Skip to content

JBT PROCARE helps Nabil Foods run 24/7

JBT_PRoCARE_Nabil_Foods

Unexpected delays can be significant for any food processing company, but for Nabil Foods, the largest producer of chilled and frozen food products in Jordan, running 24/7 to meet production schedules and deliver high quality, consistent products means there is no room for unplanned downtime.

JBT’s PRoCARE® Service Agreements are about making sure equipment and production performs to an optimum level, while minimizing downtime, and in recent years its focus on preventative maintenance has developed into a key component of Nabil Foods’ business.

Crucial support
Nabil Foods produces a high-end range of beef and chicken burgers, nuggets and ready meals, as well as desserts, which are supplied to retail and foodservice customers across the entire Middle East and North Africa region. The company has long worked with JBT, and in fact JBT has been Nabil Foods’ sole supplier of coating, frying, cooking and freezing equipment for more than 15 years.

JBT_PRoCARE_Narsi_Foods_poultry

However, having a JBT PRoCARE Service agreement in place has been vital in keeping the company’s 10+ production lines running 24/7, according to CEO Ahmed Sallakh. “We are very pleased with JBT and the direction of our partnership,” he said. “The machinery is performing at its best, but as important, is the support from JBT’s after sales service. We are able to run 24/7 because of JBT.”

With Nabil Foods currently achieving double digit sales growth, Mr Sallakh stresses that such support is crucial to ensuring production does not slow down, while maintaining the firm’s leading position in the market.

JBT_PRoCARE_engineers

Preventative maintenance
In 2018, Nabil Foods was faced with several downtime challenges following postponement of the renewal for its PRoCARE service agreement with JBT. A lack of preventative maintenance led to a number of technical issues and breakdowns during the years, with the unplanned downtime starting to affect revenue. Nabil Foods renewed its PRoCARE agreement in early 2019 and has since seen unplanned downtime dropping by 48% compared with 2018, with worn parts being replaced before potential problems become a reality.

Mr Ahmed Hussein, Engineering Manager at Nabil Foods, said: “JBT has supported us with patience, knowledge and generosity to resolve an array of challenges we were facing and to continuously develop our equipment and internal engineering services. Fundamentally, they have become a key partner for our organization, and from my standpoint, I couldn’t have expected better.”

Find out more about Nabil Foods

Learn more about JBT PRoCARE Service Agreements

JBT iOPS helps Öresundschark boost capacity and production hours

Öresundschark_meatballs_JBT_iOPS

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. 

20201125_105241_Johan Rulander_Oresundschark

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.”

JBT-iOPS-767x421-A

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. 

For more information about Öresundschark AB, visit: oresundschark.se 

Find out more about JBT iOPS

Prime Equipment highlights yield, efficiency and safety improvements in poultry processing

Worker safety is always a concern in modern poultry processing plants, and one area where JBT-Prime Equipment Group offers a significant upgrade to worker safety is in gizzard processing. JBT’s Prime Equipment Group is now offering a system that takes care of splitting, cleaning and reprocessing chicken and turkey gizzards, without allowing access to blades or peeler-rollers, marking a significant safety upgrade for the industry.

This is just one of many new developments by Prime Equipment Group – one of the most recent additions to the JBT family – which specializes in first and second processing, covering everything from feather removal to cut-up and deboning, including skinning, wing segmenting and its industry-leading water re-use installations.

agp-detail

The AGP-T Automatic Gizzard Peeler (De-Liner)

Here’s a quick look at a few of the company’s solutions:

The latest version of Prime’s patented poultry skinner, the CSK-3, announced earlier this year, is the narrowest skinner on the market, and continues to use Prime’s patented skinning technology. Effective at removing skin from cut-up chicken including breast and thighs, the CSK-Series platform is the industry standard for skinning, now in a compact format to fit the tightest layout.

Water conservation and re-use is increasingly important for poultry processors, and Prime continues to lead the field since it assisted the USDA in writing the regulations allowing re-use in poultry plants more than two decades ago. Prime’s re-use technology can save many thousands of gallons per day, helping companies to meet sustainability goals.

Water-Re-Circ-Diagram-Horizontal-600

Also new in the Prime portfolio is a laser and vision scanner aimed at quality control efforts that works well on the incoming loading dock, as well as verifying compliance with specifications of final product after packout. Able to scan and record dimensions, color, weight, as well as scan for product deformities, the QCC Quality Check Console eliminates data collection and logging errors and speeds up QC processes – and can even be integrated into existing QC systems.

ILBD-1T-screen-grab

Prime is also a leader in turkey production, designing, manufacturing and delivering complete lines for turkey processing. Its all-new OSC-1 Overhead Cut-up Line for Turkey completely automates several processes, including, turkey halving, turkey leg removal and splitting drum from thigh, all without requiring labor. Further, the turkey front half can be completely de-boned on the ILBD-3T Turkey Inline Breast Deboner with minimal labor, for a complete solution.


For more information about JBT-Prime Equipment group solutions, visit the company’s website, or call directly at 614-253-8590.

From demonstrations to innovations: JBT’s Food Technology Centers

ftc_livingston-e1558721135955.jpg

JBT’s Food Technology Centers (FTC) provide a resource where customers can view JBT equipment and solutions first-hand, see how they work, and even run their own products through the system to experience the kinds of results that can be achieved. One of the longest-established is the JBT FTC in Helsingborg, Sweden, which has served as a popular destination for hundreds of food processors for more than 40 years.

The Helsingborg FTC gives customers the opportunity to test, simulate production, conduct research, as well as optimizing and developing new applications and products using JBT’s latest processing solutions. 

“We can demonstrate equipment to customers, show them how it works, and also run their products in the machine, so it’s possible to see the results they will get,” explains Martin Andersson, JBT’s Application Manager of Value Stream Spiral Freezers and head of the Helsingborg facility.

FTC_Blur

“If a customer is hoping to achieve a certain color with a grilled chicken piece or wants to see if it’s possible to achieve a certain coating, texture or quality on a battered and breaded product, they can visit the Food Technology Centre and we can show them what’s possible with our machines.”

Complete solution
The Helsingborg FTC started life in the 1970s as a laboratory for measuring freezing times, but as the facility has grown and added more equipment over the years, it has evolved into a resource where JBT not only showcases solutions, but also refines applications and assists customers with food product development.

The 2000m² test area is now equipped with fully functioning JBT processing equipment in order to provide customers with a complete food processing plant.

JBT-RTC-Argentina-767x421

“We are now up to a facility with the ability to run a full TwinDrum Oven, we have a Double D Revoband cooker, we have Formcook Contact cookers, coating lines, a full GYRoCOMPACT Spiral freezer and a complete Advantec impingement freezer,” says Andersson. “We can also show FloFREEZE freezers in our assembly facility, plus we have a full-size Stein TFF fryer there for demonstration, as well as a smaller FA5 fryer.”

Although it might not always be possible to replicate precisely the same pre-processing of products in Helsingborg compared with a customer’s own facility, Andersson says technicians at the FTC are relentless in trying to achieve exactly the correct taste, finish and texture.

But if the exact product cannot be reproduced at the FTC, technicians can bring equipment to the customer’s site for testing in their own environment. “We are not satisfied until the customer is,” Andersson adds.

JBT also has FTCs near Edinburgh in the UK, Sandusky, Ohio in the US, and an Innovation Center in Kunshan, China. 

Learn more about the JBT Food Technology Centers

PRoCARE: the benefits of preventative maintenance

PRoCARE® is perhaps one of the most innovative and certainly among the most valued services that JBT offers. An aftermarket initiative that has been running for over a decade, PRoCARE has been developed to help make sure JBT systems and equipment are kept in optimum conditions and any downtime – in the form of costly system failures – are kept to a minimum.

“What we do is offer the customer piece of mind by taking care of the equipment we manufacture,” explains JBT Customer Care Manager Elizabeth Monasterio. “We go to the customer’s site and inspect the equipment, they receive an inspection protocol and also a service report on the visit with written recommendations. Based on that the customer may or may not have to do some repairs and we follow up to make sure they do what needs to be done.”

PRoCARE_close-up.jpg

Visits can vary from twice to four times a year, but in the case of the most sophisticated equipment, JBT technicians visit every month for four days on average, checking the equipment, calibrating and changing any parts that need attention.

Covering across JBT’s protein portfolio, JBT PRoCARE works with customers from bakery and pizza producers to manufacturers of ready meals and chicken, meat, fish and frozen vegetable processors offering a flexible program dependent on customer needs.

“We make PRoCARE flexible to customers’ needs,” says Monasterio. “On Gyrocompact freezers, we offer an Extended prorated warranty on the belt, chains and rails.  Level One offers inspections and a minimum eight hours training a year, while Level Two includes spare parts, typically in the form of a yearly package with parts stored on site. As well as a discount on original spare parts, PRoCARE also offers a discounted rate for customers for emergency service repairs.”

PRoCARE.jpg

However, one of the most important services JBT PRoCARE provides is preventative maintenance, which allows customers to control costs by taking care of equipment before it is damaged. “When equipment goes down in a plant, it’s the worst thing that can happen because you start losing production,” says Monasterio. “Preventative maintenance removes the risks of things like that happening and having to call for an emergency service, which normally involves rushing a technician out to a customer, often from an installation.”

“What customers have told us many times is it ensures a good night’s sleep,” she adds.

CONTACT JBT TO LEARN MORE ABOUT PRoCARE

%d bloggers like this: