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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.

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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.

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“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

A&B Process Systems receives safety award from ConstructSecure

JBT’s A&B Process Systems has been recognized by ConstructSecure as one of their Safest Contractors & Vendors. A&B received the Platinum Safety Award for scoring greater than 95% in the safety assessment administered by ConstructSecure.

The award from ConstructSecure, a global SaaS company that prequalifies contractors and vendors for corporations that have stringent safety requirements, is based on an assessment of current safety management systems and incident rates.   

“Our associates really get it and are on board with our culture of safety,” said Bill Thompson, A&B’s HSE Manager. “Our associates continue to go the extra mile in their daily work to help prevent safety incidents and this award is a testament to their dedication to safety.

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“Our team members do a great job of preventing incidents from occurring.  If they see a potential risk, they report it as a near miss right away and it is addressed immediately. We truly appreciate everyone’s dedication to being as safe as possible.”

Scott Raether, Director of Operations for A&B, added: “We have an incredible group of dedicated employees who believe that zero injuries are expected. We pay attention to little details and truly look out for each other. Awards are terrific, but what’s more rewarding is the knowledge that our employees are acting safely and contribute to a safe place to work.”

Learn more about A&B Process Systems’s solutions

JBT Protein North America launches Customer Care Hotline

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JBT Protein North America is excited to announce the establishment of a dedicated hotline to provide customers direct access to JBT’s best-in-class service technicians: 1-800-JBT-4YOU. The single, easy-to-remember number will act as a single source for customer care and direct access to service technicians familiar with JBT equipment and machines, providing direct, remote support in the moment of need.

In January, JBT announced JBT Protein North America’s enhanced customer-first mindset, which elevates our customer care model to put customers at the center of every project — from installation to preventative maintenance. The first initiative in this enhanced model was creating centralized teams and having detailed conversations with our customers.

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“In these conversations, JBT asked how we can best support customers and be a partner to help maximize uptime,” says Augusto Rizzolo, VP Customer Care for JBT Protein North America. “Customers told us they need service and support to be easy – one place to go where they know they can reach the right person to help with their operations, and they need a response quickly. 1-800-JBT-4YOU is our answer to all of customer care questions.”

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“When the COVID-19 pandemic struck and onsite service was impacted, we had the opportunity to test this centralized hotline to better support our customers,” continues Rizzolo. “The feedback has been extremely positive, and we are excited that this will be an ongoing service for all customers with an easy-to-remember number: 1-800-JBT-4YOU.”

At JBT, we work hard to earn customer trust and loyalty by providing the products, service and support needed to keep businesses running smoothly. As always, we want to know if there’s anything we can do to help, so be sure to call us – 1-800-JBT-4YOU. 

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.

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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

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