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JBT’s A&B contributes to award-winning Pfizer facility

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Pharmaceutical company Pfizer has been announced as Facility Integration Winner at the 2020 Facility of the Year (FOYA) Awards for the development of a new, 175,000 sq ft, state-of-the-art manufacturing site; a project in which JBT’s A&B Process Systems played a significant part, working closely with Pfizer in the design, manufacture and installation of bioreactor skids, CIP skids and biowaste systems.

Launched in 2015, Pfizer’s “Project Indigo” involved the relocation of clinical manufacturing capabilities from Chesterfield, Missouri to a new facility on the existing Pfizer Andover, Massachusetts, campus, as part of a move to expand clinical biological drug substance manufacturing capacity from 14 to 21 campaigns per year.

A&B’s brief was to provide super skids for the site to Pfizer’s specifications, successfully winning the contract after submitting an initial proposal. The project would feature the bespoke design of two bioreactor skids – one bioculture and another for dual use, with tanks, automation and platforms – as well as three Clean-In-Place (CIP) skids and two biowaste systems.

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A&B custom fabricates complete process systems into skidded modular process systems

According to A&B’s Nick McCauley, the project from initial brief to final installation was a 14 month process, which involved 3-D modelling, weekly meetings through every phase of design and manufacture, leading up to final integration into the facility. “We carried out 3D modelling, manufactured and provided the reactors and skidded system, installation of wiring and electrical and acceptance tested after completion,” he explains. “A lot of competitors don’t have all of those capabilities in-house and we’ve received a lot of positive feedback from the customer.”

Around 40% of A&B’s total business involves projects with the pharmaceutical industry, including many leading multinationals, and McCauley says that A&B is continuing to provide support to customers during the current pandemic. “We are supporting customers as much as possible and we are poised and ready to help wherever we can,” he adds.

Find out more about A&B Process Systems’ solutions

JBT’s FTNON well placed to support fresh-cut industry during COVID-19 crisis

FTNON lettuce - Heemskerk Fresh & Easy

Although grocery retail sales for fresh products have remained steady during the COVID-19 crisis, the practicalities of dealing with such an emergency have created problems across the fresh-cut, ready-to-eat sector, largely as a result of worker absences and labor shortages. JBT’s FTNON business unit – a global leader in technological solutions for fresh-cut and other industries – is well placed to help companies cope with such difficulties, thanks to ingenious systems that can dramatically reduce the amount of manpower needed.

While grocery sales started strongly at the beginning of the crisis, the situation has stabilized and demand for fresh and Individual Quick Frozen (IQF) remains consistent, according to FTNON Sales Manager, Joost Lotgerink Bruinenberg. However, a combination of workers returning to their countries of origin as lockdowns have taken effect and the need to send employees home if they develop symptoms has increased pressure on food processors. 

Fresh green salad with spinach,arugula,romane and lettuce

Fresh green salad with spinach, arugula, romaine and lettuce

This situation, says Bruinenberg, has created an opportunity for FTNON, which provides automated systems covering everything from prepping and trimming for fresh-cut to blanching, cooling and steaming for IGF and ready meals.

“For iceberg, romaine and all kinds of lettuce, we can trim or de-core automatically, so no people are needed to do that job,” he explains. “For example, one person can trim on average 150 kilograms of iceberg lettuce in an hour and if you have 1000 kg, you need around seven or eight people. We can cut it down to two people: one who is feeding the line and another carrying out manual inspection. The rest is done by the FTNON system.”

The need for such automation is going to become more important after the crisis is over, predicts Lotgerink Bruinenberg, driven by greater awareness of food safety and traceability. 

“The industry is going to become more data driven,” he says. “Who grew it, when it entered the factory, what the temperature was when it reached the production area, which store it went to; these kinds of things will become more and more important.”

Learn more about FTNON’s solutions

JBT’s Gentle Can Handling: minimizing metal can damage during sterilization

JBT Gentle Can Handling

JBT has introduced a new breakthrough for Continuous Rotary Sterilizers called Gentle Can Handling (GCH) which reduces damage to food containers as they run through the sterilization process. GCH has the potential to enable customers to achieve higher speeds and more throughput or run lighter weight cans which may provide significant cost savings. 

For over 100 years, food processors have utilized the Rotary Pressure Sterilizer (RPS) to agitate and sterilize food products in hermetically sealed metal cans. However, over time, in the relentless effort to reduce cost and increase efficiency, processors have requested higher speeds from JBT and lighter weight cans from their suppliers. 

The early days of 25 cans per minute has evolved into speeds in excess of 1000 cans per minute for the modern RPS, but a combination of the higher speeds, lighter weight cans and new can geometries has, at times, resulted in unacceptable damage to cans. However, that has all changed thanks to a global team, consisting of JBT engineers from South Africa, Belgium and the US, who collaborated to design a new technology called Gentle Can Handling. This technology can be applied to both new RPS equipment and retrofitted to existing RPS equipment.

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Andrew Prins, JBT Technical Product Manager for Retort & Rotary, said: “After a can is filled and seamed, that sealed container goes into a rotary cooker in a continuous manner, entering the pressure cooker through a valve that works like a revolving hotel door on its side, and exiting in the same manner as a sterile product. But when you make contact with the can with the ejector that pushes it out of the reel and into the valve, you may cause damage to the container. We have come up with a new shape for the ejector and modified the other transfer components so that the can is removed from the reel and enters the valve in a more stable and controlled manner which reduces the impact forces the can experiences and thus can damage is greatly reduced.”

GCH, continued Prins, allows for much greater control the whole way through the process, so there is a gentler movement of the containers from one shell to the next. And because it is much smoother, it can also potentially run faster. With a maximum speed of about 600 cans a minute per lane, JBT customers are able to process up to 1200 cans a minute over two lanes.

“Gentle Can Handling provides processors with an improved technology to reduce can damage and potentially use lighter weight cans that may provide significant cost savings.” Prins added.

Learn more about Gentle Can Handling

SafeTraces saniDART receives AOAC approval

saniDART-product

JBT ally SafeTraces has announced that it has received regulatory approval from the US-based AOAC Research Institute (AOAC-RI) for its groundbreaking rapid sanitation verification solution, saniDART™. In doing so, saniDART has become the first rapid solution for verifying sanitation effectiveness at a microbial level to receive AOAC certification.

SaniDART addresses major shortcomings of two commonly used methods for verifying sanitation effectiveness in food production: the Adenosine Triphosphate (ATP) test and the Aerobic Plate Count (APC) test. The ATP test measures the effectiveness of the sanitation processes in removing organic matter but is not a reliable indicator of bacterial inactivation. Meanwhile, the APC test is a reliable indicator for bacterial inactivation, however the 48-hour wait period for results precludes making in-process corrective actions. In contrast, saniDART functions as a powerful tool for monitoring bacterial inactivation with APC-like test quality and results available at a speed closer to that of ATP tests.

“Now more than ever, consumers and regulators are demanding high standards and visibility into food safety practices throughout the supply chain,” says Erik Malmstrom, SafeTraces Chief Executive Officer. “There is a significant unmet need in the food industry for a better, faster, and cheaper solution for sanitation verification at a microbial level. SafeTraces responded and innovated, which is what we do best. Receiving AOAC validation, the gold standard for proprietary testing methods in food safety, is a major milestone for saniDART. We look forward to delivering this groundbreaking solution to the food industry in a big way.”

Verified effectiveness
Results in the AOAC validation report (Performance Tested Method #032001) provided evidence that saniDART is effective at detecting the presence of saniTracers™, proprietary abiotic bacterial surrogates and a key component of saniDART, on stainless steel surfaces representative in food processing and manufacturing facilities. SaniTracers are manufactured by encapsulating short, non-coding DNA sequences within food-grade material particles and are applied on food contact surfaces in processing facilities, including Zone 1.

SaniTracers are degraded and removed in a similar manner as microbes during cleaning and chlorine-based sanitizing, and can be quantified by a simple swabbing and on-site qPCR test that provides results in 25 minutes. By measuring saniTracers levels before and after sanitation, saniDART provides powerful, actionable information in a pass/caution/fail format for verifying sanitation effectiveness.

mini-DART

The saniDART rapid sanitation verification solution includes saniTracers consumables, test kits, an off-the shelf qPCR reader, and a tablet with a cutting-edge augmented reality (AR) feature to identify sampling points in food processing facilities. saniDART is supported by market-leading environmental monitoring software to manage floor plans, scheduling, corrective actions, reporting, and analytics.

About AOAC International
AOAC International (formerly the Association of Analytical Chemists) is an independent, third-party, not-for-profit organization that develops standards on measuring and determining the safety and integrity of food and other products worldwide. An AOAC-Research Institute (AOAC-RI) validation means that the manufacturer’s claims have been verified by a trusted third-party laboratory.

About SafeTraces
Founded in 2013, SafeTraces is a mission-driven team of entrepreneurs, scientists, engineers, and food safety practitioners dedicated to using nature’s DNA to make food production safer, more transparent, and more sustainable. SafeTraces’ rapid, easy-to-use, and cost-effective testing solutions for sanitation verification and traceability build on groundbreaking and patented DNA-based technology.

Learn more about SafeTraces

JBT backs greater sustainability for global juice industry

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Leer la entrevista en español

Interview originally published by asozumos.es and is reprinted with kind permission.

Interview with Francisco Purroy Balda, JBT EMENA Sales & Accounts Manager – Citrus & Juice Processing Technologies and Iberia Sales Manager – Liquid Foods.

1. Could you tell us briefly about your company?

JBT is an American, NYSE-listed corporation, headquartered in Chicago, and is one of the principal manufacturers of technologies for juices and beverages based in Florida, Brazil, Italy, the Netherlands, Belgium, South Africa and China. JBT has fruit, vegetable and juice extraction technology centres in Murcia, Spain and Parma, Italy, as well as in Florida, Mexico, and other locations. JBT emerged as a spin-off business from FMC, a company well-known in the citrus world, which has grown since then, reaching many other areas of food technology both organically and as a result of being very active in purchases and acquisitions. JBT’s current turnover has reached $1,900m USD, with some 6,500 employees worldwide. 

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2. What values define the philosophy of the company?

Pancho Purroy

JBT’s Pancho Purroy

Our values are Integrity, Responsibility, Continuous Improvement and Teamwork, but most importantly Putting the Customer First. Since its very beginnings, JBT has been an organisation with a laser focus on sustainability, driven by solutions such as food preservation – covering thermal and non-thermal, and including pasteurization, sterilization, cooling and freezing, autoclaves, hydrostatic towers, and High Pressure Processing (HPP) – and fruit and vegetable extraction solutions with the clear objective of maximizing yield and minimizing waste.

We continue to work very hard not only on the aforementioned where there is always scope for new solutions, but also on helping customers make energy and water savings in processing lines and through achieving added value from byproducts. 

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HPP technology from JBT Avure is finding greater acceptance in the juice industry

3. Taking into account the current situation, what are your company’s short, medium and long term objectives?

In the first place we continue to have our foot on the accelerator developing new technological solutions at the same time as we move forward with projects for achieving organic growth, efficiencies and synergies at an already significantly-sized company. JBT will also continue to move forward with our strategic acquisition programme, while ensuring we maintain our long-term goal of achieving greater ESG and sustainability. 

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JBT is involved in the roll-out of new, remote assistance technologies

4. From your point of view, what are the principal challenges currently affecting the juice industry and why is it important for the industry to support the work of ASOZUMOS?

The serious global crisis caused by COVID-19 is changing the working models every day for more and more industries. In ours, there are the classic problems and challenges of sugars and the image of juice, as well as price and quality inconsistencies in fruits and vegetables which vary from season to season, and the threat from Brazil and other places where things suddenly seem to take a left-turn with consumers buying up long-life juice, supermarkets closing all point-of-sale juicers, the industry wondering if there will be manpower available for produce harvesting, and prices for concentrate recovering quickly.

In whatever case, I believe it is imperative we all work together in ASOZUMOS to face the challenge that remains before us of educating consumers about the benefits of 100% juice, while avoiding confusion, misconceptions with triggers for obesity or diabetes, and wrongful associations with sugary beverages.

pile of juicy oranges in wicker baskets on market counter

5. What would you say are the skills and abilities being developed at an industry level and what opportunities are there to use them for the common good?

Economy and marketing of scale firstly. A common front against false news and hoaxes. And a strong defence of the industry against the threat posed by supply from emerging markets to the principal markets of consumption where ASOZUMOS members are located. We must do everything we can to achieve on the one hand an unimpeachable industry, 100% transparent, and on the other to make sure this industrial sector really thinks about and works towards the UN’s Sustainable Development Goals (SDGs). Millennials and the ‘Generation Hashtag’ won’t accept anything else.

JBT respalda más sostenibilidad para la industria global de jugos

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Read this interview in English

Artículo reproducido con permiso de asozumos.es

Una entrevista con Francisco Purroy Balda, EMENA Sales & Accounts Manager – Citrus and Juice Processing Technologies, and Iberia Sales Manager – Liquid Foods.

1. Presente brevemente su compañía (tamaño, ubicación, idiosincrasias, etc.). 

JBT es una corporación americana cotizada en el NYSE, sede corporativa en Chicago, principales fábricas para las tecnologías de zumos y bebidas en Florida, Brasil, Italia, Holanda, Bélgica, Sudáfrica, China… centros tecnológicos para las tecnologías de fruta y verdura, extracción de zumos en Murcia y también en Parma, en Florida, en México y otras localizaciones. JBT surgió tras una spin-off de la también muy conocida FMC, referente sobre todo en el mundo del cítrico, y ha ido creciendo desde ahí a muchos otros segmentos de tecnologías alimentarias, tanto orgánicamente como mostrándose muy activa en compras y adquisiciones. Actualmente la facturación alcanza los 1.900m USD y somos unos 6500 empleados.

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2. ¿Qué valores definen mejor la filosofía de su compañía?

Pancho Purroy

Pancho Purroy, JBT

Nuestros valores son Integridad, Responsabilidad, Incesante mejora continua, trabajo en equipo y en fin, el Cliente primero. Pero sobre todo hay una cuestión básica y es que desde sus principios ha sido una organización con un enfoque nuclear sobre la sostenibilidad, siempre liderando las tecnologías por un lado de de conservación de alimentos (tanto térmicas como atérmicas, pasteurización, esterilización, enfriamiento y congelación, autoclaves, torres hidrostáticas, Altas Presiones – HPP) como por otro en las soluciones de extracción de fruta y verdura con el objetivo claro de maximizar el rendimiento y por tanto minimizar el desecho.

Seguimos de lleno en esos aspectos y ahora trabajamos muy duro no sólo en todo lo anterior donde siempre queda margen, sino obviamente con igual ahínco en eficiencias energéticas de las líneas de procesado, en ahorro de agua, en valorización de subproductos…

JBT Avure at ProPak Asia

JBT Avure es un líder en la tecnología de Alta Presión (HPP)

3. Teniendo en cuenta la coyuntura actual, ¿cuáles son los objetivos de su compañía a corto, medio y largo plazo?

En primer lugar tenemos el pie en el acelerador en todo el desarrollo de nuevas soluciones tecnológicas, se están asimismo ejecutando iniciativas en pos del crecimiento orgánico y de las eficiencias, sinergias en una compañía que ya tiene un tamaño importante. Se va a seguir avanzando además en todo el programa de compras, muy estratégico. Y no podemos quedarnos nunca atrás en ESG, sostenibilidad: las metas deben ser responsables y largoplacistas.

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JBT ahora ofrece opciones de mantenimiento virtual a larga distancia

4. Bajo su punto de vista, ¿cuáles diría que son los principales desafíos a los que se enfrenta actualmente el sector de los zumos y que se abordan mejor todos juntos contribuyendo al trabajo de ASOZUMOS?

Esta profunda crisis global del COVID-19 está cambiando día a día los paradigmas que asumíamos en tantos y tantos sectores. En el nuestro, los clásicos problemas y desafíos sobre los azúcares y percepción de los zumos, de inconsistencias de precios y calidades de fruta y verdura en las diferentes campañas, la amenaza brasileña, u otros, de repente parecen dar un giro con consumidores acopiando zumo de larga vida útil, con supermercados clausurando todas las exprimidoras en punto de venta, con la industria pensando si habrá mano de obra disponible para las cosechas hortofrutícolas, con las cotizaciones del concentrado repuntando veloces.

En cualquier caso un reto que me parece imperativo afrontar todos juntos en ASOZUMOS es todo el trabajo que sigue quedando por delante hasta conseguir que los consumidores entiendan los beneficios del zumo 100%, sin confusiones, sin asociaciones o percepciones erradas con las bebidas azucaradas, ni con desencadenantes de obesidad o diabetes.

Rainbow Fruits

5. Así mismo, ¿cuáles diría que son las fortalezas que se generan a nivel sectorial y las oportunidades que identificaría para utilizarlas por el bien común?

Economía de escala y marketing de escala por supuesto. Frente común ante las noticias falsas y los bulos. Y defensa fuerte del sector frente a la amenaza que supone el suministro desde mercados emergentes hacia los principales mercados de consumo de los miembros de ASOZUMOS. Debemos hacer lo posible para que éste sea por una parte un sector intachable, 100% transparente, y por otra un sector industrial que realmente piensa y se ocupa de los Objetivos de Desarrollo Sostenible (ODS). Millennials, generación hashtag etc no van a aceptar otra cosa.

 

JBT iOPS® Gateway: a technological solution for a changing world

2020 is likely to be the year in which JBT’s Internet of Things (IoT) offering, the Intelligent Operations or iOPS Platform, takes centerstage across the food and beverage industry, thanks to the roll-out of the virtual technology across multiple JBT solutions and the consequences of the ongoing COVID-19 pandemic. Working by collecting and learning from data in real time from systems and machinery, the iOPS system can detect potential issues before they become problems and even improve the overall efficiency of operations.

JBT’s iOPS Gateway makes use of real-time data so customers can have a better view of when machines require preventative maintenance based on numbers instead of time, explains Auke Bouwense, JBT’s Global Internet of Things (IoT) Commercial Manager for Liquid Foods.

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The technology, he continues, also enables customers to gain a far clearer idea of the true state of their Overall Equipment Effectiveness (OEE). “Customers might have the idea they are running very well, but if you compare the amount of production the machine is running with other machines, you often find it is capable of doing a lot more,” he says. “The iOPS system can make operations more efficient and, therefore, our machines more effective, and ultimately make our customers more profitable. It will also enable JBT itself to better make further improvements to our solutions.”

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JBT’s iOPS Gateway can help improve the efficiency of systems across a facility

Greater efficiencies
One area of JBT where the iOPS platform is already very much present is with JBT’s fresh-cut processing solutions provider, FTNON. The Netherlands-based unit has the technology installed in a number of its systems and Bouwense says customers often find they could be achieving greater efficiencies. “What FTNON has very much found is that although their own customers often think their machines are running well, when they engage an iOPS system and look at the effectiveness of the total line they sometimes find they are running not even at a third of the total,” he says.

The iOPS system, Bouwense explains, looks at what is going on inside the machines and what products are going through them, identifying whether there is unnecessary wastage during the process, or whether leaks or misconfigurations are leading to higher utility bills. “JBT’s iOPS technology can help reduce losses and also provide better insight into where customers are losing time,” he says.

With the onset of the COVID-19 pandemic, and greater numbers of companies moving to remote working as a result, Bouwense adds that an iOPS integration can provide an overall, accurate picture of food and beverage processing operations without always having to be there in person.

Find out more about JBT’s iOPS solution