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Fast freezing: how the ADVANTEC maintains quality at speed

Drip-loss and product damage caused by ice crystals are one of the main quality and yield challenges faced by frozen food processors using slow freezing processes. Created during slow freezing, ice crystals can damage the internal cell structure of frozen foods, risking diminishing both the quality and flavor for the end consumer.

JBT Frigoscandia’s ADVANTEC™ Impingement Freezer, which makes use of innovative air jet technology, has been developed to solve both problems, employing a faster freezing time to conserve product quality and assure taste and mouthfeel.

With the ADVANTEC freezer, dehydration is drastically minimized and yield is maximized, while shelf-life is also increased. Less dehydration means more yield and more profit. Suitable for a wide range of thin or flat products – including hamburger patties, fish filets and high value seafood products – the impingement freezer also offers surface stabilizing freezing for soft food before further slicing operations.

Fast freezing through jets of air: how the ADVANTEC system works

Preserving quality
JBT’s ADVANTEC freezing system makes use of impingement technology; high pressure air jets blown through a series of small holes that break through the boundary layer of air around the product and in the process achieve a very fast freezing time, according to JBT’s freezing applications expert, Martin Andersson. “The ADVANTEC fast freezes products using jets of air that result in far lower dehydration and higher yield compared with freezers without impingement technology,” he explains.

“In a slow freezing process, large crystals are formed which destroy the cells in fish or meat, and destroyed cells mean more drip-loss, so when you thaw out the product, you end up with a much drier meal,” continues Andersson. “When you freeze something faster, the crystals formed are small, so far fewer cells are affected and you get much less drip-loss.” The result, he says, is a much better quality end product, with an improved texture, taste and mouthfeel.

Maximizing slicing operations 
However, the benefits of the ADVANTEC aren’t just limited to conventional frozen foods. Using crust freezing, the system stabilizes deli products for slicing operations, improving throughput, yield and hygiene. Successful slicing means minimizing waste and maximizing conformity.

A continuous in-line process step, rapid chilling with the ADVANTEC impingement chiller keeps pace with the rest of your production line, delivering a uniform product temperature to the portioning line, and dramatically reducing labor-intensive manual handling. No other chilling method can offer these advantages so quickly and in such a cost-effective manner. And successful processing equals maximum throughput and quality, and minimum downtime. 

LEARN MORE about the JBT ADVANTEC™ Impingement Freezer

Radically reducing freezer downtime: the CleanFREEZE takes centerstage

Aiming to optimize freezer production by minimizing cold-to-cold downtime, while making sure no shortcuts are taken on hygiene and cleaning? JBT Northfield’s CleanFREEZE marks a step-forward from the long-established Northfield SuperTRAK Structure Supported Spiral Freezer by delivering a radically-reduced cold-to-cold time, along with important hygienic and ease-of-maintenance innovations. 

At its core, the CleanFREEZE takes the original SuperTRAK design and adds new hygienic features, including innovations that differentiate the CleanFREEZE freezer from other spiral freezers currently available. The comprehensive redesign not only minimizes the defrost full sanitation process, it also makes the freezer easier and quicker to clean, and reduces the risk of bacterial contamination.

Turnaround time
Perhaps most significantly, the cleaning turnaround time has been cut to four hours from an industry average of six. In the process, says John Bauer, JBT’s Freezer Division Product Manager, customers will be able to make real savings on time. “With the CleanFREEZE, customers don’t have to go through such a lengthy cleaning process so they can increase production and throughput, enabling them to maximize uptime,” he says.

Ease of maintenance
However, the time savings aren’t just limited to the cleaning process. The latest version of the CleanFREEZE features significant improvements to ease-of-maintenance, including the moving of fan motors to the exterior of the structure. “Having the fan motors outside allows customers to replace them easily if something fails while they continue to run production,” explains Bauer. “We’ve also added stairs to enable easier access to the mezzanine level, so the maintenance crews can have quicker, safer access to components on the mezzanine level, behind the coils and other areas.”

More than this, JBT has improved hygienic features across the CleanFREEZE, minimizing overlapping surfaces throughout its open-profile framework, and adopting capless rails. 

Customers will be able to learn firsthand about the CleanFREEZE at IPPE 2022, the International Production & Processing Expo, which takes place in Atlanta GA from January 25-27, 2022, where JBT will be highlighting its commitment to customers: “We’re with you, right down the line”™.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center. 

CLICK HERE to request more information or a meeting at the booth

The DSI Waterjet: cutting out obstacles to protein profits

DSI-800

Reduce labor and improve yield with innovative automated solutions from the DSI™ team at JBT. These systems – on display at IPPE 2022 – trim, slice and optimally portion poultry, beef, pork, plant-based protein, fish and even bakery products; in the process cutting out obstacles to having a profitable protein business.

DSI Portioning Systems employ machine vision technologies to scan food products and determine product shape, weight, and fat; preplanning and optimizing each piece for maximum value before the first servo-driven automated cuts take place. DSI systems cut with high pressure waterjets, horizontal blades, and vertical blades to maximize yield processor profit. 

More Solutions More Efficiently
JBT will display and demonstrate the DSI 800 S series Waterjet Portioning System at the International Production & Processing Expo (IPPE) in Atlanta GA from January 25-27, 2022. The DSI display will highlight the latest advances in high-yield waterjet portioning as well as an efficient and rugged new intensifier pump technology proprietary to JBT that uses 40% less power to deliver 4000 or 6000 bar water pressure. 

High-Yield Adaptive 3D Portioning (A3D)
The DSI 800 Series Portioning System is complemented by the DSI Adaptive Slicer 3D™ to achieve high-yield portioning of large-bird input product. The system combines waterjet cutting with intelligent horizontal slicing to achieve three-dimensional portioning. The new Adaptive slicer features wider lanes and improved systems to adapt to shape and size variation of incoming product to maximize yield.

“With the A3D system we have the ability to portion double weight product to template on the waterjet and then we intelligently horizontally slice the product to generate a top and bottom portion,” explains Dave Faires, DSI Director of Applications and Portioning Segment Leader. “For some applications we achieve six or eight shape-and-weight controlled portions from the original input product.”

JBT DSI Dual Robot Harvester

Labor Saving Solutions
The DSI portfolio includes labor reducing solutions for poultry processors serving quick service restaurants or retail products. The popular DSI Dual Robot Harvesting System (DRH) (pictured above) reduces the labor required to separate portions from value added elements of the portioning process such as nuggets, chunks or strips bound for downstream bulk processing such as marination. 

The latest innovation in the portfolio is a proven and exclusive solution for net weight packing and tray packing and high speed sorting or “calibrating” of fillets. JBT is introducing the proven Robotgrader system, updated and tuned for the needs of the North American market under an exclusive distribution agreement. This automated system scans product to determine shape and orientation, weighs the product in motion, and then robotically picks and places product according to maximum value at the highest production rate available in the least space required for such a solution. 

“All four DSI solutions will be on display at the expo, alongside a video kiosk demonstrating our applications and our JBT remote support and IoT solution, called iOPS,” Faires adds.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center. 

CLICK HERE to request more information or a meeting at the booth

Guarding against contaminants: the XVision FlexScan

Imagine a consumer sits down for their evening meal and finds a stone or piece of calcified bone – or worse glass or metal – in their chicken breast or steak. Such findings can lead to costly product recalls which have the potential to ruin reputations and end contracts. Guarding against such occurrences is not just essential for the health of a business – and consumer safety – but is also now mandatory under USDA regulations.

One of the most effective ways to easily and efficiently detect contaminants is through JBT’s XVision™ FlexScan™, an intelligent x-ray inspection system that is ideally suited to finding and eliminating contaminants in wet or dry environments alike.

Rethinking detection
The FlexScan rethinks contamination detection by using a new flexible modular detection system, which leverages multiple X-ray technologies to see and extract contamination from food.

“Such contaminants include metal, such as stainless steel, stone and glass that can get into poultry and red meat – and especially packaged meats – during the production process,” explains Dino Carbone, Division Product Manager at JBT XVision. “This provides a level of protection to our customers’s customers, and to the end user, so they can be assured their food is safe and of a high quality. It has become a necessary component of the production process, and one that is now required by the USDA.”

Maximum flexibility
Carbone says customers love the FlexScan’s hygienic and robust design, as well as its ability to operate in wet production environments where contamination can occur. The FlexScan also comes with an unprecedented degree of flexibility. It can be placed downstream after equipment such as a grinder or further upstream, so any contamination can be identified and expelled earlier in the production line. The advantage here, continues Carbone, is that it reduces the amount of waste and cost incurred when a customer detects contamination further down the line. “This is especially useful when customers are bringing in products from other locations,” he says.

IPPE 2022
A FlexScan machine, featuring an integrated retractable nose and rejection conveyor, will be on display as part of JBT’s presence at IPPE 2022, the annual trade expo which takes place in Atlanta GA from January 25-27. “IPPE is a show where everyone from across the industry comes together, so it’s definitely a key place for us to advise our customers on some of the new technologies and solutions that we have,” adds Carbone.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center.

CLICK HERE to request more information or a meeting at the booth

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