Skip to content

JBT’s NEOCAT Chiller boosts throughput by freeing floorspace

FATCAT_Chiller_small

For companies working in poultry processing, floorspace is often at a premium, and for those looking to expand their production area, minimizing space occupied by chilling systems is essential. This is where JBT’s new NEOCAT chiller comes in: a natural progression from the FATCAT Chiller, but with even more emphasis on reducing floorspace.

An immersion chill system featuring a brand new design, the NEOCAT, which is being rolled-out globally following successful trails in the US, has been developed to deliver a much higher pounds to linear foot ratio, in the process freeing up an extra 30% floorspace and enabling companies to increase processing throughput in facilities.

image003

As Darin Chancellor, JBT’s Chillers & Refrigeration Division Manager for the Cooling & Applied Technology (CAT) brand, explains, the FATCAT itself was originally created in 2002 to reduce floorspace inside facilities to accommodate increasing line speeds and bird weights. With line speeds only continuing to get faster in the intervening years, floorspace has gradually become the most valued and expensive area in a poultry processing facility, leading to the development of the new NEOCAT.

“By designing the NEOCAT, we were aiming to target that same concept in terms of reducing floorspace and still being able to do the throughput facilities need to do,” says Chancellor. “The NEOCAT gives our customers the option of a 30% reduction in floorspace or a 30% increase in throughput depending on how you look at it. 

“If you have 100 sq ft designated for a chiller, we can match your pounds in the NEOCAT over say 70 sq ft, freeing up 30 sq ft for increasing production.”

Largely used in conjunction with poultry processing, the NEOCAT also has extensive applications in turkey and fish processing.

Request more information about the NEOCAT

Tipper Tie highlights accessible automation for small processors

ring-sausage-clipper

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.”

kdcm-digital-control

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

Tipper_Tie_SVU6800

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. 

Tipper_Tie_SVU6800_front

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

PRoCARE_close-up

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.

PRoCARE_small

“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.”

PRoCARE_engineer_small

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

1 2 13
%d bloggers like this: