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JBT’s solutions for a post-pandemic future promise fruitful results

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For the global juice industry as it operates amid the COVID-19 pandemic, the importance of ensuring stringent food safety – combined with sustainability – has surely never been more important. But given the economic challenges many companies face, the ability to become more efficient during processing and keep waste to a minimum is arguably just as crucial.

JBT’s approach to both food safety and sustainability is encapsulated in six key Corporate Social Responsibility (CSR) principles for juice processors: aiming for food security and nutrition; ensuring economic viability; encouraging good governance; being environmentally responsible; creating acceptable working conditions; and promoting the transfer of knowledge.

“One of the six principles of sustainability is food safety: that foods are not just sustainable, but that they have to be safer,” explains JBT’s Technology Assistance Manager for Liquid Foods, José Lorente. “If you don’t clean properly, you can’t be sure of eliminating micro-organisms, and if the sterilization process is not adequate, this can result in serious problems.”

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Improved profitability
While food safety is undoubtedly important, another significant element of achieving sustainability is maximizing yield. Getting more out of the same volume of fruit – including valuable by-products or ingredients – means far less wastage and potential contamination, and improved profitability at the end of the process; a massively important consideration given the current economic pressures driven by the global pandemic.

“Recovering by-products, such as citrus essential oils, generated during citrus juice processing, enables companies not only to be more environmentally friendly, but also more profitable by being more efficient during the extraction process using the same raw materials,” explains Lorente.

“Over recent years, we at JBT have been working on maximizing and optimizing yield by developing solutions that help customers obtain more juice and by-products. Being efficient is part of sustainability. The more efficient a company, the more sustainable it becomes and the more profitable.”

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Significant benefits
A clear example of how JBT solutions can help juice customers maximize yield is when it comes to essential oils, which can be recovered during the extraction process. These include valuable d-Limonene, a natural organic solvent used as an ingredient across a wide variety of applications, from cleaning products to the aroma industry. However, what makes JBT solutions different from standard extractors is their ability to recover significantly more essential oil.

“With a standard extractor, you can recover around 55% of the essential oil present in the fruit, but thanks to the efficiency of JBT’s ORES (Oil Recovery Extraction System), customers can recover up to 65%,” says Lorente. “You have to bear in mind that otherwise this 10%, which is a contaminant, would be thrown away. By recovering that extra 10%, customers not only earn more money, they also help protect the environment.”

To achieve even better results, JBT has developed the MORE (Modular Oil Recovery Extractor) system, which recovers essential oil before it reaches the extractor. By softly scraping the peel, without damaging the integrity of the fruit, more than 90% of the essential oil available can be recovered.

Learn more about JBT and sustainability

JBT’s READYGo™ LIQUIFUSION™: the single solution to make complex systems simple

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JBT’s READYGo LiquiFusion Tanks present an innovative solution for combining multiple operations into a single tank processing system, saving money and delivering a smaller footprint in the process. Dan Wolff, Technical Sales Manager for Sales, Engineering and Estimating at JBT’s A&B Process Systems, explains how the concept works.

When a process professional starts to consider purchasing new equipment, a whole array of questions and issues come to mind. What if I need to perform multiple operations? How will I protect my product from contamination? How can I fit this equipment into the space I have?

To address these common concerns, experts across many industries are moving towards single tank processing where a single piece of equipment is used for blending, dispersion, emulsification, heating, and cooling operations. This is the concept behind JBT’s READYGo LiquiFusion Tanks; a solution which delivers a lower capital cost, reduced material handling and product transfer, and a smaller system footprint. 

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READYGo LiquiFusion Tanks are available in six standard volumes and can be customized to handle a broad range of products and processes, including four separate agitator options that can be combined to create ideal mixing for almost any application and can handle viscosities up to 100,000+ cPs. 

The optional ASME dimple jacket provides efficient heating and cooling compatible with a variety of heat transfer media. This system has been used for products such as gums, flours, cocoa, yeast, powdered egg, caseinates, condiments, juices, purees, whey, slurries, cheese, lotion, gel, shampoo, toothpaste, and more.

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In addition to all its other benefits, the LiquiFusion system offers superior low-level mixing, reduced batch time, elimination of agglomerated powders, a more homogenous blend, and increased batch uniformity. Furthermore, if the customer is interested in automating their system, a full range of optional instrumentation can be included to reduce manual processing and further protect their product from damage due to human error.

While the user should be excited that combining these processes results in less equipment to clean, they can also rest assured that the LiquiFusion is designed to be fully CIP (Clean-In-Place) ready. Our sanitary design is extremely versatile and is ready for installation in any food, dairy, confectionary, cosmetic, personal care, or pharmaceutical plant.

Dan Wolff has worked at A&B Process Systems for seven years as a Mechanical Engineer in the Tank and Vessel Group, specializing in pressure vessel engineering, agitator design, structural analysis, and standard product development. Recently, Dan moved into the role of Technical Sales Manager supporting A&B’s Sales, Engineering, and Estimating teams.

Learn more about READYGo LiquiFusion Tanks

Meeting the seasonal challenge: how PRoCARE can make a difference

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JBT’s Preservation business unit supports container filling and seaming equipment as well as in-container sterilization technology such as rotary cooker/coolers, hydrostats and retorts. Products processed through this equipment includes everything from ready meals to canned vegetables and wet petfood. What makes this industry different to others covered by JBT is that it includes seasonal and year-round customers, both of which have a common need to avoid downtime and maximize productivity. This is where JBT’s PRoCARE® program has provided customers with a means of achieving that mutual goal.

“We have seasonal customers who have production windows of only three months a year and others who run year-round, and each of them have different sets of problems,” explains JBT Preservation’s Madera, California-based Service Manager Diego Ulloa. “With seasonal customers, the main problem is they don’t have staff and operators year-round, so the knowledge can be limited and things can get overlooked. With year-round customers, they often have very short, limited maintenance windows. Downtime is more critical for those customers, and unscheduled downtime can be a real challenge for them.”

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Avoiding downtime
There is often also a problem with operator turnover, according to Ulloa, with operators retiring and companies experiencing difficulties hiring replacements. A further difficulty is that a lot of customers in the industry are on a limited budget, which can sometimes act as a restraint on the amount of maintenance they would like to do. 

The advantage PRoCARE offers, he continues, is the option to train operators and avoid unscheduled downtime by carrying out audits ahead of time. “Highly-experienced JBT technicians are able to identify potential equipment problems and can plan ahead of time by ordering parts, so that if and when a shutdown happens, actual downtime is kept to a minimum,” explains Ulloa.

“By planning ahead, JBT maintenance visits become a lot cheaper, enabling companies to better control their budget. PRoCARE customers will also see discounts on services and parts, while JBT has furtherseasonal support to help those customers with limited staff.”

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Productivity increase
To give an example, Ulloa cites the case of two customers, both tomato processors, who work on a seasonal basis. After the season is completed, JBT engineers carry out an equipment evaluation, make recommendations and order parts where needed. The engineers then return to make sure the equipment is in optimal condition for the following season.

“They’ve told us that since they started with PRoCARE, they have seen a tremendous reduction in downtime and improvement in productivity,” says Ulloa. “Some of these customers might only be running production for two-three months, so those two-three months need to be as optimal as possible.”

Learn more about JBT’s PRoCARE program

New Proseal analysis platform maximizes production efficiencies

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JBT’s tray sealing specialist Proseal has launched an advanced automated platform that captures and analyzes valuable machine data to improve the efficiency and performance of the entire production line. The new Proseal ProVision™ system enables companies to maximize the benefits of Industry 4.0 and the fully automated factory.

Using cutting edge technology, the web-based analysis platform has been developed for Proseal’s GTe and GTs range of tray sealing machines to help identify and understand the causes of downtimeand other inefficiencies, in order to maximize the production capacity of the tray sealer and increase overall equipment effectiveness. Importantly, ProVision can also be easily integrated with existing third party equipment to accurately deliver information and drive improvements throughout the whole production line.

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ProVision’s easy to use reporting tools can be used to generate advanced reports that inspect machine data and compare historical performance analysis over any given time. This helps to identify any line inefficiencies and pinpoint factors that may affect productivity in terms of both personnel and operating procedures. Additionally, data patterns can be monitored to identify root causes of problems which could otherwise be hard to diagnose.

The versatile ProVision can be viewed on any web-enabled device, including a PC, smartphone and smart TV. The Live View function allows real time and remote performance monitoring, enabling operators to work away from the line and efficiently operate multiple machines, allowing engineers to check on machine performance and provide timely interventions if any problems are detected.

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ProVision is offered at no extra cost to all new Proseal GTe and GTs machines that are supplied with an Ewon device to allow internet connection. As part of Proseal’s futureproofing of its equipment, updated software and Ewon devices can be retrofitted to pre-existing GTe and GTs machines. In addition, a scaled down version of the platform, ProVision Lite, has been devised to deliver many of ProVision’s key benefits, to older legacy machines. 

“The development of our new Industry 4.0 advanced analysis platform demonstrates Proseal’s commitment to technological innovation,” says Rob Watson, Proseal Control Systems Manager. “ProVision offers benefits to all levels of factory personnel, from managers and engineers to line supervisors and operators, delivering invaluable, fine-detailed performance data that will help production lines to operate consistently at maximum efficiency.”

Learn more about Proseal’s new ProVision system