From faux-meat veggie burgers to healthy snacking options, plant-based foods have very much stepped into the limelight over the last 12 months, with meat-replacement meals that aim to look, cook and taste like beef garnering reams of media coverage. High-Pressure Processing (HPP) systems from JBT that can extend the shelf-life and preserve the flavor of plant-based foods will be the subject of a free JBT webinar taking place on October 16.
Developed for customers in the Asia-Pacific region, the 30 minute, live HPP Plant-Based Food Trends webinar will deliver an overview of trends within the plant-based food sector, looking at how the phenomenon has spread across the food and beverage industry, and giving examples of success stories.
The webinar will also examine how HPP systems from JBT Avure can benefit plant-based foods by extending product shelf-life through the use of cold pasteurization technology. Attendees will get the chance to learn how the technology ensures food safety without the use of heat or preservatives, while maintaining fresh food characteristics such as flavor and nutritional value.
The JBT HPP Plant-Based Food Trends Webinar will take place on October 16 2020 at the following local times:
For many companies in the protein processing industry, the onset of the COVID-19 pandemic took them into unchartered territory, with increased employee absences and localized outbreaks causing havoc for processors large and small. Here, having effective support in place to avoid unexpected downtime is of crucial importance and this is where JBT’s innovative preventative maintenance PRoCARE® program has been playing a vital role.
Unlike traditional maintenance, where problems are dealt with as they arise, the focus of the JBT PRoCARE program is on anticipating issues before they become problems by applying proactive system management that helps customers stay within budget and avoid downtime. By employing proactive, preventive maintenance, JBT PRoCARE technicians help prevent breakdowns by replacing worn parts and providing an overall picture of how equipment is performing.
Additional support However, recognizing the pressure customers currently face, JBT has taken a number of steps to lend support, including via a dedicated customer careline, as well expanding PRoCARE payment options, explains Brendon Somerfield, Head of PRoCARE and Customer Care in North America for JBT Protein.
“Everybody is struggling with cashflow in these times, so at the onset of the outbreak, JBT ran a promotional program which enabled customers to delay their first PRoCARE payment by about four months,” he says. “They could still get the preventative maintenance service that they need but don’t have to worry about payment for several months. This was one of the ways we were helping customers financially.” Additionally, given the pressure some companies find themselves under as a result of the pandemic, JBT has expanded parts discounts and free virtual support.
Dedicated hotline Further support is being provided in North America through a new, dedicated Customer Care Hotline that provides customers with access to JBT’s best-in-class service technicians: 1-866-JBT-4YOU (1-866-528-4968).
Remote support in the moment of need, the hotline puts customers in contact with service technicians familiar with JBT equipment and machines, and serves as a single, easy-to-remember source for customer care. For JBT PRoCARE customers, additional support comes in form of unlimited access to the hotline.
Downtime can be a challenge for processing companies across the protein industry. But during these difficult times when many have been faced with worker absences, unexpected stoppages can be especially problematic, putting pressure not just on processors but on supply chains as a whole. JBT Proseal, which has a strong record in packaging innovation, believes its innovative downtime analyzer, ProVision, could help combat downtime while improving productivity across an entire facility.
Enabling managers to have a detailed view of all production lines, ProVisionfunctions as a virtual dashboard, giving a picture of filling and sealing in real time, and pinpointing any problems as and when they occur.
“If you are the CEO of a business and you have 10 production lines and one of those has failed for a day, you will want to know about it,” says Proseal’s Head of Sales & Control Systems, Tony Burgess. “If, in all your 10 production lines, for one minute of every hour the line stops because of a failing piece of equipment, in a month’s time that will could have added up to one day’s lost production.
“ProVision will capture all of these micro instances and build a series of data. It will tell you exactly the downtime and cause of downtime over the last 24 hours. It allows the user to focus attention on the piece of equipment on the production line that is causing the downtime and do something about it, so it has an enormous productivity benefit.”
Emerging trends A further area where Proseal sees an opportunity is in the booming online market for food ingredients and ready meals driven by increasing consumer interest in cooking at home. Proseal, Burgess reveals, is supplying eco-friendly Halo tray forming equipment to Dineamic, an Australian company which delivers chef-cooked meals to consumers across the country. “Dineamic produces their own foods, seals them with Halo pack trays made in house with a Proseal tray sealer and then sends them mail-order,” says Burgess. “Similar work is being done in other geographic locations.”
However, such developments are not just taking place in the food industry. Proseal, Burgess adds, is currently working on a project in the Netherlands for online flower orders by designing packaging options suitable for sending flowers by mail-order.
Increasing capacity and throughput while improving food safety are key considerations when it comes to replacing industrial freezers, but companies can face expensive rebuilds to accommodate new machines. Recognizing space is often at a premium, JBT’s new Frigoscandia GYRoCOMPACT® 70 Spiral Freezer has been developed to optimize capacity, as well as enhancing food safety and throughput. In fact, the GYRoCOMPACT 70 is more compact than any of its predecessors, yet offers 20% more capacity and a belt width of 700mm.
Torbjörn Persson, JBT’s Director of Value Stream & Global Product Line for Spiral Freezers, says the new GYRoCOMPACT 70 marks a significant advancement on previous versions, with the emphasis very much on boosting food safety, throughput, capacity and sustainability. “The GYRoCOMPACT 70 still has the inherent self-stacking capabilities but we have made it more hygienic and easier to clean,” says Persson. “One big change is that all of the profiles on the machine are now open, so you are able to clean all of the parts inside.”
Throughput has been improved, he continues, by speeding up the defrosting process through additional features including a new ventilation hatch and LVS QuickDry technology. The GYRoCOMPACT 70 further reduces water and energy consumption, improving sustainability in the process, by operating longer between defrosts and limiting the time it takes to carry out a defrost, which would typically consume a great deal of both energy and water.
Improved capacity is also a key advancement. Despite the freezer’s compactness, says Persson, JBT has been able to increase capacity by getting more belt into the GYRoCOMPACT 70, while the level of the freezer has also been lowered to boost interior space. “We are able to get more products into a single unit, although we still allow for products that are 50 mm in height,” he explains. “Many companies have existing facilities that the freezer needs to fit into, so size is very important. This machine can fit into the same space as an old machine, but with the advantage that it includes more capacity.”
The GYRoCOMPACT 70 has a wide range of freezing applications, covering everything from bakery to poultry and pizza, and is available across Europe and Asia.
As a global technology equipment supplier to the food processing industry, JBT has launched its new Frigoscandia GYRoCOMPACT® 70 Spiral Freezer which, the company believes, is set to take food-focused freezing to the next level.
The new freezer has a belt width of 700mm and is more compact than any of its predecessors, yet offers up to 20% increased capacity. Designed to be both sustainable and hygienic with a number of new streamlined features to further eliminate food traps and maximise food safety, the new freezer joins the GYRoCOMPACT 700mm product line which has sold over 1,700 units world-wide. The new freezer is also iOPS-ready to enable peak optimisation.
Customer feedback, combined with its pioneering of the self-stacking spiral belt, are what drive the development of the Frigoscandia brand, as Torbjörn Persson, JBTs Director of Value Stream and Global Product Line, explains: “Customers continue to require increased food safety, combined with higher efficiency in uptime and capacity.
“Of course, most industrial freezers are quite large, so the need to have food-safe freezers is really important when looking at a full food production line. One key factor is that the freezing process itself doesn’t limit growth of bacteria on contaminated products, but only stops it momentarily. This is one reason why optimized hygienic design has always been our top priority. Floor joints, reduced overlapping surfaces, reduced visible threads and pop rivets are just some of the innovations.
“We’ve also seen a clear trend for more variation in the products our customers produce, which enforces the need for flexible production lines. For example, we can now increase the capacity for chicken nuggets from around 4000 kg/hr up to 4,800 kg/hr.”
Many customers are also faced with high investment costs if they are planning to build new production facilities, says Persson, so their aim is how to put more capacity into their existing buildings. Designed for production rates of between 1.5 and 5 tons per hour, the freezer can be utilised for existing frozen food applications, while also having benefits for plants with space constraints, as its headroom has been reduced by 600mm.
Quicker drying functions, optimized airflow, less drive forces, and savings of up to 75% in oil consumption are just some of the features JBT has introduced, with further innovations in the pipeline. JBT’s iOPS system, its version of IoT (Internet of Things), analyses data in real time to maximise uptime and productivity.
“Our current developments are focused on food safety, efficiency and uptime,” adds Persson. “The Europe frozen food market is expected to reach well over 17 million metric tons by the end of 2026. We want to be ready for that.”