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iOPS Dashboard: the remote support tool that can reduce downtime

The Covid-19 pandemic has had a profound impact across all sections of industry, changing working methods and practices, including in food and beverage processing. Although vaccines are slowly being distributed, the ‘new normal’ remains in place, meaning that new maintenance and analysis solutions are also necessary.

One such highly-effective solution is JBT’s Internet of Things (IoT) platform iOPS, which has recently introduced the iOPS Dashboard for the JBT Lubricator for the Hydrostatic Sterilizer, working in conjunction with customers. A remote analysis, monitoring and support tool, the iOPS Dashboard helps to improve support, aid maintenance, reduce downtime, isolate alarms, prevent delays and keep factories running efficiently.

Consolidated view
The iOPS Dashboard provides customers – at a safe, remote distance – with a consolidated view of points of concern, including all alarm points, production rates, run-time efficiencies, upcoming and past schedules, and the current status. This provides vital information such as both actual running production speed, and real-time utilization rates of the Hydrostatic Sterilizer, explains JBT Software & Project Engineer, Rick Ripley.

“Customers can optimize their maintenance load by studying information provided by the iOPS Dashboard, including how many revolutions have taken place since the last lubrication,” says Ripley. “This almost gives them intuition and acts like an early warning system for failures.”

First year free
The iOPS Dashboard, which is available free for the first year and then on an annual subscription basis, provides the data needed to carry out a qualitative analysis of the last cycle, alongside alarms that tell managers if any area is in risk of failure, and a series of widgets that give an overall picture of how the machinery is running.

“The report gives managers all the information they would want to know,” says Ripley. “This includes information such as when was the last time the system ran, how many pins have been lubricated, along with the history. It tells a manager how their maintenance is going on a machine.”

He adds: “People can monitor their machines without having to be at the factory. For now and into the near future, remote working will continue to be the new normal and plants are feeling it too.”

Learn more about the JBT iOPS Dashboard

JBT HPP Webinar: learn about the benefits of HPP Tolling

Whether you are a smaller company interested in learning more about the advantages of High Pressure Processing (HPP) or a larger business looking to invest in the technology, JBT Avure will be hosting a webinar examining HPP and the business of HPP Tolling. For smaller companies keen to benefit from HPP, tolling offers more cost-effective access to the technology.

Taking place on Wednesday January 20 at 9 AM EST, 3 PM CET, the JBT Avure HPP Webinar will provide a chance to hear from both sides of the tolling process from speakers Joakim Lungren, CEO of HPP Nordic, and Tanya Lambert, founder of the UK-based Tanya’s Just Real juice company.

As the owner of a leading European tolling facility, Joakim Lundgren will be talking about the business aspect of running such a center, while Tanya Lambert, who uses HPP Nordic for pasteurizing the Just Real range, will be talking from an end-user perspective of taking a product to a tolling facility.

Affordable alternative
“The focus of the webinar will be on the tolling aspect of our business,” explains JBT Avure’s Lisa Wessels. “Tolling is ideal for smaller companies that can’t afford to buy machinery or put in production lines or don’t have factories. They can take their product to a toller and pay to have their product High Pressure Processed.”

She adds: “We would love for more companies and more entrepreneurs to open tolling facilities anywhere in the world, and we’d like smaller companies who maybe think they can’t afford HPP to know you don’t have to be a big company to use this technology.”

The JBT Avure HPP Webinar will take place on Wednesday January 20 at 9 AM EST, 3 PM CET

Register HERE for the webinar

JBT wins strategic order for Precifill Weight Filler in Asia Pacific

JBT has won a strategic order for the high-accuracy PrecifillTM Weight Filler in the Asia Pacific region, underlining the importance of the technology to companies in the dairy, juices and infant formula industries. In this particular instance, the Precifill will fill juices and dairy alternatives in glass bottles at 36,000 cph.

A non-contact weight filling system, the Precifill is an extremely accurate solution which minimizes product give-away. The filler, which is equipped with effective Clean-in-Place provisions, handles plastic and glass bottles, plastic cups, glass jars and cans, and can be equipped with a conditioned filling space to meet hygienic filling requirements.

Historical success
In 1990, JBT SFDS – then known as Stork – installed its first Precifill Weight Filler for white milk in bottles. Since that time, Stork and JBT have built hundreds of weight fillers, the majority of which have been installed in the dairy, juices and infant formula industry.

Following JBT’s acquisition of Stork in 2015, production of the rotary weight filling product line was transferred to the JBT St Niklaas plant in Belgium. JBT Sint-Niklaas has a 70+ year history of building and servicing rotary fillers and closers for cans, jars and bottles and is JBT’s global center of excellence for non aseptic rotary filling technology.

Industry growth
Since the early 1950’s Asia Pacific has been a key market for JBT’s rotary fillers, largely driven by the growth of the dairy industry in the region, according to Bart Mertens, JBT Product Line Director for Filling and Closing technologies. 

As well as the Precifill Weight Filler, JBT’s range includes the rinser and capper – in monobloc configuration together with the weight filler – the integrity checking and reject system, and the CIP (Clean-In-Place) kitchen.

The Factory Acceptance Test for the Precifill at JBT Sint-Niklaas is planned for Q2 2021, with installation projected to follow in Q3 2021.

Learn more about the Precifill Weight Filler 

Fresh opportunities ahead for TORR’s Engi-O system

The growth of new coffee products, such as Cold Brew, and consumer demand for fresh orange juice are likely to present increased opportunities for innovative bag-in-box filling systems from one of JBT’s newest alliance partners, TORR Industries. The company’s simple-to-operate solutions complement existing JBT technologies and are expected to help support the growth of innovative projects in the retail and foodservice sectors.

A design and manufacturing business based in Redding, California, TORR, which also markets aseptic filling machines under the Engi-O brand in Australia, specializes in bag and box packaging systems, and has grown to become one of the major vendors of filling machines for 1.5 to 5 liter packs worldwide. 

TORR technologies at customer BEL-OBST’s Belarus facility

Secure system
As TORR Sales Director Chris Rutter explains, TORR’s low acid aseptic Bag-in-Box filling system complements JBT’s portfolio of aseptic bag filling technologies, covering a wide range of products from wine to milk, cream and soups. 

TORR’s Engi-O double-membrane aseptic filling process utilizes steam and high temperatures to ensure a sterility assurance level validated by the FDA. Capable of filling 2-1500 liter containers for shipping, the closed system guarantees that sterile products like milk, cream, coconut water or vegetable pulps are not exposed to the outside atmosphere at any stage. “Any sterile liquids can safely and securely packed, meaning they can be transported without refrigeration whilst maintaining their shelf-life and complying with food safety requirements,” says Rutter. 

Emerging opportunities
“This is a very simple system and way less complicated from a machinery point of view,” he continues. “We can take the bags and put them into the boxes, so while JBT does the processing, we do the aseptic bag filling and can do also the boxing.”

Rutter views Cold Brew coffee and fresh fruit juice as being two of the most significant emerging opportunities for the technology. In the former case, Cold Brew – which provides the coffee taste without much of the bitterness – is a low-acid product that requires aseptic filling to be shelf stable. In the case of fruit juices, Rutter says being able to fill aseptically will enable retailers to be able to sell more fresh orange juice instead of the hot fill product present on most store shelves. Significant opportunities also exist on the foodservice side for ice cream mixers and fruit juices found in many fast-food outlets.

JBT Alliances
Liquid Foods Alliance Program is a growth platform allowing JBT to bring cutting-edge technological solutions to JBT customers. These solutions are typically sustainable, cost-effective, commercially viable, and complementary to the core JBT products. TORR and Engi-O alliance products are helping JBT offer a versatile solution for both low-acid and high-acid food products in a variety of packaging formats. Since the formation of alliance, JBT has received interest from customers for juice, dairy, coffee, and plant-based beverages. The TORR alliance has provided an excellent opportunity to the JBT team to engage with its customers at a deeper level, helping JBT close the technological gap and develop a thorough understanding of the customer value proposition in the aseptic filling market segment.

Learn more about TORR Industries’ solutions

More information about BEL-OBST can be found here

JBT keeps focus on sustainability with energy-saving systems

Sustainability has always been a key focus for JBT, and throughout 2020 there has been a large emphasis on improving and promoting sustainable practices both within JBT and externally across the food and beverage industry. JBT has continued to innovate, offering new and existing technology that can significantly boost customers’ sustainability credentials.

JBT’s sustainability drive is focused on four central pillars: providing solutions that reduce the total cost of ownership by enabling companies to become more sustainable in the use of energy, water and steam; solutions to reduce food waste in the production and supply chain; adapting highly-efficient solutions for the food and beverage segment; and improving sustainable practices within JBT facilities worldwide.

Substantial savings
One of the ways JBT is helping customers improve sustainability at the production level is through the Heat Recovery System (HRS) for the Continuous Rotary Pressure Sterilizer. Offered as an upgrade package for customers with existing and new (yet-to-be installed) Continuous Rotary Pressure Sterilizers. The HRS is focused on achieving optimum savings during the sterilization process for products requiring a pre-heater. 

Among its key benefits, the HRS can deliver a reduction in steam usage of up to 40% and decrease the overall thermal load of the cooling tower, resulting in substantial energy savings. In fact, the system offers a high return on investment, with a payback within two-three years based only on steam reduction costs.

Energy reduction
A further valuable sustainable solution from JBT is the Energy Recovery System for Retort Sterilizers (ERS), which makes use of a Hot and Cold water tank that acts as a battery to transfer energy between the Come-up and Cooling portions of a retort’s thermal process. The system collects energy from hot process water and transfers this energy to the cold-process water during the come-up phase. The system also improves energy recovery by using minimum steam during this phase.

The ERS can additionally be combined with JBT’s Low Energy Suction System (LESS) for Static Retorts, a passive suction system which draws in water evenly along the length of a retort. This allows less water to be used in the retort during the thermal process resulting in less steam being required to heat and less water to cool.

Ensuring savings
Other energy-savings options available from JBT include indirect heating utilizing a shell-and-tube heat exchanger, which provides energy, water and chemical savings by recovering steam condensate.

Additionally, JBT’s Rotary Pressure Sterilizer includes an Eco-Mode that enables customers to reduce steam energy consumption when the machine is operating without cans by reducing the temperature until cans are reintroduced into the sterilizer.

By continuing to assist customers in reducing their energy, JBT has helped bring sustainability to the forefront of the food and beverage industry agenda and will strive to ensure the topic gains greater prominence over the months ahead.

Learn more about JBT’s commitment to sustainability

A long-term commitment: JBT’s Retrofit Kits

JBT level fillers, weight fillers, Unifillers, can closers and cappers have a solid record for long-running performance, sometimes stretching back over decades, covering both new builds and second-hand machines. But even the best-performing equipment requires updating and upgrading after years of service, and this is where JBT Retrofit Kits come in, offering a solution that can bring filler and closer machines into the 21st century.

“We have a lot of these machines in the field that are 20-30 years’ old and are still running quite well,” explains JBT’s Ben Verbeeck. “However, after such a length of time, improvements are often needed in terms of both hygiene and filling accuracy, and we have developed solutions for that in the form of different kits.”

Person installing JBT Retrofit Kits

JBT Retrofit kits are not only capable of bringing hygiene to 2020 levels, but they can also boost filling accuracy, making sure any wastage is kept to a bare minimum. They can further improve product handling, upgrade machine hygiene and replacing obsolete OEM components, updating software programs and improving maintenance in the process. “These are solutions for machines that are still operating well, but it’s all about bringing them into the 21st century,” says Verbeeck.

Tailored packages
JBT Retrofit Kits are part of a long-term commitment to customers by ensuring that even well-seasoned equipment receives the high quality maintenance and machine upgrades that enable companies to get the most value out of solutions and realize more operational savings.

The kits offer tailored original component packages that deliver cost-effective, quality results, including effective installation, commissioning and operator training by JBT’s skilled service teams to help maximize the return on investment.

Learn more about JBT Retrofit Kits for Filler & Closer Equipment

JBT destaca o comprometimento com os processadores e exportadores brasileiros

Read this article in English

2020 tem sido um ano de mudanças para a JBT no Brasil, mas por razões positivas, não em relação à pandemia do Covid-19. Ao contrário de se intimidar devido às circunstâncias desafiadoras, a JBT continua a apoiar processadores e exportadores por meio de um grande investimento na expansão de suas instalações de fabricação e treinamento.

Inaugurada em maio de 2020, a instalação localizada em Araraquara, São Paulo, acrescentou 1.793 m2 à unidade de 11.042 m2 já existente (incluindo uma expansão de 1.016 m2 do centro de fabricação). A JBT também vem investindo separadamente em tecnologias para auxiliar os clientes no Brasil durante a continuação da pandemia, incluindo a adição de conectividade à internet (iOPS Gateway) aos equipamentos existentes da JBT para possibilitar a assistência remota, além de lançar no país óculos inteligentes inovadores PRoSIGHT para auxiliar os técnicos da JBT a diagnosticar problemas à distância.

Soluções tecnológicas
Ao discursar este ano na abertura da expansão de Araraquara, o presidente para o Hemisfério Sul da JBT FoodTech, J. Miguel Ruiz, descreveu o investimento com um exemplo do “comprometimento da JBT com o Brasil.” “A atual situação de mudança favorece empresas que exportam e, com isso, os exportadores de alimentos aumentaram e passaram a lucrar mais”, afirmou Ruiz, que explicou que a nova instalação atenderia à demanda dos clientes por novas tecnologias e planos de investimento durante e após a pandemia. 

“O investimento em nossa instalação de produção no Brasil é um reconhecimento de nossa competitividade e do bom trabalho realizado por nossa equipe no Brasil nos últimos anos”, ele acrescentou.

Protocolos de segurança
Atualmente, a unidade de Araraquara recebe tours virtuais da instalação e um número limitado de visitas presenciais, proporcionando uma atualização concisa dos mais recentes desenvolvimentos da JBT, além de uma chance de ver novas soluções e tecnologias da JBT em ação. A instalação ajudou a implementar protocolos de distanciamento social, incluindo uma câmera térmica para os funcionários e visitantes. Entretanto, a JBT também está se preparando para a vida pós-pandemia ao trazer novas soluções de esterilização UHT para o crescente setor de laticínios brasileiro e, ao mesmo tempo, assegurando que os clientes estejam mais conectados com a JBT do que nunca.

Entre em contato com a JBT no Brasil para saber mais

JBT underlines commitment to Brazil’s processors and exporters

Leia este artigo em Português

2020 has been a year for change at JBT in Brazil, but for positive reasons rather than anything to do with the Covid-19 pandemic. Far from being deterred by the challenging circumstances, JBT is continuing to support processors and exporters by making a major investment in the expansion of its manufacturing and training facility.

Inaugurated in May 2020, the Araraquara, São Paolo-based facility has added an extra 1,7934 m2 to the existing 11,0421 m2 site (including an 1,0160 m2 expansion of the manufacturing center). JBT has also separately been investing in technologies to support customers in Brazil during the ongoing pandemic, including adding internet (iOPS Gateway) connectivity to existing JBT equipment to enable remote assistance, as well as introducing innovative PRoSIGHT smart glasses to the country to help JBT technicians diagnose problems from a distance.

JBT’s PRoSIGHT uses augmented reality smart glasses

Technological solutions
Speaking at the opening of the Araraquara expansion earlier this year, JBT FoodTech Southern Hemisphere president J. Miguel Ruiz described the investment as an example of JBT’s “commitment to Brazil.” “The current changing situation favors companies that export and with that food exports have increased and become more profitable,” said Ruiz, who explained the new facility would meet customer demand for new technologies and investment plans during and following the pandemic. 

“The investment in our Brazil manufacturing facility is a recognition of our competitiveness and the good work carried out by our team in Brazil over recent years,” he added.

Customers attend a workshop at the JBT Araraquara facility

Safety protocols
Currently, the Araraquara site host both virtual tours of the facility and a limited number of in-person visits, providing a concise update of the latest JBT developments and a chance to see new JBT solutions and technologies in action. The facility has helped implement social distancing protocols, including a thermal camera for both employees and visitors. However, JBT is also preparing for post-pandemic life by bringing in new UHT sterilization solutions for Brazil’s expanding dairy sector, while making sure that customers are more connected with JBT than ever before.

Learn more about JBT in Brazil

JBT’s AsepFlex™ Aseptic Pouch Filling helping customers achieve sustainability

As pressure on food processors to switch to sustainable packaging has grown, so a trend has emerged in the pouch industry to find viable alternatives to the layers of non-recyclable plastic used to safely store baby foods, purees, soups and other products. JBT has been supporting these efforts through innovative aseptic filling systems, which allow the safe filling of recyclable pouches without damaging their integrity by subjecting them to high temperatures.

“The pouch market is changing rapidly driven by the sustainability movement,” explains Patrick de Groot, JBT President for Liquid Foods in the EMENA region. “For aseptic this is a huge opportunity as these recyclable polypropylene (PP and PE) materials are sensitive to heat, therefore the hot fill and retort process requires thick and expensive multilayers. With aseptic technology, the process is mild with only a short sterilization cycle, followed by ambient processing and filling.”

Viable alternatives
“We’ve had multiple types of packaging in the world for many years: rigid, flexible and carton,” continues de Groot. “Sustainability is gaining a lot of attention with all the big players these days, but it is not always a straightforward process to recycle these materials.”

Although pouches have been around for a number of years, their typical composition – multiple layers with aluminum, PET on the outside and a further PE layer on the inside to protect the product – meant recycling was not a realistic option. 

With awareness of sustainability continuing to grow and companies across the food industry investing in more sustainable packaging, so the pouch sector has also tried to find viable alternatives. However, de Groot explains that the problem up until now is that fully recyclable PP or PE material is unable to withstand the high temperatures used for hot filling, which has traditionally been the norm in the industry.

Aseptic filling
Here is where JBT enters the story. JBT’s innovative AsepFlex Linear Pouch Filler system is now providing customers with the means of switching to fully PP or PE pouches without suffering the detrimental effects of hot filling on the material. 

“A PP or PE pouch is not as rigid as one with aluminium or Oriented Polypropylene (OPP), and therefore is not able to withstand high temperatures used to fill most pouches on the market,” says de Groot. “With aseptic technology, you don’t need to do a hot fill or go through a retort, you can sterilize the pouch without having to expose it to high temperatures, therefore aseptic technology is attracting lots of interest as it also brings the ability to process high quality natural low acid products. 

“Aseptic technology is an add-on not only from a product quality perspective, but the technology also allows you to treat fully-recyclable PP or PE pouches with thin layers.”

Learn more about the JBT AsepFlex Linear Pouch Filler