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JBT’s PRoCARE®: working to eliminate downtime from the equation

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Downtime, for many processors and producers, is an inevitable part of the production process, which – in addition to cutting into productivity, scheduling and labor hours, to say nothing of the expense – is viewed as a phenomenon that has to be endured. But what if there were a means of limiting downtime to an absolute minimum or, better still, eliminating it almost completely? This was the objective JBT Customer Care had in mind when they set about launching PRoCARE; an ambitious initiative that aims to make downtime a problem of the past for JBT customers.

Irrespective of the pedigree of systems or equipment, the need for maintenance, regular or irregular, is a fact of life. With the best will in the world, it is unavoidable that parts become worn, equipment becomes damaged, or machinery does not always perform as expected. Such occurrences often result in downtime, with production being shifted, reduced or even halted completely while the problem is fixed.

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JBT’s PRoCARE Program is focused on taking the unpredictability of maintenance difficulties out of the equation. Instead of waiting for problems to occur, JBT Field Service Engineers take preventative action as part of the program, visiting customer facilities on a scheduled basis to tackle any weak spots before they develop into a problem.

Relieving the burden
As an annual, auto-renewal program, PRoCARE offers levels of service specifically suited to the needs and wants of each plant. With features ranging from inspections, documentation and recommendations in Level 1; up to Level 5 which includes preventative maintenance, 24/7 monitoring, guaranteed response times, training and an annual pool of service and/or automation hours to use at their discretion, there is a great solution for any budget, explains Emily Lossman, Customer Care Manager at JBT’s A&B Process Systems.

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“The PRoCARE Program takes some of the burden off maintenance staff and removes the need to keep as many components on the shelf,” she says. “It also means customers will suffer fewer unexpected downtime issues and benefit from a longer equipment life.”

As well as new customers, Lossman says, JBT is reaching out to existing and previous customers, and letting them know that this is a program that can be implemented at their facilities.

Preserving reputations
The practice of preventative maintenance becomes even more important when viewed against the considerable threat posed by involuntary lapses in food safety, lapses that can lead to product recalls and potentially damaged reputations and lost clients. “Older equipment and machinery can suffer wear that can lead to potentially harmful contamination issues,” says Lossman. “Stainless steel surfaces can get scratched and these crevices can harbor bacteria that can be missing during Clean-In-Place (CIP) procedures.

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JBT can provide riboflavin testing to verify cleaning efficacy and hydrostatic or dye penetrant testing to identify flaws. They will also provide recommendations on how to maintain that level of cleanliness.

“We also check and calibrate instrumentation, which has positive implications for product consistency: we make sure instruments are correctly calibrated, so customers achieve a consistent product every time.”

In short, Lossman says the PRoCARE Program offers headache-free ownership. With JBT effectively taking care of systems and equipment during their entire active life, customers avoid the need to pull resources off key projects, help safeguard their reputation and, as much as possible, eliminate costly, avoidable downtime.

Learn more about JBT’s PRoCARE Program

JBT to highlight frozen produce solutions for Thai processors

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JBT will be hosting a special Fruit & Vegetable Processing Seminar for processed produce exporters from northern Thailand this week to highlight how JBT’s solutions can improve systems and working practices. Taking place in the Hotel Dusit D2 on May 16, the event will highlight the potential offered by solutions such as washing systems from JBT FTNON that can be combined with effective JBT freezing technologies.

Featuring contributions from FTNON experts on produce processing, the one-day seminar will highlight the JBT portfolio and its customer care program to customers in a region – covering Chiang Mai, Chiangrai, Lumpoon and Lumpang – where most of Thailand’s fruit and vegetable processors are located, explains JBT’s Sorayut Ujjaphuree.

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Processed and frozen produce exported from the region includes edamame, okra, strawberries and sweetcorn, with countries including Japan among the main recipients.

“We can see the potential for FTNON and JBT freezing technologies here in Thailand,” says Sorayat. “That is why we set up the seminar in Chiang Mai to promote and investigate what customers are really looking for and how we can fulfill the market.”

The JBT Fruit & Vegetable Processing Seminar will take place at the Hotel Dusit D2, Chang Mai on May 16. 

Request more details about the seminar

JBT takes forklift automation forward with Crown and Hyster-Yale

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JBT, a leading global solutions provider of technologically sophisticated systems and products, has solidified deals with Hyster-Yale Materials Handling, Inc. and Crown Equipment, two of the world’s largest material handling companies, to help customers maximize the benefits of material handling automation.

JBT’s automation expertise and insight will be harnessed to deliver vehicles that can switch between manual and automated operation. By providing automation expertise, JBT will amplify and complement both companies’ ongoing research and development related to automation technologies.

The Crown DualMode T tow tractor, which offers manual and automated options, is an early result of the collaboration with Crown and is currently being piloted through Crown’s early adopter release initiative.

Meanwhile, the Hyster-Yale robotic reach truck, a pantograph truck capable of picking double-deep at heights up to 30’, has also been developed and installed at customer sites. The vehicle can also operate in manual and automated modes.

Leveraging strengths
Laura McConney, Marketing Specialist at JBT’s Automated Guided Vehicle (AGV) division, says the collaboration, which will see vehicles cobranded with the JBT and Crown/Hyster-Yale logos, will leverage the strengths of both companies. “JBT has been automating vehicles for over 30 years, while Crown and Hyster-Yale, which are among the globe’s largest forklift supply companies, produce well-designed, versatile vehicles,” she says.

“We established relationships with Crown and Hyster-Yale because we were thinking about the way market trends are moving: forklift companies are collaborating, and we think that’s a good trend.”

Delivering vehicles that operate in both manual and automated settings, McConney continues, will help companies that are hesitant about abandoning manual operations by easing the transition between manual and automated operations.

Learn more about JBT’s Automated Guided Vehicle (AGV) range

Frigoscandia LVS: a revolution in efficiency

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LVS, the JBT Frigoscandia® Refrigeration System, is a technology that has revolutionised the way modern industrial freezers function in more ways than one. Developed to make freezer and refrigeration unit combinations more efficient and effective, LVS – or Low Volume System to give the system its full name – has proven so successful since its initial introduction that it is now standard in over half of all Frigoscandia freezers. There are over 1,500 LVS systems installed globally in Frigoscandia freezers.

The reason is simple. LVS, which is available with optional LVS Quick Dry, delivers low energy consumption and optimum freezer performance by providing a dry return from the freezer’s evaporator, eliminating the need for a refrigerant pump in the process. But this is not just an idle boast.  Frigoscandia LVS Refrigeration™ is up to 20% more efficient than traditional pumped refrigerant systems achieving pressure drops of between 0.5 and 1°C, where traditional systems often have pressure drops of 3 – 5°C as measured between the temperatures in the refrigeration compressor and in the freezer.

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Substantial savings
Crucially, the lower pressure drop makes it easier for LVS to operate at lower temperatures than other systems, and the LVS system makes the system react quicker reaching operating temperature in only 20-30 minutes.

The refrigeration technology also requires 50% less refrigerant charge than traditional systems due that the freezer evaporators can never be fully flooded with refrigerant being regulated by the LVS system and a completely dry return to the compressor that also minimizes the amount of refrigerant needed.


“LVS was developed to make the freezer more efficient for the customer by reducing the amount of refrigerant – typically ammonia – by half, and by minimizing the pressure drop in the system due to the dry return of refrigerant to the compressor,” explains Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line for Spiral Freezers. 

The system works by separating liquid refrigerant from the gas and regulate the amount, he continues, and saving a lot of energy in the process. “We separate the liquid from the vapour and only bring the vapour back,” adds Persson. “This means the system is far less energy demanding and far more efficient for the customer.”

JBT will be exhibiting at IFFA 2019 in Hall 8.0, Booths G06 and H06 at the Messe Frankfurt exhibition halls from May 4-9, 2019.

Learn more about the Frigoscandia LVS Refrigeration System

JBT unveils ambitious program for IFFA 2019

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JBT’s family of companies will be staging its first joint appearance at the upcoming IFFA 2019 show on a single stand, as part of presence that will include the worldwide debut of TIPPER TIE’s all new SVU6800 high speed large sizing machine. The event will also include the opportunity for customers to learn more about steaming solutions from FTNON and cutting-edge HPP technology from Avure.

Taking place in Frankfurt, Germany from May 4-9, IFFA is a leading worldwide meat and protein show, which is staged every three years. At the forefront of the meat processing industry, IFFA acts as a vital venue for learning about trends and new developments, says Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line for Spiral Freezers.

The theme of this year’s JBT booth will be, ‘Reshaping the food processing landscape of tomorrow’, and as Persson explains, it will mark the first time the JBT family of companies has exhibited together on a single stand at IFFA. JBT companies participating will include: meat marination specialist Schröder; TIPPER TIE which produces equipment for clipping sausages among other solutions; and HPP expert Avure.

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“All of us will be together at one booth,” says Persson. “It’s about showing the breadth of JBT, not just on the freezing and cooking side, but also in HPP pasteurization, and cutting-edge equipment for meat marination and preparation.”

The theme, he says, was chosen to reflect JBT’s status as an innovative, trendsetting company that is always looking to improve its products and offer solutions for tomorrow.

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Jörg Nold, TIPPER TIE’s Director of Sales for EMEA and APAC, describes IFFA as the company’s most important trade show, explaining that the event provides an important opportunity to meet with customers and distributors, and show them the work TIPPER TIE has been doing over the past three years, including new innovations.

One such innovation is the new TIPPER TIE SVU6800, an automatic double clipper that can be used for a variety of products, including typical deli products, such as ham, chicken and mortadella, as well as dry sausages, salami, and even whole muscle products. “Thanks to the strong voiding system, whole muscles can be processed while accommodating sensitive casings,” says Nold.

TIPPER TIE will also showcase its powerful industrial line with the automated SwiStickXXL hanging line connected to a TT1815 double clipper, as well as the high speed automatic double clipper SV4800, and the labor saving TTSealH which is also connected to a TT1815.

Another highlight will be the SVF1800 low cost spreading voider machine, as well as the complete KDC-Family, which is perfect for lower volume high mix applications where flexibility and versatility are a priority.

“TIPPER TIE is a strong innovator in the field of clipping and packaging and we have solutions for every application and need, from small local butcher shops to the largest multinational corporations looking for the highest performing automated solutions,” adds Nold.

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FTNON
One of the newer members of the JBT family, FTNON, will also be present at IFFA 2019, with the focus on highlighting its steaming solutions for the protein industry, which can offer radical energy saving solutions. The FTNON DCC Belt Steamer DBS, which can offer a reduction in steam consumption of up to 90%, during the cooking of meat, fish, rice and pasta products, as well as potatoes, vegetables and fruit. 

Using DCC Belt Steamer technology, the system offers a reduction of retention time by using a 100% steam environment, as well as an increased yield due to improved steaming efficiency. Resulting in an improved product appearance, discoloration is also reduced, while the lack of steam loss means there is no requirement for energy consuming steam exhaust systems.

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Developed for pet food manufacturers, FTNON’s Pet Food Steam Tunnel PST consists of two chambers – sealed on both sides with water locks – through which a processing belt is continuously running.

“We have used our steamers in the pet food industry where we have strings of meat going through, which are then chopped in chunks before being packed,” says Jos Schröder, FTNON’s Commercial Director, who adds that the system is also used for meatballs.

JBT will be exhibiting at IFFA 2019 in Hall 8.0, Booths G06 and H06 at the Messe Frankfurt exhibition halls from May 4-9, 2019.

JBT showcases freezing innovations at IFFA 2019

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JBT will showcase its latest spiral freezer during the upcoming International Trade Fair for Meat Industry (IFFA) show, which takes place from May 4-9 in Frankfurt, Germany. Visitors to the event will be able to view JBT’s most compact and hygienic freezer to date with the highest capacity of any comparable spiral freezer.

The Frigoscandia GYRoCOMPACT® 40 Spiral Freezer has evolved from one of JBT’s best selling products, the GYRoCOMPACT® Classic 400 Spiral Freezer, which has sold over 1,100 units throughout the world.

The latest version replaces the outdated wagon drive with JBT’s patented FRIGoDRIVE system. It offers a number of benefits, including 30% faster belt speeds, more advanced hygiene features, lower running and maintenance costs, and improved serviceability. The freezer also boasts an increase in capacity of between 15% and 20% on its predecessor. A key feature is the patented self-stacking FRIGoBELT NOVA conveyor, which forms a self-contained product freezing zone.

“With the new GYRoCOMPACT® 40 Spiral Freezer, we’ve retained all the best technological features that we’ve developed over many years, and upgraded a best-selling design to meet this demand. This latest model has around 35% to 40% higher capacity than any comparable freezer of the same size,” explains Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line, Spiral Freezers.

LVS QuickDry
A brand-new option for this year is the new patented and revolutionary LVS QuickDry for fast-drying of spiral freezers after cleaning, helping save hours of non-productive time typically lost attempting – not always successfully – to take moisture out of freezers after defrosting.

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“When customers have freezers, the biggest problem – as with freezers at home – is defrosting and cleaning,” Persson says. “You can’t have a wet freezer after cleaning, so you have to dry them out and this can typically take several hours, especially with mid-sized and large spiral freezers where there’s a lot of steel. What this system does is that it shortens the drying sequence by up to one hour.”

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With drying often taking up a third for total cleaning time when it comes to spiral freezers, having a dry freezer back in operation as quickly as possible is key to avoiding downtime. The LVS QuickDry is a subsystem connected to the LVS Refrigeration™ system that is required to operate the QuickDry function together with hot-gas availability from the refrigeration system.

Yield improvement
At IFFA 2019, JBT will also be highlighting the DSI® 800 Series Waterjet Portioning System, an automated solution for portioning and trimming that has proven to consistently improve product yield and increase productivity.

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Built for high volume portions, the portioner functions as a precision machine for high accuracy intense cuts and a new generation scanner for effortless fat trimming – all-in-one.

Other products exhibited from JBT’s portfolio include the Formcook® 618 Contact Cooker for efficient sealing and searing of products and the XVision™ CCPX™ Pack™, an industry leading technology of X-ray Inspection Systems for contaminant detection of case ready, ready meals, and heat and eat products that is making its European debut.

JBT will be exhibiting at IFFA 2019 in Hall 8.0, Booths G06 and H06 at the Messe Frankfurt exhibition halls from May 4-9, 2019.

JBT’s bacon processing solutions’ sweet smell of success

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Whether it be on top of a hamburger patty or as part of a pre-packed sandwich, bacon is a commonly-found and popular ingredient for fast food and convenience snacking, but a failure to hit that expected ‘real bacon’ taste can seriously dent repeat purchases. Achieving the correct consistency, appearance and flavor has been one of the successes driving the growth JBT’s bacon processing range; a success story now driving an increasing expansion into the poultry industry.

The Formcook Contact Cooker and the Double D Revoband Continuous Protein Oven are two leading solutions from the JBT family of companies which have found favor with bacon processors for their consistent ability to deliver just such quality on a consistent basis, explains Bart Kivits, JBT’s Manager for Portioning, Coating and Cooking Applications.

“Pre-cooked bacon – cooked bacon used by fast food restaurants for putting on their sandwiches – is quite popular at the moment, but it can be quite laborious, so that’s why there’s quite a lot of interest in having it pre-cooked. A lot of customers are looking for good solutions that can deliver good quality bacon.”

Continuous cooking
“There are three ways used to cook bacon: in a microwave; in a hot air oven; and the third is a Teflon belt cooker,” Kivits continues. “We supply hot air ovens and Teflon belt cookers to make bacon in a continuous way. We don’t however supply microwave cookers because the quality of the bacon is completely different – it’s the same as when you use a microwave at home, it gives it a glazed, pale appearance, which is not very appealing to most customers.”

Instead, the Double D Revoband Continuous Protein Oven employs hot air blown at 250-260C over bacon slices, fully cooking it and resulting in a very appealing, slightly wrinkly appearance, very much like homemade bacon.

Home-cooked taste
The other option JBT offers is the Formcook Contact Cooker, a system which Kivits compares to a grilled cheese sandwich maker, which has Teflon on both sides. 

“The Formcook Contact Cooker comprises two conveyor belts made of Teflon – the same stuff you find in your frying pan at home – and in between them is the bacon,” he says. “We keep that belt at 250C, you squeeze the slices of bacon in between those belts for 60 to 90 seconds and then it comes out fully cooked before being flow-packed, principally for fast-food restaurants.

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The JBT Formcook Contact Cooker

“The cooker can also recover 100% of the fat produced by the bacon which has quite a lot of value, meaning there’s a big benefit for the processor.”

However, the Formcook Contact Cooker is not just used for cooking bacon. Kivits says the system is becoming increasingly popular for pre-cooking poultry products, such as chicken breasts, where it has been found to lessen yield loss by 4%.

“We will be displaying at the IFFA 2019 show, but if any European customer wants to see one in action, they can also visit our food technology centers in Helsingborg, Sweden and Livingston, Scotland,” he concludes.

JBT will be exhibiting at IFFA 2019 in Hall 8.0, Booths G06 and H06 at the Messe Frankfurt exhibition halls from May 4-9, 2019.

Request an appointment at IFFA 2019

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