Lowering costs In this webinar JBT will look at both the production of whole birds and cut parts with experts for each, including how to Increase productivity and lower costs with automated whole bird solutions from JBT TIPPER TIE. Specifically, this will examine how to: increase the number of whole birds bagged per hour without adding extra workers; automate the vacuum sealing and clipping of whole birds; and even improve productivity when ‘over netting’ finished product, all while lowering costs.
“In today’s Covid-19 challenged environment, managing costs, increasing production levels, and improving quality have all gotten more difficult,” saysConrad Faust, Senior Director of Product Management at JBT TIPPER TIE. “Now is the time to explore incorporating automation into your production lines and drive your business forward in the post Covid-19 world.
Tracking solutions During the webinar, customers will also be able to listen to the latest news on equipment updates and solutions specifically for Turkey Suppliers, including an update on JBT’s innovative new Turkey Overhead Cut-Up Line and line of Efficiency Tracking Solutions to help get the most out of processing lines.
“The Turkey Overhead Cut-Up System continues to shine in existing installations, bringing new levels of labor efficiency to turkey processors,” says Grant Parsons, Director of Marketing PrimeEquipment Group. “Our all-new Efficiency Tracking Solutions stem from Prime’s acquisition of MARS Food Processing Systems, which brings real-time line efficiency tracking in cut-up, and a host of other areas from live hang through the rest of the process.
“These solutions are extremely cost-effective and are all designed to allow you to measure and improve the output and yields of a variety of processes in first- and second-processing.”
After the speakers the webinar will include a short Q&A session to give delegates the opportunity speak directly with JBT experts.
The end of the Covid-19 pandemic could soon – it is to be hoped – be in sight, but meanwhile it is hugely important for companies within the food processing industry to continue to drive consumer demand. One of the ways JBT is supporting such efforts is through its Food Technology Centers (FTCs), located worldwide, including one such center in Livingston, Scotland, which has been employing innovative methods to help customers test new equipment and machinery.
In fact, the Livingston FTC – along with a similar facility in Helsingborg, Sweden – has led the way when it comes to new innovations in remote testing, allowing products to be refined to customer specifications at a safe distance.
The Livingston site, close to the Scottish capital, Edinburgh, was completely refitted after acquisition by JBT and today forms a fully functional technology centre. The centre includes adjacent offices and conference rooms, combining substantial testing capabilities for chilled, frozen and fresh foods all located at the company’s manufacturing facility.
Viable solutions However, in recent times the site has become an innovator in remote testing, developing solutions that are proving so viable, they could become a semi-permanent feature in the post-Covid world. JBT Livingston FTC’s remote testing services are offering customers the means to carry out testing – with effective real-time remote monitoring – without having the expense of international travel and hotel accommodation.
As JBT Regional Solutions Manager John Kelso explains, the FTC provides the service for customers when it comes to defining the hardware specifications. “Objectives defined enable our equipment setup for best targeting colour, fat rendering and succulence for example, among other attributes for best preparation and cooking to customer request,” he says. The facility covers the full process from coating, through frying and cooking to freezing, forming an essential part of JBT’s work with customers.
“In order for a customer to buy from us, we need to know the processing times for the equipment and that’s where the Food Tech Center comes in,” says Kelso. “Obviously, Covid has prevented a lot of customers from travelling, we still need to be able to demonstrate the best yield, color, consistency and appearance.”
Learning process Starting with video calls, Kelso and his colleagues experimented with a number of solutions for giving customers remote access to testing. However, it was quickly realized that a more flexible and dynamic solution than carrying a laptop around was required. “When video testing, it’s very necessary that someone hosts the local call to provide an interface between the customer and the process and is also able to act as a cameraman to demonstrate system features while the trial is taking place,” says Kelso.
In order to further compliment remote interactions, and move from the use of a laptop, JBT is in the process of creating a unique solution that will function like a customer on site. This person or “robot” will comprise a tablet and speakers mounted on a mobile, flexible stand, which is able to act as a remote customer, accompanying the team during the course of the trial and even forming part of the group during meetings. “With speakers and video-audio capabilities, the ‘robot’ is able to watch the trial more closely and can interact with us,” says Kelso.
Of course, experiencing the final taste of a product remotely is unachievable, but Kelso emphasises that other key elements of the process can be shared with the customer, namely product colour, appearance, internal temperatures and yield.
Europe-wide customer trials The FTC has – to date – successfully conducted remote trials with customers across Europe, including demonstrating the benefits of a Formcook Contact Cooker to a leading processor.
In fact, so successful has the solution been that JBT is introducing it to its FTC in Helsingborg, Sweden, and there is now talking of the ‘robot’-guided visits continuing once vaccination is widely available. “Despite the Covid situation, we still want to continue trials and it might be something that customers would like to see as an alternative and do even post-Covid,” says JBT’s Netherlands-based Manager for Coating and Cooking Applications, Bart Kivits. “The other advantage of doing a test like this is you get instant feedback. This is the next step from shooting videos and writing a report.”
Back in Livingston, Kelso believes the solution will impact customers positively, given that it is easier to ship three-four kilos of product to the FTC and log-in to a Zoom call than it is to deal with travel and flights. “We have been able to turn this problem into a solution, and customers have been very thankful of the effort we have taken to do this and very complementary about the time we have spent,” he adds.
“This solution represents a huge step forward in worker safety,” explains JBT-Prime Equipment’s Director of Marketing and Product Integration, Grant Parsons. “If you’re still removing excess gizzard lining on peeler-roller tables, you’ll definitely want to tune into this webinar.
JBT-Prime Equipment’s system comprises the GM-10000 Gizzard Processor, which can cut and clean up to 10,000 gizzards per hour, and the GR-TT Gizzard Re-Peeler for sorting and returning any gizzards to peeling machinery if any of the inner yellow lining has been missed.
“Removing the yellow lining manually can compromise worker safety,” Parsons says. “But the GR-TT Re-Peeler eliminates the danger entirely by removing the possibility of workers coming into contact with peeler-rollers.”
The solution has already been successfully implemented by gizzard processors in the US and Brazil, providing a safe, effective and profitable solution to gizzard processing.
The JBT-Prime Equipment Group Gizzard Webinar will be held on 10 December at 3 PM EST.
Utilizing production capacity to its maximum and avoiding unplanned downtime is essential for any protein producer, and having the tools in place to make this happen can bring both piece of mind and help increase profits. This was certainly the case for Swedish meatball producer Öresundschark AB, which has recorded benefits for its business from opting for JBT’s innovative Industrial Internet of Things performance optimization platform, iOPS®.
Öresundschark AB connected their Frigoscandia freezer to iOPS two years ago and since then their capacity utilization has increased significantly and made life a lot easier for Production and Maintenance Manager Johan Rulander. By having machinery connected, Rulander has been able to monitor and detect worn parts or potential issues before they become problems, enabling him to improve the overall efficiency of his operations and avoid unplanned downtime.
Öresundschark’s Johan Rulander with the JBT iOPS platform
Furthermore, Rulander can now quickly trouble-shoot and easily provide remote support to his production team when needed, by having machine and system data in real-time through an app on his mobile phone. “I can quickly identify the issue by checking the alarms and give advice how to fix it without having to drop what I’m doing and rush down to production to solve the issue personally,” he says. “This gives both me and the team piece of mind, and they are not as reluctant to call me and ask when issues arises and I’m reassured production will run smoothly without my presence.”
New methods JBT iOPS® has led to a completely new way of planning production and machine maintenance through predictive data for Öresundschark, according to Rulander, who regularly consults the live data feed on his phone. “I check how the machine has been running on the late shifts and I can see cleaning stops and estimate drying time to know when I can start-up production again in the morning,” he explains.
iOPS allows for connected equipment and operation monitoring, providing food manufacturers with new and unique possibilities to ensure sustainable and profitable growth through insights and proactive actions that would not have been possible to achieve in a profitable way before.
“I keep an eye on the air temperatures inside the freezer, and if they are running high for a longer period, we plan for extra defrost programs to maximize running time,” continues Rulander. “Over time, the freezing belt wears and overstretches and with inductive sensors I can monitor this and plan maintenance stops when I want them, and adjust it in good time before issues arise.”
Every food processing company knows that the key to a successful and profitable business is to keep production running without disruption. Every extra hour of production equals profit and money in the pocket.
“We run at a high pace and during certain periods we produce seven days a week, so at these times there is no room for downtime,” says Rulander. “Timely maintenance and proactively replacing parts before they break plays a major role in minimizing downtime and saving money.”
About Öresundschark Öresundschark AB has been a high valued partner of JBT since moving to Malmö, Sweden in 1999. A local family-owned business founded in 1997, Öresundschark’s high quality products have been awarded with the EU Ecolabel, a mark of environmental excellence. They produce a wide range of meat patties, chicken- and meatballs and supply the largest convenience retailers all over the region. Around 30 employees work at Öresundschark AB and their production plant generates 5,000 tons of fried, frozen and chilled products every year, all of which are processed using JBT equipment.
Öresundschark is aiming to expand its product portfolio to also include vegetarian alternatives and to ramp up productivity to reach a yearly production of 8,000 tons. “JBT ́s iOPS will help us achieve these targets faster by enabling us to run our production longer and more efficiently,” adds Rulander.