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JBT & Aurratech: bringing fog sterilization & sanitization to the globe

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JBT’s alliances are all about bringing complimentary solutions and technologies to its global customer base, which is why innovative sanitization specialist Aurratech looks certain to be a perfect fit over the coming years. Aurratech is the company behind Fog-in-Place™, a pioneering sterilization and sanitization system that guarantees 100% surface contact plus airborne disinfection with a fraction of the water and chemicals typically consumed by traditional technologies.

Fog-in-Place (FIP) can be used by food, beverage, produce, and protein processors to sterilize or sanitize equipment, piping, tanks and entire processing areas by turning biocide solution to fog in form of billions of micro-particles.

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According to company founder Caio Agmont, FIP produces low weight particles that achieve 100% surface contact by remaining suspended in the air for long periods of time through which it can reach all areas of a facility, including around odd shapes, that need to be sanitized.

FIP also reduces more than 99% of the water, waste and sanitizing solution typically associated with traditional liquid based Sanitize-In-Place (SIP) procedures, making major savings in time, energy, solution and water, with negligible environmental impact. The system can be used effectively by both food (meat, fish, eggs, bakery, fruits, vegetables, nuts and dairy) and beverage (wine, beer, juice, non alcoholic and general beverages) processors, while it also has applications in the cut flower industry.

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International interest
Far from limiting FIP’s potential applications, Agmont says its possible uses are huge and constantly expanding. “FIP is already in use among the major protein players in Brazil in the beef, pork and poultry industries for ambient disinfection,” he continues. “With our new company in Spain, we have now started supplying FIP to Spanish protein companies.”

The technology is also gaining ever greater attention in South Africa. After a listeria outbreak in 2018 – the country’s largest ever – FIP was chosen as the primary decontamination tool for big protein players in South Africa. “Aurratech just finished a new project for a dedicated FIP unit to be installed in tunnels and gyro freezers,” says Agmont. “This will enhance food safety in the freezers and create a ‘listeria free’ environment.

“Listeria is a major concern at protein industry today – everyone knows how hard is to guarantee complete disinfection inside a freezer, but with FIP, we can delivery an extra layer of protection for industry against listeria.” 

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FIP is in use among major players in the beef, pork and poultry industries

FIP applications
In Spain, Aurratech has started researching the use of FIP for lactic acid application in beef, with processors set to benefit from the system’s ability to deliver a uniform layer of the right amount of lactic acid without any wastage.

In Brazil, the company has recently finished a one year investigation with the world’s largest broiler egg company looking at the use of FIP and peracetic acid solution as an alternative to formaldehyde disinfection. The results, reveals Aurratech’s Latin America Manager Pedro Girardelli, were impressive, with better ratios than formaldehyde. “Sooner or later the formaldehyde will be banished from market, as has already happened in Europe, so it’s important the industry is prepared with an alternative technology,” he predicts. “FIP has proven to be a serious candidate for this next step at hatchery industry.”

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FIP and peracetic acid are replacing formaldehyde in Brazil’s egg industry

Proving that the technology has huge scope for possible uses, Agmont says FIP has also been employed by nursery greenhouses for fertilizer and fungicide application with great results, while it has proven effective in combating botrytis in rose production facilities in South Africa.

In the bakery sector, Agmont reveals that FIP also has been used to reduce contamination in coolers and enhance product shelf life.

However, although Aurratech is still focused on disinfection, Agmont says he has seen a shift in customer demand towards using FIP as a delivery tool for applying chemicals to products. “As with lactic acid in beef, we have also been investigating using FIP to deliver other products for cheese, dry meat, fruits and eggs to reduce the microbiology count on product surfaces and increase product shelf life,” he adds. “This could open up a titanic market for Aurratech in the near future.”

Learn more about Aurratech’s Fog-In-Place

JBT showcases solutions for the future

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At the IFFA 2019 international trade fair in Frankfurt, Germany, the JBT team (pictured above) introduced smart and innovative solutions covering the food processing chain and adding value through yield, flexibility, automation, high-hygiene, food safety, clean label and consistent end-product quality. 

Together with customers, JBT is reshaping the food processing landscape of tomorrow by designing innovative solutions setting the standard for the food industries growing expectations, needs and demands.

Among the solutions highlighted at the show was the world-renowned range of Frigoscandia® freezing systems, which continue to be a flagship brand for JBT, with the latest model the GYRoCOMPACT® 40 Spiral Freezer showcased during the fair. The Spiral Freezer is a more compact version with even more hygiene benefits and new freezing technology with the highest capacity of any comparable system.

Volume and accuracy
At IFFA 2019, JBT also had the pleasure of demonstrating the capabilities of the DSI® 800 Series Waterjet Portioning System. An automated solution for portioning and trimming, the DSI Portioner has proven to consistently improve product yield and increase productivity. Built for high volume portions, the portioner functions as a precision machine for high accuracy intense cuts. 

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During the show, JBT’s TIPPER TIE invited visitors to experience live demonstrations of their impressive clipping and packaging solutions. One of the highlights was the worldwide debut of the new SVU6800 high speed automatic double clipper designed for large products such as pumpable ham, large slicing logs and whole muscle loins. It delivers consistent length every time thanks to the strong voider even with sensitive casings. 

JBT’s meat marination specialist Schröder showcased the full scope of cutting-edge equipment for meat marination and preparation, focused around hygienic design, easier handling and less operational amounts of brine. 

On Trend
Meanwhile JBT Avure demonstrated their compelling High Pressure Processing (HPP) technology. With more than 60 years of experience and expertise in HPP science and manufacturing, Avure specializes in HPP systems for food and beverage processing with the fastest and most reliable systems in the industry. Avure helps producers implement HPP from recipe development and process validations to installation, regulatory affairs, and post-installation support.

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Other products exhibited from JBT’s portfolio included 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 in ready meals, and heat and eat products that is making its European debut.

JBT offers customized solutions to food processors at every stage of the production process, including portioning, injection, marination, coating, frying, cooking, freezing, chilling & proofing, inspection, clipping & packaging and high pressure processing ensuring the final product is delivered as requested.

FLoFREEZE: the classic solution that keeps innovating


JBT’s Frigoscandia FLoFREEZE IQF freezer is a pioneering technology in the field of individual freezing for vegetables, fruits, fish and other products, which remains at the forefront of the industry, thanks to its versatility and ability to deliver true fluidization. 
Stefan Paulsson, JBT’s Director of Value Stream & Global Product Line for Cooking & Linear Freezers, explains how the system came to be and why it remains as relevant as ever.

The inception of FLoFREEZE can be traced back to beginnings of Frigoscandia itself, the Helsingborg, Sweden-based company – now part of JBT – which worked closely with a long-established frozen food brand, also located in southern Sweden. 

Frigoscandia developed the first machine that later became FLoFREEZE together with the food brand because in the 1950s and 60s, when you took a packet of frozen vegetables out of the fridge, what you got was a frozen brick. You couldn’t take out a specific amount, you had take out everything and put it in boiling water. So they wanted to be able to freeze the products individually, and that’s how the Individual Quick Freezer (IQF) for frozen products was developed. 

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This was achieved by making sure the products move all the time when you freeze them, so they don’t stick to each other. At the end of the process, you have a product which is individually frozen and then you put it in a box and send it to your customer, and they can just pour out how much they want. The FLoFREEZE is based upon the fluidization principle in which the products behave like a liquid and basically float through the freezer. This is what creates a perfect separation of the products and a high freezing efficiency.

How FLoFREEZE works
In this range, we have two different product types – the FLoFREEZE A and FLoFREEZE M. The FLoFREEZE A focuses on smaller amounts of fruits and vegetables, from one ton an hour up to six. The FLoFREEZE M handles bigger amounts, all the way up to 18 tons per hour (When we talk tons here, we always talks about peas – how many tons of peas you can do and then it’s translated to the relevant product).

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But having a good understanding of how FLoFREEZE works, will deliver a perfect result. The FLoFREEZE delivers true fluidization, and that’s the key to achieving optimum product quality.

We do this in two ways: pulsation of the product, so the airflow is coming through the belt into the product zone on and off, moving the product up and down; and then by agitation back and forth on the belt to get the horizontal separation of the product – that’s how we get true fluidization. 

The target here is we freeze the products in their natural condition. We don’t want to destroy a strawberry. It’s very important it comes out looking like we put it in, so you get the highest product quality.

One of the good things about FLoFREEZE is it’s very good across a diversity of products. It can handle a wide range of products – any vegetables from carrots and potatoes to onions and garlic, soft fruits, sardines and even mozzarella cheese. 

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The JBT Frigoscandia FLoFREEZE

Extra features
The FLoFREEZE has been continuously improved and updated, and one such example is a Refreezing Belt that has been added for glazing. Typically applied to broccoli, where glazing is used to protect the product, water is added following freezing and then refrozen to add the glazing effect.

With a product that is wet when it comes into a freezer, you will have a lot of ice build-up in your machine, so after eight or 10 hours, you really need to start defrosting it. But with the FLoFREEZE, we have an ADF (Air Defrost) that blows ice out of the coil, so you can extend your production time. In 2018, for the FLoFREEZE M, we also introduced a Sequential Defrost (SD) feature, which provides an extra evaporator so when one evaporator is blocked with ice, you can engage the other one, enabling you to defrost the evaporator that is blocked, and in the process extending the production time.

Read more about the JBT Frigoscandia FLoFREEZE

iOPS: the joined-up solution to real-time problems

Collecting and learning from data drawn in real-time from systems and machinery can detect potential issues before they become problems or even improve the overall efficiency of operations. This is the theory behind Intelligent Operations or iOPS, the latest stage in delivering more joined-up, efficient system management solutions, which is now being offered by JBT to customers worldwide.

As Matthew Jin, JBT’s IoT (Internet of Things) Program Manager explains, JBT iOPS systems collect information and data from equipment as part of a solution that enables customers to make vital, timely decisions to improve operational running or deal with problems.

“JBT iOPS delivers a connected device experience where we can collect data and convert it into actionable insights,” he says. “Through decades of industry know-how and expertise, we can analyze and detect issues before they become a bigger problem. Through analytics, we can detect issues quickly to keep equipment running efficiently day in and day out.”

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JBT iOPS can check the functionality of systems throughout a facility

Data visualization
Provided as a turnkey solution, JBT specialists visit customers to install iOPS hardware and software, which enables the collection of up-to-the-second information from equipment and machinery. Once completed, customers can access the information through their laptop, mobile device or tablet where a program will enable them to visualize the data. JBT can customize and tailor information displays into dashboards and reports, which provide customers with vital data covering everything from yield to production to alarms and errors.

“Customers can’t afford to have downtime and they need critical equipment to be running at optimum levels, so being able to monitor key performance indicators from those processes helps customers drive throughput, improve yields and where possible avoid defects,” explains Jin.

“With real-time notification and smart reporting, iOPS empowers our customers to drive success.  In the end, everyone’s a winner when we let data do the talking.”

Click to request more information about JBT iOPS

JBT’s LVS QuickDry: the patented system that halves freezer drying time

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JBT has launched a revolutionary new system for fast-drying of industrial 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.

The LVS QuickDry is an innovative solution to drying difficulties which makes use of a patented system of condensation cycles to quickly and efficiently remove all droplets of water from spiral freezers. Unlike most traditional drying systems, which rely on fans and can take an average of two-and-a-half hours to achieve results – leading to substantial downtime – the LVS QuickDry shortens effective drying time by up to an hour.

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JBT’s LVS Refrigeration System is a patented invention that optimizes the refrigeration system by reducing energy consumption, improving freezer performance in the process.

“When customers have freezers, the biggest problem – as with freezers at home – is defrosting and cleaning,” explains Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line, Spiral Freezers. “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 it that it shortens the drying sequence by up to one hour.”

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Drying solutions
In a typical factory environment where conditions are often humid, damp and cold, drying using fans is a slow process that can leave moisture in the freezer if any attempt is made to speed it up. 

“Drying has typically been done by running fans at high speed, much like a dishwasher,” says Persson. But then, the problem is – much like a dishwasher – if you don’t open the door, it never really gets dry because it’s hard to get rid of all the moisture. And what happens is you end up with a very warm freezer that takes a long time to chill down and you still have a lot of moisture in there.”

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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. However, using conventional drying methods, this is not always the case.

“We know from our operational experience that a lot of customers dry and they are still not happy, so they have to dry for another half an hour before they can start running because if you have a wet freezer, water can start to freeze on moving parts causing problems with the mechanics,” says Persson. “The LVS QuickDry condensates the moisture to the evaporator before heating it again quickly using hot gas, so the moisture that has frozen to the evaporator drips down to the floor. This gets most of the moisture out of the freezer as quickly as possible.”

JBT brings full pasteurization package to Almond Conference

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JBT is using the occasion of this week’s Almond Conference to launch a full service pasteurization offering – from start to finish – for the almond industry. As part of its presence at the event, which takes place in the Sacramento Convention Center, California until December 6, JBT will be offering an innovative, one-stop solution for pasteurization for almond producers and processors.

With the Almond Board of California having recently made it a requirement for almonds to be pasteurized after harvesting, there is now an obligation for farmers from California – the biggest almond production region in the US – to have pasteurization systems in place.

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However, according to JBT’s Tricia Harlan, up to this stage there has not been a company willing to offer everything from a pasteurizer to a chiller to cover the entirety of the pasteurization process.

“What we are offering at the show is the pasteurizer and all ancillary equipment needed for pasteurization,” she explains. “So we’ll have conveyors, refrigeration, the steam generator, the chiller, as well as the actual pasteurizer itself, so when customers are looking to bring pasteurization from a tolling operation to in-house, they have a one-stop shop where they can get everything from us.”

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The JBT Stein JSP-I Jet Stream® Pasteurization System Compact

Complete solution
“Most of the attendees at the Almond Conference will be from California, so in some way, shape or form, they need to have their almonds pasteurized in order to sell to the retail market,” Harlan continues. For small-medium sized processors, the complete solution will include a JBT Stein JSP-I Jet Stream® Pasteurization System Compact, alongside a JBT Frigoscandia FloFREEZE® Chiller, which is used to lower the temperature of almonds following pasteurization.

“In order to operate those pieces of equipment, you need a steam generator, refrigeration systems and conveyors, all of which will be available in our solution,” adds Harlan.

JBT’s Ramesh Gunawardena will be delivering a presentation on the almond pasteurization technologies available from JBT at the Almond Conference in Room 306–307 at 11.10 am on December 5.

JBT will also be showcasing solutions for the nut industry at the Peanut & Tree Nut Processors Association (PTNPA) Convention 2019 at the Renaissance Indian Wells Resort & Spa, Palm Springs, California from January 18-21.

Frigoscandia: the freezing brand’s red hot 12 months

This is the second in a series of articles where the JBT Protein Blog reviews the highlights for 2018 for JBT brands and looks ahead to 2019. Here we speak to JBT’s Torbjörn Persson about Frigoscandia. To read the first article (a look at Formcook, Double D & Stein), click HERE.

In-line freezing, the process of lower product temperatures before entering storage, is a vital part of the cold chain where hygiene, operating time and functionality are key elements of a successful operation. JBT Frigoscandia has made meeting all three requirements in a way that surpasses customer expectations a speciality by focusing on innovation; a focus that has driven Frigoscandia’s success during 2018.

Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line for Frigoscandia, says 2018 has been all about bringing solutions originally introduced last year to market; solutions which focus on increasing operating times, complemented by compact, hygienic design.

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GYRoCOMPACT appeal
The GYRoCOMPACT range has been a consistent seller across Frigoscandia global markets. Launched two years ago, the 600 mm-wide GYRoCOMPACT 60 continues to sell well worldwide, with its compact size – alongside the GYRoCOMPACT 40 and M7 – appealing to companies seeking to freeze everything from vegetables and berries to meat, poultry, ready meals and bakery products. JBT Frigoscandia also caters to larger capacities with the M9 and M10 GYRoCOMPACT spiral freezers.

“The GYRoCOMPACT 60 is used by a large amount of customers, freezing anywhere from 1.5 tons to 2 tons an hour,” explains Persson. “It’s a very compact machine, so it fits in a lot of factories and environments.”

Introduced in 2017, the GYRoCOMPACT 40 is a container-sized freezer that has found considerable success this year, thanks to an intelligent, hygienic design. “The GYRoCOMPACT 40 is a very compact machine, so it can be fitted in many different locations,” continues Persson. “It has a very inherent, hygienic design because it is self-stacking. From a hygienic standpoint, you have less material to clean, so you have inherent hygiene through the design.”

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Extended operation
Other notable highlights for 2018 in the Frigoscandia range include FLoFREEZE, a solution for freezing vegetables, berries, and other fruits, which has recorded a strong 12 months. “We’ve had a fabulous year for FLoFREEZE, especially for the larger machines,” says Persson. “We’ve made a new machine that can operate for a very long time, from five tons to over 15 tons per hour.”

Such a development, continues Persson, is part of a general push to operate longer between defrosts for both with the FLoFREEZE and the GYRoCOMPACT. “It’s a huge work to defrost a freezer, so you want to push that work back as long as possible,” he says. “Every defrost costs time, water and heat, plus you can’t produce while you are carrying out the defrost, so a longer operating time means you can run longer and improve efficiency.”

JBT Frigoscandia will be exhibiting at leading meat industry event IFFA 2019 in Frankfurt, Germany from May 4-9, 2019, alongside fellow JBT brands Formcook, Double D and Stein.

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