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Radically reducing freezer downtime: the CleanFREEZE takes centerstage

Aiming to optimize freezer production by minimizing cold-to-cold downtime, while making sure no shortcuts are taken on hygiene and cleaning? JBT Northfield’s CleanFREEZE marks a step-forward from the long-established Northfield SuperTRAK Structure Supported Spiral Freezer by delivering a radically-reduced cold-to-cold time, along with important hygienic and ease-of-maintenance innovations. 

At its core, the CleanFREEZE takes the original SuperTRAK design and adds new hygienic features, including innovations that differentiate the CleanFREEZE freezer from other spiral freezers currently available. The comprehensive redesign not only minimizes the defrost full sanitation process, it also makes the freezer easier and quicker to clean, and reduces the risk of bacterial contamination.

Turnaround time
Perhaps most significantly, the cleaning turnaround time has been cut to four hours from an industry average of six. In the process, says John Bauer, JBT’s Freezer Division Product Manager, customers will be able to make real savings on time. “With the CleanFREEZE, customers don’t have to go through such a lengthy cleaning process so they can increase production and throughput, enabling them to maximize uptime,” he says.

Ease of maintenance
However, the time savings aren’t just limited to the cleaning process. The latest version of the CleanFREEZE features significant improvements to ease-of-maintenance, including the moving of fan motors to the exterior of the structure. “Having the fan motors outside allows customers to replace them easily if something fails while they continue to run production,” explains Bauer. “We’ve also added stairs to enable easier access to the mezzanine level, so the maintenance crews can have quicker, safer access to components on the mezzanine level, behind the coils and other areas.”

More than this, JBT has improved hygienic features across the CleanFREEZE, minimizing overlapping surfaces throughout its open-profile framework, and adopting capless rails. 

Customers will be able to learn firsthand about the CleanFREEZE at IPPE 2022, the International Production & Processing Expo, which takes place in Atlanta GA from January 25-27, 2022, where JBT will be highlighting its commitment to customers: “We’re with you, right down the line”™.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center. 

CLICK HERE to request more information or a meeting at the booth

The DSI Waterjet: cutting out obstacles to protein profits

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Reduce labor and improve yield with innovative automated solutions from the DSI™ team at JBT. These systems – on display at IPPE 2022 – trim, slice and optimally portion poultry, beef, pork, plant-based protein, fish and even bakery products; in the process cutting out obstacles to having a profitable protein business.

DSI Portioning Systems employ machine vision technologies to scan food products and determine product shape, weight, and fat; preplanning and optimizing each piece for maximum value before the first servo-driven automated cuts take place. DSI systems cut with high pressure waterjets, horizontal blades, and vertical blades to maximize yield processor profit. 

More Solutions More Efficiently
JBT will display and demonstrate the DSI 800 S series Waterjet Portioning System at the International Production & Processing Expo (IPPE) in Atlanta GA from January 25-27, 2022. The DSI display will highlight the latest advances in high-yield waterjet portioning as well as an efficient and rugged new intensifier pump technology proprietary to JBT that uses 40% less power to deliver 4000 or 6000 bar water pressure. 

High-Yield Adaptive 3D Portioning (A3D)
The DSI 800 Series Portioning System is complemented by the DSI Adaptive Slicer 3D™ to achieve high-yield portioning of large-bird input product. The system combines waterjet cutting with intelligent horizontal slicing to achieve three-dimensional portioning. The new Adaptive slicer features wider lanes and improved systems to adapt to shape and size variation of incoming product to maximize yield.

“With the A3D system we have the ability to portion double weight product to template on the waterjet and then we intelligently horizontally slice the product to generate a top and bottom portion,” explains Dave Faires, DSI Director of Applications and Portioning Segment Leader. “For some applications we achieve six or eight shape-and-weight controlled portions from the original input product.”

JBT DSI Dual Robot Harvester

Labor Saving Solutions
The DSI portfolio includes labor reducing solutions for poultry processors serving quick service restaurants or retail products. The popular DSI Dual Robot Harvesting System (DRH) (pictured above) reduces the labor required to separate portions from value added elements of the portioning process such as nuggets, chunks or strips bound for downstream bulk processing such as marination. 

The latest innovation in the portfolio is a proven and exclusive solution for net weight packing and tray packing and high speed sorting or “calibrating” of fillets. JBT is introducing the proven Robotgrader system, updated and tuned for the needs of the North American market under an exclusive distribution agreement. This automated system scans product to determine shape and orientation, weighs the product in motion, and then robotically picks and places product according to maximum value at the highest production rate available in the least space required for such a solution. 

“All four DSI solutions will be on display at the expo, alongside a video kiosk demonstrating our applications and our JBT remote support and IoT solution, called iOPS,” Faires adds.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center. 

CLICK HERE to request more information or a meeting at the booth

Guarding against contaminants: the XVision FlexScan

Imagine a consumer sits down for their evening meal and finds a stone or piece of calcified bone – or worse glass or metal – in their chicken breast or steak. Such findings can lead to costly product recalls which have the potential to ruin reputations and end contracts. Guarding against such occurrences is not just essential for the health of a business – and consumer safety – but is also now mandatory under USDA regulations.

One of the most effective ways to easily and efficiently detect contaminants is through JBT’s XVision™ FlexScan™, an intelligent x-ray inspection system that is ideally suited to finding and eliminating contaminants in wet or dry environments alike.

Rethinking detection
The FlexScan rethinks contamination detection by using a new flexible modular detection system, which leverages multiple X-ray technologies to see and extract contamination from food.

“Such contaminants include metal, such as stainless steel, stone and glass that can get into poultry and red meat – and especially packaged meats – during the production process,” explains Dino Carbone, Division Product Manager at JBT XVision. “This provides a level of protection to our customers’s customers, and to the end user, so they can be assured their food is safe and of a high quality. It has become a necessary component of the production process, and one that is now required by the USDA.”

Maximum flexibility
Carbone says customers love the FlexScan’s hygienic and robust design, as well as its ability to operate in wet production environments where contamination can occur. The FlexScan also comes with an unprecedented degree of flexibility. It can be placed downstream after equipment such as a grinder or further upstream, so any contamination can be identified and expelled earlier in the production line. The advantage here, continues Carbone, is that it reduces the amount of waste and cost incurred when a customer detects contamination further down the line. “This is especially useful when customers are bringing in products from other locations,” he says.

IPPE 2022
A FlexScan machine, featuring an integrated retractable nose and rejection conveyor, will be on display as part of JBT’s presence at IPPE 2022, the annual trade expo which takes place in Atlanta GA from January 25-27. “IPPE is a show where everyone from across the industry comes together, so it’s definitely a key place for us to advise our customers on some of the new technologies and solutions that we have,” adds Carbone.

JBT will be exhibiting at IPPE 2022 in Atlanta GA from January 25-27 in Booths C12743 and C12943 at the Georgia World Congress Center.

CLICK HERE to request more information or a meeting at the booth

JBT MEPSCO: setting the pace for injector solutions

Go to any supermarket or delicatessen to buy a meat product, whether that be hams, chicken or steaks, and the expectation will be a fresh, flavorful eating experience, but behind that product there is a great deal of technology; much of the best from JBT. Typically used to add brine to meats, injection equipment is a key element of the meat processing chain, and are one in which food safety and effectiveness are crucial to their success.

JBT Injection Equipment lead the way in the controlled injection of bone-in or boneless meat, as well as featuring a tenderizer head for boneless meat. 

For the poultry industry, the MEPSCO ULTRACAT, Junior ULTRACAT and Double Head Injector & Tenderizer offer uniform distribution, best moisture retention, and superior piece-to-piece accuracy compared with competitor systems. Meanwhile, Schröder/Wolf-tec IMAX injectors, designed and manufactured with German precision, have become the industry standard for performance, consistency, and reliability for bone-in and boneless injection, and marination, for deli meats and poultry. 

JBT Wolf-Tec IMAX Injector Needles

“The injector needles are used to infuse liquid back into the meat because you want it to be juicy as if it was fresh,” explains JBT Customer Care Business Development Manager, Humberto Hernandez. “You put the meat in one end, set-up the needles – up to 750 at a time – and there is a pump which injects brine to add flavor.” This can cover everything from hams, bacons and briskets to chicken breasts, whole chickens and steaks, Hernandez continues; in fact just about any meat product that can be found in a deli outlet.

Safety first
Of course when dealing with injecting liquids into both bone-in and boneless meat products, food safety is of the utmost concern, especially given the immense hazard that broken needle parts could pose. In the case of JBT injector systems, the needles are fused and forged to the machine using tempered steel for extra strength and resistance. 

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“In the case of some competitors, the needles are just welded, which carry the risk of breaking off and can cause a lot of problems down the line, not just in terms of company reputation, but they can also represent a food safety hazard,” cautions Hernandez. “The main benefits of using this system is that it gives flavor by adding liquid to the products. At the safe time, it is simple and safe because the JBT Injector Needles use high quality, tempered steel which won’t break off during the process.”

Hernandez estimates that between 60-70% of meat sold via grocery retail outlets is injected with brine. The remainder is tumbled or massaged; also solutions offered by JBT.

CLICK HERE to find out more about JBT Injection Equipment

JBT freezer upgrades: growing capacity as your business grows

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Efficient, effective freezing solutions that last decades are a JBT speciality, but as your business grows and develops, there comes a stage when more capacity is needed. However, spending on a new machine is not always necessary. JBT’s retrofit- and upgrade program can bring older freezers into the modern era in a quick, safe and very cost-effective way. 

JBT offers upgrades to existing equipment, from replacing old, galvanized coils with stainless steel versions and improved, more efficient fans to the innovative Internet-Of-Things solution iOPS, which provides an integrated, connected overview of all systems. As an optional extra, JBT’s ADF (Air Defrost) system – for tackling snow build-up in freezers – enables producers to run for longer periods between defrosts and cleaning.

JBT PRoCARE-Technician

“If it is time to increase capacity, we can extend the belt to get more production through the freezer,” explains JBT Technical Solutions Manager, Robin Wachmann. “We can also replace coils, moving from old, galvanized versions to stainless steel, which offers improved safety and higher capacity. Stainless steel coils will also give you security against future rust attacks which can lead to refrigerant leakage.”

Cost-effective
But how easy is it to upgrade older freezers? JBT engineers can modernize old freezer units with upgrades like an improved, automatically air-balanced fan system and connectivity to JBT’s iOPS system. Other additions, such as a fan motor frequency convertor, mean customers can save energy – and money – by slowing fans when 100% speed is not required.

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An upgrade or retrofit also offers significant advantages if space is at a premium or a new freezing solution is urgently required. “Sometimes when newer equipment is going to take up a larger space in a facility or if time is at a premium, an upgrade can be a good option,” says Wachmann. “An upgrade can further be very cost-effective because often the whole line is made for a certain volume of production and therefore if they just repair the existing one, everyone knows how to handle it and they know what they get.

“There’s a strong safety element to upgrades,” he adds. “With many old freezers, you can open the doors and go right into them. That is obviously not really up to today’s safety standards, so we can provide customers with an upgrade kit including a safety lock on the door and service handles.”

LEARN MORE about JBT upgrades and retrofits

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