increases productivity through better machinability. It is clear when molten, white when hardened, has no odour and contains no solvents. Technomelt Supra is compatible with a variety of substrates and packages, is suitable for difficult applications and has good flow behaviour. It is approved for direct food contact for use in the food industry. Liofol adhesives and coating solutions are designed for flexible packaging. With fast migration compliance for food safety, the products have good optical properties, and strong initial tack and final bond strength. Optal synthetic adhesive is an alternative to products made using traditional raw materials like casein, the price of which continues to fluctuate. Optal is suitable for wet or dry, warm or cold bottles, better cost performance ratio, longer shelf life, good water resistance and excellent machinability. It has high initial tack, is fast drying, resistant to bacteria and mould, and is dermatologically tested. Henkel New Zealand Ltd
The companyâ€™s capabilities - such as label security features, environmentally friendly products and personalisation - will be on show. Hally will also showcase its environmentally friendly label stocks, premium materials and the complete range of its material portfolios for thermal and prime applications. In addition, specialty materials for premium presentation of meat products will be displayed, including Syntherm Clear, a clear direct thermal material, and Self Adhesive Shrink, a premium label alternative to pre-printed shrink bags. Special effects on display will include embellishments such as embossing, high builds and foils, plus special elements such as QR codes, variable data and images and micro-text. In addition, a number of specialty inks and coatings will be on display, including scented inks, black light security inks and glitter coatings. The company will also exhibit its labelling solutions for meat, thermal, food and FMCG, beverage, pharmaceutical and promotional and specialty applications. Hally Labels Contact info and more items like this at wf.net.au/R174
Contact info and more items like this at wf.net.au/Q793
tions at Foodtech Packtech 2012.
Volume concept and photographic printing for aseptic packaging Tetra Pak has launched volume and printing capabilities for its Tetra Fino Aseptic packaging range. The combination of the OptiSize volume concept for new size options and Eco Flexo advanced photographic printing techniques is claimed to bring improved value and efficiency, stronger product differentiation and greater brand impact. The OptiSize volume concept allows user to produce cartons tailored precisely to
70 and 220 mL portions - with more size options to follow - thus reducing packaging materials waste. The Eco Flexo printing process brings photographic printing to Tetra Fino Aseptic packages, providing greater opportunities for product differentiation and brand impact. With OptiSize, users who previously under-filled 250 and 100 mL Tetra Fino Aseptic packages can now select carton sizes to fit 220 and 70 mL portions precisely. Developed by Tetra Pak following customer feedback, the low-cost OptiSize kit enables milk and beverage producers to change the tube diameter and/or the jaw length of the Tetra Pak A1 filling machine, thus allowing cartons to be filled precisely instead of under filling. Eco Flexo printing technology used for Tetra Fino Aseptic packages enables printing photographic images onto uncoated paperboard packaging. The use of different paper, inks, screen ruling, anilox and dot gain interactions reduces mottling effects and maximises print quality. Tetra Pak Marketing Pty Ltd Contact info and more items like this at wf.net.au/Q406
Hot product paper cups Huhtamaki has released a range of paper hot cups called Callisto. The cup offers a tactile extension to Huhtamakiâ€™s current paper hot cup range. It encompasses an insulated air gap double-wall paper structure, feels more comfortable for holders and increases design possibilities for the foodservice industry. It is made from certified, sustainable materials that meet all FDA requirements. Callisto uses embossing technology and a new material which has a distinct natural texture. Combined, they produce an embossing depth to the outer wall of the cup. The quality of the cup is considered an important part of the coffee drinkerâ€™s overall experience and Callisto has been developed for the coffee market. The double-walled cup has two lines - Standard and Customised. Callisto Standard is made up of four vibrant colours - Punky Pink, Mellow Yellow, Zesty Green and Hot Chocolate - which each feature a quirky tagline. Customised options include a square or rectangle branding window for logo placements, as well as other endless individualised designs. Both Callisto Standard and Customised ranges are available in 285, 400 and 500 mL sizes. The cups are manufactured in Australia at the Huhtamaki factory in South Windsor, New South Wales. Huhtamaki Contact info and more items like this at wf.net.au/N795
Tattoo design on bottle uses cold-activated ink technology
Chromatic Technologies Inc
Specialised inks company Chromatic Technologies Inc (CTI) has made a lasting impression on a liqueur from Tuaca. The bottle’s lion, a classic brand image for Tuaca, was redesigned as a thermochromic feature for the label on the limited-edition bottle. The ‘Perfect Chill’ bottle has met with exciting consumer response since its introduction in 2011, and has been showcased on Tuaca’s ‘Drinks & Ink 2012: A Celebration of Tattoo and Cocktail Artistry’ tours with celebrity tattoo artist Corey Miller. Miller created the custom design that adorns the Perfect Chill bottle, which was printed by Eurostampa of Italy at its North American facility in Cincinnati. The unique design of the lion shifts from a silver colour at room temperature to a stunning, vivid blue when chilled to 8°C, when the product is at peak serving for consumers. The ‘tattoo’ - using the thermochromic inks supplied by CTI - is printed on a label which adorns the bottle. CTI’s ‘thermochromic’ process uses cold-activated ink technology to convey messaging, be it an indication of cold temperatures or an extension of the product’s brand. CTI’s technology also provides for the reverse process, wherein hot beverages will display a signal on the package or label. CTI’s thermochromic inks are applied in diverse applications such as security and anticounterfeiting, food and beverage packaging, and many other types of consumer packaging. Another CTI capability, photochromic ink (ink colour changes due to exposure to UV light from the sun) is largely used in the textile market but is seeing an increase in demand for consumer packaging.
Warm left, cold right. The unique design of the lion shifts from a silver colour at room temperature to a stunning vivid blue when chilled to 8°C.
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NEW White Papers
now available online!
To buy or not to buy â€Ś because of the challenge
Implementing OEE (overall equipment effectiveness) measures in the packaging hall
Opening packages is taken for granted by most. But Arthritis Australia asks that we all be cognisant of those members of society who struggle with opening packs. The not-for-profit organisation does an excellent task of bringing to the attention of designers the challenges some members of society have and packaging designers would be wise to take note of this organisationâ€™s advice. Surely it is the duty and obligation of all packaging technologists and engineers to consider the needs of these consumers when designing packs for the marketplace. The response may be that such consumers are in the minority of the population. It would be wise, however, to remember such citizens are very much a part of our society. Such an attitude may be further dispelled when considering the statistics: nearly one in five Australians has arthritis. Arthritis impacts directly on 3.85 million people, or 18.5% of the Australian population. Add to this other disabilities and soon a sizeable percentage of the population is struggling with packs. There are many simple design features that could be incorporated into packaging to enhance the ease of opening: perhaps enlarging a 28 mm closure; putting a groove into the top of the closure where a table knife can be placed into the groove giving it more leverage; using tamper-evident seal labels rather than clip-lock closures or closures with a drop-down retaining bead. In flexible packing greater use can be made of easy-peel opening type film structures where the bag can be more easily pulled apart when opening. If each designer made the effort to improve the opening capacity of just one pack over the next year, the chances are sales would be directly affected by many more happy customers. You are encouraged to forward your success stories to this column where a reflection on this topic will be offered one year from now.
Overall equipment effectiveness (OEE) is a globally recognised best practice measure to systematically improve your processes for higher efficiencies and better productivity - ultimately leading to lower manufacturing costs and higher profitability. This application paper examines OEE metrics and how to capture them - download now!
Advanced pressure diagnostics provide valuable insight into your process Advanced pressure diagnostic technology provides a means for early detection of abnormal situations in a process environment and enables the user to proactively respond to changes in the process, troubleshoot and prevent future shutdowns. Find out how it can help prevent abnormal situations in your plant.
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Pierre Pienaar FAIP National President (retired) Australian Institute of Packaginginfo@aipack.com.au www.aipack.com.au
For these and more White Paper downloads, visit www.foodprocessing.com.au/white_papers
Industrial barcode printer Datamax-Oâ€™Neil has introduced the I-Class Mark II industrial printer. It has a fast processor, large memory and a wide selection of communication ports to meet a diverse range of applications. The printer builds on from the I-Class Mark I series with faster print speeds, faster processing and lower power consumption. It also has a larger memory,
with 64 MB Flash and 32 MB DRAM as standard features. The printer has a die-cast aluminium frame and metal cabinet. Its modular design provides the ability to upgrade in the field, with options such as internal rewind, thermal transfer and W-LAN. A gear-driven design provides for rigorous duty cycles and uninterrupted productivity. IntelliSEAQ printheads provide a long life with a durable coating and high abrasion resistance, while having a lower power consumption. The printer comes equipped with OPTIMedia, a feature that enables the printer to automatically adjust to optimum heat, speed, darkness and contrast settings to ensure high quality printing. The communication ports include serial, parallel, USB, LAN, 2 USB Host ports and SDIO, W-LAN and GPIO applicator cards. The printer has 802.11 a/b/g W-LAN option with WPA2 security protocol. In addition, the printerâ€™s Auto-Detect language emulation feature provides for seamless replacement of existing printers, while an LCD enables user-friendly configuration and operation. The bar code label printer is suitable for a range of applications including industrial manufacturing, transportation and logistics, pharmaceuticals and food and beverage. Dy-Mark Identification Solutions Contact info and more items like this at wf.net.au/N949
Renewable lightweight coffee pouches Innovia Films has developed a range of cellulose-based films that, when laminated together with other bio materials, can provide a fully renewable filmic structure suitable for coffee pouches - NatureFlex. The film provides a viable alternative to coffee producers who want a complete packaging structure that is lightweight and is able to protect their product but at the same time is also compostable and made from renewable resources. NatureFlex films comply with standards for compostable packaging including EN13432, AS4736 and ASTM D6400. Depending on the individual films selected, the finished laminate structure could be certified compostable to the same standards, subject to appropriate ink, print design and adhesive choices. If required, the pouches can be vented or a fully compostable zip closure could be added. Innovia Films Pty Ltd Contact info and more items like this at wf.net.au/N778
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Automatic tray sealers optimised Multivac has optimised the performance of its automatic tray-sealer models. It is equipping its automatic tray-sealer models, the T 700, T 800 and T 850, with dies which have greater lengths and widths. This results in increasing the performance of these tray sealers in relation to the number of packs per cycle. In addition to this, Multivac has extended its portfolio with the T 700S, T 700XS and T 800S models. The two S models are equipped with smaller dies than larger models, however are lower in price. All S and XS models can also be equipped with the Smart Sealing technology for simple sealing applications without modified atmosphere. This innovative die concept has
been available since the beginning of 2011. With this concept Multivac has improved the cycle output of automatic tray sealers for producing packs without modified atmosphere. As a result of optimised machine sequences and new die technology, it has been possible to improve the process speed and the output per cycle. The costs of running the machine and the use of resources are reduced by the machine concept. Multivac Australia Pty Ltd Contact info and more items like this at wf.net.au/Q398
Large-character printer/labeller The Linx IJ355 and IJ375 high-definition case coders are two new large-character printers from coding and marking specialist Linx Printing Technologies. Claimed to be able to cut production costs while maximising line uptime and print quality, the printers provide a cost-effective, easy-to-use alternative to other largecharacter printers, and to the labelling or pre-printing of secondary packaging. The printers use ReFresh ink recirculation system, have a robust design and printhead protection technology which result in reduced downtime and savings on consumables. The ink recirculation systemâ€™s technology provides good print quality and also avoids wasted ink during printhead cleaning, thus saving time and money ordinarily wasted on purging procedures. Ink and dust that collect on the nozzles is removed with an air knife, an ink purge takes place, then ink from this procedure is collected, passed through a high-performance filter to remove impurities from the system and recirculated. Operators only need to perform quick, simple maintenance on a regular basis in order to keep the printer in optimum operating condition. The tough stainless steel nozzle guard protects the printhead from possible damage, caused by impact with the boxes on the line, while remaining close enough to the packaging to ensure print quality is maintained. The robust stainless steel lower casing and printhead protection mean the Linx IJ355 and IJ375 are robust enough to cope with the most demanding production lines, delivering savings on consumables and minimising downtime. The printers come with a full-colour LCD interface and touch-screen operator controls, with print preview and icon-based message selection. The control unit is detachable for handheld use or for mounting in a more convenient location. A set of robust accessories is also available from Linx to provide simple and accurate mounting of the printer onto the production line. Matthews Intelligent Identification Pty Ltd Contact info and more items like this at wf.net.au/Q875
FRUIT & VEGETABLES
Fruit juice used to halve the fat in chocolate It may not make chocolate one of your five a day - but scientists have found a way to replace up to 50% of its fat content with fruit juice. ©iStockphoto.com/eli_asenova
niversity of Warwick chemists have taken out much of the cocoa butter and milk fats that go into chocolate bars, substituting them with tiny droplets of juice measuring under 30 µm in diameter. They infused orange and cranberry juice into milk, dark and white chocolate using what is known as a Pickering emulsion. Crucially, the clever chemistry does not take away the chocolatey ‘mouth-feel’ given by the fatty ingredients. This is because the new technique maintains the prized Polymorph V content, the substance in the crystal structure of the fat which gives chocolate its glossy appearance, firm and snappy texture but which also allows it to melt smoothly in the mouth. The final product will taste fruity - but there is the option to use water and a small amount of ascorbic acid (vitamin C) instead of juice to maintain a ‘chocolatey’ taste. Dr Stefan Bon from the Department of Chemistry at the University of Warwick was lead author on the study published in the Journal of Materials Chemistry. He said the research looked at the chemistry behind reducing fat in chocolate, but now it was up to the food industry to use this new technique to develop tasty ways to use it in chocolate. Dr Bon said: “Everyone loves chocolate - but unfortunately we all know that many chocolate bars are high in fat. “However, it’s the fat that gives chocolate all the indulgent sensations that people crave - the silky smooth texture and the way it melts in the mouth but still has a ‘snap’ to it when you break it with your hand. “We’ve found a way to maintain all of those things that make chocolate ‘chocolatey’ but with fruit juice instead of fat. “Our study is just the starting point to healthier chocolate - we’ve established the chemistry behind this new technique but now we’re hoping the food industry will take our method to make tasty, lower-fat chocolate bars.”
We’ve found a way to maintain all of those things that make chocolate ‘chocolatey’ but with fruit juice instead of fat.
The scientists used food-approved ingredients to create a Pickering emulsion, which prevents the small droplets from merging with each other. Moreover, their chocolate formulations in the molten state showed a yield stress which meant that they could prevent the droplets from sinking to the bottom. The new process also prevents the unsightly ‘sugar bloom’ which can appear on chocolate that has been stored for too long. The study, entitled Quiescent Water-in-Oil Pickering Emulsions as a Route toward Healthier Fruit Juice Infused Chocolate Confectionary, was co-authored by Thomas Skelhon, Adam Morgan and Nadia Grossiord at the University of Warwick. University of Warwick www2.warwick.ac.uk
Zebra Chip disease threatening Australian potato industry
FRUIT & VEGETABLES
A potato disease that causes yield losses of up to 50% is threatening the Australian potato industry, AUSVEG claims. The peak industry body for vegetable growers says that the Zebra Chip disease could be introduced into Australia if the federal government approves market access for New Zealand potatoes. If approved, the market access request would allow fresh potatoes to be imported into Australia for processing to produce French fries and potato chips. The Zebra Chip disease reportedly caused over $60 million worth of losses in New Zealand in 2008-09. The Australian potato industry was estimated to be worth $614 million in 2009-10 and represents one of Australian horticulture’s largest crops. AUSVEG is concerned about the impact of the Zebra Chip disease on the Australian industry if the market access request is approved. “The quality and scientific validity of the federal government’s advice on potato importation contains a number of claims which are not scientifically based
and this places the Australian potato industry at risk from this devastating disease,” said AUSVEG CEO Richard Mulcahy. “Placing the livelihood of these Australian potato growers and their families in danger based on import conditions constructed from poorly researched, non-scientific information is simply far too great a risk to take,” Mulcahy said. AUSVEG is urging the government to scrap the proposed importation measures as it claims the disease is not fully understood, even by DAFF Biosecurity. “The draft import conditions report is largely based on a pest risk analysis written in 2009,” Mulcahy said. “This pest risk analysis is severely out of date considering the significant advances made in the last three years of the understanding of this disease and its devastating potential. “The report also fails to consider other potential pathways for the disease into Australia, such as in nursery stock. This is a serious oversight if DAFF Biosecurity is genuinely concerned about protecting our nation from exotic pests and diseases,” Mulcahy said. The disease complex also affects other staple foods such as tomatoes and capsicums and is spread by an insect called the Tomato-Potato Psyllid and through live plant material.
DAFF releases report on imports of fresh ginger from Fiji The Department of Agriculture, Fisheries and Forestry (DAFF) has issued the Provisional Final Import Risk Analysis Report for Fresh Ginger from Fiji, which proposes strict quarantine conditions. “The department’s biosecurity scientists have undertaken a rigorous scientific and evidence-based analysis of the pests and diseases associated with the trade,” said Dr Vanessa Findlay, Chief Plant Protection Officer. “The department has consulted with industry and state governments to ensure the appropriate measures to manage any potential risk associated with importing ginger for processing are in place.” The report recommends that imported ginger must: • be free from soil and trash such as leaf matter • be grown with infield management controls or undergo a post-harvest treatment for burrowing nematode • undergo inspection and certification by the Biosecurity Authority of Fiji to ensure it is free from pests such as yam scale • be inspected and cleared by DAFF “Stakeholder comments submitted during the 60-day comment period were carefully considered and these comments combined with scientific analysis helped inform the final recommendations outlined in the report,” Dr Findlay said. DAFF requests that anyone who believes that the Import Risk Analysis (IRA) process was not properly followed submit a written appeal to the Import Risk Analysis Appeals Panel before 10 September 2012.
FRUIT & VEGETABLES
Spray-on coating delays banana ripening
Bananas ripen, soften and rot into an unappetising mush, seemingly in the blink of an eye - but a solution may be at hand.
t the 244th National Meeting & Exposition of the American Chemical Society, scientists described their efforts to develop a spray-on coating that consumers could use to delay the ripening of bananas. The coating is a so-called ‘hydrogel’, a superabsorbent material like those with many medical and commercial uses, made from chitosan, a substance derived from shrimp and crab shells. Xihong Li, PhD, who presented the report, noted that chitosan is attracting considerable attention in efforts to keep fruits and vegetables fresher longer due to its action in killing bacteria that cause produce to rot, low cost and other properties. Until now, however, it has not been used to slow the ripening of bananas. “We found that by spraying green bananas with a chitosan aerogel, we can keep bananas fresh for up to 12 days,” said Li, who is the study’s leader. “Once bananas begin to mature, they quickly become yellow and soft, and then they rot. We have developed a way to keep bananas green for a longer time and inhibit the rapid ripening that occurs. Such a coating could be used at home by consumers, in supermarkets or during shipment of bananas.” Li explained that bananas, like other fresh fruit and vegetables, are alive and actually ‘breathing’, or respirating. He is with Tianjin University of Science and Technology, Tianjin, China. Like other fresh fruit and vegetables, bananas stay alive after picking. Like people, bananas breathe, or respire, taking in oxygen and releasing carbon dioxide - but
through their skin. The more a banana respires, the quicker it ripens. Unlike many other fruits, the respiration rate in bananas does not slow down, and bananas do not ripen slowly. The banana’s pulp releases a chemical that boosts respiration, and the pulp converts into the sugars that produce that sweet, banana taste. As respiration continues, however, the process speeds up, and bananas become unpleasantly sweet and mushy. Bacteria on the banana skin start to thrive and cause the banana to rot.
Unlike many other fruits, the respiration rate in bananas does not slow down, and bananas do not ripen slowly.
In their study, Li’s team showed that the chitosan hydrogel coating slowed down respiration and killed bacteria that cause rotting, keeping bananas fresh for almost two weeks. But banana lovers should not go bananas over the hydrogel coating just yet. Li’s team is on the trail of a new ingredient for producing the hydrogel that would replace an existing ingredient that would not be used commercially. This study was supported by a National Natural Science Foundation of China Grant and the China Postdoctoral Science Foundation.
Vegetable growers concerned by rising imports “The Australian vegetable industry is now, more than ever, facing fierce competition from overseas markets and the pressure is mounting on growers to reduce their costs and operate on even slimmer profit margins,” said Mulcahy. Mulcahy urged the government to consider measures to help growers combat rising input costs and compete with overseas competition. “While growers and processors here are committed to producing the high-quality products that Australian households have come to expect, if the level of imported products that we are currently seeing increases much further then it will be a grim future for these industries indeed,” Mulcahy said.
FRUIT & VEGETABLES
Statistics showing that processed vegetable imports have increased dramatically have dismayed Australian vegetable growers. According to the Department of Foreign Affairs and Trade (DFAT) Composition of Trade Australia 2011 statistics, imports of processed fruit and vegetables increased by as much as $119 million. DFAT attributes the increase in part to the high Australian dollar. “These figures demonstrate an alarming trend that is getting worse, year on year,” said AUSVEG CEO Richard Mulcahy. “The volume of processed vegetable imports in this country has reached worrying heights and measures must be taken immediately to ensure that Australian vegetable producers are provided with a proper level playing field.” Continued high imports could jeopardise the viability of Australia growers, Mulcahy said.
Series of thermal mass air/gas flow meters The ST100 Series of thermal mass air/gas flow meters comprises two core model families: ST meters measure both mass flow and temperature, with the STP family also measuring pressure. The meters can be calibrated to measure most process gases, including wet gas, mixed gases and dirty gases. The basic insertion-style air/gas meter has a thermal flow element
that measures flow from 0.07 to 305 nmps with an accuracy of ±0.75% of reading, ±0.5% of full scale. Designed for rugged industrial processes and plants, the meters include service up to 454°C and are available with both integral and remote 300 m electronics versions. They are agency-approved for hazardous environments, including the entire instrument, the transmitter and the rugged, NEMA 4X/IP67-rated closure. The meters are available with 4-20 mA analog, frequency/pulse, alarm relays and additional digital bus communications including Fieldbus, Profibus and Modbus. They are adaptable with a plug-in card replacement that can be changed out by plant technicians in the field. The meters store up to five calibration groups to accommodate broad flow ranges, differing mixtures of the same gas and multiple gases and obtain up to 1000:1 turndown. The ST100 Series has obtained full certification from the HART Foundation for its hardware and DD files. The ST100 offers three different types of flow sensor: the fast-response FPC-style is suitable for compressed air and clean gas applications; the fast-response, general-purpose, FP style is the sensor used with FCI’s VeriCal in-situ calibration option; and the unshrouded S-style is suitable for wet or dirty gases, or erratic flows. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/Q586
Carbon dioxide transmitters Rotronics’ CO2 transmitters range is based on the NDIR (non-dispersive infrared) measuring
principle and is primarily
SnapShot universal ATP rapid hygiene surface swabs are economical
used to measure carbon
swabs that are compatible with most luminometers.
dioxide (CO2). The probes are precalibrated and reportedly have a lifetime of more than 15 years in normal applications. Automatic baseline correction means sensors require no further calibration if they are used in
Each version of SnapShot is designed to replicate the ATP reaction by generating the same light output as the device it is replacing. This may eliminate the need to change current pass/fail threshold settings on the luminometer or within an established quality control program. Made with a liquid-stable reagent and built-in Hygiena snap valve
indoor air applications.
technology, the swabs are tolerant to temperature abuse and can test
Pryde Measurement Pty Ltd
wet or dry surfaces and liquid samples.
Contact info and more items like this at wf.net.au/Q168
The swabs have a premoistened swab bud and a write-on swab label. They are stable for up to 12 months at refrigerated temperatures or four weeks at room temperature. Key Diagnostics Pty Ltd Contact info and more items like this at wf.net.au/M685
PathogenTesting with BAX® System Q7 If you can pipette you can use the BAX® PCR system
Yes/No results as soon as the next day for: • Salmonella • Listeria spp. and Listeria monocytogenes • E.coliO157:H7, Cronobacter, Campylobacter,
Staphylococcus aureus, Vibrio and Yeast & Mould
AOAC and AFNOR approved methods High Specificity and Sensitivity due to PCR
• Reduce your false positives • Avoid false negatives to protect
your brand name
1300-735-292 | www.thermofisher.com.au
Elisa Systems Food AllergenTest Kits One of the most extensive ranges on the market • Simple extraction process • No allergenic materials used in the kits • Reagents supplied in a liquid format • Excellent technical support and
validation data available
• Manufactured in Australia Elisa Systems range: Almond, Buckwheat, Crustacean, Egg, Gliadin, Hazelnut, Lupin, Milk, Casein, Beta Lactoglobulin, Mustard, Peanut, Sesame, Soy
Sensor switch for fill-level detection Baumer claims its LBFS switch is a reliable alternative to vibratory level switches. The LBFS sensor can detect the levels of viscous or dry materials and can be fitted on tanks or pipes in any desired position. The sensor is insensitive to flow, turbulence, bubbles, foaming and suspended solids and its compact, smooth sensor head resists media adhesion, even with sticky media. The company says the sensor’s short response time enables rapid fill-level detection and accurate, reliable fill-level compliance. The level switch can detect media levels in tanks, vessels and pipes. It can also be used for overflow prevention, pump protection against dry running and media separation with oil/water mixtures. It is suitable for a range of application areas, including domestic water, wastewater, HVAC filters, hydraulic systems, oil and gas, bioenergy,
wood pellets, grain mills, rail transport and pump systems. The sensor is housed in a compact, sturdy and corrosion-resistant stainless steel enclosure. It can be installed easily using Teflon tape sealing. Configuration is facilitated by the PC-based FlexProgrammer 9701. A short response time of 0.2 s means the level switch operates reliably even with fast filling processes. The device has a rated operating temperature range of -40 to +115°C. The LBFS operates on the frequency sweep principle using a high-frequency signal emitted by the sensor which experiences a phase shift in the sensed medium. When this sensor encounters a medium having a dielectric constant outside the defined range, an electronic signal is triggered. The sensor’s good sensitivity over a large measuring range for dielectric constants from 1.5 to over 100 enables limit detection with a range of powders, granulates and liquids, and even difficult substances such as polyamide granulates and paper. Transtech Electronic Control Contact info and more items like this at wf.net.au/Q031
Insertion electromagnetic flow meter Bürkert’s Type 8045 insertion electromagnetic flow meter has been re-engineered. The meter now has a cut-off feature which is claimed to optimise use in low-flow applications. This function allows the operator to set a lower limit, under which the measurement value is set as zero. This parameter feeds through to display, totalisers, outputs and downstream process conditions. A menu-configured digital input has also been added to the meter, allowing control system initiated reset of totalising functions, hold mode go-to, zero-point calibration and other functions. This has been added to facilitate remote control capabilities via site control systems. An adjustable backlit display for reading and programming in dim conditions has been added. The meter has integrated diagnostics to support local operation, with a simple and conspicuous green/orange/red LED status indication. The 8045 flow meter is an all-purpose unit with no moving parts, making it suitable for a range of processes, including those with particulate contamination. Processes must be conductive, measuring >20 µs and up to 400 mm process pipe diameter. Insertion mag flow meters insert a sensor finger with integrated electronics into the process flow, rather than replacing a portion of the pipework as full bore mag flow meters do. Insertion mag flow meter types are claimed to be advantageous where the accuracy (~0.5%) of a full bore mag flow meter is not required and ~2% accuracy will suffice. The flow meter is claimed to be easier to install and service than a full bore mag flow meter for this type of application. Burkert Fluid Control Systems Contact info and more items like this at wf.net.au/Q584
Salmonella spp. kit for food samples Qiagen has announced that its mericon Salmonella spp. kit, in combination with the QIAsymphony RGQ automation platform, has received validation from the AOAC Research Institute, an independent thirdparty organisation that evaluates analytical methods for use in food safety and other testing. The kit provides all necessary reagents for detection of Salmonella subspecies and runs on
Cell Biosciences has launched the Neogen ANSR molecular platform. ANSR for Salmonella is claimed to be the
automates entire workflows from food sample to
first pathogen test available for the system and provides results after only
the final result. The research institute validated
10 minutes of reaction time. ANSR requires only a single reaction tempera-
the kit on the platform, as well as manual use, for
ture, which eliminates the heating and cooling cycles of polymerase chain
low- and high-throughput testing of eight different
reaction (PCR) methods.
food sample types.
ANSR is an isothermal amplification reaction test method that exponentially
As a result of this certification, food industry
amplifies the DNA of any bacteria present in food and environmental samples
labs can now process more samples and improve
to detectable levels in only 10 min. Combined with ANSRâ€™s single enrich-
efficiency by automating their Salmonella workflow
ment step, Neogenâ€™s pathogen detection method can provide DNA-definitive
using the kit and platform. The mericon workflow
results for Salmonella in as little as 18 h from the time the sample is taken.
was said to perform as well or better than the
the QIAsymphony RGQ modular system, which
Pathogen test for Salmonella
The ANSR system combines molecular-level accuracy with a small benchtop
ISO reference method for selected foods, earning
footprint and a simple procedure.
Performance Tested Method certification.
Cell Biosciences Pty Ltd
Qiagen Pty Ltd
Contact info and more items like this at wf.net.au/Q346
Contact info and more items like this at wf.net.au/Q838
AUTOMATION, SENSING & ROBOTICS
Food and water safety provide new challenges for today’s sensors Sensors that work flawlessly in laboratory settings may stumble when it comes to performing in real-world conditions, according to researchers at the US Department of Energy’s Oak Ridge National Laboratory.
hese shortcomings are important as they relate to safeguarding food and water supplies, said Ali Passian, lead author of a Perspective paper published in ACS Nano. In their paper, ‘Critical issues in sensor science to aid food and water safety’, the researchers observe that while sensors are becoming increasingly sophisticated, little or no field testing has been reported. “Although sensor researchers are keenly aware of the various issues challenging their particular technologies, outsiders may perceive an overestimated level of performance or, in certain cases, the availability of ‘uber-sensors’,” the researchers wrote. Co-authors are Rubye Farahi and Laurene Tetard of ORNL and Thomas Thundat of the University of Alberta. Salmonella, E. coli, pesticides and mercury are among key targets for sensors, so a clear public understanding of their capabilities - and limits - is essential, particularly because food and water make for highly complex chemical and biological environments, Passian said. “Given the current physics of sensors, these hazards pose especially difficult challenges that will require further research and successful demonstration,” Passian said. The researchers explored paths necessary to ensure that sensors work as intended and can help protect the public - a goal they are confident can be achieved. “While human and animal sensory capabilities are highly specific and can recognise the molecular fingerprints of many potentially harmful substances, developing similar and superior sensing capabilities is faced with many chal48
lenges for which nanoscience may provide new solutions,” Passian said. Nanosensors take on a variety of shapes, sizes and architecture. In some devices, nanoparticles (gold, silicon, magnetic composites or polymers) or nanowires (gold, polymers or composites) that react in the presence of the targeted substance are incorporated into the instrument. Advantages of nanosized particles in sensors include low cost, high surface-to-volume ratios, high sensitivity, unique optical and electrical properties and fast response, but these are intertwined with offsetting traits. A number of issues are inherent in the design and operation of nanosensors. For example, the fact the nanosized particles are so tiny can reduce the probability of interactions with the substance to be measured. Consequently, sensor developers are burdened with reaching a balance between reliability, cost effectiveness, portability, robustness and mass producibility. Passian and the co-authors also stressed the need for a real-time flow of information to allow for quicker response time to assess risk, damage and notification of the affected populations. Ultimately, while many quality control measures are in place, requirements will continue to be refined. “With the ever-growing global population and unpredictable natural phenomena such as earthquakes, early development of better sensor technology for food and water safety is vitally important,” Passian said. Oak Ridge National Laboratory www.ornl.gov
pH meter smartphone accessory Sensorex has developed a mobile accessory for pH measurements. Compatible with Apple iPod, iPhone and iPad devices, the PH-1 pH meter accessory measures and records pH values in the
AUTOMATION, SENSING & ROBOTICS
lab or field for use in environmental, educational and industrial applications. The PH-1 accessory plugs into a standard Apple dock connector and uses a Sensorex pH electrode
Stainless steel fieldbus junction box
to measure pH with accuracy to 0.01 pH. The app
Turck has introduced a stainless steel version of the company’s junction boxes, featur-
displays pH, millivolts, ambient temperature and
ing FM approval for Class 1, Division 2, Groups A, B, C and D hazardous locations
solution temperature in real time. The CE marked
and rated IP67.
device supports 1, 2, 3 or more calibration points
The junction box features a cast 316 stainless steel housing to resist corrosion in
and sends readings by email for later analysis. When
salt-spray environments, including chloride corrosion, to ensure continuous connectiv-
used with a GPS-enabled device, the pH meter
ity operation. Designed for use on offshore drilling platforms and other ocean-bound
app will record measurements with both timestamp
equipment, the company’s stainless steel junction boxes can be mounted directly on
and geographic coordinates, which may eliminate
the machine in hazardous environments, with no enclosure required. Further, to ensure
transcription errors and improve efficiency.
the device meets industry specifications, the junction box receptacles are also stainless
Powered from the Apple device, the product
steel and rated IP67 as long as the ports are covered or connected.
requires no supplemental energy source. Its pH
The stainless steel junction boxes are available in six and eight port models, and
measurement range is 0-14 and it operates in
can be utilised with M12 and 7/8″ connector sizes. They can also be used with the
ambient temperatures of 0 to 40°C, in solutions of
company’s minifast connectors. Stainless steel junction boxes are designed to house
0 to 100°C. Data history can be grouped by date
existing circuit boards and receptacle housings. These junction boxes simplify the
or location and exported individually or in .csv
connection of multiple field devices for Profibus-PA and Foundation fieldbus networks.
format via email.
Turck Australia Pty Ltd
Envirosensors Pty Ltd
Contact info and more items like this at wf.net.au/R158
Contact info and more items like this at wf.net.au/R130
Compact pressure sensor with NPN circuit Suitable for pneumatic applications in robotics and handling, ifm efector’s PQ compact pressure sensor series is now equipped with NPN circuit. Using a sealed measuring cell, these sensors detect the pressure in the vacuum and overpressure range. The piezoresistive silicon cell measures, depending on the selected unit, between -1 and 10 bar or -1 and 1 bar. Due to the special sealing of the measuring cell, the pressure sensors are insensitive to liquids such as condensed water and deposits that might occur in the system. The sensors have good overload resistance and an accuracy of < ±0.5%. The sensors’ slanted 4-digit display can be electronically rotated by 180° and read at a distance, from the front or from above. The display colour is selectable, with a green display colour for the acceptable range and red when the switching point is exceeded or not reached. Two programmable switching outputs or one switching output and one diagnostic output provide flexible use. The sensors are easy to install by means of integrated mounting holes; a range of accessories is available for this. The NPN circuit makes the unit suitable for exportation. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q115
Oxygen analyser Michell Instruments has released the XTP601 thermo-paramagnetic oxygen analyser to provide fast, accurate measurements of oxygen levels in various background gases. Capable of measuring oxygen from 0-1% up to 0-25% and suppressed zero ranges, such as 90-100%, the analyser provides solutions for applications ranging from biogas plants to monitoring blanketing gases in oil tankers. The XTP601 is configurable to suit specific applications and budgets with three options: a blind transmitter version (settings, controls and readings accessible via application software); a transmitter with status LEDs (settings,
AUTOMATION, SENSING & ROBOTICS
controls and readings accessible via application software); and a full display analyser (settings and readings are accessible with on-screen controls or via application software). All of these options may be rated for either safe or hazardous area use. Hazardous area classifications are available for ATEX, IEC Ex with cCSAus pending approval. The full display version of the XTP601 has a touch-screen interface to enable easy operation without needing to remove the lid. This means that users can calibrate, change settings and interrogate the instrument in the hazardous area without the need for a ‘hot permit’. Menus allow easy access to information on oxygen concentration; analyser status; a graph showing oxygen trends over a user-defined time period; alarm history; minimum and maximum concentrations; and other parameters to aid diagnosis of plant conditions. Free software is available for the XTP601 to enable users to monitor, operate and calibrate any version of the instrument remotely via a PC or control system. AMS Instrumentation & Calibration Pty Ltd Contact info and more items like this at wf.net.au/R165
Conveyor roller sensor The Telemecanique XUY fully integrated roller sensor uses a multibeam photoelectric sensor across the width of the conveyor and is easily installed between the conveyor rollers
Signal conditioning for RTD sensors
to detect all objects passing over the rollers
National Instruments has an-
mounting styles, the XUY can be installed
nounced the NI PXIe-4357 RTD
and moved without the need for tools.
- no matter their shape, colour or position. Featuring a design that eliminates the time consuming and more costly traditional
module as an addition to its SC
Encased in a 12 mm diameter aluminium
Express sensor measurement
tube, the roller sensor can be ordered to
family for PXI Express. The high-
suit roller conveyor widths from 200 to 900
performance module is optimised
mm and, depending on the conveyor width,
for temperature measurements
will accommodate from one to six sensors
with Pt100 RTD sensors for a
across the tube.
variety of thermal monitoring
The roller sensor includes a spring-loaded
end and the options of three types of end-
The NI PXIe-4357 RTD module
mounting clips: 7/16 hexagonal, 8 mm and
integrates sensor-specific signal
adhesive types. It has the ability to be
conditioning with 24-bit, delta-sigma ADCs to sample all 20 channels at 100 Sa/s
installed between the conveyor’s rollers,
and offers typical accuracies of up to 0.09°C. To expand a system’s channel
which helps protect the sensor from direct
count, engineers can integrate additional NI PXIe-4357 modules or use other SC
mechanical impact. Thirty-degree angle
Express modules to add complementary sensor inputs, including thermocouples,
adjustment means the sensor is easy to
strain gages, accelerometers and FBG optical sensors, to the same system.
set up and align on a target object, and
National Instruments Australia
the use of special convex lens avoids dust
Contact info and more items like this at wf.net.au/R163
accumulation on the sensor face. Schneider Electric (Aust) Pty Ltd Contact info and more items like this at wf.net.au/R160
Small industrial robot The IRB120T is a variant of the IRB120 robot. While keeping its compact, agile and lightweight features, the 6-axis variant delivers a substantial increase in the maximum speeds of axis 4, 5 and 6, resulting in cycle time improvements of up to 25%. This agile and fast robot also offers a repeatability of 0.01 mm. It can also be mounted at any angle, either in a cell, on top of a machine or close to other robots on the manufacturing line. Its faster speed improves its suitability for pick-and-place applications, particularly in the food and beverage and packaging industries. There are also benefits for assembly applications for electrical and electronics and automotive parts manufacturers. The robot comes with the ABB IRC5 compact control, including superior path motion, userfriendly FlexPendant programming, RobotStudio offline programming, flexible RAPID language
AUTOMATION, SENSING & ROBOTICS
and powerful communication capabilities. ABB Australia Pty Ltd Contact info and more items like this at wf.net.au/R159
Robot guided sensors Displacement laser triangulation sensors from MicroEpsilon Messtechnik are designed to be able to provide high-precision laser sensing solutions for robot measurement tasks, such as distance measurement and guidance. These sensors are small with integrated electronics. Measuring ranges are from 2 to 1000 mm and fast measuring cycles of up to 50 kHz widen the scope of application. The gapControl sensor can be installed on a robot arm for measuring various types of gaps. Here, gap measurement data is used to guide the robot along the work piece or for controlling welding robots. The reflectControl system can be integrated into a robot for detecting paintwork defects using deflectometry. A robot continuously adjusts the position of the system to help complete measurements
within a short time frame.
The Sigrist OilGuard provides online continuous monitoring of water for traces of mineral oils, using the fluorescence principle. It can be used to monitor any water type, including process, waste, raw and potable water. Oil in water detection is often essential to meet licence conditions and to protect equipment. The product offers virtually maintenance-free operation by using a non-contact flow cell and a dual UV beam. These features eliminate signal drift, as commonly experienced with other types of monitors, and compensate for any UV light intensity degradation. The non-contact flow cell means no regular cleaning is required and ensures long-term stable operation. The product is also available in an IECEX certified hazardous area version. B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/R157
Bestech Australia Pty Ltd Contact info and more items like this at wf.net.au/R164
Slippery coating evicts biofilms A new slippery technology that has been shown to prevent more than 99% of bacterial slime from forming on surfaces may prove a boon in food processors’ battles to keep surfaces hygienic.
iofilms stick to just about everything, from stainless steel food preparation equipment, copper pipes and steel ship hulls to glass catheters. The slimy coatings are more than just a nuisance, resulting in decreased energy efficiency, contamination of water and food supplies, and - especially in medical settings - persistent infections. Even cavities in teeth are the unwelcome result of bacterial colonies. But now a team of Harvard scientists has developed a slick way to prevent the troublesome bacterial communities from ever forming on a surface. In a study published in the Proceedings of the National Academy of Sciences (PNAS), lead co-authors Joanna Aizenberg, Alexander Epstein and Tak-Sing Wong coated solid surfaces with an immobilised liquid film to trick the bacteria into thinking they had nowhere to attach and grow. “People have tried all sorts of things to deter biofilm buildup - textured surfaces, chemical coatings and antibiotics, for example,” says Aizenberg, Amy Smith Berylson Professor of Materials Science at the Harvard School of Engineering and Applied Sciences (SEAS) and a Core Faculty Member at the Wyss Institute for Biologically Inspired Engineering at Harvard. “In all those cases, the solutions are short-lived at best. The surface treatments wear off, become covered with dirt or the bacteria even deposit their own coatings on top of the coating intended to prevent them. In the end,
bacteria manage to settle and grow on just about any solid surface we can come up with.” Taking a completely different approach, the researchers used their recently developed technology, dubbed SLIPS (slippery-liquid-infused porous surfaces), to effectively create a hybrid surface that is smooth and slippery due to the liquid layer that is immobilised on it. First described in the journal Nature last year, the superslippery surfaces have been shown to repel both water- and oil-based liquids and even prevent ice or frost from forming. “By creating a liquid-infused structured surface, we deprive bacteria of the static interface they need to get a grip and grow together into biofilms,” says Epstein, a recent PhD graduate who worked in Aizenberg’s lab at the time of the study. “In essence, we turned a once bacteria-friendly solid surface into a liquid one. As a result, biofilms cannot cling to the material, and even if they do form, they easily ‘slip’ off under mild flow conditions,” adds Wong, a researcher at SEAS and a Croucher Foundation Postdoctoral Fellow at the Wyss Institute. Aizenberg and her collaborators reported that SLIPS reduced the formation of three of the most notorious, diseasecausing biofilms - Pseudomonas aeruginosa, Escherichia coli and Staphylococcus aureus by 96-99% - over a 7-day period. The technology works in both a static environment and under flow, or natural conditions, making it particularly
The word 'SLIPS' is coated with the SLIPS technology to show its ability to repel liquids and solids and even prevent ice or frost from forming. The slippery discovery has now been shown to prevent more than 99% of harmful bacterial slime from forming on surfaces. (Image courtesy of Joanna Aizenberg, Rebecca Belisle and Tak-Sing Wong.)
The SLIPS technology for preventing biofilm formation as compared to a Teflon coated surface. (Photo courtesy of Joanna Aizenberg and Tak-Sing Wong.)
suitable for coating implanted medical devices that interact with bodily fluids. The coated surfaces can also combat bacterial growth in environments with extreme pH levels, intense ultraviolet light and high salinity. SLIPS is also non-toxic, readily scalable and - most importantly - self-cleaning, needing nothing more than gravity or a gentle flow of liquid to stay unsoiled. As previously demonstrated with a wide variety of liquids and solids, including blood, oil and ice, everything seems to slip off surfaces treated with the technology. To date, this may be the first successful test of a nontoxic synthetic surface that can almost completely prevent the formation of biofilms over an extended period of time.
The approach may find application in medical, industrial and consumer products and settings. In future studies, the researchers aim to better understand the mechanisms involved in preventing biofilms. In particular, they are interested in whether any bacteria transiently attach to the interface and then slip off, if they just float above the surface or if any individuals can remain loosely attached. “Biofilms have been amazing at outsmarting us. And even when we can attack them, we often make the situation worse with toxins or chemicals. With some very cool, nature-inspired design tricks, we are excited about the possibility that biofilms may have finally met their match,” concludes Aizenberg.
Speed monitor The SICK MOC3SA Speed Monitor meets
Online turbidity analyser
the safety levels of PL e according to EN
The Swiss-made Sigrist AquaScat turbidity
ISO 13849, SIL3 in compliance with IEC
analyser uses a free-falling sample design in
61508 and SIL3CL, according to EN62061.
which the water sample is never in contact with
Applications include the speed-dependent
the cell. The cell measures turbidity through the
release of mechanical door latches during
entire sample by the 90° scattered light principle
machine operation or the operation of drives
(ISO 7027). This contactless design eliminates
with safely reduced and monitored speeds.
fouling and the necessity for regular cleaning.
It has a number of differing operating
Dependability of readings is enhanced by
modes, permitting adaptation of the monitoring
stable Zerodur optics calibration which is initi-
solution to the required safety level. The design
ated automatically by the AquaScat WTMA or
aid software tool automatically suggests the
manually by the AquaScat WTM. Both units have
optimum operating mode for a particular use.
a fine resolution of 0.001 NTU for low-turbidity
Configuration is then easily undertaken via
two rotary switches on the module housing.
For high-turbidity applications, the AquaScat
The MOC3SA supports varied sensors and signals - including ‘non-safe’ - so that
HT will offer the same non-contact reliability in
the same Motion Control module can be used regardless of the sensor involved. The
difficult applications. The AquaScat P is for ap-
company claims this simplifies users’ purchasing and stock-keeping.
plications under pressure. All AquaScat models
The Speed monitor permits the monitoring of mechanical door latches on palletis-
The operator interface is a touch-screen col-
persons. The doors are only released for machine operation when the drive is at a
our graphic display. The product features two
standstill or the speed is so low that it no longer poses any danger.
4-20 mA and a choice of digital outputs, and a
The MOC3SA is a solution when the operation of a drive during maintenance, setup or testing work is involved, such as on a filling plant, conveyor system or rotary table, in order to safely reduce and monitor the drive speed during these operating modes. Sick Pty Ltd Contact info and more items like this at wf.net.au/Q361 58
have a range of 0-4000 NTU.
ers, processing machines or transfer stations between handling systems or robots and
data-logger which stores data onto its internal microSD card. B-R Controls Pty Ltd Contact info and more items like this at wf.net.au/R106
Hygienic dicer for cheese and meat products The FAM Hymaks dicer has been developed for the cheese and meat industries, which have high sanitation standards. It complies with major industry standards, such as EN 16722-2005, NSF-3A-14159-1-2002, EHEDG Hygienic Equipment Design Criteria and USDA Guidelines for the sanitary design and fabrication of dairy processing equipment. and it does not have any exposed bores, threads or bolts in
Range of foodgrade lubricants
the product area that can harbour product residue and bacteria.
Rocol’s Foodlube range of food-
All surfaces in the product area are self draining.
grade lubricants has been inde-
The dicer’s single-piece design prevents minute crevices,
To avoid lubricant contamination, bearings and seals are situated more than 25
pendently assessed for safety.
mm away from produce, while sanitary seals and gaskets close off the product area
The range is NSF H1 certified,
completely from the non-product area.
HACCP Aust accredited and
The dicer is capable of slices from 1.5 to 25 mm, strip cuts from 3 to 60 mm and dices from 3 to 40 mm. The machine’s capacity is up to 5500 kg per hour.
manufactured using only FDAlisted ingredients.
The dicer can handle large blocks of soft, semi-hard or processed cheese that can be
The lubricants are claimed to
cut chilled or frozen to as low as -10°C. Products such as bacon, poultry, ham, beef and
protect and increase equipment
pork can be cut chilled or frozen to as low as -16°C. It is also suitable for dicing pet food.
life and efficiency. The distinc-
It has striking power potential of 20.5 kW with two synchronised motors of 5.5 and 15
tive blue band helps ensure the
kW (7.5 and 20 hp respectively). Its steep infeed chute results in a smooth product flow.
correct product is used for an
A digital variable frequency drive allows finetuning and setting of drum speed and
application, reducing the risk of
spindle via touch screen.
Summit Machinery Services
ITW Polymers & Fluids
Contact info and more items like this at wf.net.au/R035
Contact info and more items like this at wf.net.au/R037
Fresh-cut produce dryer Key Technology has redesigned its Auto Dryer, adjusting the controls, motor and structure. Like the original dryer, it removes surface water from fresh-cut produce and vegetables, but it also enables continuous line flow. The dryer achieves fully automated, uninterrupted loading and unloading. Compared to batch drying, the dryer is claimed to increase throughput in smaller floor space while reducing labour and improving worker safety and sanitation. The dryer can handle 500-1360 kg of product per hour per drum, meaning the fourdrum model can handle up to 2000 kg/h when drying lightweight products and up to 5443 kg/h when handling heavier products. The dryer may reduce product damage and maximise drying efficiency by loading a constant flow of product into dryer drums via a spiral layering method that eliminates product slug. With centrifugal pressure, the unique spiral layering achieves uniform drying while reducing wear on mechanical parts. The redesigned hood system enables access to the drum for cleaning. The stainless steel dryer is designed to food safety standards to minimise cracks and crevices that can harbour bacteria. The control system monitors the condition of the drum and automatically adjusts the spin speed if an out-of-balance condition is detected, reducing wear. Key offers an optional package with the dryer that includes a dual-level storage belt, dewatering feed shaker and discharge belt conveyor. Addressing fresh-cut processors’ need to relocate their production lines, the company designed the dryer so it can be moved with a forklift and the configuration of the system can be modified in the field. Key Technology Australia Pty Ltd Contact info and more items like this at wf.net.au/M465
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Innovate to survive Masterclass
AIFST will hold a two-day event - Innovate to Survive – a Masterclass in Innovation - on Wednesday October 31 and Thursday November 1 at the Sydney Showgrounds, Homebush Sydney. In order to be globally competitive and survive long term under increasing domestic and international tough economic conditions, the Australian agriculture and food manufacturing sectors must work ‘smarter’ rather than ‘harder’. Part of working smarter is being innovative all the way along the value chain including production, processing, value adding, and marketing. The hands on intensive meeting will include sessions such as creating a culture of innovation, breaking down barriers to innovation, capturing market opportunities with technology innovation, and visions for the future and all will include case studies, and panel discussions. Expert speakers from companies, research organisations and government have come together in this first meeting of its kind to address the breaking down barriers to innovation, capturing market opportunities and exploiting knowledge ecosystems. The program will conclude on November1 with three concurrent workshops that are able to be booked separately. • Workshop 1 – Accessing Government support for Innovation. What does the industry want? Where are the gaps? • Workshop 2 – Open Innovation models. How do they work? What is happening in food companies? What are other industries doing? • Workshop 3 – Getting smarter with IP. How to get smarter in identifying and protecting IP in consumer foods. To find out more please visit www.aifst.asn.au or call the AIFST National Office on (02) 9870 8688. The Australian Institute of Food Science and Technology is a national association representing individuals like you from all sectors of the Australian food and allied industries, giving you exposure to all aspects of the agrifood sector. The Institute was founded in 1967 and is a member of the International Union of Food Science and Technology Organisations (IUFoST). AIFST has a strong reputation for facilitating food learning, networking and communication regardless of company size, industry segment or professional qualification. AIFST continues to strive for improvement in all its functions, with the aim of maximising professional standing and opportunity for all its members. To find out more about becoming a member please visit www.aifst.asn.au/membership.htm. AIFST
Laser scanner The TiM300 laser scanner has a range of 2 m and is suitable for applications such as collision prevention and reversing protection on mini-AGVs and mobile platforms or monitoring projections and occupancy on storage and retrieval devices. The scanner has a compact and robust metal housing, a scanning angle of 270°, integrated teach-in function and four switching outputs. Power consumption is below 4 W. The device operates with an infrared transmitter light and gives good detection capability, even with black surfaces with just 10% object reflectivity. Suspension monorails can be reliably distanced even in curves, the company claims; the drive paths of autonomous vehicles (as well as the vehicle itself) can also be monitored laterally; and double-depth shelves can be checked for occupancy as well as for any projections. The TiM300 offers up to 16 triple field sets in the form of signalling, warning and stop fields. They permit vehicles to react to the position and distance of detected objects depending on both the current situation and in advance. Four switching outputs are available for this purpose. The scanner has pre-parameterised triple sets ex works covering the most common monitoring cases. The SOPAS interface from Sick is claimed to offer comprehensive programming for which the TiM300 has a USB interface. An alignment aid is also available. Sick Pty Ltd Contact info and more items like this at wf.net.au/Q369
Third-party audits and food safety
Part II: Harmonisation of standards and a process-based approach Globally, food has never been safer. Driven by food scares and a heightened focus on risk mitigation, there has been a move by governments, manufacturers and retailers to join forces and put independent third-party assessment and certification at the heart of food safety.
oday’s global food supply chain is exponentially more complex than it was 50 years ago and yet, the food products that are grown, processed, packaged and sold in all corners of the globe are significantly safer than they have ever been. That these apparently conflicting facts can simultaneously exist is largely an output of the collaboration and transparency that is being led by the most influential food manufacturers and retailers. Two particular areas have worked together to bring this about; the first of these is the harmonisation of standards. Harmonised, robust food safety management system standards and schemes have brought increased transparency and best practice sharing across sectors and geographies. The Global Food Safety Initiative (GFSI) was formed in 2000 by leading global retailers and manufacturers specifically to address food safety issues and the lack of harmonisation in food safety standards and schemes. Together with the International Organization for Standardization (ISO), they have driven the move towards a manageable set of globally accepted management systems-based standards and schemes. This move has benefited suppliers as well, driving down costs by significantly reducing the number of audits they have to undergo and ensuring the audits that take place are addressing potential risks. In 2004, ISO 22000, the first global food safety management system, was issued. FSSC 22000, a complete food safety certification scheme, was developed in 2010 to meet the needs of food supply chain stakeholders. FSSC 22000 is owned by the Foundation for Food Safety Certification, an independent, not-for-profit organisation. January 2012 marked the 1000th FSSC 22000 certificate being issued. 64
Through the harmonisation of standards, the market at large could now easily benchmark against international standards and GFSI-recognised schemes such as ISO 22000 and FSSC 22000. As Mark Overland, Director for Global Certification at Cargill, commented. “We are rolling out FSSC 22000 to over 1000 plants in 67 countries. Having the same level of food safety execution at every plant is an expectation from our customers.” Along with the Foundation for Food Safety, both the GFSI and ISO have to be applauded as very important initiatives. The GFSI’s work on harmonising standards and schemes has resulted in there now being only 12 approved standards from a starting point of 100, which is clearly a significant achievement and we may expect the number will decrease in the future.
Process-based approach The second area is that of an evolving assessment approach, one driven by the strategic needs of clients and the technical expertise of auditors, which has led to a transition in the role of assessments and auditors. The single-snapshotin-time checklist style is fading into the history books and being replaced with dynamic process-based management systems audits. Delivered through auditor competency and sector specific expertise, these audits focus on the systems and processes that strategically underpin organisations and their supply chains, and it is this holistic approach that is gaining a foothold amongst retailers, manufacturers and suppliers. Food safety is embedded in the culture at ACP Europe. As a specialist in the provision of carbon dioxide, ACP cannot
T H ER M A L
HEAT TRANSFER SYSTEMS
TH ER M A L INDUSTRIES
Through the harmonisation of standards, the market at large could now easily benchmark against international standards and GFSI-recognised schemes such as ISO 22000 and FSSC 22000.
afford any food safety issues. “FSSC 22000 delivers a whole new approach to risk management and quality assurance,” explains Mr Speelmans, Safety Health Environmental Quality Manager. “Through LRQA Business Assurance, the whole network of interacting processes is assessed and monitored, thus providing greater assurance to both internal and external stakeholders and protecting our brand reputation.” While FSSC may have come in for some criticism for being costly, the cost savings in real terms are potentially huge and the value of harmonisation is clearly supported by Wrigley, a subsidiary of Mars, Incorporated, which stated that, “Wrigley’s North American factories saw on average a 25-50% reduction of audits by retailers with the adoption of FSSC 22000.” In direct opposition to the holistic approach embedded into FSSC 22000, the certification body that undertook the audit at Jensen Farms which lays at the heart of the Listeria outbreak commented that “the audits are intended to assess whether the client’s operations are in compliance with current baseline industry standards - not to improve those standards or push a client towards best practices”. This is a crucial difference with the management system audit approach where improvement and best practices are a significant part of the process. Part III will conclude this article. See also Part I. Lloyd's Register Quality Assurance Contact info and more items like this at wf.net.au/Q412 www.foodprocessing.com.au
Less work for better returns: macadamia sorting system is an all-round cracker PROCESSING
Better returns, reduced loss, improved product quality and a high throughput rate: the new dehusking and sorting system at the Macadamia Processing Company’s (MPC’s) Alphadale facility has been a success for growers and processors alike. “Since the 1990s, the macadamia industry has approached quality by applying reject penalties in payment systems,” said MPC’s General Manager, Steve Lee. “This has caused farmers to spend many hours sorting and resorting macadamias on their farm before delivery to the factory. It’s a costly process for growers and we felt there had to be a better way.” “So we set about developing a system that removes the need for farmers to sort their own nuts, increases yield per hectare, reduces potential quality losses and maintains the value of the macadamias.” “We also wanted to centralise the task of dehusking and sorting nuts without slowing down the current rates of receiving and processing,” added Kevin Quinlan, Supply Chain Manager - NIS (Nut-In-Shell) at MPC. “This meant we needed machinery with high throughput rate that was highly efficient and could be operated with minimal supervision by staff.” MPC wanted a system that was at the cutting edge of macadamia processing with new cleaning technology, combined with the latest NIS and kernel colour sorting machines. It had to be efficient and able to handle high volumes while handling the macadamias in such a way as to minimise damage. “There were some challenges because this is a first for the industry,” Quinlan said. “It was not just a matter of installing existing equipment.” MPC devised a solution based on a mix of standard machinery and specifically designed machinery to meet its needs. “Some of the new machinery is available commercially and we used that where appropriate,” Quinlan said. “However, we had to design some of our own equipment as there is not much macadamia-specific machinery available commercially anywhere in the world. Some of the standard equipment had to be modified in terms of its operating parameters, both physical and programming, especially for the new colour sorters.” All design work was carried out in-house, with MPC’s engineering staff drawing on past experience to design and manufacture a system that would suit the company’s needs. In researching the new system, MPC found that by reducing the interval between nut fall and delivery to the factory, growers’ returns would be improved as quality would be maintained. Not having to store nuts for sorting reduces the possibility of storage defects like discolouration, mould and internal discolouration (brown centres). The new cleaning machinery removes trash, rock and rejects from consignments before they are sampled and placed in silos. This service is provided free of charge to MPC’s growers. When combined with the kernel colour sorters, MPC is now able to remove all rejects that were formerly removed by on-farm hand sorting. For growers requiring full dehusking, MPC has worked with Alstonville’s House With No Steps to develop a system that offers full dehusking at a cost of 6 cents per kilogram of input weight. “The new system is allowing us to operate at our same receiving and processing speeds,” Quinlan said. “For our growers, they are experiencing a reduced workload and considerable cost savings, often up to 10 cents per kilogram. “From our perspective we are seeing good quality nuts reaching the factory and our processing speed has been maintained. Most importantly, consumers will get to taste the higher quality kernel produced from our changes and we believe this will see increased demand for our products,” Quinlan said. “We see the new system as a win for both the grower and the consumer,” Lee added.
Does it stack up? Grading Weighing Slicing Batching Deheading Pinboning Filleting Trimming Freezing Portioning Checkweighing Tray loading Production Software (Innova) Marel is the leading global provider of advanced and further processing industries.
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Lower pasteurisation temperature may limit spore germination Even if milk has been pasteurised to kill off microbes that can cause food spoilage and disease, certain bacterial strains can survive the heat shock as spores and cause milk to curdle in storage. Now it seems that higher pasteurisation temperatures may aid spore germination.
esearchers in the Milk Quality Improvement Program at Cornell’s College of Agriculture and Life Sciences have identified the predominant spore-forming bacteria in milk and their unique enzyme activity, knowledge that can now be used to protect the quality and shelf life of dairy products. “Control of food spoilage is critical in a world that needs to feed 7 billion people,” said Martin Wiedmann, food science professor and study co-author. “Approximately 25% of postharvest food is spoiled by microbes before it is consumed.” The study, published earlier this year in Applied Environmental Microbiology by the lab of Wiedmann and Kathryn Boor, the Ronald P Lynch Dean of the College of Agriculture and Life Sciences, identified the predominant strains of spore-forming bacteria, which can foul milk and other food products. The culprits, Paenibacillus bacteria, are ubiquitous in nature and cause off-flavours in a variety of foods and curdling in dairy products. As spores, the bacteria can survive in dormant form for years despite the best practices in cleaning, processing and packaging. In fact, the bacteria may be uniquely adapted to overcome the twin tactics of dairy protection: pasteurisation followed by refrigeration. According to co-author and research support specialist Nicole Martin, the spores are not only resistant to heat, the small jolt of heat during pasteurisation may actually stimulate them to germinate. Some can reproduce in refrigerated dairy products at temperatures that would stymy other types of bacteria. “We studied 1288 bacterial isolates in raw milk, pasteurised milk and the dairy farm environment; however, only a handful 68
of strains accounted for 80% of the spore-formers present,” said Wiedmann. “They grow well in milk - and possibly other foods - at temperatures as low as 6°C, and we can identify Paenibacillus because of their uniquely high galactosidase enzyme activity at 32°C.” They also investigated how pasteurisation affects the presence of such bacteria. In the US, concerns about food safety have prompted many dairy processors to increase pasteurisation temperatures above the 72°C minimum set by the government. Anecdotal reports, however, suggested this practice actually led to more spoilage once the products were refrigerated. Tallying bacterial numbers throughout the refrigerated shelf life of milk pasteurised at two different temperatures - 76°C and 79.5°C - the Wiedmann-Boor lab found that lowering the temperature significantly reduced bacterial growth during refrigerated storage, especially by 21 days after pasteurisation. The findings are already being applied in the field. The Wiedmann-Boor Lab was enlisted by Upstate Niagara, a cooperative of more than 360 dairy farm families throughout western New York, to further improve the quality of its award-winning milk by assessing milk samples for spore-formers. Data on samples that contained spore-forming bacteria are now being analysed using DNA fingerprinting to identify the types of organisms present and where they might have come from. Martin said she hopes the collaborative project will become a model for how to approach spore-forming bacteria in individual dairy processing plants.
Servicing the Food Industry for over 30 years Food grade hoses for all applications - FDA approved Standard grade and Premium grade food hose options available Stainless steel end connectors in BSM, RJT and Tri Clover All food hoses hygienically assembled All food hoses pressure tested, tagged and capped Wash down hoses and guns, pressure wash hoses and accessories Protect lanolin lubricant that is 100% natural and food grade approved 92 convenient locations Nationally, all IS09001:2008 accredited
Multichannel analytical transmitters Liquiline CM444 and CM448 multichannel analytical transmitters have a rugged plastic NEMA4X/IP66/67 housing that is leak-proof and corrosion-resistant, suitable for non-hazardous
applications in water, wastewater, oil, gas, chemical and power industries. They accept inputs from up to eight Memosens digital sensors, recognising any combination of sensors and starting operation immediately. All sensors can be precalibrated in the laboratory and are recognised automatically by the transmitters.
The transmitters can be field-upgraded to accept additional inputs by plugging in additional modules. Optional current inputs are available for processing signals from other process devices such as flow, level or pressure sensors. Outputs from the transmitters include up to eight 4-20 mA current outputs with HART, as well as ethernet, Profibus and Modbus TCP or 485 networks. An integrated web server provides remote access via any web browser. Additional outputs include up to four relay outputs capable of switching 24, 115 or 230 VAC. The relay outputs can be used to sound alarms, start or stop cleaning functions, activate a controller or perform other functions. In addition to actual process values provided by the sensors or analog inputs, mathematical functions can be used to calculate a maximum of six â€˜virtualâ€™ process values. The transmitters have backlit graphic displays that alert users to errors and display load curves, as well as drop-down menus for monitoring values. The data logger can maintain up to eight separate data logbooks. It has an adjustable scan time of 1 s to 6 h and a logbook that keeps track of up to 75 calibrations. Endress+Hauser Australia Pty Ltd Contact info and more items like this at wf.net.au/Q576
Rotary drum screen for solid removal from wastewater CST Wastewater has introduced its Rotary Drum Screen for high-efficiency screening of industrial wastewaters. The screen is constructed of stainless steel, including the base Offering enhanced durability, hygiene and serviceability, the screen has non-lubricated chains and nonmetallic drive sockets. It is self-cleaning and corrosion resistant and has no mechanical parts in contact with screened solids. The screen is designed to handle high fat and grease loadings. It is suitable for use in general food and beverage production, slaughterhouses and abattoirs, tanneries, pulp and paper mills, textile plants and plastic manufacturing facilities. The internally fed Rotary Drum Screen can use wedgewire or perforated hole drums. The internal feed tank controls inlet velocities and distributes the flow evenly onto the screen face.
Interworld Electronics has released the DT-5K IP65 desktop keyboard from iKey Industrial Peripherals.
frame, and is fully enclosed for OHS odour and aerosol control.
IP65 fully sealed stainless steel keyboard The DT-5K combines a silicon rubber keypad with an integrated Hulapoint II pointing device housed in an industrial-grade stainless steel case. The DT-5K keyboard is resistant to dirt, dust, water, ice and corrosives. It is easy to clean with disinfectants, making it suitable for food processing, laboratory and medical environments. The DT-5K measures 412.8 x 200.2 x 45.7 mm and operates within a temperature range of -20 to +60ÂşC. For panel-mount applications, the PM-5K provides the same functionality as the desktop version with a rear stud-mounting stainless steel bezel. Interworld Electronics & Computer Industries
CST Wastewater Solutions Contact info and more items like this at wf.net.au/Q847
Contact info and more items like this at wf.net.au/Q870
Insist on the best
Vikan cleaning tools for your facility
The Vikan brand â€“ your guarantee of the best > An unparallelled reputation for excellence built over 100 years > Supplying safety critical environments with superior cleaning performance > Meeting the stringent criteria of Global Regulatory Authorities > Manufactured exclusively from FDA-approved materials > Quality and environmentally certified to international ISO standards > Independently tested and documented in published reports > Occupational health and safety benefits through ergonomic design > Manufactured in Europe using only renewable Eco-electricity
Metal and X-ray detectable pen To minimise the risk of foreign matter entering the food chain, WR&D Wells has developed the Detecta-pen. The retractable pen is food grade and made of shatterproof metal-detectable plastic. A range of ink and pen colours is available. Wells claims that using the pen may reduce the risk of small particles entering the food chain, should the product fall into ingredients or a blending machine, as all components are detectable. For bakery environments where buttery or oily surfaces can make writing difficult, a pressurised or felt-tipped pen is available. The Detecta-pen Ice Pen has been de-
signed for use in very cold conditions and is claimed to work in sub-zero conditions. Other detectable pen products such as highlighters, permanent markers, whiteboard markers and steel pens are available. The pens are manufactured using an X-detect compound plastic. The plastic is both metal detectable and of a sufficient density to be X-ray detectable.
Flexible V-belt slicer for fruit and vegetables The FAM Lifis is a hygienic, flexible V-belt slicer with a large product opening, which allows the free and smooth passage of the product towards the cutting wheel. It is designed for cutting a range of vegetables, including lettuce, rhubarb, leek, celery and cabbage, as well as fruit. The machine easily handles prod-
WR&D Wells Pty Ltd
ucts up to 180 mm in diameter, for
Contact info and more items like this at wf.net.au/Q553
firm, whole or pre-cut products, and 220 mm in diameter, for compressible leafy products. Designed according to European CE directives, the Lifis has stainless steel safety switches, including a trapped safety key which can only be removed after all rotary parts have come to a complete stop. Sloped plate work, rounded corners and a minimum of hex cap screws reduce varnish build-up. Washdown stainless steel motors are available. The Electro-Flex system allows the electrical cabinet with integrated touch screen to be either fixed to the machine or placed at a distance. Immediate access to cutting programs, production and maintenance data is provided by PLC and touch screen. Variable frequency drives for both the slicing wheel and the conveyor belts offer a precise speed control and maximum flexibility producing different cutting sizes. The discharge chute gently decelerates the cut product, minimising damage. Its jointless shape and sloped surfaces prevent product residue accumulation. The system has a quick-replace system for the V-belts. The machine can be extended with a second set of V-belts with separate variable frequency drive for a better product alignment and a more even supply of the product to the machine conveyor belts. Summit Machinery Services Contact info and more items like this at wf.net.au/R026
Vision sensor for quality control checks ifm efectorâ€™s vision sensor O2V for packaging, production and quality control checks objects for presence, size, position or completeness. Standard vision sensors check components by means of defined contours, whereas the vision sensor O2V compares by means of variable features. Instead of a defined contour, the user determines relative features used by the sensor to assess an object or a scene. Within adjustable tolerances the sensor determines characteristics such as the area of an object (number of pixels), the inner and outer object size of irregular object geometry, roundness or compactness or the number of
available holes. Additionally, the grey-scale values can also be used for assessment. A number of evaluation parameters enable a range of applications. Thirty-two scenes with up to 24 different models can be saved in the unit. Parameters can be set via the menu-guided parameter setting software. The O2V can be used as a stand-alone system: camera, illumination and evaluation are integrated into a compact metal housing with the protecting rating IP67. The temperature range of -10 to 60Â°C enables a range of applications. The ethernet process interface is used for image transmission and connection to the controller. ifm efector pty ltd Contact info and more items like this at wf.net.au/Q156
Hygienic swing doors for food processing areas DMF Dortek GRP swing doors are designed for food processing areas,
pharmaceutical facilities, hospitals and laboratories. They are claimed to offer a range of benefits over lined timber doors or stainless steel doors. In the food production sector, good HACCP practice requires a smooth, nonporous ledge-free construction. Doors must be easy to clean, have a smooth, non-absorbent surface and must exhibit hygienic standards equivalent to that of pharmaceutical cleanrooms. The doors have a seamless moulded construction with no joints or ledges to harbour bacteria. They are easy to clean, lightweight, durable and claimed to be maintenance free. Its water-resistant design means no warping, swelling or rusting. The doors offer good temperature and sound insulation and built-in colour design. The option of fire resistance up to 4 h with concealed intumescent strip is available. DMF International Pty Ltd Contact info and more items like this at wf.net.au/R070
DIN rail-mounted energy and power meters The iEM3000, EM3500 and PM3200 series three-phase DIN rail-mounted energy and power meters are designed for energy reporting, bill validation and cost allocation applications. Designed to be simple, reliable and efficient to use, Schneider claims the meters make energy efficiency more accessible for tertiary and industrial buildings. The iEM3000 offers both direct connect and CT-connected meters, basic meters for manual reading, pulse outputs for water, air, gas, electricity, steam (WAGES) applications, and multitariff meters with digital inputs, digital outputs and communications. These help users divide consumption over four periods to help discriminate peak and off-peak consumptions, workdays and weekends, or different energy sources (for instance, utilities vs generator). The meters share numerous design features that may help save installation time, costs and space for panel builders. Easy comb connections and the separation of power and communication connections help increase safety and make wiring simpler for the installer. Schneider Electric (Aust) Pty Ltd Contact info and more items like this at wf.net.au/Q295
Plant design, project management and maintenance services Transfield Worley - a multidisciplinary company with expertise in engineering, project delivery, maintenance and process optimisation - is exhibiting at Foodtech Packtech 2012. Its Food and Beverage Division specialises in the design, construction and maintenance of process facilities, with a focus on supporting the
cost-effective operation of New Zealand’s food and beverage manufacturers. The team comprises a number of experienced engineering and project professionals with offices throughout New Zealand to provide clients with local support and easy access to its services. Transfield Worley’s business offerings include feasibility studies, maintenance and shutdown planning so that production downtime is limited and asset potential is maximised. The company’s business offerings are divided into four streams. Select helps turn the idea into a viable project from technical to commercial feasibility. Deliver focuses on getting the definition right and ensuring a successful execution. Improve looks at the efficient operation of current assets and existing facilities through cost-effective maintenance, shutdowns and minor capital work programs. Optimise services are specialised offerings such as asset management to assist with the best maintenance options for plants and technical safety and risk engineering to ensure plants operate without undue risk to personnel or product. Transfield Worley’s specialist energy efficiency arm, Demand Response, has the expertise to offer solutions for energy costs, such as pumps, compressed air systems and refrigeration and heating optimisation. Transfield Worley Ltd Contact info and more items like this at wf.net.au/Q812
Ventilex manufactures the finest and energy efficient Coolers Belt Dryers Flash Dryers Fluid Bed Dryers Air Dehumidifiers Steam Sterilization Air Pollution Control Continuous Steam Pasteurisation For the Food Manufacturing Industry
Brolton Group Pty Ltd
69 Princes St, Riverstone, NSW, 2765, Australia Sydney Ph: +61 2 98381311 Perth Ph: +61 8 6263 4426 Fax: +61 2 9838 3113 E: email@example.com www.brolton.com.au www.sanddryer.com.au
Safety barrier reels ReCoila has designed a specialised reel that can alternate between being a buffer and a thoroughfare. The BAR Series reels provide a solution for areas that are designated as both thoroughfare and restricted access, such as warehouse roller doors where deliveries come in and stock goes out, but visitors need to be made aware of ‘No Entry’ rules. Traditionally for this type of application, businesses have used traffic cones, bollards or signs, but when access is required multiple times a day, bollards and similar barrier methods can be cumbersome and are sometimes not put back in place and, as is the case with wall signage, are some-
times not seen at all. When mounted on the side wall of a doorway or access way, the BAR Series reels allow staff to easily unwind up to 15 m of chain or tape and attach it to a hook on the opposite wall. The barrier is quickly and easily retracted when pedestrian or vehicular access is required. The safety barrier reels are highly visible in orange or yellow and have a durable impact- and UV-resistant outer case coupled with a heavy-duty spring mechanism, making them suitable for harsh industrial environments. The reels are suitable for use by general industrial and engineering companies, warehouses, transport and logistics operators, public works and outdoors, the hospitality and catering sector, as well as in mine and quarry operations. ReCoila Pty Ltd Contact info and more items like this at wf.net.au/R071
READY MEALS FILLING MACHINERY
Robotic packaging automation cell for case-packing clamshells The Adept ClamPAC Packaging Automation Cell gently packs clamshells into cases at high speeds and is claimed to reduce the total cost of ownership by delivering a standardised, fully integrated solution that can be dropped into any line. ClamPAC is a standardised modular system that the company adapts to each customer’s production line. Before delivery, customer-specific modifications are made based on the size and design of the clamshells, the case sizes and the speed of the line. Adept claims this approach makes it faster and more cost effective for customers to deploy a robotic solution for casepacking clamshells. Key to the design of ClamPAC solutions are SoftPIC grippers and graspers. Adept selects grippers or graspers specifically for each customer’s range of products. Made of soft silicone that conforms to the shape of the
Food Fillers - designed to handle difficult to fill products such as rice & pasta
clamshell, the grippers provide a direct vacuum path to the product, helping the system achieve gentle handling and reliable operation at high speeds. For lines that package multiple clamshell sizes and/or designs, the grippers can be changed in less than 2 min. Adept Technology International Ltd
Ph: +61 2 8814 3100 76
Contact info and more items like this at wf.net.au/R022
Food-grade lubricant Ultra FG, the Ingersoll Rand food-grade lubricant, has an extended life which optimises rotary screw compressor performance by reducing the time to service components and increasing maintenance intervals. Ultra FG lubricates moving parts, dissipates heat, resists degradation from food and chemicals, and does not react with sealing materials, plastics and elastomers. Traditionally, food-grade lubricants can be used for approximately 1000 h before needing to be replaced. Ultra FG has an operational life of approximately 6000 h. Its temperature stability prevents formation of damaging abrasive deposits and, when
mixed with water, the lubricant does not break down into harmful components such as acids and alcohols, which can varnish components and lead to premature failure. The lubricant has an advanced synthetic composition that incorporates advanced additive technologies that include antiwear agents, rust inhibitors and antioxidants. The lubricant can prevent build-up of particulates in critical areas of a compressor by promoting the breakdown of some substances and by absorbing others so they can be carried to filters and separators for removal. To minimise health risks to consumers, Ultra FG lubricant exceeds industry requirements for incidental food contact by meeting the requirements of FDA Title 21 CFR 178.3570 regulations. It is also H-1 compliant for the US Department of Agriculture and has been kosher and parve certified. The lubricant also contains an antimicrobial agent that not only inhibits growth of any contaminations but also provides good neutralisation, protecting the lubricant from spreading bacteria or mould spores. CAPS Australia Pty Ltd Contact info and more items like this at wf.net.au/R039
Upscaling the production of ethnic ready meals
Affordable cooking equipment ©iStockphoto.com/Daniel Bendjy
such as continuous spiral ovens and mini flame grills provide a cost-effective bridge for producers of ethnic ready meals to meet skyrocketing demands.
he popularity of ‘food’ shows on TV and global population migration combined with the trend towards higher quality, healthy packaged foods have resulted in amazing growth in ready-to-eat ethnic foods. Whether it is fresh salsa, hummus, gyro meat, Chinese stir fry or tofu, many ready-to-eat ethnic foods that were once considered specialty items found in the ethnic food isle of a grocery store are now mainstream offerings. The growth and interest in these types of foods, in fact, has been so phenomenal in the last decade that many of these products no longer seem ‘ethnic’ at all. Furthermore, this trend shows no signs of slowing any time soon. According to consumer market research firm Mintel, the sales of ethnic foods in the US will grow by another 20% in the next couple of years, with diversity increasing substantially from earlier in the decade when Mexican/Hispanic were dominant with over 60% share of the ethic food sales. 78
More recently, Asian and Indian foods grew by 11 and 35% respectively. Other foods of ethnic origin, such as hummus and tofu, have grown by hundreds of percent in popularity around the globe. To meet the dramatically increasing demand, many smaller, specialty food processors are increasing the variety and type of ready-made ethnic and global fare offerings. Hummus, for example, is now offered in organic and non-organic varieties such as artichoke, eggplant, garlic, roasted red pepper and even chocolate. Yet, the challenge to smaller food processors is how to expand production to meet the explosive demand for these products. Where modest food processing equipment was adequate even five years ago, many now must find cost-effective equipment that can serve as a bridge to meet higher volume requirements while also retaining the authenticity and quality of the dishes they produce.
Handling warp-speed growth
used directly inline with a continuous oven. Adjustable flame burners allow for the enhancement of flavour, colour and yield. The spiral ovens, available in full-size, mini and micro sizes, are recommended for steaming, roasting, broiling and baking, as well as post pasteurisation, and can be coupled with a chiller and loading systems to suit processing needs. Aronson adds that one of the other benefits of the spiral oven is its compact size, which translates to high-volume output in a relatively small space. Because the oven spirals in a vertical direction, the footprint can be quite small.
Spiralling kabob sales When Exotic Foodline LLC (Richardson, TX) began operations in 2002, the market for its frozen Middle Eastern, Indian and Pakistani dishes was less than CEO Mansur Kaiser had anticipated. “It took five or six years before the market for these foods began picking up rapidly, and supermarkets were getting interested in our line,” Kaiser explains. “Now, the North American market for these ethnic foods is so strong that I believe it is going to be similar to that of England, where there has been a high demand for years.” Kaiser adds that with strong sales in the US now, he looks forward to exporting his line into Canada and the Middle East soon, where his types of ethnic dishes promise to be popular. Kaiser says Exotic Foodline is also expanding its selection of frozen foods. “Our biggest sellers are the grilled barbecue items, particularly kabobs (marketed under the brand name Colonel Kababz). But we also now offer a selection of snack items such as tandoori chicken wings and samosas, plus several new entrees such as chicken tikka masala and biryani,” explains Kaiser. Kaiser feels that now that frozen Indian, Pakistani and Middle Eastern foods have caught on, he needs to address the requirements for mass production, which far exceed the capacity of the existing grilling system that he customised in-house. “We are now looking at Unitherm cooking systems equipment to help us produce the higher volumes of foods that we need in the future,” says Kaiser. Kaiser adds that one of the unique attractions of Unitherm equipment is the availability of compact cooking systems that have powerful features, yet small footprints. In addition to saving on space, some systems can also keep capital investments lower. “If I need from 150-250 kg/h of production, I don’t want to have to buy equipment that handles 2500 kg/h,” Kaiser explains. “That would be much more expensive and take up too much space.” “Also, we offer many BBQ items that can’t be prepared on just any type of equipment. So we tested our product on a Unitherm spiral oven and it came out just like it does on the open fire grill. It was very good quality. So that kind of cooking system could be a good bridge for us to produce higher volumes efficiently,” adds Kaiser.
Economical expansion The explosive growth of ethnic and global foods has also created a need for Panache! Creative Cuisine to meet high volume opportunities without requiring major capital outlays, according to company president Jonathan Stack. “We are launching a new line of Street Foodz that will span our six core categories (sandwiches, salads, entrees, snacks and sides, breakfast and desserts) with ethnic flavour profiles. We plan to incorporate Indian, Asian, Mediterranean, European, Cuban, Latin American and other styles of foods into that line, which will require considerably higher volumes.”
The food processing equipment issue was familiar to Jack Aronson, CEO of Garden Fresh Gourmet brand foods (Ferndale, MI), the producer of a broad line of handcrafted, all-natural salsa, guacamole, tortilla chips, hummus and other ethnic foods. Starting out as a husband-and-wife team that began making a fresh blend of artichoke salsa on a small table in the back of their restaurant, Aronson’s company has grown from $4 million in sales in 2004 to over $100 million this year. “We’re experiencing a lot of growth in ethnic foods.” Aronson explains. “So there is an inherent need for those products to be fresh and natural, and to use authentic ingredients. That’s one of the reasons why ethnic foods like salsa, guacamole and hummus are healthy.” His passion for creating authentic traditional foods led Aronson to questions about what kind of food processing equipment would enable Garden Fresh to meet skyrocketing demands while still retaining the traditional appearance, taste and texture of the foods that were previously handcrafted in a small kitchen. In addition to increases in the varieties and volumes of salsas, the company wanted to keep up with the booming popularity of hummus throughout much of the world, because much of Garden Fresh’s growth was due to the rapid growth of that product. At the same time, Garden Fresh was looking to expand its product line to include Lebanese kofta, cubano peppers and possibly other ethnic dishes, so flexibility of equipment was also important. “With an eye to the present and future, we looked at a lot of different types of equipment,” Aronson says. “Then a business associate mentioned that Unitherm Food Systems makes a cutting-edge line of cooking and chilling equipment that might be suitable for our company.” The line includes equipment that is compact yet surprisingly productive and affordable, such as mini flame grills and continuous mini spiral ovens and chillers. Another important thing was Unitherm had Garden Fresh ship its original product to the factory kitchen where they tested the products using different types of cooking and chilling equipment, Aronson says. “They recommended specific systems as well as parameters such as cook times and temperatures,” he says. Aronson says the equipment he bought brought him up to speed in product volume while also enabling him to retain the quality that is essential to Garden Fresh foods. It also allows him the flexibility to handle his growing assortment of products. “When I do things on a large scale, for example, such as eggplant for my hummus, it goes through the fire-roaster in about 45 seconds,” explains Aronson. “If it is a thick product, like carrots, it also has to be cooked on the inside. So, we put the carrots through our fire roaster to get the caramelisation that enhances appearance, and then we bake them in the spiral oven, which finishes the cooking process.” Garden Fresh also uses the new fire roaster to cook peppers that are used in several dishes, including salsas. “We used to roast peppers on a gas grill, which was a very painstaking method,” Aronson says. “But when we got a large account, it was obvious that we needed a new approach. Now, using a spiral oven, I can do 500 kg of vegetables on the spiral oven in the time it took me to do 10 kg on a gas oven.” Unitherm’s flame griller and mini flame griller systems function as standalone cookers or as searing ovens that may be
Space saving designs make incorporating equipment into production areas simpler.
Garden Fresh tested different types of Unitherm equipment to ascertain its suitability for their products.
Stack says that his company has been growing at a doubledigit rate for the past five or six years, partly due to the success of Panache’s kosher operation Bubbie’s Gourmet. “We’ve been studying this growth opportunity for several years,” Stack says. “Unitherm has given us valuable help in understanding our choices of affordable equipment that can allow us to produce ready foods in much higher volumes and still retain or even enhance our quality standards. Also, they have some very innovative designs and that allows us to incorporate more equipment in a limited space along with the ability
Cost effective equipment can help processors meet the growing demand for ethnic ready foods
to process different types of food using the same equipment.” The type of equipment Panache! is considering includes spiral ovens and chillers, as well as flame tunnels, mini flame grills and rice and pasta cookers. These types of cooking systems provide Panache! with the capability of producing ethnic and world foods that include traditional ingredients and global taste profiles while also featuring authentic textures, markings, colour and highlights. Unitherm Food Systems www.unithermfoodsystems.com
Checkweigher range Multivac MR821 checkweighers are available in three weight ranges, from 10 to 6000 g. They are designed as dual-range weighers, which enables them to achieve a wide range of legally calibrated weights. The checkweighers can be adapted to a range of applications. The transport conveyor and weighing modules are mounted on a robust twin
beam carrier, on which almost all conveyor modules configurations can be fitted. The construction is designed for maximum weighing accuracy with rigidity against flexing, reduced vibration and absence of torsion. The MR821 checkweighers can be equipped with multifrequency metal detectors, which are adapted to specific user requirements in order to achieve optimum sensitivities. The detectors are suitable for a range of metals, such as iron, stainless steel, copper, aluminium, brass, bronze and titanium. The checkweighers and metal detectors are equipped with either a 12.1″ colour touch screen or a 5.7″ monochrome display. The clearly structured user interface makes the operation of the units simple to use. In addition to potential-free contacts, the MR821 units also offer a serial and an ethernet interface. The transport belts, which can be removed without tools in a quick-change system, enable the units to be cleaned quickly and simply. The floor stand is constructed in brushed stainless steel in accordance with the Multivac Hygiene Design. The checkweighers have light transport conveyor modules, brushless drive motors and low-friction belts. Multivac Australia Pty Ltd Contact info and more items like this at wf.net.au/R126
FOR COATING Improve performance and increase productivity for the most demanding coating applications, with Spraying Systems’ PulsaJet® automatic spray nozzles.
High speed cycling delivers faster line speeds and high production rates. Accurate spray placement from PulsaJet® gets oil, lubricant or mist on target with minimal waste and no overspray. Tip changeover and tip stock-holding is eliminated because PulsaJet® provides a wide range of flow rates from a single spray tip. Clog-resistant spray tips reduce costly interruptions and Pulsajet® can be retrofitted.
TALK TO THE EXPERTS IN SPRAY TECHNOLOGY TODAY TO SOLVE COATING AND MISTING PROBLEMS.
Spraying Systems Co.
AUSTRALIA 7 Sara Grove, Tottenham 3012 Victoria • Ph: (03) 9318 0511 • Fax: (03) 9315 3223 • firstname.lastname@example.org
NEW ZEALAND 12E Saturn Place, Rosedale, Auckland 0632 • Free Ph: 0800 777 291 • Fax: (09) 916 1172 • email@example.com
Dimples the solution to energy efficiency PROCESSING
Leading up to the 1 July deadline and impending introduction of the carbon tax, Teralba Industries was approached by a number of food processing plants to find a solution that would help them reduce their carbon footprint and energy costs. Teralba worked with each business closely to calculate the energy savings they could expect while illustrating the reduced impact on the environment that Teralba’s solutions delivered. One such plant, based in Tasmania, had a consistent outflow of 85°C dirty hot waste water from its process lines and an inlet water temperature of approximately 15°C which had to be heated to 90°C, consuming a total of 365 kW/h. Calculations suggested that recovery of waste heat would avoid the consumption of 647 t coal per annum, saving approximately $84,000 per year in fuel costs. Carbon dioxide emissions of 1780 t per annum would also be avoided,
further increasing the possible savings to $128,000 per annum. The end result was a Dimpleflo heat exchanger designed by Teralba Industries that met the client’s specific needs, saved money in energy costs and reduced the plant’s overall carbon footprint. Utilising field testing and analysis data, Teralba Industries says it can design and install Dimpleflo solutions that successfully save businesses money on a daily basis. Teralba Industries Contact info and more items like this at wf.net.au/R003
Frequency inverter The MOVITRAC LTP B frequency inverter is suited to a variety of drive solutions in a wide range of applications. The unit series has been designed for universal use, offering good motor control of both induction and permanent-magnet synchronous motors (with or without encoder feedback). A range of control options including an ‘energy saving function’ makes the inverter efficient and energy efficient. A
range of I/O and communication interfaces ensure quick and efficient integration into a variety of control systems. An intuitive parameter structure, with standard factory settings and an integrated key pad, may shorten the commissioning process. Easy to install, reliable and efficient, the inverter is available in six frame sizes from 0.75 to 160 kW for a supply voltage of 230 or 400 V. It is available in two housing variants: IP20 for cabinet mounting; and IP55 for field mounting, suitable for operation in challenging ambient conditions.
SPX LAUNCHES THE NEW INNOVATIVE APV CAVITATOR
The unit is fitted with a dedicated ‘safe torque off’ binary input which immediately disables the drive in emergency conditions. According to the distributor, the inverter can deliver up to 200% torque from zero speed. It is suitable for applications with inherent high starting torque characteristics including conveyors, crushers, winders and mixers. SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/N888
SPX has added an innovative new modular process
Compressed air vacuum system
technology to its family of mixing and dispersing equipment. The new APV brand Cavitator offers breakthrough benefits for heating liquids without scale
Exair’s Premium Chip Vac
build-up as well as provides solutions for many of the most
system is used to clean
difficult mixing and dispersing challenges for food and
chips or other dry materials from fixtures, floors and
beverage processing. The APV brand Cavitator is another
work surfaces of machin-
example of how SPX continues to focus on innovation
ing centres, lathes, saw
to better address the needs of its customers. SPX can
mills and other industrial equipment. The vacuum easily attaches to a 205 L drum and can be moved
leverage its extensive industry experience and process
from drum to drum to keep materials separate for recycling. To
expertise to support customers in applying the new APV
prevent material contamination, a poly drum liner can be inserted
brand Cavitator to their process. To learn more, visit us
into the drum.
Compressed air powered, the vacuum attaches to open-top steel, fibre or plastic drums. It is quiet (77 dBA) and has no motors or impellers to clog or wear out. Available from Compressed Air Australia, the vacuum system comes with a Chip Vac, lever lock drum lid, shutoff valve, 0.1 µm filter bag, 3 m flexible static resistant vacuum hose (38 mm ID), heavy duty aluminium tools, 6.1 m air hose, drum dolly, tool holder and quick connect fittings. Compressed Air Australia Pty Ltd Contact info and more items like this at wf.net.au/N227
Phone: +61 2 9763 4935 www.spx.com
Software gives vegetable producer the Greenlight for efficiency
Large compressed air nozzle The Exair 1 NPT Large Super Air Nozzle, available from Compressed Air Australia, delivers 3005 g of blowing force for blowoff, cooling and drying applications. Constructed of stainless steel, it is suitable for use in corrosive, high-temperature food and pharmaceutical environments.
CostaExchange, part of the Costa Group, is a major grower, packer, marketer, distributor and exporter of fresh fruit and vegetables. The business has an economic presence in more than 30 regional and rural communities across Australia, including farms, packing facilities and distribution centres. Identifying a need to measure and manage its quality performance across multiple product categories, CostaExchange selected Muddy Boots’ Greenlight Quality Control to improve visibility and pinpoint areas where improvements are needed. Muddy Boots says its award-winning Greenlight Quality Control ensures consistency in measuring product quality attributes. Its mobile technology software captures and processes information at the point of input, enabling businesses to identify problem areas and collaborate with suppliers to deliver improvements. Using Greenlight gives increased transparency and a wider sharing of data, giving businesses a clearer view of site, supplier and product performance along the chain. “Quality excellence is a core pillar of the Costa business strategy, fundamental to this is the ability to measure and manage our quality performance across multiple product categories, across a diverse supply base,” said Brett Heather, Group Technical & Alliance Manager at CostaExchange. “The deployment of the Muddy Boots Greenlight system into our business gives us the visibility (by trending performance over time) to highlight areas where improvements are needed, be that product temperature, size, weight, aesthetics and so on. “With improved quality management, through the utilisation of Greenlight QC, Costa sees significant benefits flowing, with improved efficiencies, reduced rejections, enhanced reputation and a stronger bottom line performance,” said Heather.
Exair claims the nozzle has a force more than eight times that of standard air nozzles, making it suitable for blowing heavy materials and in situations where the nozzle can’t be mounted close to the target surface.
The aerodynamic design directs compressed air to a single point of convergence, delivering a concentrated stream of high-velocity airflow. It also meets OSHA standard 29 CFR 1910.242(b) as the compressed air is ejected from holes that can’t be blocked. At 80 psig, the air consumption is 135 scfm and the sound level is 99 dBA, meeting the OSHA standard for 2 hours of use per day without hearing protection. The nozzle has a 1½″ (38 mm) hex body for installation using a standard wrench or socket.
Muddy Boots Software Ltd
Compressed Air Australia Pty Ltd
Contact info and more items like this at wf.net.au/Q982
Contact info and more items like this at wf.net.au/M436
Sustain Save Save quality product time No pulsation or meshing rotors, no damage
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Combating antimicrobial resistance Since the mid-1990s, Denmark has reduced animal consumption of antimicrobial agents by 60% without reducing its agricultural output. Bearing in mind that the global consumption of antimicrobial agents for animals is almost twice the size of human consumption, Denmark’s efforts are a shining light in the global struggle against antimicrobial resistance.
enmark was the first country to ban the use of antimicrobial agents as growth promoters on a scientific basis and to establish a national surveillance. The National Food Institute was involved from the outset and has participated in the surveillance of antimicrobial agent consumption and resistance since the mid-90s. In a comment in the journal Nature, Professor Frank Møller Aarestrup, the National Food Institute, Technical University of Denmark, gave his explanation of the success of the Danish efforts.
Cross-sector collaboration “There are three secrets to the Danish success. Since 1995, we have had a national surveillance program, DANMAP, which enables us to continually monitor changes in resistance and document any problems. The 1990s saw political willingness to introduce regulations of the consumption of antimicrobial agents. And there was and still is cross-sector collaboration between farmers, the food industry, researchers and authorities,” said Professor Frank Møller Aarestrup. One of the key steps was the ban on growth promoters, but an essential element is also the Danish surveillance system which documents resistance developments and is able to propose solutions. Each year, the DANMAP surveillance program monitors the consumption of antimicrobial agents - from farm to table to hospital bed - and investigates the incidence of antimicrobial resistance in animals, food and humans. The program is a joint initiative of the National Food Institute, Statens Serum Institut and the National Veterinary Institute, Technical University of Denmark. The DANMAP program was the first of its kind in the world but has now been emulated in many countries. In some coun86
tries, data are not available from all animal species and the programs do not integrate data from animals and humans in the same way as in Denmark. “All countries that wish to limit their consumption of antimicrobial agents for livestock could learn from the Danish experiences. It only takes some adaptation to local conditions, and we have evidence to show that reducing the consumption of antimicrobial agents prevents the incidence of resistant bacteria. One very effective initiative is that Denmark introduced a ban on veterinarians profiting from writing prescriptions for antimicrobial agents. The consumption of therapeutic antimicrobial agents dropped by almost 30% in 1995, and in Denmark the ban has not resulted in falling agricultural productivity,” says Professor Frank Møller Aarestrup.
Voluntary stop and ‘Yellow Card’ working In July 2010, the Danish Veterinary and Food Administration introduced the so-called ‘Yellow Card’ scheme aimed at reducing the increasing antimicrobial consumption. At the same time, Danish agriculture introduced a voluntary ban on one of the antimicrobial agents, cephalosporin, which is essential for treating humans. The initiatives helped reduce antimicrobial consumption by almost 25% over two years and consumption of cephalosporins decreased by almost 49% in 2010 for pigs. “It is indeed positive to see that both the total consumption and the consumption of cephalosporins have dropped. Resistance to cephalosporins is a rapidly increasing problem in both humans and animals. It is therefore important to maintain the positive development,” says Frank Møller Aarestrup. Technical University of Denmark (DTU) www.dtu.dk
Dietary supplements and ingredients resource The 2012 USP Dietary Supplements Compendium provides unbiased, scientifically sound
specifications on a host of dietary supplements and ingredients. It offers international dietary
supplement manufacturers of all sizes a comprehensive resource for finding suitable, unbi-
ased and scientifically sound analytical methods, and specifications for the identity, quality
Precision Powder & Liquid Blending
and purity of ingredients and products.
As raw materials used in dietary supplements are sourced from around the world and global manufacturing of finished products accelerates, a new resource now available can help manufacturers, suppliers, laboratories and regulatory agencies ensure the quality of these ingredients and products. Published by the US Pharmacopeial Convention (USP), the 2012 ers in developing quality specifications, testing new products, qualifying raw materials and protecting their overall supply chains. In addition to analytical methods and specifications, DSC includes essential information such as the regulatory framework for dietary supplements, industry guidance documents and tables of dietary intake levels. Other practical features for manufacturers, ingredient suppliers, contract laboratories and regulatory agencies include checklists for Good Manufacturing Practices audits used by the USP Dietary Supplement Verification Program; Good Agricultural Practices from the American Herbal Products Association; and US Federal Trade Commission (FTC) and Food and Drug Administration (FDA) guidelines on appropriate labelling for dietary supplements. DSC standards also can be used as the basis for buyer-supplier relationships and contractual agreements regarding expected quality of dietary supplement components. Now offered in a two-volume set, DSC contains more than 550 monographs for finished products, dietary ingredients and other components common to dietary supplement manufacturing, derived from the United States Pharmacopeia-National Formulary (USP 35-NF 30) and Food Chemical Codex (FCC), Eighth Edition. The 2012 DSC includes 64 new dietary
Product Design Services Unitech Industries specialise in the custom manufacture of nutritional beverages and premixes for the New Zealand and International food, dairy, beverage, bakery and pharmaceutical industries.
USP Dietary Supplements Compendium (DSC) can assist dietary supplement manufactur-
Unitech can assist with the provision of a range of services surrounding the supply of your product including; formulation design, product validation trials, regulatory and or label claim compliance, sourcing materials, manufacture, quality assurance and delivery. Contact Unitech to determine the possibilities for improving and developing your quality products to create new market opportunities.
supplement monographs and approximately 150 excipient monographs. U.S. Pharmacopeial Convention
Flavour enhancer for powdered and canned soups
Israeli company LycoRed has adapted its natural enhancer Sante for flavour enhancement of powdered and canned soups. The company claims the product will allow salt reduction of up to 30% without tomato flavour notes. Sante can also be used for partial or total replacement of a variety of artificial flavour enhancers such as MSG. The company claims the product improves mouthfeel and texture while boosting the taste profile. It is suitable for use in liquid or powder formulations and is stable at high temperatures and variable pH. The company claims that replacing 0.2% MSG in a chicken soup mix with an equivalent quantity of Sante liquid reduced sodium content by 25% and maintained flavour quality. LycoRed www.lycored.com
Applied food testing library Thermo Fisher has announced that its Applied Food Testing Library is available online. This compilation of more than 230 application notes, case studies, validated methods, webinars and technical posters by industry experts is designed to help food science professionals with routine and special challenges. The practical repository covers: allergens, authenticity and traceability, beverage and drinking water, chemical contaminants, food processing, microbiological organisms, non-targeted screening, physical contaminants, quality control and trace elements. Examples of information available in the library include: case studies on laboratories confirming the presence of listeria in food and environmental samples; an audio podcast on analysing persistent organic pollutants (POPs) in food; information on how to identify arsenic species in fish tissues and how to
achieve fast non-targeted screening and confirmation of 510 pesticides at low parts-per-billion levels. The Applied Food Testing Library is available at www.thermoscientific.com/fsnews. Thermo Fisher Scientific Contact info and more items like this at wf.net.au/R074
Teaching effective handwashing
Vitamin K-7 product Frutarom Health has announced increasing market share of its uniK2 Vitamin K-7 product in western Europe. By activating a protein called osteocalcin and producing optimal binding of calcium in the bones, and by improving the collagen status in bone, uniK2 is claimed to be effective in improving bone quality and strength. The ingredient is derived from natto, one of the richest natural sources of vitamin K2, which has been traditionally consumed in Japan for centuries. The product is produced in a GMP-certified Japanese factory following ecological principles by recycling near 100% of the waste to produce other materials or re-used to generate thermal energy. uniK2 has recently received kosher certification, opening new markets for the product. Frutarom says a number of supplement manufacturers are also using the product for cardiovascular health, while food processors are incorporating uniK2 into food applications such as dairy foods and confectionery. The recommended daily dosage of Vitamin K2 is 45 µg/day, making it a cost-effective and appealing ingredient for the supplement and functional food markets. For manufacturers, uniK2 is available in two levels of concentration as uniK2 MK-7 powder 0.2% and uniK2 MK-7 oil 0.15%. This allows multiple use options for functional-food applications. Frutarom www.frutarom.com/
The GlitterBuddy kit can be used to show staff how well they do wash their hands. The kit is made of durable paper-board and folds down to a compact box that contains all the items of the kit for convenient transport and storage. When unfolded, the ‘scary germy face’ invites users to look through his mouth to see his ‘devilish pals’ on their hands. Black light illumination is provided by the SpotShooter 8, which shows all the ‘GlitterBugs’ ‘hiding’ on hands. The kit contains the GlitterBug Potion, which is dispensed onto hands from the metered pump pack. Users rub this into their hands as they would a hand cream. Under the UV light, the GlitterBug will make hands shine. Users wash their hands as they would normally and dry them. They can then take another look under the UV light to check how effective their handwashing is. If they see any areas glow, such as around nails, in the cracks or around the back of hands, then it means they were not washed correctly. Staff will know instantly how thoroughly they washed their hands and how possible contamination could occur. Also, with the increasing use of waterless antimicrobial handwashing gels, GlitterBug can be used to show staff how well they are spreading the gels and sanitising their hands. Arrow Scientific Contact info and more items like this at wf.net.au/N623
Kiel Industries Pty Ltd The Short Run Specialists Whilst most companies are suffering a downturn in the market place, Kiel Industries are expanding their world class facility in regional Victoria. Currently the Morwell facility provides an area of 4,800 sq. metre factory comprising the state of the art modern rotational moulding machines capable of producing products from bollard caps to 5000 litre rainwater tanks. The additional facility will provide another 2,500sq. metres to house another machine transferred from their Mirboo North site. Rotational moulding is best known for the manufacture of tanks, but it can be used to make complex medical products, toys, leisure products such as spas, and highly aesthetic point of sale products. Kiel Industries specialise in providing in house design with their own unique and affordable tooling facilities. Customers can take their ideas and have them transformed into workable products. With 20 years plus experience in design and manufacturing of quality materials handling equipment, Colin can design and guide customers through the process to finalisation. An innovative approach and sound engineering background has led to the development of a range of plastic bins. Made from robust UV stabilised materials, the Kiel range of bins have been designed for ease of use. The advantages of rotational moulding are: •
That hollow parts can be made in one piece with no weld lines or joints. The end product is essentially stress free.
Moulds are relatively inexpensive.
Lead time for the manufacture of a mould is relatively short.
Short production can be economically viable.
No material wastage in that the full charge of material is normally consumed in making the part.
It is possible to make multi layer products
Different types of products can be moulded together on the one machine.
The machinery at Kiel Industries is world class, having the only 3 of its kind in the world, Kiel Industries has the capabilities to manufacture from 1–10,000 parts for their customers depending on their requirements. For further information please contact: Kiel Industries on (03) 5135 3900
David Boger, Vice President Sales and Marketing, Flexicon Corporation
Exponential growth in the use of bulk bags has spawned an entire manufacturing segment dedicated to producing specialised equipment that not only fills and discharges bulk bags, but offers various degrees of automation and integrates filling and unloading operations with upstream and downstream equipment.
s the number of bag filling equipment options increases, so should the ability of the specifier to evaluate standalone equipment and integrated systems against current and anticipated needs. This article addresses the â€˜fillerâ€™ half of the bulk bag handling equation, offering the six most important parameters to consider when satisfying any individual bulk bag filling requirement with top efficiency and cost-effectiveness.
1. Anticipate maximum capacity The difficult but critical question: how many bulk bags will you need to fill per week during the useful life of your next bulk bag filler? With few exceptions, buying a more costly filler with higher capacity than you now need will be less costly than replacing a filler you outgrow, unless that filler can be retrofitted with performance enhancements at a later date. Capacity requirements run the gamut, from one bag per week to 20 bags per hour. Where your volume falls should, in part, influence your decision to specify a manual, semiautomated or fully automated machine. Generally speaking, the more manual the filling operation, the more output is subject to variation. When gauging the capacity and payback of manual equipment against automated equipment, you need to determine the average pace at which operators can attach, detach and cinch bag spouts, remove filled bags, load pallets and conduct all other filler-related operations. When estimating the time allocated to these manual functions, it is advisable to anticipate a pace that an operator can realistically maintain throughout an entire shift while avoiding fatigue or injury. For the lowest volume applications, a basic manually operated filler will maximise your return on investment. Choose a filler
design that affords unobstructed access to the bag spout and loops, facilitating rapid manual insertion and removal of bags. This class of filler is typically equipped as standard with fill head height adjustment via fork truck to accommodate all popular bag sizes, a feed chute vent port for dust-free air displacement during filling and an inflatable cuff to seal against the bag inlet spout and ensure it does not collapse on itself during filling. The cost of a scale system can be avoided by placing the entire filler onto an all-purpose plant scale, providing the filler is properly equipped for in-plant mobility. Alternatively, if a forklift is unavailable to remove filled bags, configurations are available with a three-sided base that provides access from the open side using a pallet jack. The time required to prepare empty bags for filling, and to remove filled bags from beneath the filler, can have as much or greater influence on maximum filling capacity than the rate at which material enters the bag. As such, adding a roller conveyor allows filled bags to be rolled out of the filling area for spout cinching and pallet/bag removal while another bag is being filled. Adding such a conveyor system, however, generally requires a filler with rear posts and a cantilevered fill head equipped with hooks that release bag loops automatically, so if higher capacity is in your future, a rear post configuration may be your best choice today. Further increasing the capacity of systems equipped with roller conveyors to the next level generally entails adding an automated pallet dispenser which places pallets and slip sheets onto the roller conveyor upstream of the filling operation, further reducing the time required for each filling cycle by limiting manual operations within the filling station exclusively to loading an empty bag.
BULK HANDLING, STORAGE & LOGISTICS
The six guidelines you need to specify a bulk bag filler
BULK HANDLING, STORAGE & LOGISTICS
2. Evaluate safety against manual operations required at any given level of capacity
feed rate) by a slide gate or other valve that must close the instant a precise target weight has entered the bag. Non-freeWith manual and semiautomated filling operations, the potential flowing titanium dioxide (TiO2), for example, may flow in a for worker fatigue and injury can increase according to required trickle and then in clumps, and it may bridge above the flow output per shift, relative to the type of bulk bag equipment specified. control valve, making it a poor candidate for gravity feeding. For non-free-flowing materials, a metered feeding system is Consider that the connection points of a conventional filler are often beyond the reach of most operators, even when short required to feed the filler accurately and consistently. Metering bags are being filled. But adding the height of a roller conveyor systems can include a flexible screw conveyor, screw feeder, to the height of a bulk bag to the length of its bag loops puts rigid auger, drag disk, bucket elevator, rotary airlock valve or the connection points for bulk bags of only 122 cm in height other device that does not rely on gravity alone to deliver at approximately 213 cm above material to the filler. the floor! The selection of a metering This requires an operator to system can hinge on the availstand on a platform, a ladder able space above the filler, since specifiers have the ability to tailor bulk bag filling or on the roller conveyor while surge hoppers and filter receivers systems according to capacity requirements, straining to reach overhead spout with rotary airlock valves may expandability, safety concerns, plant hygiene connection points and insertrequire more headroom than ing hands between temporarily considerations, ancillary filling needs, upstream is available. In these cases, the disabled moving parts. Difficultdischarge housing of a flexible equipment and sanitary standards. to-reach spout connection points screw conveyor can often fit can therefore compromise safety between the filler inlet and the as well as capacity - two problems ceiling joists, while eliminating that can be solved with the addition of a fill head that lowers the need for a flow-control valve. and pivots to the operator at floor level. For products that are easily aerated, pneumatic conveying Repetitive manual tasks such as releasing bag hooks, placing systems should be avoided, since the conveying process can cause pallets on a roller conveyor or actuating bulk material delivery the material to require a much lengthier densification/deaeration also increase the potential for error and injury, justifying semi- cycle to achieve the desired fill weight and package stability. If sufficient headroom exists above the filler, a surge capacor fully automated equipment for all but the lowest volume ity equivalent to the weight of a filled bag can be employed applications. to reduce cycle times while maintaining accurate fill weights. 3. Ensure dust is contained This configuration allows bag changeover to occur while the Even the most rudimentary filler is likely to be equipped with subsequent batch is in the process of being weighed. When a an inflatable spout seal to hold the bag spout firmly in place pneumatic conveyor is used as the material delivery system, during filling. However, not every fill head is vented to a dust the filter-receiver can be sized to hold the weight of an entire collector to filter displaced air and dust, and to vacuum ambient bulk bag to apply this method. dust in the operatorâ€™s vicinity during disconnection and cinchFor the same reason, a surge hopper above the filler can be ing. It is therefore important to confirm that the filler you are considered when using mechanical metering devices to move considering is so equipped, particularly when contamination of material to the filler from both storage vessels and plant processes. the product or plant environment cannot be tolerated.
4. Determine your need for multifunction filling If your plant fills drums, boxes or other containers as well as bulk bags, multifunction fillers can boost production, undercut the cost of separate equipment and reduce the amount of floor space required. Multifunction fillers can be switched from bulk-bag to drum-filling mode in seconds by positioning the swing-arm-mounted drum-filling chute under the fill head discharge port. The chute automatically rotates to deliver material to all four drums on a pallet. Similar adapters for boxes, totes or other containers are also available with varying levels of automation.
5. Match the feed source to your material and your filler Filling capacity, accuracy and efficiency are often limited by the ability of upstream equipment to feed material consistently and in sufficient volumes. High-capacity, semi- or fully automated fillers therefore require high-capacity feeding systems that are typically automated and feed material into the filler by gravity or by a metering device. The ability to gravity-feed material depends on whether a material storage vessel can be located above the filler and on the materialâ€™s flow characteristics. The more free-flowing it is, the more accurately its flow can be varied (down to dribble92
6. Comply with sanitary requirements
While all fillers can be constructed of stainless steel with ground and polished welds, their designs can preclude sanitising according to government standards. If your application must meet sanitary requirements, your choices should be limited to designs that are accepted by the agencies to which you must comply, or to which you elect to comply for assurance that sanitary conditions can be maintained.
Conclusion With an almost unlimited combination of filler designs, features and upstream equipment from which to choose, specifiers have the ability to tailor bulk bag filling systems according to capacity requirements, expandability, safety concerns, plant hygiene considerations, ancillary filling needs, upstream equipment and sanitary standards. While numerous available options can complicate the selection process, they can also yield a highly efficient and cost-effective solution to any given filling problem, providing that fundamental steps are taken to evaluate equipment against precise requirements. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/
Manual dump system Flexicon’s manual dump system collects dust generated during manual tipping, compacts empty bags and conveys bulk material downstream. The dust-free system comprises a receiving hopper, dust collector, bag compactor and flexible screw conveyor. A bag infeed chute through the sidewall of the hopper hood allows the operator to pass empty bags directly into the bag compactor, causing dust generated from both tipping and compaction to be drawn onto the system’s two cartridge filters. An automatic reverse-pulse filter cleaning system releases short
BULK HANDLING, STORAGE & LOGISTICS
blasts of compressed air inside the filters at timed intervals causing dust build-up on the outer surfaces to fall into the hopper, conserving useable product. Filters are readily accessed by removing the interior baffle and replaced rapidly using quick-disconnect fittings. The compactor employs a large pneumatic air cylinder to compress bags into a removable bin that accommodates 50 to 80 bags. The main door and a flapper door within the bag infeed chute are equipped with safety interlocks that prevent operation of the compactor unless both doors are closed. The hopper discharges into an enclosed, flexible screw conveyor designed to handle a broad variety of materials including free-flowing and non-free-flowing bulk materials from large pellets to submicron powders, including products that pack, cake, seize, smear, fluidise, break apart or separate, with no separation of blended products. Flexicon Corporation (Australia) Pty Limited Contact info and more items like this at wf.net.au/Q554
Freezer picking solution Swisslog has launched FreezerPick, a solution in which picking is moved out of the freezer into chilled environments, resulting in efficient order fulfilment. FreezerPick is suitable for companies such as retailers, food and beverage manufacturers, 3PLs and pharmaceutical companies that handle frozen products and deliver directly to stores. FreezerPick is ergonomically designed goods-to-person picking located in the chilled environment. Cases are delivered in store shelf sequence to the picker. After picking, order pallets are lowered back into the deep-freeze environment with orders ready to be dispatched. This ensures cases stay in chilled environments for only a few minutes, complying with major regulations. FreezerPick is based on four different systems: Pallet Storage, Miniload Buffer Storage, Case Picking and Layer Picking. The solution is scalable and flexible in operation, the company says, allowing it to be tailored to each user’s requirements. FreezerPick is designed for single case picking, automated layer-pallet building and full pallet out-feed. A fully automated version is also available. The product may offer space savings due to high-bay warehouse storage. The company claims it offers good accuracy of order fulfilment and reduces health costs as a result of ergonomically designed workstations. Swisslog Australia Contact info and more items like this at wf.net.au/Q000
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Waterproof pallet wrapping TechnoWrapp has upgraded its A800 and A800 4E automatic ring wrapping machines with an integrated top sheet applicator. The high-speed machines are for wrapping palletised loads with stretch film and a waterproof top sheet. These highly productive wrapping machines are designed to keep film usage to a minimum with up to 350% material savings claimed, and yet ensure complete hermetic sealing of the pallet stack. The ring technology rotates the film cartridge around the palletised load, combining smooth horizontal and vertical movements to cover the load, while still maintaining the integrity of the load corners.
BULK HANDLING, STORAGE & LOGISTICS
TechnoWrapp has integrated top sheet applicators that place a sheet of polyethylene on the top of the load which, together with the lateral wraps, creates a waterproof covering of the product. The electronic prestretch system with a tacho generator enables smooth dispensing of the film and a high degree of prestretch. The wrapping machines use as little as 96 g of film, which is achieved by prestretching the film to more than 400%. On a pallet measuring 800 x 1200 x 1500 mm high, using nine layers of film and a standard film reel of 500 mm wide x 23 Âľm, only 96 g of film is used. The pallet/load is static so the stability and integrity of the stack is maintained during the high-speed wrapping process. The automatic pallet stretch wrapping machines can wrap up to 130 pallets/h and hermetically seal the top and sides of the load. Optional extras include an auto reel changeover, stretch film splicer and pallet lift in wrapping area. HBM Packaging Technologies Contact info and more items like this at wf.net.au/M233
BULK HANDLING, STORAGE & LOGISTICS
Margherita Forcolin, Insiel
Intelligent cargo for more efficient, greener logistics Smart cargo that knows where it is, where it is going, when it needs to be there and who is handling it would revolutionise the freight industry, improving efficiency, saving suppliers and recipients time and money, and helping protect the environment. EU-funded researchers have developed a proof-of-concept ‘intelligent cargo’ system that promises all those benefits and more.
illions of trucks, freight trains and cargo ships are on the move around the world each day. Combined, they account for more than 14% of global greenhouse gas emissions and consume around a third of total energy consumption. Wastefully, many of those vehicles are travelling empty. Despite efforts to improve freight transport efficiency, a cargo truck plying Europe’s roads will currently still spend around half of its working life empty - returning from a delivery or travelling to pick up its next shipment. But what if cargo was made aware of its context and purpose? It could find space on a passing truck, let logistics operators know where it is and keep recipients informed of its estimated time of arrival. Perishable and hazardous goods could be closely monitored, transport routes dynamically changed to avoid congestion and the entire transport industry made dramatically more efficient. “Put simply, intelligent cargo is about giving cargo the capacity to understand who I am, where I am, what my mission is and what I should do if something goes wrong,” said 96
Margherita Forcolin at IT services company Insiel in Italy. “From an artificial intelligence point of view, it’s a basic level of intelligence - it simply reacts to what’s going on around it, but from a logistics viewpoint it’s a huge step forward.” Insiel coordinated a consortium of 22 companies, universities and research institutes in defining concepts and developing technology for an intelligent cargo system based on a combination of sensor networks, wireless communications and ambient and artificial intelligence. Supported by €8.25 million in funding from the European Commission, the team behind the EURIDICE (European Inter-disciplinary Research on Intelligent Cargo for Efficient, Safe and Environment-Friendly Logistics) project implemented their system in eight different pilot studies involving transport and logistics operators across Europe. EURIDICE aimed to use ‘cooperative systems’ - systems (or objects) that communicate with each other and their surroundings - to provide the right information in the right place at the right time at low cost, using modern communication networks.
PLANT WIDE SOLUTIONS FROM FRESCO SYSTEMS We are dedicated to the design, manufacture, installation and commissioning of Bulk Materials Handling and Processing Equipment. engineered and manufactured in house. We strive to ensure our customers receive the latest proven technology while aiming to reduce costs, improve operations and increase quality. Visit our website to learn all about our comprehensive range of Fresco Systems designed, manufactured equipment and systems, all supported by international technologies.
BULK HANDLING, STORAGE & LOGISTICS
Intelligent cargo The EURIDICE definition of intelligent cargo is built on six key capabilities. To begin with, the cargo needs to be able to identify itself so an operator at a warehouse can ask a container, pallet or box for its unique ID and determine what is inside. The operator, in turn, should then be able to access information services from the owner, haulier and customs authority to determine the nature, route and clearance status of the goods. The cargo also needs to be aware of its context, enabling it to report, for example, that it is inside a truck on the road or waiting to be picked up in a storage depot. It should also monitor and report its status, which, depending on the type of cargo, could mean checking its temperature, humidity and whether it is still sealed or has been hit or damaged in any way. This information, combined with artificial intelligence technology, enables the cargo to act independently and make autonomous decisions; for example, alerting logistics planners automatically if it deviates from the predefined route, if there is a delay. “There are two parts to the system: the sensors, data storage, software and transmission components on the cargo and a connected fixed infrastructure that handles the overall management of the system,” explains Forcolin, who coordinated the development and deployment of EURIDICE. Precisely what components need to be used and how depends on the intended application. A shipping container, for example, could be fitted with a range of sensors to monitor all of its contents and its whereabouts, whereas a product package could be tagged with an RFID chip that simply tells logistics operators what it contains and where it is going. The back-end infrastructure is similarly flexible. It could be installed by a logistics company to manage all of its operations or by a third-party service provider offering services to a cluster of transport firms, suppliers and product recipients. “There are many different business models we have looked at. Ultimately, how a system like this is implemented and used will be determined by the end users and the market,” Forcolin notes. “The overall concept is to have cargo that is able to communicate important information about itself to the infrastructure and from there to all the stakeholders in the transport chain. Though we talk about intelligent cargo, from a technical viewpoint it’s really cargo intelligence - it’s a distributed intelligence achieved through different means and processes.”
Solving real-world problems The enormous potential of the approach was demonstrated by the EURIDICE team in eight pilot implementations that showed how intelligent cargo and cargo intelligence can solve a variety of real-world problems within different areas of the freight industry.
A shipping container, for example, could be fitted with a range of sensors to monitor all of its contents and its whereabouts, whereas a product package could be tagged with an RFID chip
One pilot focused on using the system to interconnect transport and production processes. Working with Italian eyewear manufacturer Safilo, a project partner, technology was implemented to provide the company with automated real-time information about the whereabouts of eyewear components, from before they leave the supplier’s factory until they check in at the company’s warehouse. Equipped with the real-time information about all the parts - even from different suppliers - Safilo could better schedule assembly and manufacturing processes, avoiding delays, reducing costs and improving production efficiency. With Fiorital, another pilot end user, the logistics requirements were different. The company deals with the distribution of perishable consumer goods such as fresh fish and needs to closely monitor the status, storage conditions and transport history of its products. In the trial, the EURIDICE implementation enabled Fiorital to monitor in real time the temperature and conditions of the product during transport and receive automated alerts in the event of an incident. And what happens after the goods have been safely delivered on time? With Gebrüder Weiss, an Austrian logistics service provider, the EURIDICE system was implemented to optimise the return of empty pallets and boxes and ensure that trucks do not return empty. The trucks automatically advertise that they have space available and the boxes and pallets inform operators that they have been unloaded and are waiting to be returned. “Individually, the pilots represented elements of a real-world supply chain. Together, they covered an almost complete supply chain scenario,” Forcolin said. “There are so many possibilities for this type of intelligent system. Looking ahead, I can imagine having an intelligent system on the cargo communicating with the vehicle, which in turn communicates with the transport infrastructure, the roads, ports, etc - it’s the vision of the ‘Internet of Things’.” With several of the partners continuing to build on the work carried out in EURIDICE, that vision of a more intelligent, more efficient and more environmentally friendly transport sector could come about sooner rather than later. Article courtesy of CORDIS (Community Research and Development Information Service).
Handling Bulk Powders and Granules We are System Designers, Suppliers, and Integrators.
Bulk Bag Filling system. single side operation for Trade Approved weights product consolidation automatic discharge & bag accumulation for semi-automation
Bulk bag discharge directly to a flexible wall feeder, through the wall to a manual bagging process.
Large IBCâ€™s, including cone valve technology mounted above feeders, to meter powder into a mixing vessel.
bag filling palletising pallet dispensers slip sheet applicators conveyors pallet wrappers hooders
Disc in casual contact with seat. Seat pressurised giving a positive seal.
Okura robot, 3 separate product infeeds,
3 separate palletising lines, simultaneously!
Pressure releases allowing valve to open/close quickly
Posi-flate Inflatable seat
Great for process work
for Powders and granules. Very long life, fast acting, May be fitted with white FDA approved seats.
TAWI Vacuum-assisted Lifting: Special models built to suit.
High speed COBRA in action
Single products to total Turn-key Systems
If you need to handle powders, You should consult a professional
The Professionals in Powder Handling and Packaging Systems and WNFood1213a
Head Office VIC - Tel: (03) 9457 8244 Fax: (03) 9457 7695
Palletiser range The flexible, fast and accurate MACH palletiser is suitable for operators aiming for efficiency gains in handling and logistics. It can be custom designed and provided as part of a complete palletising solution to provide a fully automated pallet stacking operation that maximises use of storage and container space.
BULK HANDLING, STORAGE & LOGISTICS
The MACH palletiser can handle bags, crates or boxes in one machine, for weights up to 50 kg per packaged item. Multiple pallet configurations, matching shape and size of material handled, are preprogrammed or easily set by using the touch-screen control panel. The MACH palletiser range includes five models to cater for a large range of speeds, from 13 to 35 bags/min depending on layout. The capacity of the palletiser can be further enhanced with a telescopic conveyor which pre-empts where the next bag, box or crate will be placed, minimising gripper movement. A number of features such as the centralisation unit, the squeeze collar and the pneumatically controlled sliding doors ensure that the bags, crates or boxes are placed accurately and squeezed for optimal fit on the pallet. For boxes and crates, the centralisation unit also gently places them on the layer to prevent product spillage. Wyma Engineering (NZ) Ltd Contact info and more items like this at wf.net.au/Q841
Schenck Process ramps up its investment in bulk handling
Following the acquisition of Redler, the next phase of Schenckâ€™s bulk handling growth strategy is the recent purchase of Mac Process and Clyde Process. Schenck Process Australia Pty Ltd Ground Floor 65 Epping Road North Ryde NSW 2113, Australia T 1300 551 645 Australia wide T + 61 2 9886 6800 email@example.com www.schenckprocess.com.au
Planetary gear units SEW-Eurodrive has added two sizes to its P-Series products: P072 and P082. With these two additions, the P-Series covers rated torques up to 500 kNm. The planetary gear units are suitable for applications where low speeds and high torques are required. The P-Series units are available in 11 sizes with torques ranging from 24 to 500 kNm. The units are designed so the gearmotor is directly mounted in front of the planetary gear unit. This eliminates the need for couplings, intermediate flanges and adapter flanges. Several different designs enable the gear units to be optimised for the user’s application. SEW’s gearmotors offer a variety at the input. This results in precise gear unit ratio grades. The designs can be combined with the planetary gear unit in helical or bevel-helical gear versions. The P-Series is
BULK HANDLING, STORAGE & LOGISTICS
designed to be short and compact. The gears feature high torsional rigidity and can transmit high torques. Users can select the standardised planetary gearmotors from a catalogue. The CAD database DriveCAD makes it possible to quickly create 3D models and 2D dimension sheets using DriveGate, the SEW customer portal. The company’s modular system provides users with a range of options as well. The industrial planetary gearmotors can be used in all applications where heavy objects are moved at low speed including: plate conveyor drives in conveyor systems, silo discharge systems for mixers and agitators, remote drives for wood pulp presses in the pulp and paper industry and bucket wheel drives for mining. SEW-Eurodrive Pty Ltd Contact info and more items like this at wf.net.au/Q839
BULK HANDLING, STORAGE & LOGISTICS
New racking standard brings Australia up to date
he new standard will bring Australia up to date with the latest international knowledge and experience in the design of storage systems and cold-formed steel structures.
Racking is a system, not a product Even though each component of a steel racking system may be a ‘standard’ component, compliance with the standard depends on how these components interconnect to make a system, the level of load it is required to hold, the presence or absence of seismic loads and so on. Essentially, compliance with AS4084-2012 is a rack-by-rack, application-dependent proposition. While the designer is responsible for ensuring the steel racking systems are fit for purpose, meet the user’s requirements and budget, and provide acceptable safety margins to ensure safe, long-term operation, the responsibility of ensuring the systems are properly used and maintained falls squarely on the user.
Key changes to design The major change to the Australian steel storage racking standard is the switch from using a “permissible stress” design philosophy to a “limit states” design approach. This change brings the Australian standard into line with most of the advanced rack design codes in the world, including the European racking standard EN15512:2009 and the Rack Manufacturers Institute Specification from North America. It also brings the standard into line with the relevant crossreferenced companion Australian standards including AS/ NZS4600:2006 Cold Formed Steel Structures and AS41001998 Steel Structures. From a structural design perspective, the limit states approach offers advantages over the permissible stress format. It allows the designer to consider the application of different margins of safety to different types of loads (dead loads, storage loads, live loads, seismic loads) to facilitate design optimisation, while guaranteeing a prescribed level of safety across different combinations of loads. Other changes in the new standard include expanded and improved testing provisions, including statistical evaluation, and the inclusion of advanced methods of structural analysis and finite element analysis. Compared to the 1993 standard, the new standard has the potential to result in more structurally efficient and finely tuned designs. The result is that modern storage racks are generally lighter and cheaper than older racks, while still possessing the required minimum level of structural safety good news for end users. 102
A new standard covering the design of steel storage racking systems was released on 29 February 2012, after the previous standard remained unchanged for 18 years. The new standard is called AS40842012 Steel Storage Racking. Dr Murray Clarke, Structural Design Manager, Dematic, discusses some of the key changes in the standard.
Key changes to operational requirements and end-user responsibilities Users should be aware of a number of important changes: • No changes to storage system configuration are allowed without the approval of the equipment supplier or a structural engineer. • The vertical clearance requirement for pallets stored above heights of 6 m has been increased from 75 to 100 mm. This is aimed at reducing the risk of accidental impact with beams during pallet put-away and retrieval. • The ‘flue space’ between pallets backing on to each other has been increased by 50 mm, reducing the risk of an adjacent pallet being accidentally dislodged when storing or retrieving pallets. • A minimum of two ground anchors must be used per baseplate on racks where forklifts are used. • Minor changes to rack load signage whereby the dimension from ground to first beam level and from first to second beam level must be noted explicitly on signs.
User responsibilities Storage system users should ensure their systems are professionally audited each year. Many storage system users are either unaware or routinely ignore these requirements. Recent rack collapses in New Zealand have shown the importance of regular system audits to identify existing rack damage that could compromise performance during a seismic event or overloading of the structure. Failure to conduct annual audits could expose users to litigation and potential penalties should an incident occur.
What the standard doesn’t cover Like the standard before it, the new steel storage racking standard is only relevant for closed-face racks such as ‘selective’, ‘narrowaisle’ and ‘double deep’ racking. It does not cover open-face racks such as ‘drive-in’ or ‘cantilever’ racking. When designing open-face racks, designers will need to seek guidance from other international standards and codes such as FEM 10.2.07 for drive-in racking and FEM 10.2.09 for cantilever racking. These codes can be used in conjunction with AS/NZS4600-2005 Cold Formed Steel Structures to obtain structurally sound racking designs consistent with best practice. Dr Clarke is a member of the Standards Australia committee for steel storage racking and represents Dematic at the European Racking Federation (ERF) technical meetings. The ERF is a division of the widely known European industry body Fédération Européenne de la Manutention (FEM). Dematic Pty Ltd Contact info and more items like this at wf.net.au/N774
Helical bevel gearboxes for residue-free cleaning NORD Drivesystems has developed a family of two-stage, helical bevel gearboxes designed for
BULK HANDLING, STORAGE & LOGISTICS
Stainless steel industrial linear motor
easy and residue-free cleaning. The company says the washdown gear units have no indentations or dead spaces where dirt or liquids could accumulate. The gearboxes’ smooth surfaces enable
LinMot’s stainless steel
cleaning liquids to be easily washed off in all
industrial linear motor
installation positions. The systems can withstand
has an IP69K protection
frequent, intense, aggressive cleaning with acid
rating and is constructed
and alkaline solutions. Manufactured from diecast aluminium, they resist corrosion better than
of FDA-approved materials. The linear direct drives’ technology together
steel models, NORD claims.
with the smooth, hygienic design makes the motor
The family comprises five sizes with torques
suitable for applications in food, pharmaceutical,
from 90 to 600 Nm, all of which are available as
packaging machines and other industrial applica-
closed or lightweight open versions. NSD tupH,
tions with harsh environments.
a sealed surface conversion system, makes the
The LinMot motor is suitable for replacing pneu-
aluminium drives as robust as their stainless steel
matic systems and belt-driven and ball screw linear
counterparts and many times more durable than
systems in food processing machines, particularly
anti-corrosion paints, says NORD.
in harsh or aseptic environments.
The product range includes hygienic, reliable,
LinMot claims its systems reduce system com-
wet cell versions of geared motors. Modifications
plexity, energy and maintenance costs, increasing
available include extended temperature opera-
machine uptime and machine throughput. LinMot’s
tion, protective finishes and special lubricants.
linear direct drives allow machine designers to
A line of SK 200E frequency inverters for dis-
develop compact solutions, as no servomotor or
tributed installation are available in four sizes,
gear head is required.
from 0.25 to 22 kW. The devices can adapt to
The one IP69K-rated connector is directly mounted
a range of requirements, with options including
on the motor and only one cable between linear
AS-interface and the safety function ‘safe torque
motor and servo controller is required, which may
off’. Two analog inputs, that allow for variable
simplify installation time and commissioning.
speed adjustment and can actively and autonomously control process values, are available.
Motion Technologies Pty Ltd Contact info and more items like this at wf.net.au/R129
NORD Drivesystems (Aust) Pty Ltd Contact info and more items like this at wf.net.au/N809
Control & Power Switches Extensive Range of
Stainless Steel & Insulated Enclosures
www.krausnaimer.com.au Adelaide Sydney Melbourne Brisbane Tel: (02) 9797 7333 Tel: (03) 9720 9777 Tel: (07) 3252 8344 Tel: (08) 8371 1443 Fax: (02) 9797 0092 Fax: (03) 9720 9766 Fax: (07) 3252 1497 Fax: (08) 8371 0901 Linked with an Australian Wide Distribution Network
Vacuum lifting system range Compressed Air Maintenance NZ will exhibit its vacuum lifting systems at Foodtech Packtech 2012. Vacuum lifting is a simple and easy way to remove the weight from repetitive lifting and handling activities common in food handling and production. It is a fast and efficient way of lifting and manoeuvring a wide range of products at various stages in the production process and may assist with health and safety improvements in the workplace.
Global Machinery & Supplies will be exhibiting at Foodtech
production, vacuum lifting is suitable for a range of applications.
Packtech 2012. The company will showcase its Backsaver 900 materials handling and lifting device. The Backsaver 900 is a mobile hydraulic battery-operated lifting device capable of lifting various sizes and types of bins, barrels and boxes to an ergonomically usable height, creating better work standards and greater productivity. The Backsaver can be moved throughout a factory and is completely waterproof. Global Machinery & Supplies
BULK HANDLING, STORAGE & LOGISTICS
Materials handling and lifting device
Used within inwards goods and materials, intermediate production steps and for packing and stacking on completion of Vacuum lifting systems are effective with imperfect surfaces and the porous packaging materials of sacks and bags. With a large range of lifting attachments available, any reasonably solid product or packaging can be lifted within a weight range of 15 to 270 kg. For the food industry, vacuum lifting systems are available in food-grade stainless steels, including cavity-free system components, and are designed to withstand frequent washing. Compressed Air Maintenance NZ www.compressedair.co.nz
Contact info and more items like this at wf.net.au/Q801
BULK HANDLING, STORAGE & LOGISTICS
Chocolate lovers have long been hoping for scientific evidence that chocolate is good for you.
he study, published i n the journal Hypertension, examined the effect of regular cocoa flavanol consumption on cognitive function in people with mild cognitive impairment (MCI). While cocoa flavanols have been shown to help support circulation and cardiovascular health, the study builds on previous research that suggests cocoa flavanols may benefit the brain. “For the first time, regular cocoa flavanol consumption has been shown to positively affect cognitive function in older adults with early memory decline,” said Dr Giovambattista Desideri, author of the study and Director of the Geriatric Division of the University of L’Aquila. “Importantly, the improvements in cognitive function were seen over a relatively short period of time; and, while further research is required to confirm and expand on these findings, this provides encouraging evidence that regular consumption of cocoa flavanols might be effective in improving cognitive function in elderly subjects with mild cognitive impairment. The findings provide promising indications that the development of novel dietary approaches for improving health as we age - especially cognitive health - is a real possibility.”
The study The researchers based the study on the hypothesis that regular consumption of cocoa flavanols would positively affect cognitive performance in people with MCI, which is a condition in which people experience greater memory loss than is expected for their age but is not so severe as to impact on daily activities. Up to 20% of people over 65 have MCI and more than 6% of people aged 70 to 89 develop MCI each year. The study saw 90 healthy older people with MCI consume a cocoa flavanol drink that contained high (HF), intermediate (IF) or low (LF) amounts of cocoa flavanols (approximately 990, 520 or 45 mg of flavanols respectively). The participants consumed the drink once a day for eight weeks but did not change their diets otherwise. The taste and appearance of all the drinks was the same and they were calorically and nutritionally matched, enabling the blinding of product identities throughout the study. The HF and IF drinks were produced by Mars using its Cocoapro process, while the LF drink was made with a highly processed, alkalised cocoa powder.
Benefits for an ageing population “We already understand how important diet is to health and previous research has provided consistent evidence of the benefits of cocoa flavanol consumption for cardiovascular health,” said Catherine Kwik-Uribe, a study author and R&D Director at Mars Botanical. “The results of this latest research build on these earlier findings and provide promising indication that diets that contain cocoa flavanols may offer significant benefits as we age. This is of great interest given the ageing populations in much of the developed world.” Harold Schmitz, Executive Director of the Mars Center for Cocoa Health Science, said the study has improved understanding of cocoa flavanols and may one day lead to dietary recommendations for cocoa flavanol intake. So there’s good and bad news for all the chocoholics out there. On the one hand, chocolate consumption could soon be considered part of a healthy diet. On the other, you might have to wait until your memory starts to falter before the doctor prescribes a family-sized block of chocolate. No doubt self-medication for MCI will go through the roof. 106
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March 2012 total CAB audited circulation (Aust + NZ): 6697 readers (90% personally requested) Printed and bound by Webstar +61 2 9748 0020 Print Post Approved PP247345/00010 ISSN No. 1039-8414 NOTICE: All material published in this magazine is published in good faith and every care is taken to accurately relay information provided to us. Readers are advised by the publishers to ensure that all necessary safety devices and precautions are installed and safe working procedures adopted before the use of any equipment found or purchased through the information we provide. Further, all performance criteria was provided by the representative company concerned and any dispute should be referred to them. Information indicating that products are made in Australia or New Zealand is supplied by the source company. Westwick-Farrow Pty Ltd does not quantify the amount of local content or the accuracy of the statement made by the source.
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Published on Sep 6, 2012
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