FOOD

Control what is made

-Simon Ganley, Ganley Engineering Have you ever wondered how manufacturers control what they make so they produce everything to the top of the specification and only use the minimum amount of energy to achieve that? Well, most bulk manufacturers of food and industrial products use sensors that sit in or on the line that measure what is being made to automatically control the process. And world-wide, NDC Technologies have grown to become the largest suppliers of this technology. There is a limit to how long any manufacturer can afford to fill up the scrap bin with substandard product, how long they can waste money on power consumption and how long they can compete with companies who do things properly. So, some of the things we do in NZ and elsewhere, is control the moisture and resin in MDF and particle board. This is done with a succession of sensors that control up at the wet-end and provide total control at the finished product. We control sugar moisture on-line and new developments will see the control of colour and lactose where degrees of brown have been an issue. Developed in NZ, most biscuits are now automatically process controlled with colour and moisture which saves huge amounts of energy, staff time and ingredients. The world’s largest French fries maker controls the moisture, oil, colour, bed depth and temperature at the fryer. Other makers produce anything at all. The same goes for potato and corn crisps. The big producers became big because they control what they make. Controlling production provides a fast payback. For confectionery, we control the layers of syrup when it is sprayed in the pan to make up hard-shell products and for chocolate the top producers control the moisture and cocoa butter. For milk powder, pharmaceuticals and other products made […]

EECA building energy use picture amongst NZ food and beverage businesses

The Energy Efficiency and Conservation Authority (EECA) is building a picture of energy use in the NZ Food and Beverage sector (not including dairy, meat and seafood). Importantly, the findings of this project will help EECA to design effective programmes to support energy efficiency and decarbonisation for the Food and Beverage sector. To participate in the study – a simple survey, which is due in by the end of October – should take 15-20 minutes and can be completed online at: https://www.surveymonkey.com/r/MTPVXPP

Food and beverage led economic recovery highlights the importance of Foodtech Packtech show in 2021

Locally and globally the environment, freight, food safety, traceability and security are becoming increasingly relevant to consumers and governments. As people ask where their food came from, food and beverage manufacturers need support and expertise to ensure that they meet the demands of buyers and legislators alike. It is times of intense change where a trade show spanning decades provides vital support to the industry by showcasing new technology, products, solutions and know-how. Meeting industry specialists is essential to helping you innovate and stay relevant through New Product Development and Process Improvement. Running from April 13 to 15 at ASB Showgrounds the co-located Foodtech Packtech and Materials, Handling and Logistics Expo give visitors the opportunity to meet over 200 new and existing suppliers in packaging, ingredients, logistics, machinery, technology and much more. Whether you are looking to take your new plant food solution the rest of the world, launch the family’s secret sauce or ensure that your multimillion-dollar global company is keeping up-to-date, this show will help you achieve your goals. Packed with features the event is a one-stop shop, with two shows key to the food and beverage industry under one roof. You will meet new and existing suppliers, as well as industry experts, and associations, so you can help New Zealand kick start the economy. Seminars With 32 seminars and workshops across three days, you are connected with the experts and answers to your most pressing food processing, manufacturing, packaging, sustainability and distribution questions. Business Growth Hub The show’s Business Growth Hub is supported by the Food Innovation Network, Auckland Unlimited, NZ Food Awards, Callaghan Innovation, New Zealand Trade & Enterprise and New Zealand Institute of Food Science & Technology Inc. You can book a one-on-one session at https://www.foodtechpacktech.co.nz/visitor-information/business-growth-hub/. Digital Lean Introductory Workshop A Digital Lean Introductory Workshop […]

NDC sensors control manufacturing at the front line

-Simon Ganley Most customer food complaints relate to colour. Too dark is considered to be over cooked or baked. Too light is perceived to be underdone. You wouldn’t believe just what people complain about. But businesses have to take complaints seriously and it costs to deal with them. So now a lot of food manufacturing companies are adding colour to the other parameters they measure and control, saving a lot of money by doing so. There is a good chance that a biscuit you buy in NZ will have had the manufacture controlled by colour rather than moisture. The measurement was developed in NZ with NDC and is being rolled out world-wide. This saves a manufacturer a fortune in power consumption, scrap, waste, staff time and raw materials. And dealing with complaints. Next time you eat fries at top quality franchised restaurants, they will have had the manufacture controlled with moisture, oil, colour, bed depth and temperature – all on the one NDC sensor that sits above the fryer. Coffee is another application. The top brands of coffee have NDC sensors controlling the colour, moisture and caffeine. They also control tea. Sugar is another application that is being developed at the moment. NDC controls the manufacture of pretty much all the sugar made and sold in NZ. “Wet” sugar moisture can be controlled to 0.1% on-line and dry sugar to 0.006%. But customers are alert to shades of brown that creep into refined sugar. Strangely the colour we see in sugar isn’t brown. It is actually in the blue/green part of the spectrum. Lactose is another product that downgrades with shades of brown and manufacturers of quality products build NDC sensors into the fluid bed driers to maintain top yield prices. When we talk about product control with colour, we […]

ABB Ability Liquid Routing Library launched for food and beverage production

Process automation technology provides customers with optimal routing and ‘cleaning-in-place’ to increase efficiency and reduce costs. ABB has launched ABB Ability Liquid Routing Library which is a control engineering inventory for food and beverage manufacturers and those in other liquid related industries, including tank farms, pharmaceuticals and chemical resin plants. The new digital application draws on ABB Ability System 800xA, the most powerful Distributed Control System (DCS) automation platform in the market and will support routing and cleaning in place (CIP) functionalities needed for liquid-led production. It can be used wherever products are transported, stored or processed in tanks and lines and is particularly relevant to dairy, brewing, sugar, mills and edible oil application programming. Ready-made objects including libraries, typicals, and templates for product routing, with recipe-based CIP, track and trace, preventive plant maintenance, Excel-based bulk data tools are made available for customers through the library. Functionalities include alarm handling, alarm propagation between different units, queue handling for online production changes, control and supervision of process objects, interlocks and transfer of product and equipment settings like product codes, unit names and unit states. ABB Ability Liquid Routing Library will support food and beverage customers in their digitalisation journey. Customers are driving innovation in process automation, digitalising their production sites for greater speed, consistency and quality and Liquid Routing Library is an important piece of this jigsaw. Having a complete library for product routing, with ready-made objects and templates will allow users greater visibility and understanding of what is happening at each stage of the process. We know that routing and cleaning in place support are vitally important in food and beverage plants. This is built-in and at-any-stage ABB support from experts or additional documentation is available. Operators will be able to diagnose issues quicker than before and have solutions ready, […]

Ganley Engineering process control specialists

Khamal Ganley, Gill Ganley and Simon Ganley. Assisting New Zealand companies go forward with great technology. Ganley Engineering Ltd a family company, based north of Auckland, covers all of New Zealand. They are the country’s premier suppliers of manufacturing process controls systems and have been so for the past 25 years. The company consists of Simon, Khamal and Gill Ganley, all of whom bring levels of expertise to represent NDC Technologies, exclusively, for advice, sales and service. Ganley Engineering specialises in on-line and at-line process control. Process control places NDC Technologies sensors in a manufacturing line to measure and control moisture, oil, fats, protein, brix, caffeine, nicotine and colour in real-time. The sensors talk directly to the manufacturing machinery so that levels of moisture (and other components) are automatically and instantly adjusted to the top of the specification or yield. The sensors also display exactly what is being made on trending SCADA screens so operators and management can monitor the production yields. This means manufacturing companies save a lot on power consumption, staff time, scrap, downgrade and raw materials. They also save on not having to do repetitive lab tests and having staff to run them. Companies are now able to make products they could never have economically made before. The sensors can be placed above a line, into a fluid bed drier and in a variety of other locations. They have no recalibration or maintenance schedules so are basically fit and forget. NDC have tens of thousands of these sensors controlling a wide variety of applications world-wide, including NZ. NDC Technologies is the world’s largest manufacturer of process control sensors. They work in closely with multi-nationals to develop solutions to meet specific manufacturing needs. Ganley Engineering has in the past 30 years worked with many NZ companies and developed […]

NZ food industry benefits from leading-edge portable drying technology

Drying Solutions Ltd founder Robert and wife Paulette Barnes with their Rexmoi dryer, a unit that services the food and pet-food industry. When Robert Barnes was asked by a friend to build a dryer to dehydrate macadamia nuts 25 years ago, he never thought it would be the start of his own drying machine business. Robert, an electrician and refrigeration engineer by trade, set up his own refrigeration and air-conditioning company in 1989, attracting Port of Tauranga as one of his clients. Since 1995 he has also been using his skills to develop highly innovative Rexmoi Dryers. He sold the refrigeration and air conditioning business five years ago to focus solely on Drying Solutions Ltd. Now Robert is gearing up to exhibit a Rexmoi dryer, at his fourth Foodtech Packtech show next month. Robert says he is proud that his dryers enable people to turn ordinary products, in some cases waste material, into high-quality, high-value finished goods for the ultimate benefit of New Zealand. Rexmoi dryers use a refrigeration system, rather like a heat pump, to create a warm, dry enclosure where the products are dried. Warm, dry, filtered air flows over the product to remove the moisture which is then condensed and drained out through a small pipe. The product is laid out on stainless steel trays mounted on trolleys for easy handling. Several different types of tray are available to suit the various products such as wet slices, nuts, raisins, pet-food and bushy material. The dryers use much less energy than other drying systems and are totally enclosed so no smells or gases are emitted into the atmosphere. They are covered by several patents and trademarks. The drying process is controlled by a programmable controller which Robert sets in conjunction with the client to provide an optimum drying […]

Beyond meat? The market for meat substitutes is way overdone

Paul Wood AO Adjunct Professor in Biotechnology, Monash University Meatless burger maker Beyond Meat has just reported quarterly earnings of US$67.3 million – much better than market expectations of US$52.7 million. It is now forecasting sales of US$240 million for the 2019 year, nearly three times that of 2018. But the company is yet to make a profit, let alone one big enough to justify its current market valuation of about US$13 billion. Since it listed on NASDAQ in May, its shares have surged more 700%. Investors’ enthusiasm reflects high hopes in the future fortunes of a company promising to put the sizzle into a meat substitute. Interest is booming in plant-based meat substitutes and lab-grown meat alternatives. The appeal is summed up by Beyond Meat’s mission statement: “By shifting from animal to plant-based meat, we are creating one savoury solution that solves four growing issues attributed to livestock production: human health, climate change, constraints on natural resources and animal welfare.” How realistic is this? The data suggests not very – that meat alternatives might play a positive role but in no way are going to save the planet. Investment appetite Predictions about the market potential for plant-based or lab-made meat vary. A lot of it appears to be only slightly better than sheer guesswork. One prediction, by the well-known Barclays, is that the market could be worth US$140 billion, or 10% of the US$1.4 trillion meat market, in the next 10 years. It’s such projections that have fuelled investors’ appetite for companies working on ways to make plant-based protein look and taste like meat. There’s Impossible Foods, for example, whose burger “bleeds” beetroot juice and is the meat (substitute) in Burger King’s Impossible Whopper. The privately held company has reportedly raised more than US$500 million, and is valued at US$2 billion. Other players in […]

Assisting product development with new mini aseptic solution

In today’s fast moving food and drink industry innovation is king. Everyone is looking for the next product to give their business the edge and food fashions and trends come and go with increasing speed. Food manufacturers often need to use seasonal ingredients, potentially offering limited edition flavours or varieties of key products: from herbal ice creams and summer berry drinks, to fruity condiments and vegetable smoothies. As a result, the life of innovative products is often shorter than has been seen previously and it can be hard for new product developers and marketers to pick which will survive in the market and which will fall away. All of these factors create challenges for operational factories and production lines. No business wants to invest in a fully-scaled line for a product that may have limited (albeit still successful) sales. The new HRS Asepticblock Mini Series allows manufacturers to produce new trial products with the minimum amount of product in a short time, reducing the unnecessary expense or wastage that can accompany full scale trials, and alleviating the need to suspend or interfere with the routine production of regular products. It allows the reproduction of a full scale final pack, but from as little as 20 to 50 kg of product. The Aseptic Mini Block Series was born from the need of many of small- and medium-sized customers to produce relatively small quantities of aseptic products, but who are prevented from doing so by high upfront capital costs and low return on investment. Traditional aseptic processing lines consist of two sections; one section is the steriliser or pasteuriser (based on a suitable heat exchanger according to the product type), and the other is the aseptic filler. The HRS Asepticblock Mini Series is designed for such producers working with a range of […]

What do your motors really do?

In 1969, the first home security system was born, consisting of four peepholes and a camera that could be moved to look through any of them, broadcasting the images to a monitor. Nowadays, we can now stream and view a feed of our home security cameras on our mobiles, giving homeowners greater piece of mind. Here, Markus Brettschneider, of ABB’s food and beverage program, explains how food plant managers can add a similar level of connectivity to retrofit most motors with smart sensors to bring their plants to the digital age. Industry as a whole is utilising technologies and solutions enabled through the industrial internet of things (IIoT). Gartner predicts that 25 billion devices will be connected to the internet of things by 2020, with some agencies predicting even double this amount. This presents plant managers with a conundrum. Most food manufacturing and processing plants currently have motors powering essential equipment such as mixers, conveyors and packaging machines. These motors are just motors and do not play in the same league as the other intelligent devices in their factories. With years of service often left in the motors, it’s difficult for plant managers to justify replacing motors that work effectively for the sake of an upgrade with any smart features. However, there are alternatives to a complete overhaul in order to connect motors to the IIoT. Instead of investing in new, more intelligent or smart equipment, plant managers should invest in sensors that provide similar functionality to connected devices. For example, ABB offers smart sensors, which can be fitted to almost any standard low voltage induction motor. The pocket-sized sensor, dubbed ABB Ability Smart Sensor, is directly attached in a couple minutes to the motor’s frame, without wiring. By using sensors that feed performance data to the cloud through a […]

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