JBT Formcook is one of the undoubted pioneers of contact cooking, the innovative method for sealing moisture into protein products by employing teflon belts, which can improve both yield and flavor. However, in spite of the challenging situation caused by the Covid-19 pandemic, Formcook is continuing to help new and established customers start up new cooking lines, thanks to JBT’s effective remote support options.
Originally established in Helsingborg, Sweden in 1989, Formcook became part of JBT in 2014, by which time the company had gained a strong reputation as an innovator in contact cooking. In fact, the original concept was developed and adapted by Formcook founder, Winje Green, during a visit to the US in the company’s early years in the process becoming the first oven manufacturer to use a moving teflon belt for cooking.
Significant advantages Lars Håkansson, JBT’s Sweden-based Regional Application Manager for Formcook explains that the use of a teflon belt gives Formcook’s two models – the Contact Cooker and the Combi Cooker – significant advantages over other belt-based cooking systems. “The system functions much life a teflon pan at home by bringing together a teflon belt over a heating plate, and as a result the products don’t stick,” he says. “You can put egg on it and lift it off very easily. Compared with a mesh belt, the product doesn’t stick.”
The Formcook teflon system is principally used to set the surface of protein products such as chicken fillets to prevent moisture or yield loss when they move on to a main oven. “After the contact cooking, we run the chicken fillet into an oven and it will not stick to the surface because we have closed the top and bottom surfaces,” explains Håkansson.
“That makes it first of all more juicy because you have a closed surface so moisture is kept inside. Also, by not sticking to the belt, you achieve a higher yield because normally if you put a raw product on a wire belt, 2-3% of the product will stay on the belt.”
Across the protein processing industry, the onset of the COVID-19 pandemic has put pressure on traditional labor sources, with illness-related worker absences and localized outbreaks being felt keenly in poultry and meat processing plants. Given this pressure it is perhaps unsurprising that there has been an increase in interest in JBT’s innovative AGV (Automatic Guided Vehicle) range; a solution that enables companies to save labor for higher value tasks and safeguard 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.
ROI advantages According to Mark Longacre, Application Engineering Manager for JBT’s AGV division, JBT has received more inquiries, more frequently since the start of the pandemic, with companies having become more aware of the labor- and ROI-related advantages offered by the AGVs. “I think the whole ROI picture is changing,” he says. “Companies in the past were looking at it purely as a financial equation, but now I think they are starting to understand some of the risks with the labor force. You want to save labor for the highest value added task and driving forklifts is not something where you have to use labor.”
Increasing interest Growing awareness of challenges in the labor market have led to increasing interest in JBT AGVs from meat and poultry processors, with many companies looking to introduce more automation. “On the poultry side, there is interest in using the AGVs at the in-feed of the processing plant and at the end of line, where things have been processed and we are carrying pallets out,” says Longacre.
There has also been 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,” continues Longacre. “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.”