r Fm 20130101

32
Technology for Today’s Food Production & Packaging Market Cover Stor y p. 10 www.foodmanufacturing.com   January/February 2013 Vol. 26 No. 1 Vol. 26, No. 1  utting the Cutting the Mustard Mustard From farmhouse basement to 70,000-square-foot manufacturing space, Oregon’s Beaverton Foods has been spicing up meals around the world for nearly 80 years. From farmhouse basement to 70,000- square-foot manufac- turing space, Oregon’s 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 & Valves 18 Exclusive Feature:  Truth in Labeling & What It Means for You The legal battle over industry labeling practices has begun. Here's 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: Poult ry Industry Foreign objects detection in poultry processing operations gets a hi-tech upgrade. CONTENTS  7 What's the Buzz Insiders reflect on the latest news 26 Product Review Latest product releases 28 Food Safety Update Meat, poultry and seafood

Transcript of r Fm 20130101

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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

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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

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Industrial RTD (PT100) Probes with

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PR-14Starts at

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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

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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

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

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

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

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

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

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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

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

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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

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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

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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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

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

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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

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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

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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

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

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

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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

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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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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

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

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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

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

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

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

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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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

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

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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

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

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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

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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

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

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

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

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

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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

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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

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

8222019 r Fm 20130101

httpslidepdfcomreaderfullr-fm-20130101 2132

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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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

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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

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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

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

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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

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 +

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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

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

httpslidepdfcomreaderfullr-fm-20130101 3232

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

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

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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

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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

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

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

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

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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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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

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

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

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

8222019 r Fm 20130101

httpslidepdfcomreaderfullr-fm-20130101 2132

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

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

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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

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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

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

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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

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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

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Used Carriers in 20rsquo and 40rsquo sizes starting at $9500 New BOHN coolersfreezers starting at $10500

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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

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-

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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

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offers a wide range of motors for

practically any pump application

56J

Close-coupled

Explosion-proof

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hellipplus an unlimited number of

custom designs

With medium voltage motor

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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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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

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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

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

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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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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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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

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bull 1 frasl 2 -200 HP batch and inlinebull Free trials in your plantbull Many sizes in stock

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Adhesive Sealant CoatingFor Food Applications

Watch our video

wwwmasterbondcomTel +12013438983

LEEM Filtration A Division of North American Filtration Inc

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Filter Leaves for ALL Pressure Leaf Filters

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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

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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

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

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

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

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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

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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

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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 +

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+ INDUSTRIAL + SWEETLAND+ HERCULES + SPARKLER

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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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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

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

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

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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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

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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

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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 +

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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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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

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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

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

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

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

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

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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

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

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FOR SALERENT

PO WER

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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

1-800-243-ROSS

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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 +

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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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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

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

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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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

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

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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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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

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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

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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

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

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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

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

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

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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

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

httpslidepdfcomreaderfullr-fm-20130101 1932

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

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

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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

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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

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

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

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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

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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

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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 +

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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

8222019 r Fm 20130101

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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

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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

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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

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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

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

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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

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

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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

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

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

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

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

8222019 r Fm 20130101

httpslidepdfcomreaderfullr-fm-20130101 3232