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Tipper Tie highlights accessible automation for small processors

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Having access to effective, reliable – and economically-priced – sausage clipping machines is crucially important in keeping small and mid-sized processors functioning and profitable, and this is the concept behind the DCM and KDCM from JBT Tipper Tie, with the focus very much on delivering an efficient solution without breaking the budget.

German-built and designed machines, the semi-automatic systems have been developed to provide simple, precise solutions, which can help processors achieve substantial savings compared with standard table clippers. Less giveaway and more throughput are also key features of systems that deliver simple automation capable of boosting efficiencies and avoiding unnecessary wastage, according to Tipper Tie’s Conrad Faust.

“We call them semi-automatic machines because the operator physically closes the gate of the machine and the machine will automatically clip, cut and separate the product,” he explains. “It has a low entry price for our customers and it’s really versatile, especially if you are running high quality products or anything that’s delicate – the machine is very good for those products.

“It will run rings, straight products and a pretty large variety of different diameters, so for smaller customers, butchers and meat lockers where they don’t necessarily have big long steady runs, it’s the perfect machine for all different kinds of sausages. They are also best for natural casings which are very sensitive.”

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The KDCM’s modern, digital display

Reliable results
Compared with a simple table clipper application, Faust describes the DCM and the KDCM as much faster, much more repeatable and more precise, and capable of far higher throughput and less giveaway. “These are simple, precise, reliable systems, and with the double clippers there are big savings versus a standard table clipper because you can use shirred casings instead of higher cost pre-clipped casings,” he says. “This increases output, decreases cost and reduces waste – all of it increasing productivity.”

Also available is the KDCMA, a fully automatic version of the KDCM, where the machine rather than the operator is driving production. “With the KDCMA, you get even more throughput without having to rely on the operator because it will automatically communicate with the stuffer and is capable of running much faster,” says Faust. “It has a sizing range of 25-120 mm, so we have a large variety of different diameters that can be run on it. Plus, it is excellent for sensitive and natural casings – that’s where it really excels.”

Learn more about Tipper Tie options for smaller processors

Tipper Tie heralds advances in protein sizing machines

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JBT Tipper Tie has made important system advances over the last 12 months, not least of which has been the development of the all-new SVU6800, which has been designed for the sizing and clipping of difficult-to-run whole muscle and large products, heavy hung smoked or dried sausages, and salami.

The fastest in its class, which can run up to 65 cycles per minute, the SVU6800 is capable of running products ranging from 50-200 mm, according to Tipper Tie’s Conrad Faust, who says the machine’s very robust design has been developed for maximum uptime, with long intervals between servicing. 

Smoked pork sausages hanging

“One of the ways you can actually see this is the size of our cam followers,” says Faust. “If you compare our cam followers with those of other manufacturers, ours are significantly larger at double or triple the size, resulting in significantly longer run times before you need to replace them. This is important because cam followers are often one of the limiting factors with sizing machines: you are always rebuilding because the cam followers have reached the end of their useful life.”

More efficient
The other principal design goal for the SVU6800, continues Faust, was to be able to handle large, whole muscle processing of hams, roast beef and other in-demand products where there was a need to cleanly separate through whole muscle for consistent length every time. 

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Crucially, the SVU6800 is principally servo or permanent magnet motor driven, enabling the elimination of almost all the pneumatic cylinders and eliminating the pneumatic conveyor motor. The effect of this change, says Faust, has been to deliver a machine that is more efficient as well as being faster. 

“With the SVU6800 we have been able to reduce the number of electronic switches and sensors – which means we have reduced the potential for misaligned or failed sensors causing downtime,” he explains. “Thanks to the robust design of the SVU6800 and the elimination of unnecessary electronics in the washdown area, the reliability and uptime of the machine is improved.”

The SVU6800 is also available with up to 300 mm of air-free slack-fill for over-spreading for form-shaped products. “No corners were cut when designing and creating this solution,” Faust adds.

Learn more about Tipper Tie’s SVU6800

Proseal places focus on shelf-life and packaging innovations

Chicken Breast Diced Photo - Proseal

With awareness of the importance of sustainability growing worldwide – among protein producers and consumers alike – so demand has increased for solutions that offer enhanced shelf-life and make use of non-plastic alternatives, writes Tony Burgess, Head of Sales & Control Systems at one of the newest additions to the JBT family, tray sealing solutions specialist, Proseal.

In competitive markets handling highly perishable foods, maximizing both shelf-life and throughput is vital, so at Proseal we are seeing a strong interest in our high-speed tray sealers that can be trusted to deliver efficient sealing and Gas Flush (MAP) processing and keep up with the required speeds of production.

To deliver this, cycle speed is naturally key, but another important requirement of today’s packaging line is the ability to follow motion and use intelligent buffering capabilities that enable trays to feed continuously into a tray sealer without having to pre-sort and adjust pack spacing. This valuable time saving technology is demonstrated by Proseal’s ProMotion™.

Proseal GT1s Tray Sealing Machine_small

Alternative Materials
More recently the plastic narrative in the consumer media has led to many companies and retailers seeking alternative materials, or light weighting their existing plastic trays. Over the past 20 years at Proseal, we have been working closely with film suppliers in order to devise viable solutions that are able to meet the sealing needs of trays made from both plastic and cardboard, without causing a need for costly modifications to machinery by our customers.  

This includes Halopack®, a gas-tight cardboard tray suited to skin packaging, which offers an 80% reduction in plastic from some traditional plastic trays and is made up from 90% recycled cardboard. And another recent innovation, the plastic ‘snap-pack’ style tray, which seals the portioned product into two separate cavities in the same tray, allowing the consumer to ‘snap’ off and open one half of the pack and dispose of it, whilst the other half remains hermetically-sealed in its gas-flushed environment – allowing the customer to fully benefit from the maximum shelf-life of the product whilst reducing food waste.

Fish Whitebait Halopack WHITE View 1

Automated Control Systems
The need for intelligent technology is also evolving in processing lines and such intelligent technology is demonstrated in all Proseal tray-sealers through its many features and benefits. Proseal’s market-leading control systems can see our machinery act as ‘the spine of the packaging line’, integrating all the line machinery components to be driven through the Proseal touch screen.

This ensures that in the event of a problem, the Proseal machine is able to flag an error in a peripheral piece of machinery and pass a stop signal to the feeding equipment, enabling the line to come to a controlled stop in order to avoid overfeeding the tray sealer and prevent unnecessary product or packaging waste.

Learn more about Proseal’s solutions

PRoCARE in Europe: helping processors avoid potential hazards

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From worn components to hidden bacteria, hazards that have the potential to cause breakdowns or worse in food processing facilities can be easy to miss during a casual inspection, that is until their presence finally causes drastic action to be taken. JBT’s innovative PRoCARE Service Agreements give customers the reassurance that such issues are identified before they become problems by turning a standard working relationship into a proactive partnership.

JBT Technical Solutions Managers, Stewart Linford and Joel Thomas, are two of JBT’s leading proponents of PRoCARE in the UK, Ireland and France respectively, which has given both a thorough understanding of the real benefits the agreements offer to customers.

“For me, the added value of PRoCARE is regular inspections, regular deliveries of parts, oil and even chemicals, and in the process we are able to further develop our working relationships with customers and better understand their needs,” explains Stewart. 

As well as providing best practice advice on cleaning facilities and the use of chemicals, PRoCARE provides regular inspections to customers, preventing damage to the belts and drive systems of equipment and replacing worn parts to avoid breakdowns. The service also provides customers with Capex forecasts, giving them a better oversight into how their equipment is performing.

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“We inform them of new technical developments that are coming out and pass knowledge to our customers, so it becomes more of a partnership relationship and it’s a lot different from the old inspections,” says Joel. “It’s much more proactive: we find issues that can get missed by the customer that require the knowledge & skills only the OEM can provide. There’s also more flexibility in terms of what can be included, such as being much more proactive in training operators for example.”

Preventative cleaning
PRoCARE is regularly – and effectively – used by JBT customers in the three territories, where service engineers have advised on the correct cleaning of machinery. “Often people don’t use the right chemicals and cleaning processes to prevent the corrosion of equipment and even experience contamination from listeria and other hazardous bacteria,” says Joel. “Through PRoCARE, we can help customers maintain equipment at an optimal level of hygiene.”

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Similarly, Stewart says JBT helped one UK customer improve cleaning procedures to make sure machinery was kept in the best possible condition. “The customer was having very high bacteria counts, but we showed them how to bring that down within two days and they were very happy with the results,” recalls Stewart. “They now carry out a deep clean once a month.

“Through PRoCARE, customers can call any time with an idea or a problem and we will help with either making that idea a reality or solving the problem.”

In these pandemic times, virtual support options have become more important and PRoCARE is no exception. As well as offering remote, preferential phone support for PRoCARE customers, Stewart says JBT support engineers have been making use of platforms – notably Zoom – that have risen to prominence in recent months. “We are really trying to leverage the new technology that’s available to help review service inspections and it seems to be working well,” he adds.

Request more information about PRoCARE in Europe

Find out more about PRoCARE Service Agreements

Proseal support helps keep food packaging lines running

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The fast-response service on which JBT’s tray sealing specialist Proseal has built its reputation is proving invaluable in enabling food customers globally to maintain production and output at a time of greatly increased demand, with the pandemic having placed immense pressure on food supply chains at a time when social distancing measures and absences from work are creating additional challenges on production lines.

Proseal continues to go above and beyond, doing its best to ensure that its existing industry-leading turnaround times are being maintained and to provide immediate help to customers to ensure machinery can run at peak optimum performance. The company’s in-house manufacturing teams are working flat out to meet the increased demand, liaising closely with the planning team to prioritise tasks dynamically throughout each day.

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This heightened manufacturing capacity has been made possible by the dedication of Proseal employees and the measures that have been put in place to ensure their health and safety in line with official protocols such as social distancing.

Spare part production and dispatch has been speeded up wherever possible and this has been aided by Proseal’s strategic stockholding of standard parts. Machine tooling production, which is normally completed within a two-week lead time, has also been accelerated; in several recent instances tooling has been designed, manufactured, tested and dispatched within a matter of days to meet customers’ emergency requirements.

Beef Large Joint Photo - Proseal

Equally important, Proseal continues to provide 24/7 phone support to diagnose and troubleshoot issues, providing a vital helpline to customer’s engineering teams. Allied to this, the company’s online and virtual Provision system helps to monitor downtime, OEE, and error management in order to proactively identify issues before they become problems.

For ongoing production matters, Proseal’s comprehensive Test Kitchen facilities also remain operational, enabling food companies to carry out shelf-life trials and seal integrity testing. As well as continuing to support new product development processes, the service can also assist companies having to adjust existing recipes, adopt new tray formats or materials to compensate for any shortages in their supply chains.

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The Test Kitchen has more than 15,000 trial plates in stock along with vast stores of trays and films in different materials. Testing facilities include a vacuum tank, gas cylinders for MAP and gas analysers. In addition, Proseal’s ProTest™ unit is able to measure how much force is required to peel a film lid from a tray, enabling the user to determine if the seal strength is suitable for the product’s lifecycle. 

To maintain safe working practices, tests are being carried out by the Test Kitchen team in isolation, with samples and reports sent back and forth between the customer and Proseal, rather than the customer coming to the Proseal site. “We have always recognised how essential it is for food companies to be able to maintain production and that is why we have continued to invest heavily in our range of support services,” explains Proseal’s Tony Burgess. “We are delighted that this investment means we have been able to provide the fastest response for customers during these very testing times.”

Request more information about Proseal solutions

JBT PRoCARE: proactive solution delivers savings

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Traditional equipment maintenance – dealing with problems as they arise – often involves unnecessarily expensive, unbudgeted and unsatisfactory quick fixes. JBT’s PRoCARE program, by contrast, anticipates issues before they become problems, applying proactive system management that enables protein customers to keep within budget and avoid costly downtime.

In some cases, using PRoCARE has saved protein customers thousands of dollars in unnecessary parts expenditure. And, given the pressure some companies find themselves under as a result of the pandemic, JBT has expanded parts discounts and free virtual support, while also providing extended payment terms for the rest of 2020.

Brendon Somerfield, Head of PRoCARE and Customer Care in North America for JBT Protein, says the emphasis for PRoCARE is on proactive, preventative maintenance for customers. “PRoCARE is proactive, staying ahead of any issues that might come around, and providing inspections and PM visits from highly experienced technicians,” he explains.

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Downtime avoided
A typical recent example that Somerfield quotes is of a customer for JBT’s DSI portioning range who estimates having PRoCARE in place has saved them $250,000 dollars worth of parts through proactive management by helping with parts budgeting, thanks to regular visits and contact with JBT service technicians. Another example Somerfield gives is a Frigoscandia GYRoCOMPACT Spiral freezer customer that could have been faced with a substantial downtime as a result of an equipment problem that was not immediately apparent. 

“The customer was experiencing premature drive chain stretch and wear, and they weren’t aware of that,” he says. “It was an older piece of equipment and some of the sensors had been neglected in previous years.

“Being in there twice a year, we were able to catch this and offer a rebuild for their machine. A premature stretch on a critical drive component can potentially lead to major downtime events. We likely saved them 12-16 hours’ downtime and that’s pretty critical for a weekly production shift.”

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Ongoing support
PRoCARE, says Somerfield, is a continuously evolving platform, which gives customers the option of a monthly payment plan with zero percent financing, helping them maintain a reliable and consistent budget throughout the year. 

Furthermore, with many companies experiencing unstable cash flows and production capacities as an indirect result of the pandemic, JBT PRoCARE is now offering them a sixty-day payment plan, as well as an additional parts discount. Instead of the standard 5% PRoCARE parts discount, JBT PRoCARE is offering a 10% discount for the rest of 2020 for qualifying DSI opportunities. Additionally, JBT is providing free remote support for PRoCARE customers over the months ahead, ensuring the JBT commitment to proactive service is maintained.

Find out more about PRoCARE

Proseal: a proven track record in sustainability

Beef Halopack - Proseal

Proseal may be one of the newest additions to the JBT family, but the packaging equipment specialist is no newcomer when it comes to sustainability. In fact, the company, which was acquired by JBT in June 2019, has helped drive major breakthroughs in sustainability for the protein industry, enabling retailers to significantly increase shelf-life for beef while eliminating wasteful over-packaging.

An innovator in environmentally-friendly packaging systems with a manufacturing presence in Europe, the US and Australia, Proseal is a leading manufacturer of tray sealing equipment for a range of protein food products including categories such as red meat, pork, poultry, fish, seafood and ready meals. 

Beef Meatballs Photo - Proseal

Boosting shelf-life
However, Proseal has also been at the forefront of developing systems that improve product shelf life whilst minimizing the use of plastic at the same time. In terms of chicken, the company, which has its headquarters in Adlington, Cheshire, UK, produces a leading-edge ‘Gas Flushing’ solution which can achieve a very low gas residual and in some cases more than double a product’s shelf-life. 

‘Gas Flushing’, sometimes referred to as Modified Atmosphere Packaging, is a food packaging method where the Earth’s normal breathable atmosphere has been modified by either a single gas or a mixture of gases. It is generally used with a barrier film with low oxygen transmission.

“All the chicken you typically buy in the UK has had a different cocktail of the Earth’s atmosphere injected inside that chicken tray before it is sealed,” explains Proseal’s Head of Sales & Control Systems, Tony Burgess. “We put in a different blend of atmosphere which can extend shelf-life from four days to 10 days.”

Proseal HQ

Incredible achievement
Even more significant is Proseal’s ‘Skin’ packaging for beef, fish and other protein products. In the case of beef steak, says Burgess, the product is gas flushed with oxygen to keep the haemoglobin content high in the beef, before being skin-packed in plastic film; a process which can extend shelf-life from a previous norm of 10 days to 28 days. “This was an incredible achievement and was a huge win for retailers and supermarkets,” he says.

“The packaging world is developing a lot into how can it extend shelf-life, how can it come up with films that can be laser perforated, and all of these things are pushing packaging so far away from rigid lids,” continues Burgess.

“There is also a big move away from plastic towards cardboard or aluminium and the beauty of our tray sealing system is it can work with any of these materials. We work closely with the packaging industry, we have a test kitchen and operate an open door to carrying out packaging trials with companies.”

Learn more about Proseal’s solutions

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