Post on 08-Aug-2018
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Technology for Todayrsquos Food Production amp Packaging Market
Cover Story p 10
wwwfoodmanufacturingcom JanuaryFebruary 2013
Vol 26 No 1Vol 26 No 1
utting theCutting the
MustardMustard
From farmhouse basement to
70000-square-foot manufacturing
space Oregonrsquos Beaverton Foods
has been spicing up meals around
the world for nearly 80 years
From farmhouse
basement to 70000-
square-foot manufac-
turing space Oregonrsquos
Beaverton Foods has
been spicing up meals
around the world for
nearly 80 years
10 Cover Story
8 Industry Target Meat Processing
14 Questions and Answers Pest Control Patricia Hottel of McCloud Services discusses the risks
of Hantavirus and what food processors need to know to
keep their facilities safe
16 Tech Niche Pumps amp Valves
18 Exclusive Feature Truth in Labeling amp What It Means for You The legal battle over industry labeling practices has begun
Heres what food processors can do to ensure their brands
are safe from litigation
20 Product Spotlight Feeding
22 Brainstorm Poultry Processing Industry experts weigh in on the more automated future of
poultry processing
30 Industry Insider Poultry Industry Foreign objects detection in poultry processing operations getsa hi-tech upgrade
CONTENTS
7 Whats the Buzz mdash Insiders reflect on the latest news
26 Product Review
mdash Latest product releases
28 Food Safety Update mdash Meat poultry and seafood
8222019 r Fm 20130101
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reg omegacom
reg
copy COPYRIGHT 2013 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
Sanitary RTD Sensors with Integral Cables
for Use in CIP Clean-In-Place Applications
PRS-3-100-CB SeriesStarts at
$132
reg
74-05
bull 1 frasl 4 Diameter Probe Design for Standard Dutyor 3 frasl 8 to 3 frasl 16 Stepped Probe Design forHeavy Duty Applications
bull Probe Lengths of 3 4 5 and 6 AvailableFrom Stock Other Lengths Also Available
bull Process Connection is a 1frac12-16 AMP Tri-Griptrade(Tri-Clampreg Compatible) Standard Other Sizesand Styles Available Flanges Conform toASME BPE-2007 Standard to Assure Trouble
Free InterchangeabilityVisit omegacomprs-3-100-cb
Food Processing Equipment
Heavy Duty Stainless Steel Penetration
Probe with ldquoTrdquo Style Handle
Industrial RTD (PT100) Probes with
Miniature Aluminum Protection Head
PR-14Starts at
$99
Visitomegacompr-14
88312$94
Visit omegacom88312 Visitomegacomprs-3-100
PRS-NB9WSeries
Starts at$105
Sanitary RTD Sensors with
Polypropylene or Stainless SteelConnection Heads
8222019 r Fm 20130101
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8222019 r Fm 20130101
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FOOD MANUFACTURINGreg (ISSN 1056-5078 USPS 006-428) (GST Reg 844559765) is a registered trademark of and published 9 times a year (monthly except bi-monthly inJanuaryFebruary JulyAugust and NovemberDecember) by Advantage Business Media 100 Enterprise Drive Suite 600 Box 912 Rockaway NJ 07866-0912 All rights reserved underthe USA International and Pan-American Copyright Conventions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any meansmechanical photocopying electronic recording or otherwise without the prior written permission of the publisher Opinions expressed in articles are those of the authors and do not necessarilyreflect those of Advantage Business Media or the Editorial Board
Periodicals Mail postage paid at Rockaway NJ 07866 and at additional mailing offices POSTMASTER Send return address changes to FOOD MANUFACTURING PO Box 3574Northbrook IL 60065-3574 Publication Mail Agreement No 41336030 Return undeliverable Canadian addresses to ImexPitney Bowes PO Box 1632 Windsor Ontario N9A 7C9
Subscription InquiriesChange of Address contact Omeda Customer Service PO Box 3574 Northbrook IL 60065-3574 847-559-7560 Fax 847-291-4816 email abfmomedacom Change of address notices should include old as well as new address If possible attach address label from recent issue Allow 8 to 10 weeks for address change to become effective
Subscriptions are free to qualified individuals Subscription rates per year are $54 for USA $63 for Canada $108 for Mexico amp foreign air delivery single copy $7 for USA $14 for otherlocations prepaid in USA funds drawn on a USA branch bank
Notice to Subscribers We permit reputable companies to send announcements of their products or services to our subscribers Requests for this privilege are examined with great care to besure they will be of interest to our readers If you prefer not to receive such mailings and want your name in our files only for receiving the magazine please write us enclosing your currentaddress mailing label Please address your request to Customer Service PO Box 3574 Northbrook IL 60065-3574Printed in USA Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained here-in regardless of whether such errors result from negligence accident or any other cause whatsoever The editors make every reasonable effort to verify the information published but AdvantageBusiness Media assumes no responsibility for the validity of any manufacturers claims or statements in items reported Copyright copy2013 Advantage Business Media All rights reserved
The Advertising Index is provided as a reader service Although every attempt has been made to make this index as complete as possible the accuracy of all listings cannot be guaranteed
4CONTENTS wwwfoodmanufacturingcom
AD INDEX
JanuaryFebruary 2013
JanuaryFebruary 2013
American Wholesale 29
Baldor Electric Company 31
Bel-Ray Company 3
Bird-X Inc27
Bunting Magnetics Company 19
Clarion White Oils 15
Dow AgroSciences 13
Dynamic Conveyor Corporation 16
Gorman Rupp Company 11
GreCon Inc 21
Hinds-Bock Corporation 5
Kamflex Corp17
Kelly Container Inc 29
Leem Filtration Products Inc 29
Lubriplate Lubricants Company 9
Martin Sprocket amp Gear Inc 32
Master Bond Inc 29
Material Transfer amp Storage Inc 7
Omega Engineering Inc 2
Powder-Solutions Inc29
Process ExpoFPSA 23
Ralphs-Pugh Co Inc 12
Ross Charles amp Son Company 29
schenckAccuRate 24
UBM Canon (SouthPack) 26
UBM Canon (WestPack) 25
Wabash Power Equipment Co 29
utting the MustardCutting the MustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods has been spicing up meals around the world for nearly 80 years
10 Cover Story
8 Industry Target Meat Processing
14 Questions and Answers Pest Control Patricia Hottel of McCloud Services discusses the risks of Hantavirus and
what food processors need to know to keep their facilities safe
16 Tech Niche Pumps amp Valves
18 Exclusive Feature Truth in Labeling amp What It Means for You The legal battle over industry labeling practices has begun Heres what food
processors can do to ensure their brands are safe from litigation
20 Product Spotlight Feeding
22 Brainstorm Poultry Processing Industry experts weigh in on the more automated future of poultry processing
30 Industry Insider Poultry Industry Foreign objects detection in poultry processing operations gets a hi-tech upgrade
7 Whats the Buzz mdash Insiders reflect on the latest news
26 Product Review mdash Latest product releases
28 Food Safety Update
mdash Meat poultry and seafood
8222019 r Fm 20130101
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8222019 r Fm 20130101
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6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 732
7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
WR D IUHHAgraveRZLQJ VWDWH
0RVW FRPSDFW IRRWSULQW LQ WKH LQGXVWU
([FOXVLYH SLYRWLQJ FRQGLWLRQLQJ DUPV RXWSHUIRUP
RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
HTXLSPHQW LQYHVWPHQW
6WDQG DORQH XQLW RU LQWHJUDWHG ZLWK RXU EXON EDJ
GLVFKDUJLQJ VVWHP
ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 832
JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 932
Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1132
Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1232
12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
8222019 r Fm 20130101
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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reg omegacom
reg
copy COPYRIGHT 2013 OMEGA ENGINEERING INC ALL RIGHTS RESERVED
Sanitary RTD Sensors with Integral Cables
for Use in CIP Clean-In-Place Applications
PRS-3-100-CB SeriesStarts at
$132
reg
74-05
bull 1 frasl 4 Diameter Probe Design for Standard Dutyor 3 frasl 8 to 3 frasl 16 Stepped Probe Design forHeavy Duty Applications
bull Probe Lengths of 3 4 5 and 6 AvailableFrom Stock Other Lengths Also Available
bull Process Connection is a 1frac12-16 AMP Tri-Griptrade(Tri-Clampreg Compatible) Standard Other Sizesand Styles Available Flanges Conform toASME BPE-2007 Standard to Assure Trouble
Free InterchangeabilityVisit omegacomprs-3-100-cb
Food Processing Equipment
Heavy Duty Stainless Steel Penetration
Probe with ldquoTrdquo Style Handle
Industrial RTD (PT100) Probes with
Miniature Aluminum Protection Head
PR-14Starts at
$99
Visitomegacompr-14
88312$94
Visit omegacom88312 Visitomegacomprs-3-100
PRS-NB9WSeries
Starts at$105
Sanitary RTD Sensors with
Polypropylene or Stainless SteelConnection Heads
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 332
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 432
FOOD MANUFACTURINGreg (ISSN 1056-5078 USPS 006-428) (GST Reg 844559765) is a registered trademark of and published 9 times a year (monthly except bi-monthly inJanuaryFebruary JulyAugust and NovemberDecember) by Advantage Business Media 100 Enterprise Drive Suite 600 Box 912 Rockaway NJ 07866-0912 All rights reserved underthe USA International and Pan-American Copyright Conventions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any meansmechanical photocopying electronic recording or otherwise without the prior written permission of the publisher Opinions expressed in articles are those of the authors and do not necessarilyreflect those of Advantage Business Media or the Editorial Board
Periodicals Mail postage paid at Rockaway NJ 07866 and at additional mailing offices POSTMASTER Send return address changes to FOOD MANUFACTURING PO Box 3574Northbrook IL 60065-3574 Publication Mail Agreement No 41336030 Return undeliverable Canadian addresses to ImexPitney Bowes PO Box 1632 Windsor Ontario N9A 7C9
Subscription InquiriesChange of Address contact Omeda Customer Service PO Box 3574 Northbrook IL 60065-3574 847-559-7560 Fax 847-291-4816 email abfmomedacom Change of address notices should include old as well as new address If possible attach address label from recent issue Allow 8 to 10 weeks for address change to become effective
Subscriptions are free to qualified individuals Subscription rates per year are $54 for USA $63 for Canada $108 for Mexico amp foreign air delivery single copy $7 for USA $14 for otherlocations prepaid in USA funds drawn on a USA branch bank
Notice to Subscribers We permit reputable companies to send announcements of their products or services to our subscribers Requests for this privilege are examined with great care to besure they will be of interest to our readers If you prefer not to receive such mailings and want your name in our files only for receiving the magazine please write us enclosing your currentaddress mailing label Please address your request to Customer Service PO Box 3574 Northbrook IL 60065-3574Printed in USA Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained here-in regardless of whether such errors result from negligence accident or any other cause whatsoever The editors make every reasonable effort to verify the information published but AdvantageBusiness Media assumes no responsibility for the validity of any manufacturers claims or statements in items reported Copyright copy2013 Advantage Business Media All rights reserved
The Advertising Index is provided as a reader service Although every attempt has been made to make this index as complete as possible the accuracy of all listings cannot be guaranteed
4CONTENTS wwwfoodmanufacturingcom
AD INDEX
JanuaryFebruary 2013
JanuaryFebruary 2013
American Wholesale 29
Baldor Electric Company 31
Bel-Ray Company 3
Bird-X Inc27
Bunting Magnetics Company 19
Clarion White Oils 15
Dow AgroSciences 13
Dynamic Conveyor Corporation 16
Gorman Rupp Company 11
GreCon Inc 21
Hinds-Bock Corporation 5
Kamflex Corp17
Kelly Container Inc 29
Leem Filtration Products Inc 29
Lubriplate Lubricants Company 9
Martin Sprocket amp Gear Inc 32
Master Bond Inc 29
Material Transfer amp Storage Inc 7
Omega Engineering Inc 2
Powder-Solutions Inc29
Process ExpoFPSA 23
Ralphs-Pugh Co Inc 12
Ross Charles amp Son Company 29
schenckAccuRate 24
UBM Canon (SouthPack) 26
UBM Canon (WestPack) 25
Wabash Power Equipment Co 29
utting the MustardCutting the MustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods has been spicing up meals around the world for nearly 80 years
10 Cover Story
8 Industry Target Meat Processing
14 Questions and Answers Pest Control Patricia Hottel of McCloud Services discusses the risks of Hantavirus and
what food processors need to know to keep their facilities safe
16 Tech Niche Pumps amp Valves
18 Exclusive Feature Truth in Labeling amp What It Means for You The legal battle over industry labeling practices has begun Heres what food
processors can do to ensure their brands are safe from litigation
20 Product Spotlight Feeding
22 Brainstorm Poultry Processing Industry experts weigh in on the more automated future of poultry processing
30 Industry Insider Poultry Industry Foreign objects detection in poultry processing operations gets a hi-tech upgrade
7 Whats the Buzz mdash Insiders reflect on the latest news
26 Product Review mdash Latest product releases
28 Food Safety Update
mdash Meat poultry and seafood
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 532
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 632
6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 732
7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
WR D IUHHAgraveRZLQJ VWDWH
0RVW FRPSDFW IRRWSULQW LQ WKH LQGXVWU
([FOXVLYH SLYRWLQJ FRQGLWLRQLQJ DUPV RXWSHUIRUP
RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
HTXLSPHQW LQYHVWPHQW
6WDQG DORQH XQLW RU LQWHJUDWHG ZLWK RXU EXON EDJ
GLVFKDUJLQJ VVWHP
ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 832
JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 932
Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1132
Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1332
regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
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bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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httpslidepdfcomreaderfullr-fm-20130101 432
FOOD MANUFACTURINGreg (ISSN 1056-5078 USPS 006-428) (GST Reg 844559765) is a registered trademark of and published 9 times a year (monthly except bi-monthly inJanuaryFebruary JulyAugust and NovemberDecember) by Advantage Business Media 100 Enterprise Drive Suite 600 Box 912 Rockaway NJ 07866-0912 All rights reserved underthe USA International and Pan-American Copyright Conventions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any meansmechanical photocopying electronic recording or otherwise without the prior written permission of the publisher Opinions expressed in articles are those of the authors and do not necessarilyreflect those of Advantage Business Media or the Editorial Board
Periodicals Mail postage paid at Rockaway NJ 07866 and at additional mailing offices POSTMASTER Send return address changes to FOOD MANUFACTURING PO Box 3574Northbrook IL 60065-3574 Publication Mail Agreement No 41336030 Return undeliverable Canadian addresses to ImexPitney Bowes PO Box 1632 Windsor Ontario N9A 7C9
Subscription InquiriesChange of Address contact Omeda Customer Service PO Box 3574 Northbrook IL 60065-3574 847-559-7560 Fax 847-291-4816 email abfmomedacom Change of address notices should include old as well as new address If possible attach address label from recent issue Allow 8 to 10 weeks for address change to become effective
Subscriptions are free to qualified individuals Subscription rates per year are $54 for USA $63 for Canada $108 for Mexico amp foreign air delivery single copy $7 for USA $14 for otherlocations prepaid in USA funds drawn on a USA branch bank
Notice to Subscribers We permit reputable companies to send announcements of their products or services to our subscribers Requests for this privilege are examined with great care to besure they will be of interest to our readers If you prefer not to receive such mailings and want your name in our files only for receiving the magazine please write us enclosing your currentaddress mailing label Please address your request to Customer Service PO Box 3574 Northbrook IL 60065-3574Printed in USA Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained here-in regardless of whether such errors result from negligence accident or any other cause whatsoever The editors make every reasonable effort to verify the information published but AdvantageBusiness Media assumes no responsibility for the validity of any manufacturers claims or statements in items reported Copyright copy2013 Advantage Business Media All rights reserved
The Advertising Index is provided as a reader service Although every attempt has been made to make this index as complete as possible the accuracy of all listings cannot be guaranteed
4CONTENTS wwwfoodmanufacturingcom
AD INDEX
JanuaryFebruary 2013
JanuaryFebruary 2013
American Wholesale 29
Baldor Electric Company 31
Bel-Ray Company 3
Bird-X Inc27
Bunting Magnetics Company 19
Clarion White Oils 15
Dow AgroSciences 13
Dynamic Conveyor Corporation 16
Gorman Rupp Company 11
GreCon Inc 21
Hinds-Bock Corporation 5
Kamflex Corp17
Kelly Container Inc 29
Leem Filtration Products Inc 29
Lubriplate Lubricants Company 9
Martin Sprocket amp Gear Inc 32
Master Bond Inc 29
Material Transfer amp Storage Inc 7
Omega Engineering Inc 2
Powder-Solutions Inc29
Process ExpoFPSA 23
Ralphs-Pugh Co Inc 12
Ross Charles amp Son Company 29
schenckAccuRate 24
UBM Canon (SouthPack) 26
UBM Canon (WestPack) 25
Wabash Power Equipment Co 29
utting the MustardCutting the MustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods has been spicing up meals around the world for nearly 80 years
10 Cover Story
8 Industry Target Meat Processing
14 Questions and Answers Pest Control Patricia Hottel of McCloud Services discusses the risks of Hantavirus and
what food processors need to know to keep their facilities safe
16 Tech Niche Pumps amp Valves
18 Exclusive Feature Truth in Labeling amp What It Means for You The legal battle over industry labeling practices has begun Heres what food
processors can do to ensure their brands are safe from litigation
20 Product Spotlight Feeding
22 Brainstorm Poultry Processing Industry experts weigh in on the more automated future of poultry processing
30 Industry Insider Poultry Industry Foreign objects detection in poultry processing operations gets a hi-tech upgrade
7 Whats the Buzz mdash Insiders reflect on the latest news
26 Product Review mdash Latest product releases
28 Food Safety Update
mdash Meat poultry and seafood
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6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
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7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
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([FOXVLYH SLYRWLQJ FRQGLWLRQLQJ DUPV RXWSHUIRUP
RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
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GLVFKDUJLQJ VVWHP
ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
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JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1432
14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
8222019 r Fm 20130101
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1732
The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2432
24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
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WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
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HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
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Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
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Filter Leaves for ALL Pressure Leaf Filters
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+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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httpslidepdfcomreaderfullr-fm-20130101 432
FOOD MANUFACTURINGreg (ISSN 1056-5078 USPS 006-428) (GST Reg 844559765) is a registered trademark of and published 9 times a year (monthly except bi-monthly inJanuaryFebruary JulyAugust and NovemberDecember) by Advantage Business Media 100 Enterprise Drive Suite 600 Box 912 Rockaway NJ 07866-0912 All rights reserved underthe USA International and Pan-American Copyright Conventions No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any meansmechanical photocopying electronic recording or otherwise without the prior written permission of the publisher Opinions expressed in articles are those of the authors and do not necessarilyreflect those of Advantage Business Media or the Editorial Board
Periodicals Mail postage paid at Rockaway NJ 07866 and at additional mailing offices POSTMASTER Send return address changes to FOOD MANUFACTURING PO Box 3574Northbrook IL 60065-3574 Publication Mail Agreement No 41336030 Return undeliverable Canadian addresses to ImexPitney Bowes PO Box 1632 Windsor Ontario N9A 7C9
Subscription InquiriesChange of Address contact Omeda Customer Service PO Box 3574 Northbrook IL 60065-3574 847-559-7560 Fax 847-291-4816 email abfmomedacom Change of address notices should include old as well as new address If possible attach address label from recent issue Allow 8 to 10 weeks for address change to become effective
Subscriptions are free to qualified individuals Subscription rates per year are $54 for USA $63 for Canada $108 for Mexico amp foreign air delivery single copy $7 for USA $14 for otherlocations prepaid in USA funds drawn on a USA branch bank
Notice to Subscribers We permit reputable companies to send announcements of their products or services to our subscribers Requests for this privilege are examined with great care to besure they will be of interest to our readers If you prefer not to receive such mailings and want your name in our files only for receiving the magazine please write us enclosing your currentaddress mailing label Please address your request to Customer Service PO Box 3574 Northbrook IL 60065-3574Printed in USA Advantage Business Media does not assume and hereby disclaims any liability to any person for any loss or damage caused by errors or omissions in the material contained here-in regardless of whether such errors result from negligence accident or any other cause whatsoever The editors make every reasonable effort to verify the information published but AdvantageBusiness Media assumes no responsibility for the validity of any manufacturers claims or statements in items reported Copyright copy2013 Advantage Business Media All rights reserved
The Advertising Index is provided as a reader service Although every attempt has been made to make this index as complete as possible the accuracy of all listings cannot be guaranteed
4CONTENTS wwwfoodmanufacturingcom
AD INDEX
JanuaryFebruary 2013
JanuaryFebruary 2013
American Wholesale 29
Baldor Electric Company 31
Bel-Ray Company 3
Bird-X Inc27
Bunting Magnetics Company 19
Clarion White Oils 15
Dow AgroSciences 13
Dynamic Conveyor Corporation 16
Gorman Rupp Company 11
GreCon Inc 21
Hinds-Bock Corporation 5
Kamflex Corp17
Kelly Container Inc 29
Leem Filtration Products Inc 29
Lubriplate Lubricants Company 9
Martin Sprocket amp Gear Inc 32
Master Bond Inc 29
Material Transfer amp Storage Inc 7
Omega Engineering Inc 2
Powder-Solutions Inc29
Process ExpoFPSA 23
Ralphs-Pugh Co Inc 12
Ross Charles amp Son Company 29
schenckAccuRate 24
UBM Canon (SouthPack) 26
UBM Canon (WestPack) 25
Wabash Power Equipment Co 29
utting the MustardCutting the MustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods has been spicing up meals around the world for nearly 80 years
10 Cover Story
8 Industry Target Meat Processing
14 Questions and Answers Pest Control Patricia Hottel of McCloud Services discusses the risks of Hantavirus and
what food processors need to know to keep their facilities safe
16 Tech Niche Pumps amp Valves
18 Exclusive Feature Truth in Labeling amp What It Means for You The legal battle over industry labeling practices has begun Heres what food
processors can do to ensure their brands are safe from litigation
20 Product Spotlight Feeding
22 Brainstorm Poultry Processing Industry experts weigh in on the more automated future of poultry processing
30 Industry Insider Poultry Industry Foreign objects detection in poultry processing operations gets a hi-tech upgrade
7 Whats the Buzz mdash Insiders reflect on the latest news
26 Product Review mdash Latest product releases
28 Food Safety Update
mdash Meat poultry and seafood
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6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 732
7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
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RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
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ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 832
JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 932
Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
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Backed By Plant Surveys
Tech Support
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Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1332
regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
8222019 r Fm 20130101
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1732
The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
8222019 r Fm 20130101
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
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8222019 r Fm 20130101
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6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
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7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
WR D IUHHAgraveRZLQJ VWDWH
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([FOXVLYH SLYRWLQJ FRQGLWLRQLQJ DUPV RXWSHUIRUP
RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
HTXLSPHQW LQYHVWPHQW
6WDQG DORQH XQLW RU LQWHJUDWHG ZLWK RXU EXON EDJ
GLVFKDUJLQJ VVWHP
ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
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JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
8222019 r Fm 20130101
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
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WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
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httpslidepdfcomreaderfullr-fm-20130101 632
6wwwfoodmanufacturingcom
Volume 26 No 1973-920-7000 bull Fax 973-920-7531
NPR reported in January that the FDArsquos own figures indicate that
42 percent of foodborne illness cases in 2010 were related toproduce contamination Since then many high-profile produce
outbreaks suggest the figure in more recent years could be even higher
This week the FDA proposed new rules that would overhaul food safety
for produce processors and packers in addition to regulations that would
impact the entire food manufacturing industry
I spoke with Angela Spivey a partner with the law firm McGuireWoods and
a member of the firmrsquos Food and Beverage industry team Spivey says therersquos
a good chance that large food processors will already be in compliance with the new rules being proposed
but that small and medium-sized processors could find the new requirements more challenging
In addition to rules governing fruit and vegetable growersrsquo hygiene practices mdash hand-washing the useof sanitary wash water etc mdash the FDA has proposed rules that would implement stricter planning require-
ments across all food industry segments Spivey says ldquoHaving a simple HACCP plan is not enoughrdquo as the
proposed Preventative Control Planning requirement mandates not only HACCP planning but the imple-
mentation of Good Manufacturing Practices (GMPs) written Standard Operating Procedures (SOPs) specific
hygiene programs food defense plans and supplier verification protocol among other practices
The primary burden created by these requirements will be for many manufacturers merely a
concern over adequate documentation Large processors likely have GMPs HACCP plans and the like
in place and functioning The trick could simply be ensuring that these plans are sufficiently docu-
mented according to regulatory standardsBut Spivey warns that industry-leading processors could face other concerns Though large pro-
cessors are likely up-to-speed with regard to food safety protocol these processors could see the
new documentation requirements lead to breaches of trade secret Any audit documents turned over
to food safety regulators will be open to Freedom of Information Act (FOIA) requests and the informa-
tion contained within them could become a matter of public record For this reason Spivey says she
recommends ldquothat policies and procedures likely subject to FOIA requests not contain proprietary
information such as formulations or specific processesrdquo
For the most part food processors support these new regulations in part because they level the
playing field In the responses to the reader survey reported in this issuersquos Food Safety Update (p
28) several readers wrote that they support mandatory HACCP planning and the constant presence
of USDA inspectors in meat and poultry facilities primarily because they do not believe risk-taking
processors should get a leg up by sidestepping food safety protocol In the wake of the new rulesrsquo
proposal the Grocery Manufacturers Association (GMA) released a statement that read in part
Consumers expect industry and government to work together to provide Americans and con-
sumers around the world with the safest possible products FSMA and its implementation effort
can serve as a role model for what can be achieved when the private and public sectors work
together to achieve a common goal
The GMA and other industry actors will no doubt be actively involved in the rulemaking process
ahead The public mdash including industry mdash will have 120 days to read and comment on the proposedrules At that point the FDA will take about a year to review public comments and write the final
regulations After that point processors will have one to two years to become fully compliant
But Spiveyrsquos advice to her clients regarding updating and redacting proprietary information from
documentation is sound Despite the seemingly expansive timetable for compliance she says ldquoDo it
now Donrsquot waitrdquo
JanuaryFebruary 2013
EDITORS NOTE
FDArsquos New Rules What
We Know In January the FDA released two proposals for new rules under 2011rsquos FoodSafety Modernization Act (FSMA) The rules are being touted as a significant over-haul of the nationrsquos food safety system and are largely supported by industry
Krystal Gabert Editor
krystalgabertadvantagemediacom
Vice President of Sales
TOM LYNCH bull 973-920-7782 Fax 973-607-5492
tomlynchadvantagemediacom
Editorial Director
JEFF REINKE bull 973-920-7784 Fax 973-607-5605
jeffreinkeadvantagemediacom
Editor
KRYSTAL GABERT bull 973-920-7020 Fax 973-607-5459
krystalgabertadvantagemediacom
Associate Editor
LINDSEY JAHN bull 973-920-7795 Fax 973-607-5503lindseyjahnadvantagemediacom
Production Manager
SUSAN FRANK bull 973-920-7158 Fax 973-920-7541
susanfrankadvantagemediacom
Contracts Coordinator
KAREN MULRENAN bull 973-920-7141karenmulrenanadvantagemediacom
Art Director
RYAN CONGDON bull 973-920-7764
ryancongdonadvantagemediacom
Web Production Specialist
MARCELLUS SCHOOLER bull 973-920-7025
marcellusschooleradvantagemediacom
Customer Service Supervisor
ALYSSA ADAIR bull 973-920-7789
alyssaadairadvantagemediacom
Circulation Manager
GAIL KIRBERGER bull 973-920-7482 Fax 973-267-7542gailkirbergeradvantagemediacom
List RentalsAccount Executive
STATLISTICS
Jen Felling - PostalTelemarketing bull 203-778-8700 ext138
Turk Hassan - Email Lists bull 203-778-8700 ext 144
Reprints
The YGS Group
JESSICA STREMMEL bull 717-505-9701 ext105
Reprint Division
3650 West Market Street bull York PA 17404
jessicastremmeltheygsgroupcom
Advisory Board
ANDY JUAREZ Engineering Manager Tree Top Inc
MIKE SCHMID Managing Partner Wolfgang Candy Co
STEVE VAN TASSEL CEO Weetabix North America
CRAIG SHIESLEY General Manager of Silk White Wave Foods
ADVERTISING REPRESENTATIVES
National Sales Manager
KEVIN WARD
100 Enterprise Drive Suite 600 Box 912
Rockaway NJ 07866-0912
973-920-7194 Fax 973-920-7542
kevinwardadvantagemediacom National Sales Manager
JAMES PEASE
199 East Badger Road Suite 101 bull Madison WI 53713
973-920-7774 Fax 973-607-5460
jamespeaseadvantagemediacom
CORPORATE OFFICES
100 Enterprise Drive Suite 600 bull Rockaway NJ 07866-0912
973-920-7000 Fax 973-920-7531Chief Executive Officer
RICH REIFF
President
GEORGE FOX
Vice President FinanceTreasurer
THERESA FREEBURG
Vice President Human Resources
SUSANNE FOULDS
8222019 r Fm 20130101
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7
Patented design delivers superior performance
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MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
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JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
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LinkedIn go to wwwlubriplatecom
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8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1332
regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1632
16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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7
Patented design delivers superior performance
6DIHO DQG HIiquestFLHQWO UHWXUQV RXU KDUGHQHG PDWHULDOV
WR D IUHHAgraveRZLQJ VWDWH
0RVW FRPSDFW IRRWSULQW LQ WKH LQGXVWU
([FOXVLYH SLYRWLQJ FRQGLWLRQLQJ DUPV RXWSHUIRUP
RXWGDWHG YHUWLFDO FRPSUHVVLRQ SODWHV )DFWRU WHVWLQJ RI RXU VSHFLiquestF PDWHULDOV SULRU WR
HTXLSPHQW LQYHVWPHQW
6WDQG DORQH XQLW RU LQWHJUDWHG ZLWK RXU EXON EDJ
GLVFKDUJLQJ VVWHP
ampXVWRP HQJLQHHUHG IRU RXU DSSOLFDWLRQ UHTXLUHPHQWV
MATERIAL MASTER tradeBULK BAG MATERIAL CONDITIONER
hat s WhatsThe The
As culinary trends continue to evolve one constantis a desire for even more choices Consumers havevarying and multiple needs for their food and beveragechoices Some consumers find a healthy balance withless complex ingredient lines is important while otherswant bold or ethnically-inspired taste experiences
Young people are especially adventurous and foodsavvy They donrsquot want to miss the latest food news
whether itrsquos trendy flavors pop-up restaurants or thenewest food truck in townmdash Robin Ross Associate Director of Culinary Kraft
We are finding that a lot of businesses affectedby the new registration renewal requirement areunaware of their obligations The confusion arises
because there are so many laws that overlap Thedanger is a company will inadvertently fail to renewunder the FSMA and face a denial of entry of itsgoods into the US That could be catastrophic forbusinesses across the supply chainmdash Ann Marie Gaitan Managing Director FDA Solu-tions Group
We are pleased to reach an agreement[with UFCW Local 1995] that is good for
our associates and allows us to be com-petitive in the regionmdash John Hackett President of Mid-SouthDivision Kroger
We see great potential with the BluePrintbrand as consumers increasingly seekthe benefits of the nutrients enzymes andfresh taste of raw juice The acquisitionof BluePrint a market leading brand thatoffers innovative products and programsprovides Hain Celestial with the opportunityfor expansion into the premium raw juice
categorymdash Irwin D Simon Founder President andChief Executive Officer Hain Celestial
The [Environmental Assessment]states that the FDA has found that[AquaBounty genetically engineered]salmon is safe to eat However weare deeply concerned that the po-tential of these fish to cause allergicreactions has not been adequatelyresearched FDA has allowed this
fish to move forward based on testsof allergenicity of only six engineered
fishmdashtests that actually did show anincrease in allergy-causing potentialFurther there have been no safetytesting of fish grown in Panamawhere AquaBounty intends to raisethe salmon The health and safetyof fish can be affected by growingconditionsmdash Michael Hansen PhD Senior Sci-entist Consumers Union
8222019 r Fm 20130101
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JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1332
regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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JanuaryFebruary 2013
8 wwwfoodmanufacturingcomINDUSTRY TARGET MEAT PROCESSING
Patty PaperCompany supplies
FDA- and USDA-ap-proved patty paper
to the meat poultry
seafood dairy bakery
and deli industries
Company uses a pat-
ented FDA-approved
paper packaging
system No contami-
nation by unapprovedstrings or cardboard
is possible because
of the way the paper is packaged
Hollymatic wwwhollymaticcom
Food Processing BladesMeatMiser Generation II Food Processing Blades are now avail-
able in sizes ranging from 395rdquo (100 mm) to 12rdquo (3049 mm) Theblades reduce waste and improve per piece yield for meat and
poultry processors They are engineered for maximum performance
and minimal waste with deeper ldquoarcuatesrdquo or ldquoswooping teethrdquo
than earlier blades for a cleaner and more aggressive cutting action
The beveled edges replace more traditional scallop-edge blades that
can rip or tear meat and are slower through the cut These blades
reduce waste and rework by poor cuts cutting rework costs and
increasing output and finished product net weight
Hyde Tools Inc wwwhydebladescom
Washdown-Safe
ThermalTransferCodingThe IP DataFlex Plus
thermal transfer
overprinter features
an IP65-rated printer
body installed on the web and an IP55-rated
stainless steel controller installed on eitherside of the packaging machine Food-grade
stainless steel brackets support the printer
body Other features include a gold anodized
IP cassette and sealed printer and controller
connectors The unit provides a high quality
print at 300 dpi and uptime by offering the
following benefits
Zero ribbon breaks via patented and best-
in-class clutchless bi-directional ribbon
drive mechanismLow cost of ownership by using various rib-
bon saving features
Fast and easy-to-use large color touch
screen that is intuitive incorporating easy-
to-learn icon-based controls
Error-free coding supported by CLARiSOFT
software that limits what operators can do
and provides easy instructions to complete
and upload messages Ability to operate printer using the host
machine interface and easy-to-use integra-
tion protocol to automate operation
Videojet Technologies Inc
wwwvideojetcom
bull
bull
bull
bull
bull
X-Ray Inspection SystemThe Pack 400 HC x-ray inspection system can help food
manufacturers in the packaged meat poultry and dairy
industries increase operational and energy efficiencies of
their production lines while meeting the strictest hygiene
and food safety requirements The machine can simulta-
neously inspect for foreign bodies including metal glass
stone and bone as well as checking products for cor-
rect weight size and shape The systemrsquos design reduces the time required to perform cleaningprocedures with interlocked hinged louvers that can easily be operated and lifted reducing the
time dedicated to reassembly after cleaning The system also includes a conveyor belt designed
for easy removal reducing downtime during production line changeovers or after product spill-
ages
Eagle Product Inspection wwweaglepicom
Enhancements to VibratoryConveyorsThe Iso-Floreg family of stainless steel vibratory conveyors fea-
tures a new patent-pending drive arrangement frame design
and screen clamp These features maximize machine efficiencyenhance sanitation and improve ergonomics on processing
and packaging lines These conveyors use independent frame-
mounted drives and spring arm assemblies that distribute energy
equally to all parts of the conveyor bed in a controlled natural-
frequency operation Company fabricates the conveyor bed from one sheet of stainless steel to
eliminate welds within the product zone where bacteria can build up The systems are ideal for
foods including meat poultry seafood fruits vegetables and more
Key Technology Inc wwwkeynet
Crust Freezers for Deli-Log SlicesSpinning at up to 2000 RPMs high-speed deli-log slicers
can be optimized for high repeatability with crust-freezing
know-how and high-efficiency cryogenic freezers Crust-
freezing deli logs prior to slicing can increase productivity
Companyrsquos Food Team works with beef poultry and pork
processors to define the ideal crust-freezing temperature
and crust-freeze depth to match the slicing operation A
hygienic in-line tunnel freezer rapidly chills with either
high-efficiency liquid nitrogen or liquid CO2 Hygienic design provides easy access for cleaning The
freezer is also modular so tunnel extensions can be easily added to meet rising demand
Linde wwwlindeuscom
8222019 r Fm 20130101
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
To visit us on Facebook Twitter or
LinkedIn go to wwwlubriplatecom
and click on the desired icon
ISO 21469 Compliant
ISO 9001
Registered
Backed By Plant Surveys
Tech Support
Lubrication Software
Machinery Tags
Training
Follow-Up Oil Analysis
ESP
Lubriplate reg
Extra Services Package
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1032
JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
8222019 r Fm 20130101
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1332
regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
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444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
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bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
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MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
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Adhesive Sealant CoatingFor Food Applications
Watch our video
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LEEM Filtration A Division of North American Filtration Inc
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Filter Leaves for ALL Pressure Leaf Filters
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and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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Advanced SyntheticLubricants
For the Food Processing Industry
Lubriplate reg H-1 Lubricants
100 Synthetic NSF H-1 Registered Lubricants
Engineered from the ground up to provide unsurpassed performance
in food processing plants These high performance 100 synthetic
lubricants provide extended lube intervals multiple application
capability lubricant inventory consolidation and improved
performance All while maintaining strict H-1 safety requirements
SFGO Ultra Series - Multi-Purpose Fluids
bull 100 Synthetic (PAO)-Based Multi-Purpose Fluidsbull Extremely Versatile Recommended for Air Compressors
Hydraulic Systems Bearings Gearboxes and Chains
bull Available in 13 ISO viscosity grades
SynXtreme FG Series Greases
bull 100 Synthetic Calcium Sulfonate Complex Greases
bull Super Multi-Purpose Ideal for a Variety of Applications
bull Excellent Anti-Wear and Extreme Pressure Protection
bull High Temperature Stability - Up to 700˚F ASTM Drop Point
PGO-FGL Series - Gear Lubricants
bull Ultra High-Performance Advanced Polyalkylene Glycol
(PAG)-Based Gear Lubricants
bull The Ultimate Gear Lubricants for Demanding Applications
SSO-FG Series - For Canning Equipment
bull Designed for use in CanningSeaming Machinery
bull Provides Excellent Anti-Wear and Corrosion Protection
Lubriplate reg Lubricants Newark NJ 07105 Toledo OH 43605
1-800-733-4755 E-Mail LubeXpertlubriplatecom
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1432
14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
8222019 r Fm 20130101
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1732
The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2432
24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
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Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
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AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
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Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
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bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
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Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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JanuaryFebruary 2013
10 COVER STORY
Beaverton Foods Inc is currently the larg-
est processor of specialty mustards in the
country and operates out of a 70000-
square-foot food processing facility in Hillsboro
Ore shipping about 30 million units per year
But its beginnings are much more humble
The company can trace its roots to 1929 and
to Rose Biggi an Italian immigrant who movedto Beaverton Ore as a teenager and soon found
herself working with a most unfamiliar crop
horseradish Rose began grinding and bottling
horseradish root in her farmhouse basement
She sold her product store-to-store and often
bartered throughout the Great Depression
As the economy improved so did business
and the Biggis soon had a growing operation
on their hands Under the leadership of her son
Gene the company began making specialtymustards Up to that point the specialty mustard
market in the US was primarily an import busi-
ness Beaverton Foods aimed to offer a smaller-
quantity local product that mimicked the quality
and flavor of imports In order to keep up with
the market Gene soon became what his son
Domonic calls a ldquomustard connoisseurrdquo
Domonic Biggi is now the CEO of Beaverton
Foods the third generation of Biggis to head up
the growing company But while operations have
certainly scaled up over the years the companyrsquos
commitment to quality and to small batch pro-cessing has remained consistent
From a mustard seed After operating in Beaverton for over 70 years
Beaverton Foods relocated to its current Hillsboro
facility 11 years ago and hasnrsquot looked back
The company now employs 72 workers at the
Hillsboro processing facility running two produc-
tion shifts and one sanitation shift Five staffmechanics oversee changeover which is in high
demand in a facility that produces as many prod-
ucts as Beaverton Foods
ldquoWe refer to ourselves as a micro-batch
processor so it is more labor-intensiverdquo says
Domonic Biggi With 700 product formulas and
a proliferation of packaging options the facilityrsquos
three production lines must continually be modi-
fied to accommodate new product
ldquoAll our lines are pretty flexible We have so
many different pieces of packaging from glass
to plastic to squeeze and food service Some
lines are specialized for squeeze bottles but theyhandle multiple squeeze bottles packages so
wersquore very very flexiblerdquo says Biggi
Biggi acknowledges that this method of pro-
duction may not be the quickest but itrsquos what
keeps the customers coming back Co-packing
currently makes up about 15 to 20 percent of
Beaverton Foodsrsquo business and the companyrsquos
co-packing customers demand variety that can
only be delivered in small batches
ldquoItrsquos nice when you can run a formula all dayevery dayrdquo says Biggi ldquoItrsquos very efficient But
wersquore not in that business Wersquore not in the wid-
get business Our business is specialty mdash small
quantities small batches Itrsquos what co-packers
Krystal Gabert Editor
utting theCutting the
MustardMustardFrom farmhouse basement to 70000-square-foot manufacturing space Oregonrsquos
Beaverton Foods Inc has been spicing up meals around the world for nearly 80 years
8222019 r Fm 20130101
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 1532
15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
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Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
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bull
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bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
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Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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Gorman-Rupp has been manufacturing pumps for food processing applications
since the thirties From commercial fisheries in Alaska to the potato fields of North
Dakota yoursquoll find Gorman-Rupp pumps being used for process waste handling
fluming water recirculation meat packing and produce processing applications
Whether you require standard centrifugal self-priming submersible or positive
displacement pumps yoursquoll find the right Gorman-Rupp pump for the job
JanuaryFebruary 2013
like They can have a variety of flavors Wersquore like an Indy car
[team] we can change the tires and gas up and lube up and be out
going again Thatrsquos how our l ines are quick changoversrdquo
A new kind of mustardBut Beaverton Foods isnrsquot quick with everything Product develop-
ment at the company is more distance runner than Indy car racer
The company currently offers many kosher and gluten-free prod-
ucts and is looking to expand these lines mdash but not too quickly
ldquoItrsquos hard to change a formulardquo says Biggi ldquoYoursquove got to get
your supplier to comply or go find it It changes your labels It can
change the quality of your product and how it tastes so we take
our time doing itrdquoThe companyrsquos RampD staff along with the Biggi family create a hybrid
focus group for formulating new products and not just to meet dietary
requirements The company is always on the lookout for food trends
that may create a market opportunity for Beaverton Foods
Product development is spurred by both internal and external
forces Sometimes a client will point out demand for a new product
sometimes food magazines and other sources will spark an idea with
Domonic or Gene and the development process will begin
ldquoThere are a variety of ways to be creative I guess if yoursquore
creative yoursquore always creative looking for inspiration in different
spots It can come from anywhere mdash sometimes itrsquos a restaurant
sometimes a supermarketrdquo
In fact the company recently launched a new wasabi product
that comes in a container big enough to accommodate the addi-
Beaverton Foods CEO Domonic Biggi displays some ofthe locally sourced horseradish root that has become astaple of the companys recipes
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
8222019 r Fm 20130101
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
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bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
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bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2532
Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
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Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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12 COVER STORY wwwfoodmanufacturingcom
JanuaryFebruary 2013
tion of soy sauce The product is designed for
inclusion into sushi kits put together by gro-
cery stores and food service companies but is
labeled for individual sale to consumers as wellThe new packaging lists ingredients as well
as gluten-free and kosher certifications The
company aims to offer customers an alternative
to typical wasabi products which according to
Biggi are ldquochemically derived mustard powders
coming out of China They call it lsquoJapanese
horseradishrsquo but therersquos not even horseradish
in it Wersquore actually putting out an authentic
wasabi productrdquo He continues ldquoWersquore looking
for people who want real product Therersquos someconsumer education to be done there but itrsquos
a nice niche to have Wersquoll take that niche and
grow it instead of trying to be cheaper and faker
and not wasabi rdquo
While Biggi and the RampD crew focus on
product development the company employs
two full-time quality control employees who
make sure that the many products coming off
production lines are safe The companyrsquos needto process multiple small batches each day cre-
ates a unique challenge for these employees
as quality control samples must be
taken and stored from each batch
processed
ldquoSQF drives our food safety pro-gram hererdquo says Biggi noting that
the company is audited by the FDA
in addition to third party auditors
like Sysco and Costco The com-
pany is also required to stay com-
pliant with kosher and gluten-free
guidelines with regard to products
designated as such
Putting a lid on itThough Beaverton Foods pack-
ages a remarkable variety of prod-
uct the majority of it is bottled
and much of the production still
involves horseradish In fact
the companyrsquos Inglehoffer brand
cream-style horseradish is its most
popular product
The company receives and pro-cesses several million pounds of
horseradish per year all of which
is sourced from a
local third-generation
farmer
Beaverton Foods
employs a proprietary
method of clean-
ing the horseradish
before it is ground
and sent to small
batch blenders where
it is combined with
other ingredients
like mustard seeds
which have been wet-
milled into slurry and
transferred to storage
tanks prior to useThough Biggi says
ldquoNo two days are
alike hererdquo most
days see three filling
lines running during
the morning shift and
three running during
second shift
Production sched-ules are made only a
single day in advance
Even so Biggi says
ldquoProduction changes
at least once every
dayrdquo as Beaverton adapts i ts production to meet
incoming customer demands
After that most orders are shipped within a
day or two of production
In the past 20 years distribution has shifted
toward a more robust self-distribution model
In the early 1980s Biggi estimates that 95
percent of orders were filled through a variety
of distribution companies Over time many of
those distributors have consolidated offering
more limited service options and Beaverton
Foods has taken on a greater share of its own
distribution Biggi says roughly half of all orders
are now filled directly ldquoAs we get bigger and
bigger we can afford to cut out the middle man
and ship directrdquo
It all comes back toquality
Biggi notes that he has a lot to live up to
standing in line behind his father and grand-
mother He knows well the companyrsquos unique
history which he calls the ldquofamily legendrdquo
ldquoItrsquos not just about putting yellow mustard
on a hot dog Itrsquos about putting authentic stone-
ground [mustard] on a brat Just take it up anotchrdquo he says
And when Biggi reflects on the companyrsquos
mission and its future he says ldquoIt all comes
back to qualityrdquo
Small batch blenders are used to combineingredients before bottling
8222019 r Fm 20130101
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
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bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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regtradeTrademark of The Dow Chemical Company (ldquoDowrdquo) or an affiliated company of Dow ProFume is a federally Restricted Use Pesticide
Always read and follow label directio ns copy2013 Dow AgroSciences LLC U38983085129983085010 (1212) BR 01098308571598 DAPMPRFM0 056
Keep food quality high and your facility up and running using ProFume reg gas fumigant with Precision Fumigationtrade tools
and techniques Fully customizable with real-time monitoring and results documentation itrsquos technology that reduces
downtime mdash in no time Learn more about the intelligent solution for precise pest management at wwwGetProFumecom
8222019 r Fm 20130101
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
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FOR SALERENT
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Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
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MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
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Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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14
JanuaryFebruary 2013
14
QQ AA
JanuaryFebruary 2013
Briefly tell us about the recent hantavirus outbreak at
Yosemite National Park
At last count nine visitors to Yosemite National Park con-
tracted hantavirus while visiting the park and three people
died from the disease The majority of campers were stay-
ing at the Signature Tent Cabins in the Curry Village site
The park service is still investigating the cause but possible
causes include contamination in cabin sites by deer mice orstorage sites associated with the cabins
What is hantavirus and what risks does it pose to food
manufacturing facilities
Hantavirus is not a foodborne illness so it doesnrsquot pose a
risk to the food a facility produces but can place employees
at risk especially if they are involved in pest management
procedures involving one of the rodent species that car-
ries hantavirus Proper training should be provided to theseemployees on how to prevent transmission It is also impor-
tant to educate employees who may be involved in clean
up of fecal material and urine of the carriers The disease is
relatively rare but it does have a fairly high fatality rate
How is hantavirus spread and what risks does it pose to
plant safety
It is important to make sure employees are educated in theproper procedures to follow when handling equipment or
surfaces which may have been contaminated with fecal pel-
lets or urine of the hantavirus-carrying rodents Hantavirus
is transmitted by airborne droplets of urine saliva and fecal
material The mode of transmission to humans is through
inhalation So the
concern is for pro-
tecting employees
and contractors who might be involved in the capture con-
trol and clean-up of these rodents
What conditions are favorable for deer mice infestation
We have seen higher numbers of deer mice in certain partsof the United States this year When environmental condi-
tions such as temperature are more favorable and food is in
greater abundance we expect populations to be higher We
had an unusually warm winter in 2012 and that seems to
be contributing to higher populations of rodents in general
including deer mice
What can food companies do to prevent deer mice infes-
tation and Hantavirus
Exposure to hantavirus can be reduced by managing rodents
around the facility Many of the procedures used for manag-
ing commensal rodents like the house mouse will work for
deer mice Reducing conditions which support the growth
of rodent populations around the facility must be done in
conjunction with exclusion methods Keeping vegetation
away from the structure and reducing exterior food spills are
important
Seeds insects and weeds around the structure can providefood sources for these animals They will also take advan-
tage of food spills which may contain grains nuts pet
food seeds or grain-based products Maintaining vegetation-
free barriers and reducing food spills are important in deer
mouse management
A recent outbreak of hantavirus at Yosemite National Park has raised
concern about potential rodent infestation and hantavirus outbreaks in
manufacturing plants including food facilities Patricia Hottel of McCloud
Services discusses the risks of hantavirus and how food companies can
keep their employees safe from the disease
QQ AA
QQ AA
QQ AA QQ AA
Hantavirus Are YourHantavirus Are Your
Employees at RiskEmployees at Risk
with Patricia Hottel Technical Director McCloud Services
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
8222019 r Fm 20130101
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
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HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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15
JanuaryFebruary 2013
Clarionreg Food Grade Lubricants are
precisely formulated to reduce the
risk of contamination to your food
operations Our full line of NSF H-1
registered and NSFANSI Standards 60
and 61 certified food grade lubri cants
and greases inhibit corrosion and
provide exceptional performance
With Clarion you can safeguard yourequipment your product and your
reputation while helping build a more
sustainable future Itrsquos what we do
Call 855-MY-CLARION or visit
clarionlubricantscom
For a more sustainable future
Sealing and preventing access are
also critical If there are openings
in the building which lead from the
exterior to the interior use seal-
ing materials like the metal meshes
(Xcluder or Stuff-it for example)
to seal these small openings Allopenings frac14-inch or larger should be
sealed Keep exterior doors closed
while not in use or install screens if
doors are left open for ventilation
purposes Screens must be a mini-
mum of frac14-inch mesh Screen win-
dows and vents which may provide
access if they are left open or do not
have tight fitting louvers
Traps or monitoring blocks can be
used on exterior areas for monitoring
purposes Traps are also advised on
interior areas Multicatch (curiosity)
traps can be used on interiors and
exteriors Mouse-sized snap traps
or clam-shell type traps can be used
inside stations as well Snap traps
can be baited with peanut butter (if
allergens are not a concern) sun-flower seeds or commercially-avail-
able lures Sealing of interior areas to
prevent access to wall voids and sub
slab areas is also advised
If a facility is breeched by deer
mice or a hantavirus outbreak
what actions should be taken
If despite preventative measures
deer mice enter the structure interior
traps should be used to eliminate the
pests Snap traps can be baited as
listed above Fortunately the interior
of a food plant is not the preferred
habitat for deer mice and they rarely
will build up populations inside the
typical food-plant environment Most
deer mice captures in food plants are
new introductions from the exterior
However they may nest in exteriorsheds garages or similar areas
Good practices for decontamina-
tion of surfaces and PPE should
be followed for employees These
practices can be found at the Center
for Disease Control Site at wwwcdc
govhantavirus and will include
Use of disinfectants to sanitize
surfaces which may have become
contaminated with rodent feces urine
or nesting materials
Double bagging of captured
rodent carcasses and removal to exte-
rior disposal sites
Use of gloves and in some cases
respiratory protection when conduct-
ing cleanup or handling equipment
respiratory protection will be required
especially in enclosed areas wherethere is a chance of inhaling airborne
contaminants
Washing hands post cleanup or
after handling rodent equipment
Patricia Hottel is technical direc-
tor at McCloud Services based
in Hoffman Estates Ill McCloud
Services serves the largest food-relat-
ed brands in the US For more infor-
mation please visit wwwmccloudser-
vicescom
Interview by Lindsey Jahn Associate
Editor
bull
bull
bull
bull
QQ AA
TECH NICHE PUMPS amp VALVES
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
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Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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16 TECH NICHE PUMPS amp VALVES
JanuaryFebruary 2013
Sanitary PumpsSanitary Pumps offer application versatility They are ideal for any ap-
plication where bacteria and contamination must be avoided or frequent
clean-up is required Product features include
Quick disassembly design for easy cleaning
No valves to clog or vapor lock
Ability to handle thin liquids like soups and juices
Efficiently moves viscous slurries like peanut putter candies and jam
Ability to handle fluid temperatures to 400ordmF and solids up to one inch in
diameter
150 standard models meet 3A sanitary requirements
Standard mechanical seals
Close-coupledopen throat design
Moyno Inc wwwmoynocom
bull
bull
bull
bull
bull
bull
bull
bull
Fire-Safe GlobeValvesThe Clampseal fire-safe
forged globe valves are
designed for plants wherefire safety is a major con-
cern The fire-safe valves
are available in Y angle and
T-pattern configurations in
05- through 4-inch sizes
up to ANSI 4500 pressure
ratings and with NPT butt
weld or socket weld ends
The valve contains a simple
mechanism that compen-sates for thermal expansion
As a result of this and other
design features the valve
meets API fire-safe standards by high margins The testing procedure
calls for the test valve to be placed in-line and pressurized for 75 of
rated pressure then subjected to a 1400 to 1800degF fire for 30 minutes
The valve is then quenched with water to cool it to ambient temperature
cycled to prove operability then subjected to further testing The valve is
required to maintain strict leakage allowances during and after the burn Conval wwwConvalcom
Sine Pumpsfor CheeseCurdsCompanyrsquos sine
pump technology
produces power-
ful suction with
low shear and no
pulsation Largeopen cavities allow
the transfer of curd
with little damage
producing a higher
yield and fat content
while reducing fines
Undamaged curd requires less dressing reduces fines and prevents
plugs in the drain table resulting in less down-time and higher productiv-
ity Unlike lobe pumps the pumps are engineered for long service lifeeliminating the high cost and inconvenience of off-site factory remanu-
facturing or reconditioning The pumps meet 3-A SSI
MasoSine wwwmasosinecom
17www foodmanufacturing com
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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The most trusted name in Stainless Steel Conveyors Since 1974 Kamflex has engineered and manufactured qualitystainless steel sanitary conveyors Our engineering responsetime is the best in the industry and our quality has no equal
Contact Kamflex the next time you need a stainless steel conveyor
Let us make it easy for you
1321 West 119th Street Chicago Illinois 60643-5109 Tel 1bull 800 bull 323 bull 2440
wwwkamflexcom
17wwwfoodmanufacturingcom
Rotary Valve with High-capacity Rotor
DesignThe SD Series of rotary valves is designed to provide increased bulk
material throughput efficiency in feeding and metering applications The
construction provides a larger pocket area between the vanes of the rotor
enabling greater pocket-fill capacity Calculated at 100 pocket-fill capac-
ity the valves can move over 5 more cubic feet per revolution (CFR) of
bulk material than a comparable 8-vane rotary valve The valve housings
are cast to ensure strength in the composition and solidification of the
housingrsquos metallurgy and to eliminate dimples crevices and pits on the
housingrsquos product contact areas and other surfaces The valves are avail-
able in cast iron or 304 or 316 stainless steel in 4 square-flange sizesfrom 6 to 12 inches and 4 heights from 10 inches to 18 inches They can
perform in temperature applications up to 250ordmF
ACS Valves wwwacsvalvescom
AC Variable Speed Drive for PumpControlThe AC30V series combines ease-of-use with high levels of control for
applications where reliable accurate motor speed control are key re-quirements Offered in three frame sizes that cover a power range of 1
through 25 HP (075 kW to 185 kW) with additional models to 150 HP
planned the series features conformally coated PC boards to protect
against corrosion when used in harsh environments and a choice of
integrated filtering options for compatibility with commercial and in-
dustrial instal-
lations The
series can be
mounted as
either an IP20
backplate
or through-
panel drive
Operating
temperature
range for the
new drives is
0degC to +50degC
Modular de-sign enables
the quick-
and-easy
addition of a range of extensions to suit specific applications These
include popular communications options such as Profinet Profibus and
EtherCAT plus a range of IO modules A multi-language graphical key-
pad can be mounted on the drive or can provide remote access to all
drive functions to facilitate fast and easy configuration without expert
user knowledge Parker Hannifin Corporation wwwparkercom
18 EXCLUSIVE FEATURE
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
8222019 r Fm 20130101
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
8222019 r Fm 20130101
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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JanuaryFebruary 2013
18 EXCLUSIVE FEATURE
William Shakespeare once wrote
Whatrsquos in a name That which
we call a rose
By any other name would smell as
sweet Shakespeare while perhaps the greatest
writer in the English language would never
have made it as a lawyer Because as a recentlitigation trend makes clear what is in a namewhat label one gives to describe an item
makes a huge difference at least with regard tothe potential liability of a food manufacturer
One of the most explosive litigation trendsin our tort system right now is the large uptick
in the number of suits targeting the labelingpractices of food manufacturers Indeed a huge
number of such suits were filed in 2012 alone
And more such suits appear to be on the wayin 2013 The New York Times documented
this trend in an article on Aug 18 2012 titledldquoLawyers From Suits Against Big Tobacco Target
Food MakersrdquoThe current landscape of such lawsuits can
be divided into three categories
Lawsuits by individuals orgroups of plaintiffs againsta food manufacturer
Most of the lawsuits related to labelinginvolve groups of plaintiffs suing a food manu-
facturer Most allege that the labeling of a fooditem was deceptive One recent example is the
recently-settled suit against the maker of fruitroll-ups alleging deceptive advertising based
on the word ldquofruitrdquo1 The plaintiff alleged thatshe ldquorelied upon the representations [that the
product was lsquomade from fruitrsquo] in making herdecision to purchase the products at [a] pre-
mium pricerdquo1 The defendant moved to dismissIn what may have been a surprise to some in
the food industry the court allowed parts of thecase to proceed toward trial
The chief focus in recent months hasappeared to be on foods labeled as ldquonaturalrdquo
or ldquohealthyrdquo One example is a recent lawsuitfiled against a manufacturer of granola bars
alleging that the bars were deceptively labeled
as ldquoall naturalrdquo 2
Another is a proposed classaction challenging ldquoAll-Naturalrdquo labeling againsta manufacturer of nutrition bars when the bars
allegedly contain synthetic ingredients The suitsurvived the defendantrsquos motion to dismiss in
late 20123 Such suits at least in recent months have
mostly been filed in one of two jurisdictions mdashCalifornia and New Jersey California appears
for now to be the favored forum for these suits
based in large part on that statersquos strong statu-tory prohibitions against false or deceptive
advertisingThese suits have met with mixed success
thus far While some have resulted in multi-million dollar settlements against the food
manufacturer and certifications of class actionsothers have been dismissed For instance one
recent case resulted in a settlement that offered
consumers who had purchased the allegedlydeceptively labeled product $4 for each jarpreviously purchased up to $20 total 4 On the
other hand a California state court recentlydismissed a class action against a manufacturer
of coconut water holding that allegations thatthe defendantrsquos product contained a false nutri-
tional label were preempted by federal law5 The court also found that other claims related to
the productrsquos ldquosuperiorrdquo hydrating powers wereallowable puffery5
The fate of this litigation whether it is merelya blip or as the New York Times suggests
a threat akin to the tobacco litigation is stillundecided as many of them have been filed
only recently Whether these suits move forwardand result in large monetary awards will bear
watching by those in the food industry
Lawsuits by one foodmanufacturer againstanother
There have also been recent lawsuits bythose in the food industry against others in the
food industry related to labeling One exampleis a lawsuit by a group of sugar growers against
Archer Daniels Midland Co and three other highfructose corn syrup producers alleging that
the defendants conspired to deceptively brandcorn syrup as a ldquonaturalrdquo product equivalent to
sugar6 The sugar growers allege that they have
lost business as a result of the alleged decep-tion Recently the trial court rejected the defen-dantsrsquo motions to dismiss and allowed the suit
to proceed against most of the defendants By
all accounts the financial stakes are potentiallyhuge considering the plaintiffs have alleged
A Rose by Any Other Name Is a
Lawsuit The Courtroom Battleover the Labeling Practices of
Food Manufacturers Trent Taylor Partner McGuireWoods LLP
19wwwfoodmanufacturingcom
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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19g
JanuaryFebruary 2013
that the defendants have already spent at least
$50 million on their rebranding effort
Actual and ThreatenedLawsuits by GovernmentalAgencies Against FoodManufacturers
The third category of recent labeling lawsuits
is perhaps the most fear-inducing for thosein the food industry It involves actual and
threatened lawsuits by governmental agenciesagainst food manufacturers This is perhaps
due to state and local governments ldquobecom-ing alarmed at the escalating costs of caring
for people with diseases [caused by eatingunhealthy foods] and are putting pressure on
food companiesrdquo as noted by the aforemen-tioned New York Times article
An example of a threatened lawsuit is therecent investigation by New Yorkrsquos attorney
general against the makers of energy drinks
The investigation centers on whether these com-panies are deceiving consumers in a number ofways including the amount of caffeine in their
drinks the health risks generated by consump-tion of large amounts of caffeine whether all of
the ingredients in the drinks are properly dis-closed and whether the drinks are dietary sup-
plements or foods To date the New York attor-
ney general has issued subpoenas to the energydrink makers as part of the probe The FDA is
reportedly investigating the industry as wellState and local governments are not the only
ones pursuing this strategy The Federal TradeCommission has won settlements from compa-
nies for claims related to a productrsquos health ben-efits In addition public interest groups are also
getting into the act suing over labeling of variousfood products
Overview of Proposition 37 On another front various state legislatures
appear to be moving to expand laws requiring
accurate labeling of food products For instancelegislatures in at least 20 states have intro-
duced legislation that would require the label-ing of genetically engineered food Though only
one state has passed such legislation thus far(Alaska) it appears to only be a matter of time
before more are passed In fact in California anew law requiring labeling of genetically engi-
neered food was narrowly defeated as a ballotinitiative in November 2012
This proposed law known as Proposition
37 or The California Right to Know Genetically
Engineered Food Act would have required label-ing on raw or processed food offered for sale to
consumers if it is made from plants or animalswith genetic material changed In addition
Proposition 37 would have prohibited the labelingor advertisement of any such food as ldquonaturalrdquo
or ldquoall naturalrdquo Enforcement of any violationswould have been through existing regulations
and the Consumer Legal Remedies Act whichincludes actual damages injunctive relief res-
titution punitive damages and attorneysrsquo feesMany observers believed that if Proposition 37
had passed it would have had a huge impact onthe food industry mdash increasing compliance costs
and opening the door to a whole new target oflitigation Passage looked likely just a month
or two before Election Day with polls showingthat the measure was leading by more than 40
points but a late focus on the proposed lawrsquos
problems turned the tide and led to a six-pointdefeat of the Proposition
However the battle appears to be far fromover The Proposition 37 campaign spokes-
woman Stacy Melkin said after its defeat thatthey plan to win the
labeling debate overthe long-term and
that ldquo[w]e showedthat there is a food
movement in theUnited States and
it is strong vibrantand too powerful to
stoprdquo It appears thatthere may be a simi-
lar ballot initiativein Washington State
in November 2013and there are current
legislative efforts topass similar mea-
sures in Connecticut Vermont and New
Mexico MoreoverUS senators have
proposed legisla-
tion to permit statesto pass laws like
Proposition 37(though the latest
effort picked up amere 26 votes in the
Senate)The stakes in this
new wave of lawsuits
are high The addition or omission of literally one
word in a label can potentially lead to millions ofdollars in liability for a company millions more
in legal fees and even lead to investigations intosuch practices by federal and state authorities
Those in the food industry should follow thistrend closely and take steps to prepare for pos-
sible litigation
1 Lam v General Mills Inc no 311-cv-05056
(ND Calif) 2 Janney v General Mills no 412-cv-03919
(ND Calif)
3 Colucci v Zoneperfect Nutrition Co no 12- 2907 (ND Calif) 4 Nutella Marketing and Sales Practices
Litigation no 311-cv-01086 (D NJ) 5 Shenkman v One World Enterprises LLC no
BC467165 (Los Angeles County) 6 Western Sugar Cooperative et al v Archer-
Daniels-Midland Co et al case number 211-cv-
03473 (CD Calif)
buntingmagneticscom
(800) 835-2526or 316-284-2020 (outside USA and Canada)
copy2013 Buntingreg Magnetics Co
Rejection is Good
Ensure product safety with integration into vacuum fillers
MeatLine 05
Metal Detector
20 SPOTLIGHT ON CONVEYING
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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20 SPOTLIGHT ON CONVEYING
JanuaryFebruary 2013
ConveyorChangeoverInnovationsCompany is ramping up
technology to help cus-
tomers with changeoverefficiency Growing to
hundreds of available
application-specific in-
novative options the
changeover offerings range from low-tech adjustable bracket and rail
assemblies to fully automated guide rail systems The following pro-
grams and events are available
New videos and web pages on conveyor changeover solutions
A new white paper ldquoPackaging Line Changeover Conveyor
Technology that Cuts Timerdquo An upcoming webinar ldquoHow to Increase Line Efficiency by Reducing
Changeover Timerdquo Live on February 7th at 2pm EST
An ROI analysis tool that compares purchase cost to changeover man
hours
Nercon Eng amp Mfg Inc wwwnerconcom
bull
bull
bull
bull
Measuring Wheel Encoderfor Conveyor SystemsThe MA20 measuring wheel encoder provides posi-
tion and speed feedback for conveyor systems Thetwo-in-one device combines a high-resolution optical
incremental encoder and a precise measuring wheel
Capable of resolutions as high as 25000 ppr the
encoder provides precise measuring results even at
very low conveyor speeds The measuring wheel
encoderrsquos HEX switch allows the user to select from
16 predefined resolutions between 100 and 25000
ppr These pre-set resolutions ensure that the multi-purpose encoder meets a range of applica-
tion requirements and minimizes inventory requirements for manufacturers Featuring continuouslyadjustable contact pressure the encoder eliminates measuring errors and ensures reliable surface
contact without slip Measuring 200 mm in circumference the wear-resistant measuring wheel is
available in a variety of rubber hardnesses (Shore durometer between 40 or 70) to ensure optimal
adhesion to conveyor materials
The Baumer Group wwwbaumercom
SanitaryConveying
for PowdersThe P-Series Venturi
Loader is designed for
conveying powders
in sanitary applica-
tions It can be used
for loading hoppers as
well as loss-in-weight
feeder refill applica-
tions and meets 3A
Dairy sanitary require-ments The efficient
and compact venturi
power unit utilizes compressed air to create
its vacuum convey source This eliminates the
need and expense for a separate blower pack-
age making it a more economical solution for
applications requiring lower rate conveying
over shorter distances The unit also includes
a large area automatic reverse jet filter forefficient powder conveying The loader body
is made of DIN 14404 (AISI 316L) stainless
steel with internal and external electropolished
surface passivation The modular construction
and sanitary design without pockets or dead
spaces allow for easy disassembly and clean-
ing as well as simple expansion with exten-
sion modules The unit comes standard with a
115230 VAC 15 amp controller
K-Tron wwwktroncom
LowPressureContinousDense
PhaseConveyorsE-finity is a patented
continuous dense
phase convey system
for fragile materials Precise pressure monitoring and airflow corrections
allow the system to operate efficiently under all conditions while gently
inducing materials through the convey line in slug form The unit is ideally
suited for granular and pelleted materials and has proven itself on many
projects for pet foods cereals nuts and grains The air controls can em-ploy a single air source to operate 2-3 different systems simultaneously
The result is a significant cost savings in both equipment and installation
with continued savings in operation and maintenance moving forward
Mac Process wwwmacprocessinccom
Dense Phase PneumaticConveyorsThese vacuum and pressure dense phase systems are
best suited for conveying materials when degradation andsegregation are unacceptable They use low-volume high-
pressure air to convey at low velocity ensuring minimal
powder damage Gas booster points along the conveying
line can be used to control powder velocity Depending on
the application either vacuum or pressure designs can
be used Both have PLC-based systems with easy-to-use
operator interface Systems can include multiple sources
and destinations Sanitary-grade specifications and quickly
demountable features are available
Powder Process-Solutions wwwpowder-solutionscom
21wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
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WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
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bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
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HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
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JanuaryFebruary 2013
Multichannel Distribution amp OrderFulfillmentReal Time Solutions order fulfillment systems help solve the most de-manding order fulfillment challenges found in todayrsquos manufacturing
warehousing and distribution center environments The line of order
fulfillment solutions includes
RF picking
Pick-to-light
Voice picking
Mobile pick cart systems
High-speed put systems
Sophisticated order fulfillment softwareWarehouse control systems
Whether the application requires shipping
direct to the consumer or replenishing stores
these solutions aid in determining the appropriate mix of picking tech-
nologies for an individual operation
Intelligrated wwwintelligratedcom
bull
bull
bull
bull
bull
bullbull
Sanitary VibratoryConveyorsThese sanitary vibratory conveyors
combine proprietary vibrating technol-
ogy with continuously welded stainless
steel troughs to effectively convey high
value and sensitive materials while
safeguarding against product contamination and protecting particle shape
and integrity The conveyors feature Companyrsquos own forced vibration
drive system to create a gentle efficient linear conveying action suit-
able for low-maintenance 247 operation Designed to meet FDA USDA
and 3-A standards and regulations the conveyors eliminate the risk of
contamination common to belt and roller conveyors as well as the risk
to product and particle integrity common to pneumatic conveyors and
may be quickly accessed or disassembled by one person for inspectionand cleaning The vibrating conveyors are available in 11 17 and 23rdquo
standard rectangular widths in lengths up to 40 feet and in custom sizes
and configurations to suit a variety of product process and plant require-
ments Fully enclosed tubular trough designs are also available
Witte Company Inc wwwwittecom
Horizontal MotionAccumulatingConveyorThe Slipstick Horizontal Motion
Accumulating Conveyor is designed for
sanitary on-line storage of product The
one-piece seamless conveyor pan elimi-
nates cracks crevices and moving parts in
the process stream reducing the risk of cross-contamination that com-
monly occurs when using a belt storage unit The gentle horizontal mo-
tion of the conveyor is suited for the storage and discharge of the most
fragile products The machines can be equipped with a pneumatically
actuated product dam and level sensors to meter product to downstream
equipment
TripleS Dynamics wwwsssdynamicscom
Electric PumpOptions for VacuumConveyors
Variants of the VS series of vacuum
conveyors feature electric pump op-
tions These new pump options mount
a purpose-designed Electric Switch
Box Assembly (EPV) directly on the
receiver Because the EPV includes a
non-return valve and vacuum relief
valve as standard the unit can be
coupled to any electrically driven
vacuum pump assembly providing
greater flexibility for end users
Volkmann wwwvolkmannUSAcom
BRAIN
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
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Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
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24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
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JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
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JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
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WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
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bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
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HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
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22
Te Food Manufacturing Brainstorm features industry expertssharing their perspectives on issues critical to the overall foodindustry marketplace In this issue we ask
Poultry has long been one of the least automated food pro-cessing sectors As automation equipment becomes moresophisticated how will poultry processors see their businesspractices change
John Kadinger Market Manager Key Technology
As poultry processors automate manual processes and as automated equipment becomes more sophisticated
one of the most important business practices that will need to change is employee training Automating manual
processes and transitioning the labor force from unskilled work toward becoming skilled technicians helps eliminate
highly repetitive manual tasks with high injury rates and addresses the challenges associated with a growing short-
age of unskilled labor Having well trained people operating maintaining cleaning and supervising automated equip-
ment improves the effectiveness of that equipment
As automated equipment becomes more sophisticated business practices will also change in the areas of process
monitoring and record keeping Many automated systems facilitate record keeping and utilizing this capability will
help satisfy the FDArsquos Food Safety Modernization Act and enable processors to quickly deliver the necessary data to
inspectors who visit the plant to verify compliance In addition to addressing changing industry guidelines improved
record keeping can help assure that final product quality and food safety is being maintainedThe processors that understand the interaction of the line components and consider the system as a whole can better select machines that
work harmoniously and integrate controls so the machines communicate seamlessly This high level of integration which could include connect-
ing equipment to a plant-wide SCADA network helps maximize the output of the equipment while maintaining the highest product quality and
operational efficiency In order to fully achieve the benefits of a well-integrated line processors will likely become more dependent on suppliers
who can provide deep industry expertise and integration services
R INBRAIN
STORMSTORM
JanuaryFebruary 2013 lt
Lindsay Galas Global Marketing Manager for Meat amp Poultry Videojet
Sophisticated automation in poultry processing will further standardize packaging increasing product safety We
have seen some of this improvement due to the shift from in-store butchers to case-ready retail packaging By elimi-
nating the handling of raw poultry in the backroom of supermarkets today many food safety issues are better con-
tained However food safety challenges have shifted from butchers to processors making it even more of a focus for
processors While automation will continue to decrease contamination risks due to less potential hazard points in the
packaging process the risk for incorrect labeling and coding on poultry products increases due to more system com-
plexity
Automated systems are only more efficient if managed correctly Increased regulation mdash including traceability
country-of-origin and allergy information mdash make labeling and coding on even the most standard poultry products
confusing and often requires manual entry and system monitoring One challenge for poultry processors today is
managing more and increasing complex codes which escalate the risk of coding and labeling errors in turn risking product safety Customersare turning to more comprehensive and reliable coding systems which are integrated into automatic packing lines to reduce coding errors and
ensure product safety without downtime
One way to reduce coding errors is investing in Code Assurance solutions which use advanced coding equipment and software to ensure
the right code is on the right product every time Combining automated packing technology with advanced coding equipment and networked
software can decrease the risk of human coding errors For example code selection during a line changeover can be as simple as scanning a
UPC which enables poultry processors to easily and efficiently run pre-programmed production cycles reducing code errors Code Assurance
solutions in an automated poultry processing environment improve customer safety and the bottom line
F d amp
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2332
Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2432
24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
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Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
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JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
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JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
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httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2332
Food ampBeverage
Full-Strength
Food ProcessingSuppliers Association
When you make the effort to travel to a show yoursquore looking for
concentrated information from suppliers to your industry
At PROCESS EXPO yoursquoll findhellip
ur supply chain
optimize production efficiencies
Food amp beverage experts Straight up
wwwmyprocessexpocom
NOV 3-6 2013
CHICAGO
McCormick Place
South Hall North Hall
Get the free mobile app at httpgettagmobi
copy 2 0 1 2 F P S A
No other North American show can match
PROCESS EXPOrsquos precision focus onfood amp beverage processingpackaging
24
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2432
24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2532
Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
8222019 r Fm 20130101
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JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2432
24
For pneumatic conveying and
air filtration inquiries contact
Mac Process
7901 NW 107th Terrace
Kansas City MO 64153
888-657-3098
salesmacprocessinccom
wwwmacprocessinccom
For weighing and feeding
inquiries contact
Schenck AccuRate
746 E Milwaukee Street
Whitewater WI 53190
800-558-0184
mktgsarinccom
wwwaccuratefeederscom
Together as one company Mac Process and Schenck AccuRate lead the industry in
the design of material handling systems for a wide range of food manufacturing
applications From cereals to pasta snack foods baking and many others over 100
in-house engineers custom designbuild 100 compatible systems for pneumatic
conveying air filtration and sanitary weighing and feeding Our Clean Design Initiative
ensures easy to clean equipment without added cost or complexity World renowned
technologies like E-finitytrade CRA Valve Line SEntry Receiver Line MECHATRON reg 3-A
Sanitary Feeding Systems DEA Open Frame Weighfeeding and our optimum control
systems are proven to improve food quality reduce waste and lower operating costs
Mac Process Schenck AccuRate Your global source for
pneumatic conveying air filtration weighing and feeding solutions
Safe quality products made from easyto clean sanitary food process systems
Kevin Stump ProductMarketing ManagerBettcher Industries Inc
Historically utilizing equipment designedto mechanically debone poultry meat at
high volumes has led to quality and yield
problems Consequently much of this
product has
been classified
as mechani-
cally separated
chicken (MSC) a
lower-value des-
ignation As timeand technology
evolves these
systems are
becoming better
at avoiding bone
contamination but challenges will always
remain regarding their ability to maximize
meat yields
The answer lies in adopting automation in
concert with other processing methods that
are somewhat more labor-intensive but whichdeliver a highly attractive ROI This ldquobest of
both worldsrdquo approach involves using more
automation while also augmenting poultry
yields and generating higher product prices
As one example of this dual-track solu-
tion the Whizardreg TrimVactrade is a light-
weight powered hand tool that combines
trimming and vacuum technology for the
best possible white meat recovery The
TrimVac tool enables processors to harvestsub-tender white meat from beneath the
wishbone ldquoeyerdquo muscle lean meat that
anchors the breast muscle to the breast
frame as well as lean meat along the rib
keel and back
Tomorrowrsquos poultry processing plants
will find their greatest success in how they
exploit the best that automation offers
while minimizing the downside problems
and risks Innovations such as the TrimVacmake it easier for processing plants to
adopt automated production methods
without sacrificing product yields quality or
price levels
R INBRAIN
STORMSTORM
wwwfoodmanufacturingcom 25
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2532
Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2832
JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2532
Christy Miller Marketing Manager Eagle Product Inspection
Automation is an important trend within the meat and poultry industry as computerized equipment increasingly replac-
es manual work Currently automated machinery can perform tasks including inventory management material handling
quality control and product inspection Automation improves yield by enhancing control and consistency reducing the
potential for process errors at each stage of production By limiting the scope for these errors manufacturers can opti-
mize the process by which raw material is converted to commercial product ensuring the highest possible levels of raw
material utilization and the minimal amount of waste
For this purpose poultry and meat processors are increasingly implementing x-ray inspection equipment as it can provide multiple simultaneous
inspections of different lines with conveyor speeds up to 120 feet per minute for contaminants such as metal stone glass dense plastics and calci-
fied bones Other benefits of automation and x-ray inspection include reduced risk of contamination as a result of human error reduced labor costs
higher productivity and ensured product consistency This in turn improves sanitization and aids process certification
Concerning standard protocols for the integration of machinery in an industrial environment the latest x-ray systems are network capable provid-
ing remote access Remote access permits technicians to quickly diagnose and correct issues reducing downtime and avoiding unnecessary ser-
vice call costs This feature becomes increasingly important as production lines now employ x-ray systems as critical control points in their Hazard
Analysis amp Critical Control Points (HACCP) program
and cannot run without this x-ray system being
fully operational X-ray machines with networkingcapabilities also improve the traceability of products
through software that gathers and communicates
data such as barcodes from different systems and
stores it for future reference This advanced soft-
ware aids meat and poultry manufacturers in case
of recall allowing them to trace a product back to
any point on the production line Eric PfeifferDirectorof Sales ampMarketingHyde IndustrialBladeSolutions
In our experience the
larger poultry processing
plants are utilizing a high level of automation pres-ently especially when compared to other meat cat-
egories That being said there is still a fair amount
of hand work involved especially in the secondary
processing applications
The major processors all seem to be keenly
focused on improving efficiency and through-put
(birds per minute) in order to pay for the increased
capitalization of the new technologies theyrsquore
considering Processors are eager for any pro-
cess improvement that they can utilize and thiscan range from expensive changes such as more
highly automated equipment to more affordable
alternatives such as faster or more efficient motors
as well as innovations in blade design
Processors will need to rely more heavily on
successful preventive maintenance programs as
any work stoppage is a cost in terms of labor and
lost production And growers will continue to be
presses for bird size uniformity Automation gener-
ally requires uniformity of work pieces
Ultimately itrsquos about removing variability One
would think that employee costs (payroll benefits
health care etc) would decrease in the face of
increased automation However new technology
generally implies that a need will arise for more
highly trained and educated employees
Register today at
WestPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at WestPack this
February Increase your knowledge and your network as you engage
with like-minded peers and industry professionals Gain fresh ideas
from stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Industry Peers New Technologies Ideas and InspirationThought Leaders
Connections like these cannot be made at your desk
February 12ndash14 2013 Anaheim Convention Center
Anaheim CA
26 PRODUCT REVIEW
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2832
JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2632
JanFeb 2013
Bulk Bag Discharger withMaterial DelumperMATERIAL MASTERtrade Bulk Bag Discharging
System features a fork-lift loaded bulk bag
lifting frame with adjustable height receiving
frame Unit features a Flo-Mastertrade bulk bag
massaging system to promote positive material
flow a Seal-Mastertrade bag spout access cham-ber and a Sure-Sealtrade spout clamping system
for dust-tight material discharge Product dis-
charge transition includes a fully mounted ma-
terial delumper to break up material being fed
into downstream process The Seal-Mastertrade
bag spout access chamber features interlock
switches to prevent material delumper from
operating unless both chamber doors are in the
closed secured position Equipment framework
features loss-in-weight load cells located abovefloor level for enhanced protection
Material Transfer wwwmaterialtransfercom
Programmable Temperature amp ProcessControllersCompany introduces its new high quality high accuracy series of 132 DIN programmable
temperatureprocess meters and PID controllers with RS-232 amp RS-484 communications
The user friendly easy to configure Dpi32and CNi32 are the first full series of instru-ments with programmable color displays The CNi32 features two outputs mdash control
alarm or retransmission of process variable mdash as well as universal inputs mdash thermocou-
ple RTD and process voltagecurrent This series has free software active X controls and
built-in 24 Vdc excitation standard on units without DC power or communication options
It can be used to monitor or control a process temperature in a heat treating application
fabricating metal parts
Omega Engineering wwwomegacom
Register today at
SouthPackShowcomPlease use promo code AB
Leave your office behind and expand your skill set at SouthPack this
March Increase your knowledge and your network as you engage with
like-minded peers and industry professionals Gain fresh ideas from
stimulating sources and face-to-face meetings
CUTtheCORDand connect live
Connections like these cannot be made at your desk
Industry Peers New Technologies Ideas and InspirationThought Leaders
March 6ndash7 2013Orange County Convention Center
Orlando FL
27wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2832
JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2732
JanuaryFebruary 2013
Multi-Lane Muffin Batter Depositing
LineCompanyrsquos family of pre-deposited muffin lines is available in sev-
eral sizes for production rates ranging from 264 to 800 muffins per
minute with capacities up to 18000 pounds per hour for either
baked or pre-deposited frozen muffins Automatic tray denest-
ing automatic paper cup denesting and batter depositing using
Companyrsquos industrial depositor are included These lines can be
operated with a minimal amount of labor and the high percentage
of up time leads to high yield and low operating costs The indus-
trial depositor uses diving spouts for clean accurate depositing ofthe most viscous batters including those containing a high concentration of frozen fruit or berries Optional modules include a moist streusel deposi-
tor a dry ingredient topper for nuts sugar chocolate chips sprinkles and oat flakes and an extra large intermediate hopper which can be insulated
and will accept multiple batches from the mixing bowls
Hinds-Bock Corporation wwwhinds-bockcom
Safety Interlock SwitchD4SL-N Safety Interlock Switches are available with four- five- or six-contacts to satisfy varied
application needs The IP67-rated unit can be mounted in four different directions without
needing to rotate the head Two wiring methods minimize wiring time and make possible
one-touch attachment and removal Easy-to-view LED indicators allow users to quickly
check switch status from any direction The item delivers a minimum of one million opera-tions and boasts a minimum key holding force of 1300 N It is available with two types
of wiring Connector-type wiring models feature a conector cable that reduces potential for
mis-wiring facilitates fast maintenance and allows easy switch replacement Terminal block-type models
include a detachable terminal block to significantly increase wiring efficiency
Omron Scientific Technologies Inc wwwsticom
Traceability SoftwareThe Specialized Inventory Management with Barcode Accuracy
(SIMBA) Lite 2012 is designed to provide food processors with the
ability to process label and track their products from ldquofield or dock
to customerrdquo The system is designed for companies that process
in bulk (similar or same products into constant weight cartons) The
system allows a production line worker to change content of product
labels with a fingertip on the computer or touch screen capturing
product information (weight size color grade) and printing a label
with a barcode identifier for that tote or carton The label information
is stored in the unitrsquos
inventory system
which then providesproduction and in-
ventory reports The
cartons may then be
accumulated onto a
pallet and tracked
with a single pallet
identifier This integrated system gives the user complete traceability
of the product from receiving to shipping The cartons or pallets can
be stored and tracked by location within the warehouse cooler orfreezer At the time of shipping the Van Loading feature tracks each
carton or pallet onto a specific van A Bill of Lading is then produced
automatically
Dynamic Systems Inc wwwa-barcodecom
28 FOOD SAFETY
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2832
JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2832
JanuaryFebruary 2013
FOOD SAFETY
Meat Poultry and Seafood
F
ood safety is an important consideration
across the food processing spectrum but
meat poultry and seafood processors faceespecially stringent regulatory standards As
food safety regulations change mdash with 2011rsquos
Food Safety Modernizat ion Act (FSMA) and later
the FDArsquos new food safety rules proposed this
January mdash the stringent standards that have
bolstered food safety in meat processing facili-
ties could act as examples for other manufactur-
ers looking to beef up their processes For this
reason wersquove asked meat poultry and seafood
processors about their own food safety practicesand what they see for the future of food safety
The FSMA has made Hazard Analysis amp Critical
Control Points (HACCP) planning and other food
safety protocol mdash already mandatory in seafood
and meat processing facilities mdash mandatory
across all food manufacturing segments We
asked meat poultry and seafood processors ldquoDo
you think this is an appropriate changerdquo 952
percent of respondents reported believing thatldquoall food segments should be held to the same
high standardrdquo with only 48 percent respond-
ing that ldquomeat poultry seafood and juice have
unique challenges that
make higher standards
necessaryrdquo None of therespondents to this sur-
vey reported believing
that food safety protocol
should be left up to the
discretion of the indi-
vidual processor and its
customers
This response coin-
cides with another that
shows 100 percent ofsurvey respondents
believe the ldquoregulatory
guidance for food safety
planning in meat and
seafood processing facilities is appropriate to
address the specific challenges and critical con-
trol points associated with processingrdquo Indeed
much of the data wersquove collected across the food
industry tells us that while frustrated with manyof the regulatory burdens placed on manufactur-
ers food processors mdash in very high numbers
mdash support strict regulatory oversight of food
safety practices
In fact 905 percent of survey respondents
reported that the presence of USDA officials in
meat poultry and seafood processing facilities
ldquoincreases food safetyrdquo while 95 percent see
ldquono impact on food safetyrdquo No respondents
reported seeing a decrease in food safety due
to the presence of USDA inspectors When
asked to expand upon this topic one respondent
noted the need for ldquoincreased inspectionrdquo while
another stated ldquoThere are always operations
that will try to push the limits Having inspec-
tion provides oversight at those operationsrdquo Still
another respondent observed that ldquosince USDA
officials are present in meat poultry and seafood
processing facilities there is a higher standardfor safety (and quality) Someone is physically
present to ensure the safety of the food and that
in turn makes it [safer]rdquo
This broad-based support for USDA oversight
and inspection however doesnrsquot mean meat
poultry and seafood operators donrsquot see room
for improvement As seen in the pie chart at
left though 905 percent believe the presence
of USDA inspectors in facilities increases foods
safety only 684 percent think the program iscost-effective One reader noted ldquoAny plant
operating under an effective and functional
HACCP program should mitigate the need for
constant regulatory oversight An effective
HACCP program that is properly implemented
and managed combined with periodic regulatory
audits of the program can be very effectiverdquo
And like the rest of the food industry meat
poultry and seafood processors take HACCP
planning seriously As seen in the chart abovemeat processors utilize a variety of resources
when writing implementing and revising HACCP
plans When asked about the frequency of
HACCP revision survey respondents reported
HACCP plans are a living document con-
stantly open to revisionmdash476
Once per yearmdash333
Less frequently than once per yearmdash142
Twice per yearmdash48With broad support for comprehensive HACCP
planning and strong regulatory oversight meat
poultry and seafood processors are committed to
keeping food safe for consumers
bull
bull
bull
bull
Krystal Gabert Editor
The Food Safety Update section of Food Manufacturing is designed to offer our readers insightinto the state of food safety concerns across the industry We received hundreds of responses tothis monthrsquos survey on meat poultry and seafood processing
Do you feel that the current system under
which USDA officials are present during
processing times at meat and poultry pro-
cessing facilities is a cost-effective way to
ensure food safety
0 20 40 60 80 100
Yes
684
No
316
Consultation with equipment manufacturers 526
The publicly available HACCP guidance published by the FDA 842
What factors have been key to effective HACCP and food safety
planning in your facility
Internal QAQC experts 842
Outside advisorsconsultants 789
Suggestions from plant-floor staff 737
Advice from 3rd part regulators and government auditors 737
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision-maker FOR INFORMATION OR TO RESERVE SPACE
CLASSIFIEDS 29wwwfoodmanufacturingcom
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 2932
JanuaryFebruary 2013
EQUIPMENT AND MATERIAL
We sell your equipment find that talented job applicant and bring your consulting service to the industry decision maker FOR INFORMATION OR TO RESERVE SPACE
CALL James Pease Advantage Business Media at Phone (973) 920-7774 Fax 973-607-5460 or e-mail at jamespeaseadvantagemediacom
24 7 EMERGENCY SERVICE
BOILERS20000 - 400000 Hr
DIESEL amp TURBINE GENERATORS50 - 25000 KW
GEARS amp TURBINES25 - 4000 HP
WE STOCK LARGE INVENTORIES OF Air Pre-Heaters bull Economizers bull DeaeratorsPumps bull Motors bull Fuel Oil Heating amp Pump Sets
Valves bull Tubes bull Controls bull CompressorsPulverizers bull Rental Boilers amp Generators
847-541-5600 FAX 847-541-1279WEB SITE wwwwabashpowercom
FOR SALERENT
PO WER
EQUIPMENT CO
444 Carpenter AvenueWheeling IL 60090
wabash
AMERICAN WHOLESALE CONEW USED WALK-IN-COOLER-FREEZER BOXES
REFRIGERATION SYSTEMS - EQUIPMENTLarge Inventory All Sizes
bull Buy bull Sell bull Nationwide bullWholesale Prices
Phone 1-877-220-8882 bull Fax 216-426-8883 wwwawrcocom
Refrigerated ContainersThinking about Cold Storage-Try a Rental
bull 20rsquox8rsquox8rsquo6rdquo amp 40rsquox8rsquox8rsquo6rdquobull Three Phase 230460 voltsbull Temp Range -15F+40Fbull Blast Freezer -30 Starting at $30500
Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500
wwwkellyfreezercom
Toll Free 866-713-6307 bull Fax 860-668-2871
Wersquoll Sell World Wide
N O W R E N
T I N G
HIGH SHEAR
MIXERSWorldrsquos Widest SelectionSingle Stage to Ultra High Shear
bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock
Ross will beat any major manufacturerrsquos quote
1-800-243-ROSS
USA Tel 631-234-0500 bull Fax 631-234-0691 wwwhighshearmixerscom
Adhesive Sealant CoatingFor Food Applications
Watch our video
wwwmasterbondcomTel +12013438983
LEEM Filtration A Division of North American Filtration Inc
227 2$ s 2-39 0HONE s ampAX
wwwleemfiltrationcom
Filter Leaves for ALL Pressure Leaf Filters
+NEW + REBUILT ++RECOVERED +
All Makes ndash All Kinds+ DURCO + NIAGARA
+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER
+ AMA + LFC+ US FILTER amp Many Others(We also manufacture pressure leaf
and tubular element filters)
Industry INSIDER 30
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3032
JanuaryFebruary 2013
Improving Foreign Objects amp
Contamination Detection Joe Cowman President Gainco Inc
Poultry processors strive to pro-
vide a finished product thatis 100 percent free of bonefragments and foreign objects
Traditional methods of finding foreignobjects rely on human inspection andtools such as metal detectors Butdetecting certain objects like soft bonefragments and very small metal particlesremain big challenges Left undetectedthey can degrade the quality of the
finished product affect product pricingadversely and hurt brand reputation
The most serious cases can bringabout costly product recalls resulting insignificant monetary fines plus damageto a companyrsquos reputation that may takeyears to reverse
Flawless Information mdash InstantlyThe volume of product output by the
typical poultry processing plant neces-sitates speed as well as accuracy in thedetection of foreign objects Ideallyprocessors would like to be able to cap-ture flawless information instantly Themore equipment and systems can helpprocessors achieve that outcome thebetter it is for product quality and bot-tom-line financial performance
The Technology is Herehellip but whatabout Practical Applications
There is a significant degree ofresearch going on to find better andfaster ways to test and safeguard pro-cessed poultry products Fortunately agood deal of this ldquopurerdquo research hasbeen transferred into commercial appli-cations that are as effective as they areaffordable
For example newer ldquodual energyrdquox-ray detection systems such as thosemanufactured by Anritsu can analyze
two different x-ray energy signals allow-
ing them to distinguish between theproduct and the contaminants Thiscapability results in a higher detectionrate of certain types of bones and bonefragments such as wishbones fan bonesscapula bones and other thin low-den-sity bones
Newer detection equipment is alsomore adept at inspecting overlappingand randomly oriented poultry products
without negative side effects like falsepositives or a missed detection
Pipeline Inspection SystemsThere have also been new improve-
ments in the speed and accuracy ofpipeline x-ray inspection systems forpumpable products such as poultry trimand first-grind chicken or turkey meatNot only are these pipeline systems
highly accurate and effective in detect-ing small bone fragments metal andother foreign material theyrsquore capableof processing as much as eight tons ofproduct per hour
With preset memory capabilities ableto handle 100 or more separate recipestodayrsquos pipeline systems are highly ver-satile and flexible for poultry plants that
process a variety of products
Case Inspection SystemsDetection systems have also been
commercialized for end-of-line inspec-tion activities These systems providethe assurance of confirming quality afterproducts have been packaged Itrsquos notunheard for foreign objects to end upin a packaged product even after all of
its contents have gone through priordetection screening so this step pro-vides an added measure of assurancefor processors
Consider the Big PictureIn our dealings with poultry proces-
sors sometimes we find that detectionsystems and equipment have beeninstalled at different times and in dif-ferent places along the processing lineOften this piecemeal approach hasended up causing operational inefficien-cies mdash or worse dangerous ldquoholesrdquo inthe system
Thatrsquos why itrsquos important for a proces-sor to work with specialists who canview an entire process line and offer rec-ommendations that will achieve all qual-ity objectives in the most cost-efficientand labor-saving manner Itrsquos even betterif that specialist can deliver a full sys-
tem or equipment solutions saving theprocessor time effort and added costsin an attempt to devise a solution usingmultiple suppliers Gainco Inc is a Gainesville Ga-basedmanufacturer and supplier of yield man-agement and food safety plus weighingsizing and distribution systems Gaincois the exclusive authorized distributorof Anritsu detection systems to the USpoultry processing industry ContactJoe Cowman at (770) 534-0703 orJoeCowmangaincocom
This monthstopic
POULTRY
Fl id P f
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3132
copy2012 Baldor Electric Company
Fluid Performance
Drive Down Your EnergyUseIn a motor-pump system the life
cycle cost of the motor is about
2 of the total expense with
electricity consumption comprising
over 97 of the motors total
cost By upgrading to a Super-Ereg
NEMA Premiumreg efficiency motor
substantial energy can be savedhellip
immediately Since most pump
systems are oversized for worst
case conditions and are operated
well below that point adding an
adjustable speed drive to operate
the motor at a lower speed (insteadof using a valve) can in most cases
save over 60 of the energy used
These applications can pay for the
cost and installation of the drive
in less than a year with rebates
available from most utilities while
reducing energy consumption for
many years afterwards Both the
US Department of Energy and
Natural Resources Canada accept
Baldorrsquos Super-E motors as an
energy-saving upgrade
and API 547 compliantdesigns are
available ABB
brand IEC metric
motors are offered
in standard or ATEX
configurations
for export or
replacementon imported
equipment through
100000 Hp
OEM pump
manufacturers and
pump assemblers will find a wide
range of Baldor Reliance stock
and custom motor configurations
to meet your specific application
requirements For OEMs that
manufacture their own submersible
pumps Baldor can supply stator-
rotor sets in many different frame
sizes and ratings for low andmedium voltage use
All Baldor Reliance motors are
made in America and distributed
through 32 stocking warehouses
in North America giving you the
fastest stock motor delivery in the
industry
Motor-driven pump systemsrepresent 30 of all motors used in
North America
Baldor Electric
Company
recognizes
the
need for robust energy efficient
motors for this application and
offers a wide range of motors for
practically any pump application
56J
Close-coupled
Explosion-proof
Vertical P-base with solid shaft
Submersible and immersible
designs
hellipplus an unlimited number of
custom designs
With medium voltage motor
horsepower ratings to 15000 and
stock motor voltages in 115230
and 230 for single phase and 200
230460 460 575 and 23004000
volt for three phase designs therersquos
a Baldor Reliancereg pump motor
for your next pump system design
or retrofit replacement need For
special applications and strict
industry specification requirementsIEEE 841-2009 API 610 API 541
Lifetime Cost
of an Electric Motor
Energy 973 Initial Purchase 2
One Rewind 07
wwwbaldorcom479-646-4711
8222019 r Fm 20130101
httpslidepdfcomreaderfullr-fm-20130101 3232