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JBT Proseal’s ProVision: a key tool in limiting downtime

Proseal tray sealing ProVision Press images laptop machine line_small

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, ProVision functions 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.

Learn more about Proseal’s ProVision

JBT GYRoCOMPACT 70 Spiral Freezer presents advances in safety & space optimization

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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.”

JBT_GC70_Spiral_Freezer

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.

Learn more about the Frigoscandia GYRoCOMPACT® 70 Spiral Freezer

JBT takes next steps in spiral freezing

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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.

The JBT Frigoscandia GYRoCOMPACT 70 Spiral Freezer

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.”

Learn more about the Frigoscandia GYRoCOMPACT® 70 Spiral Freezer

JBT Formcook: boosting yield for protein processors

JBT Formcook is one of the undoubted pioneers of contact cooking, the innovative method for sealing moisture into protein products by employing teflon belts, which can improve both yield and flavor. However, in spite of the challenging situation caused by the Covid-19 pandemic, Formcook is continuing to help new and established customers start up new cooking lines, thanks to JBT’s effective remote support options.

Originally established in Helsingborg, Sweden in 1989, Formcook became part of JBT in 2014, by which time the company had gained a strong reputation as an innovator in contact cooking. In fact, the original concept was developed and adapted by Formcook founder, Winje Green, during a visit to the US in the company’s early years in the process becoming the first oven manufacturer to use a moving teflon belt for cooking.

jbt_formcook_contact_cooking_poultry

Significant advantages
Lars Håkansson, JBT’s Sweden-based Regional Application Manager for Formcook explains that the use of a teflon belt gives Formcook’s two models – the Contact Cooker and the Combi Cooker – significant advantages over other belt-based cooking systems. “The system functions much life a teflon pan at home by bringing together a teflon belt over a heating plate, and as a result the products don’t stick,” he says. “You can put egg on it and lift it off very easily. Compared with a mesh belt, the product doesn’t stick.”

The Formcook teflon system is principally used to set the surface of protein products such as chicken fillets to prevent moisture or yield loss when they move on to a main oven. “After the contact cooking, we run the chicken fillet into an oven and it will not stick to the surface because we have closed the top and bottom surfaces,” explains Håkansson.

JBT_Formcook_contact_cooking_hamburgers

“That makes it first of all more juicy because you have a closed surface so moisture is kept inside. Also, by not sticking to the belt, you achieve a higher yield because normally if you put a raw product on a wire belt, 2-3% of the product will stay on the belt.”

Learn more about JBT Formcook

JBT Formcook: the innovative system for improving yield and value

At these times of tightening purse strings and changing consumption patterns, being able to offer shoppers more for their money, with improved quality, is likely to make financial sense for many companies. This is the solution offered by JBT Formcook’s Contact and Combi Cooking systems, which can significantly improve cooked yield, delivering better value in the process.

The Contact Cooker and the Combi Cooker are the two signature solutions from Formcook, a world leading JBT brand of in-line, non-stick contact cooking. Both the Contact and the Combi versions make use of a solid, Teflon belt that can cope with all sorts of small, fluid products that would not be suitable for a steel belt, explains JBT Regional Solutions Manager Marcelo Scharlack. “Products such as mincemeat, which would stick tremendously, and other meats and poultry that would be very difficult to cook on a steel belt are ideal for contact cooking,” he says. 

JBT_Formcook_poultry

In the case of the Contact Cooker, the system functions much the same as a skillet – or frying – pan would at home, but with significant added benefits for the entire cooking process. “What we found is the contact cooker enhances the operation for other ovens because it seals the surface of the product and as a result can deliver huge savings in terms of weight loss,” explains Scharlack. “If you cook a chicken breast, you would typically expect to have a yield of 80%. By sealing with a teflon belt we can save up to 10% more, so it adds up to a significant amount of money.”

JBT_Formcook_scallops

Although both similar in design, the primary difference between the Contact and Combi models is that the Contact Cooker features a telfon belt on both sides of the product, cooking it as it moves along. The Combi Cooker has a single teflon belt while hot air cooks the top surface; an approach which is particularly well suited to non-flat shaped products, such as (meatballs). 

“The contact cooking system employed by both solutions is the most effective method of transferring heat, providing fast cooking, high yields, quick changeovers and easy cleaning,” adds Scharlack.

Learn more about JBT Formcook contact cooking solutions

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