Hosted by John Bauer, JBT Product Manager for Freezers, the JBTConnect webinar will look in detail at the advantages offered by the CleanFREEZE’s incredible features, including external fan motors and Clean-in-Place (CIP) technology.
Radical redesign The newly-launched CleanFREEZE marks a step-forward from the long-standing Northfield SuperTRAK Structure Supported Spiral Freezer, with a system that offers innovations in both hygiene and cleaning. A radical redesign of the freezer has been focused on making the machine easier and faster to clean and has significantly reduced the risk of bacterial growth across the structure.
According to Bauer, the CleanFREEZE takes the original SuperTRAK design and adds new hygienic features, including innovations that differentiate the CleanFREEZE freezer from other spiral freezers and go beyond what is currently available on the wider market.
The JBTConnect Northfield CleanFREEZE Spiral Freezer webinar will take place on June 24, 2021 at 03:00 PM Eastern Time (US and Canada)
First established in 1982, JBT’s Sandusky, Ohio Food Processing Technology & Training Center, has long provided customers with the opportunity to watch equipment in action before installing it into their factories. However, far from resting on its figurative laurels, the center is now breaking new ground, explains facility manager John Arnold.
The Sandusky Tech Center was originally set-up almost four decades ago to focus on the Stein brand, but since then we have progressed enormously and now have the ability to demonstrate almost all JBT Protein equipment. Our on-site testing capability features portioning, marination, coating, frying, cooking, weighing, material handling, and mixing equipment. We also have substantial freezing technologies, which we are now complementing with a new Northfield CleanFREEZE spiral freezer that will be available for testing mid-summer 2021.
Customers come in for different reasons: they might be looking at new equipment and want to know how it performs, in which case we can run product testing and look at how the process works in a conveyorized system. Or it could be an R&D project and maybe they can’t get time on an actual production line and want to have a look at how their new product cooks or freezes. It could be a case of wanting to look at a different process with the aim of increasing yield and throughput. We also work with industry partners by providing the facility and equipment for clean label ingredients, new types of coatings or other processing aids that are used in the production of food items.
Of course with Covid, travel has been tougher especially between countries, so we will video the process or use online platforms to make it a virtual visit. For people travelling internationally who can’t get here, using these technologies and platforms allows them to watch the equipment in action, even at a distance.
This is not to say the pandemic was not without its challenges. A key element of what we do – in-house, hands-on training – was effectively halted as a result of the situation, but the expectation is this will be back on track by mid to late summer 2021.
The ability of the TIPPER TIE TTSealH to increase productivity and lower costs for companies sealing sausage meats and other products with high speed clippers will be the subject of a new JBTConnects Webinar on May 20, with customers able to find out how the system can make a noticeable difference to throughput across a range of industries.
A productivity accessory for the TIPPER TIE TT1815 or TT1512 double clippers, the TTSealH delivers key performance benefits to meat processors, as well as to chemical, confectionary, and dairy manufacturers. The precision-engineered state-of-the-art system for packaging pumpable product improves productivity and lowers packaging costs for processors seeking greater throughput beyond the capabilities of bench clippers or semi-automatic closure machines.
Key benefits “The TTSealH is a heat-seal machine which converts flat-stock film into a sealed casing, which can then be stuffed with any pumpable product,” explains TIPPER TIE’s Conrad Faust. “The big advantage here is that instead of using a more expensive pre-shirred casing which has to be changed every 90 seconds when you are running quickly, the flat-stock film heat-seal machine will eliminate those casing changes. Instead of having to change casings every 90 seconds, you only have to change a roll of film every three or four hours, or longer depending on the product.
“That gives you a lot more productivity and throughput during the course of the day, as well as reducing your cost because the flat-stock films can be cheaper than a pre-shirred casing and a lot less waste.”
Plant-based protein alternatives is an industry that has grown in significance hugely over recent years, and will likely continue to do so. Here, JBT’s Sales Director Sergio Rabadán Velazquez explains what is driving the trend and why all players in the industry need to pay close attention.
Ask what have been the key trends of the last 12 months and the answer for most people – with good reason – will be an obvious one. But away from the pandemic, another important trend has been making an impact and will continue to do so in the months and years ahead: the demand for plant-based meat substitutes across a wide swathe of products. At JBT, we have working closely with the processing industry to develop tailored solutions to fit individual product needs.
Of course the subject of plant-based foods at JBT is not a new one. We have been working for a number of years on applications that substitute animal protein for vegetable protein. But what has happened in more recent times? There has been a huge change with a focus on a reduction in the production and consumption of meat because of its impact on the environment and a growing interest in proteins generated by plants. There is also a perception among many consumers that vegetable protein is better for a healthy diet than animal protein.
How significant is this trend? Well according to a study carried out by Euromonitor International, global sales of meat and milk alternatives reached US$36 billion in 2019 and are continuing to grow. Sales of meat substitutes rose by 9% between 2019-2020 compared with 4% over 2018-2019.
As these figures indicate, one of the most important segments within plant-based foods has been the growth in products based on plant proteins that seek to imitate traditional, meat-based products. This has led to an enormous boom in hamburgers, sausages and bacon based on vegetable proteins.
To meet this demand, we at JBT have designed new processes for our customers who are formulating new products based on the raw materials. We help customers develop these products, adapting to each of the individual processes, the kind of product being developed, and the best means of processing it, at our Food Technology Centers, including at our facilities in Helsingborg, Sweden and Livingston, UK. We can assist customers in the development of the products, and following that we carry out practical testing in a factory setting.
Increased demand JBT’s considerable experience in delivering solutions for the plant-based foods industry has proven invaluable given the huge increase in demand at a consumer-level, and the need for processors to develop products that effectively mimic the taste and appearance of meat-based foods, often at speed.
An increased awareness of environmental concerns is fueling a desire on the part of many consumers worldwide to consume less meat. if you have a product that says it can effectively substitute meat in terms of taste, aroma, color to that which you have on your plate, and it comes not from animals, but from plants, people are willing to pay the same amount or more money for it. This has led to a demand especially for plant-based hamburgers, followed to a lesser extent by sausages and bacon substitutes.
However, substituting a meat-based product for a plant-based alternative that offers the same eating experience is far from easy. Taking plant proteins and developing a protein that imitates the text, color, taste and aroma of meats is very difficult to achieve. We at JBT have designed and developed processes and systems – from cooking to freezing – which do just that, but which furthermore are tailored to meet the needs of each individual processor, while also complying with stringent hygiene standards required when handling plant-based products.
It seems likely plant-based meat substitutes are here to stay, and we at JBT will make sure customers produce foods that deliver and optimum experience, from taste to texture, time and time again.
As food technologies and solutions have improved, so consumer buying habits have evolved, with an increasing emphasis on ready-to-eat (RTE) meals. However, handling such ready-made foods during freezing brings risks, including avoiding hazardous bacterial outbreaks. Protecting end consumer health and brand reputation has been key to the development of new freezing solutions from JBT, which are focused on eliminating possible bacterial growth.
Potentially deadly bacteria, such as listeria, that cause serious health emergencies can lead to factories being closed down – permanently. Even if this does not happen, the damage that can be caused to a brand’s carefully-honed reputation can be considerable, never mind that a food borne emergency can put consumers – adults and children alike – at risk.
JBT’s unique, hygienic solution combines disinfection with hot steam sanitation and innovative Fully Welded Enclosures (FWE), a hygienic design which removes the risk of bio film and microbiological growth in a freezer unit. “Steam sanitation works best with fully welded enclosures as normal caulked panels cannot endure the heat,” explains JBT’s R&D Manager Christopher Fogelqvist. “Cracks, worn parts, scratches—all defective points—are places where food can get caught and bacteria can grow. The one goal is to ensure no contamination that could harm the health of a consumer.”
Hygiene by design Offered across JBT’s entire Frigoscandia freezing equipment range, an indication of FWE’s success and trend towards the ready-to-eat market is the fact that quote requests for the technology doubled during 2020. “When it comes to designing freezer surfaces, we want to avoid having crevices because bacteria can get in there,” says Fogelqvist. “JBT’s freezing equipment range has been designed with open profiles, sloping and minimized overlapping surfaces, so that when you flush the freezer during cleaning, you don’t have any hidden surfaces with risk of bacteria growth.”
Fogelqvist says JBT achieves this by minimizing overlapping surfaces and fasteners, using welding to deliver freezers that are hygienic by design down to the smallest components of the machine. “The FWE is designed to ensure effective and efficient cleaning over the life of the equipment,” he adds.
The JBT Frigoscandia GC70 features a Fully-Welded Enclosure
Greater awareness The growth in the ready-to-eat category, he continues, has brought greater awareness across the food industry of the risk posed by bacteria. “Consumers are now eating more fresh frozen food directly from packages. This is a big change in behavior,” says Fogelqvist. “At minus 40C, bacteria growth slows down. The problem is that when the system is thawed out, the bacteria starts growing again, so to have a clean machine is crucial.”
Longer lifespan However, the FWE design does not just enable steam sanitation and ensure against bacteria growth. The design has a much longer lifespan than traditional enclosures, with far greater endurance against cleaning agents and temperature fluctuations. The JBT fully-welded design also guards against water penetration of joints or cracks which can cause freeze shattering. Replacing an enclosure is expensive, complex and takes time, leading to a loss of production hours, which every customer wants to avoid as much as possible.
“The Fully Welded Enclosure market is growing very quickly due to the increase of RTE foods and in combination with effective steam sanitation and good, hygienic design it is the best investment for protection of end consumer health and food producers’ plants,” adds Fogelqvist. “JBT’s design with a fully welded inside and outside, in combination with stress free joints, and a superior internal hygiene, will provide a long-lasting solution for the toughest food producers during the full equipment life cycle. JBT always strives for smartness in our design.”