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JBT Proseal: boosting safety and productivity through innovation

2020-06-16 Proseal tray sealing ProVision Press images laptop machine line 03

Keeping production and packaging lines moving in these challenging times has become a key consideration for companies across the food processing industry, with worker illnesses and absences placing pressure on supply chains. Add to this the need to minimize downtime and the continuing growth of internet shopping and companies have a lot to think about.

JBT Proseal, which has a strong record in packaging innovation, is rising to meet these challenges with new developments in automation and data analysis, which have been designed to improve both productivity and food safety.

Limiting downtime
Focused on making life easier for processing companies, ProVision is a downtime analyser which gives managers a dashboard providing an overall view of all production lines and pinpoints any problems that might be occur. “If you are the CEO of a business and you have 10 production lines and one of those has failed for a day, you will want to know about it,” says Proseal’s Head of Sales & Control Systems, Tony Burgess. “If, in all your 10 production lines, for one minute of every hour the line stops because of a failing piece of equipment, in a month’s time that will could have added up to one day’s lost production.

“ProVision will capture all of these micro instances and build a series of data. It will tell you exactly the downtime and cause of downtime over the last 24 hours. It allows the user to focus attention on the piece of equipment on the production line that is causing the downtime and do something about it, so it has an enormous productivity benefit.”

Dynamic growth
A further area where Proseal sees an opportunity is in the booming online market for food ingredients and ready meals driven by increasing consumer interest in cooking at home. Proseal, Burgess reveals, is supplying eco-friendly Halo tray forming equipment to Dineamic, an Australian company which delivers chef-cooked meals to consumers across the country. “Dineamic produces their own foods, seals them with Halo pack trays made in house with a Proseal tray sealer and then sends them mail-order,” says Burgess. “Similar work is being done in tother geographic locations.”

However, such developments are not just taking place in the food industry. Proseal, Burgess adds, is currently working on a project in the Netherlands for online flower orders by designing packaging options suitable for sending flowers by mail-order.

Learn more about Proseal solutions

JBT to host free Prepared Food webinars

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JBT will be hosting free webinars on September 7, 14 and 21 – in English, Spanish and Polish – focusing on JBT’s innovative solutions for secondary processing of prepared foods, including effective systems from pre-mixing ingredients, preparing recipes, sterilization and pasteurization, to filling and post filling treatments.

Prepared Foods is a big field of discussion, but the webinars will focus on Liquid Prepared Foods such as Sauces and Soups with or without particles. From chunky fruit and vegetable pieces to thick vegetable soups, viscous products – especially those containing large particles – are not always simple to handle, but JBT provides solutions that can process viscous products (of over 600 cP) and large particles measuring more than 9mm. 

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Customized solutions
“JBT can provide a solution for medium to high volume preparations and soups that are either high in viscosity or have large particles that are sensitive to damage,” says JBT’s Miguel Sánchez, who explains that after meeting with the customer to better understand their needs and requirements, JBT presents a customized solution using a combination of JBT machines.

The objective of the webinars, Sánchez continues, is to give customers an awareness of the technology and an understanding of how JBT can provide a source of knowhow across a range of different product areas. “We are the perfect partner for improving quality using the brands we have,” he adds. “We also support customers through R&D and via our tech centers, which is quite unique.”

The JBT Prepared Foods webinars will be held on September 7, 14 and 21. To register free-of-charge for the English, Spanish or Polish sessions, simply click on the link below:

07 September 10 am CET in Spanish: https://bit.ly/32JWyjx 

14 September 10 am CET in English: https://bit.ly/2YNzCig 

21 September 10 am CET in Polish: https://bit.ly/2Ey0Mml 

SeamTec seamers strengthen JBT’s leading role in infant formula industry

JBT has announced the shipment of seven more SeamTec high-speed closers for powder to serve the Global Infant Formula Powder industry, further strengthening JBT’s leadership position in the infant formula key growth areas of Europe and Asia Pacific.

Requested by three new customers, the SeamTec seamers, which feature line speeds ranging from 150 to 550 cans per minute (cpm), have been developed and manufactured at JBT’s Sint-Niklaas, Belgium, site.

Since its introduction some 10 years ago, JBT’s SeamTec for Powder Seamer has led the market for medium-to-high speed clinchers and closers for the infant formula powder industry. SeamTec seamers set new standards in terms of hygienic design, can and cover format change-over, reliability and cleanability.

JBT’s SeamTec for Powder Seamer is a leading system for the infant powder industry

“Recently three new customers confirmed their confidence in JBT and the JBT SeamTec seamer technology by placing orders for a total of seven new machines with JBT Sint-Niklaas, Belgium,” says JBT’s Produce Line Director for Filling & Closing, Bart Mertens. “All three customers are currently using non-JBT clinching and closing technology.”

Three of the machines are being supplied to a leading player in the infant formula can making industry, while two more are being shipped to a global market leader in the infant formula filling industry. During August 2020, a further two SeamTec seamers successfully passed the Factory Acceptance Test and have been made ready for shipment to Asia.

“These new machine shipments to Europe and Asia-Pacific further strengthen JBT’s leadership position in these key growth regions for the infant formula industry,” adds Mertens.

Learn more about the JBT SeamTec Seamer for Powder

JBT Proseal: meeting the quality petfood challenge

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JBT’s Proseal tray sealing technology is enabling pet food manufacturers meet growing demand for high quality products and packaging, as well as providing mass customization solutions that can help businesses diversify and introduce online ordering for home delivery services.

A recent report from Transparency Market Research has predicted a CAGR of 6% in the global pet food market over the next decade, reaching an expected value of US$168.3 billion by 2029. Increasing consumer demand for premium quality products has led manufacturers to use high quality materials and ingredients while streamlining  production techniques and processes, with the corresponding need for appropriate quality packaging to reflect this premium image.

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The comprehensive Proseal tray sealer range has the flexibility to perform in a wide range of disciplines, including Gas Flush Modified Atmosphere Packaging (MAP), Vacuum MAP with lid control and Skin Packaging. In particular, the company’s advanced sealing systems ensure absolute control and integrity of the seal between the lid and the tray, a vital requirement for applications that incorporate a substantial controlled-retortion-process or other High Pressure sterilization processes after sealing. 

The tray sealers also include several Proseal-developed features that help to maximize performance, reliability and efficiency, such as the company’s pioneering Eseal® energy saving technology, ifilm™ intelligent film monitoring, and ProTect™ RFID access login system that provides full audit trail visibility and layered security.

In addition, Proseal’s AP60 linear conveyor tray sealing system is able to provide bespoke automated solutions for high speed applications and demanding production conditions, based around individual customer production processes and requirements.

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Among the system’s many features, the length and width of the indexing conveyor can be customized to accommodate de-nesting and filling requirements. Full or partial vacuum systems can be incorporated to enable post seal processes such as retort or High Pressure Processing (HPP), and X-ray inspection systems and checkweighers can be included after sealing for enhanced quality control. The AP60 also offers seamless integration with third party process equipment including depositors, multihead weighing applications and CIP systems with sealing speeds of up to 240 packs per minute.

Furthermore, Proseal’s AP60 benefits from shared technology across the Proseal machinery range. Options can be specified and retro-engineered, allowing a more flexible approach to each distinct application. All Proseal machines offer a user-friendly interface and easy to maintain design, with a rugged and hygienic food industry approved construction geared to full washdown protection.

“As the pet food market continues to expand, we are keen to provide solutions for companies requiring a significant upscale in their production of core products in new packaging formats, which can be met on one machinery platform,” says Tony Burgess, Head of Sales and Control Systems, Proseal. “The flexibility of our technology and the wide variety of machines available, including fully integrated conveyor systems, mean we can offer a full turnkey production line solution which is key for this particular market. We are delighted that our expertise can help companies to achieve a point of differentiation in the competitive pet food sector.”

Learn more about Proseal’s packaging solutions

JBT AGVs: the automated solution to labor problems

JBT AGV

Among the many consequences of the COVID-19 pandemic, perhaps one most keenly felt by the global food industry has been pressure on traditional labor sources. Worker absences due to illness or localized outbreaks can play havoc with the supply chain, increasing pressure on processors. One growing area offering a practical, cost-effective solution is JBT’s innovative AGV (Automatic Guided Vehicle) range; a solution that is enabling companies to save labor for higher value tasks and increase social distancing.

More than simple robotic systems, JBT AGVs feature an advanced navigation system which creates a virtual map of the surroundings in which it operates, allowing it to safety move around the working area. Further, JBT AGVs now come with 2D and 3D cameras for safe positioning and vertical stacking of pallets above the level of the AGV. 

Different applications
According to Mark Longacre, Application Engineering Manager for JBT’s AGV division, such innovations are helping spark an expansion in the use of AGVs from manufacturing areas – where the vehicles would be used to move raw materials or finished goods – to warehousing and distribution. “In the past, AGVs were more of a horizontal transport solution and now they are getting much more vertical where we are storing in warehouses, in some cases quite high,” he says. “It’s not to say that those manufacturing applications have gone away. They really haven’t, but now we are also seeing this growth in the warehousing side.”

As demand for different applications has grown, so has the advancement on what Longacre describes as natural environment navigation, where the AGVs create a baseline map by sensing the features and contours of the surrounding environment. “As the AGVs operate, they compare what they see with their sensors to that baseline map, and accurately navigate in that environment,” explains Longacre. “By recognizing the natural environment and not adding special navigation aids or markers , it makes installation quicker and less costly.”

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Strong ROI
Longacre believes much of the recent increase in interest in JBT AGVs can be put down to pressure on the labor market as well as greater awareness of the strong ROI offered by the solution. “Companies in the past were looking at it purely as a financial equation where they looked at how many forklift operators they had and how much labor they were going to save, but now I think they are starting to understand some of the risks associated with the labor force,” he says. 

“I don’t think they are going to abandon the financial models, but I think they are going to weigh things a little differently. You want to save labor for the highest value added task and driving forklifts is not something where you have to use labor.”

Learn more about JBT AGVs

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

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

JBT’s Unifiller innovations reduce Total Cost of Ownership

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JBT has introduced new, unique features for the JBT Unifiller, the volumetric piston filler for high value products, with key attributes such as a unique seal-less and self-draining fill station concept, which substantially differentiates the Unifiller from conventional piston filling technology.

A new Configure to Order (CTO) option and in-line check weighting are now being included with the Unifiller as a means of significantly enhancing existing processes, enhancing safety and minimising giveaway.

The two innovations will help further boost the three key benefits of the Unifiller: Clean In Place (CIP) without fill station disassembly; unmatched fill accuracy; and high product particle quality. These also make the Unifiller an even better solution for filling high-value segments, including sauces, jams and sweet spreads, ready meals, cream and condensed milk in metal or glass containers.

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Configure to Order
JBT has recently completed a Configure to Order (CTO) exercise on the Unifiller with the objective of reducing the cost and delivery time, says Bart Mertens, JBT’s Product Line Director for Filling and Closing Equipment. 

The CTO exercise also includes an upgrade of the basic machine with features that were previously optional, including: sealed upper guarding with standard safety glass for enhanced operator safety and chemical resistance; a stainless steel central column for longer life, lower risk of blockage and improved hygienic; easy-to-clean, hygienic electropolished fill stations; and a single point container height adjustment for more convenient can format change-over.

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How the JBT Unifiller valve filling principle works

Minimize giveaway
To further reduce the Total Cost of Ownership, JBT is also now offering optional in-line check weighing technology, for speeds of up to 700 cpm (containers per minute). “The use of this technology in combination with the Unifiller allows for the monitoring of the fill accuracy performance of each individual fill station and features automatic on-the-fly fill volume adjustment to minimize giveaway,” explains Mertens.

Additionally, the Unifiller, ensures E-mark compliance by rejecting under- and over-filled containers that fail to comply with the standard in order to protect downstream sterilization equipment.

Learn more about the new JBT Unifiller

A&B Process Systems receives safety award from ConstructSecure

JBT’s A&B Process Systems has been recognized by ConstructSecure as one of their Safest Contractors & Vendors. A&B received the Platinum Safety Award for scoring greater than 95% in the safety assessment administered by ConstructSecure. 

The award from ConstructSecure, a global SaaS company that prequalifies contractors and vendors for corporations that have stringent safety requirements, is based on an assessment of current safety management systems and incident rates.   

“Our associates really get it and are on board with our culture of safety,” said Bill Thompson, A&B’s HSE Manager. “Our associates continue to go the extra mile in their daily work to help prevent safety incidents and this award is a testament to their dedication to safety.

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“Our team members do a great job of preventing incidents from occurring.  If they see a potential risk, they report it as a near miss right away and it is addressed immediately. We truly appreciate everyone’s dedication to being as safe as possible.”

Scott Raether, Director of Operations for A&B, added: “We have an incredible group of dedicated employees who believe that zero injuries are expected. We pay attention to little details and truly look out for each other. Awards are terrific, but what’s more rewarding is the knowledge that our employees are acting safely and contribute to a safe place to work.”

Learn more about A&B Process Systems’s solutions

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