International Meat Topi cs

Volume 7 Number 3 (2016) Meeting meat’s technical needs

CONTAMINATION Control of foreign bodies within the meat supply chain

SAUSAGE PRODUCTS Effective and reliable vacuum supply

GOOD VIBRATIONS Tuning into food metal detection frequencies

PROCESSING SYSTEMS We look at options from around the world

MEAT ANALYSIS French success story ensures consistent quality

LUBRICATION Preventing pneumatic component failure

PUBLISHED BY Positive Action Publications Ltd chewing the fat

PUBLISHER & E DITOR Nigel Horrox: [email protected] he O’Neill Report on Tackling we all know, ‘the proof of the Drug Resistant Infections pudding is in the eating’. MARKETING TEAM TGlobally, that primarily looks Some parts will slip easily down Claire Fussey: [email protected] Colin Foster: [email protected] at drug resistance in the human and the gullet, whereas one part – the Tim Brown: [email protected] veterinary arenas, has just been proportion of blame placed at the Alison Burdass: [email protected] published and, although it makes a door of agriculture and the call to lot of sense, many in our industry minimise antibiotic usage in PRODUCTION will feel he has favoured the human livestock – may not be so easy to Sarah Dove: [email protected] use of antibiotics over their use in digest! the veterinary field. This is an area in which some DESIGN & D IGITAL The Report champions the need countries have already made great Matthew Baker: [email protected] for a global public awareness advances. All one can say to O’Neill campaign, improving sanitation and on this point, is ‘Look East, young SUBSCRIPTIONS preventing the spread of infection, man!’ Sally Walker: [email protected] reducing the unnecessary use of This being said, overall, one has to antibiotics and improving the global praise the Report and its various ACCOUNTS surveillance of drug resistance in recommendations, which are Anne Smith: [email protected] man and animals. generally common sense and well Interestingly, the Report highlights balanced. the specific promotion of new, The big challenge now is whether rapid diagnostic tests to determine the governments of our world will The copyright for material appearing in International Meat Topics is held by Positive Action Publications Ltd. antibiotic choice before treatment take notice of this Report and how Production of editorial material, in whole or part, from this begins and the development of many of them will convert its wise publication requires written permission of the copyright holder. Positive Action Publications, its editors and the vaccines and alternative treatments words into actions? contributors accept no liability for the contents of – something which the poultry Unfortunately, some of the International Meat Topics and the views expressed in it are statements and opinions of the authors and do not industry is already well into. countries for which this Report is necessarily constitute representations of fact. It also champions the need to the most relevant will say it is a

The publishers accept no liability for late or non-delivery. increase the supply of new British report and therefore not No refund can be made after fulfilment has begun. antibiotics that are effective against applicable to their country. How Positive Action Publications Ltd reserves the right to use email addresses supplied to it for promotional activities. drug resistant bacteria. wrong they will be. This Report is good as far as it This is a global report that is International Meat Topics (ISSN 2045 6948) is published goes but all that has been achieved relevant to everyone and you ignore six times a year (February, April, June, August, October and December) by Positive Action Publications Ltd and so far is to bake the pudding and, as it at your peril! n distributed in the USA by Mail Right Int., 1637 Stelton Road, Piscataway, NJ 08854. Periodical Postage Paid at Piscataway, NJ and additional mailing offices. Postmaster: Send address changes to International Meat Topics, Positive Action Clean production; no waste! Publications, c/o Mail Right Int., 1637 Cover Picture: (Photo courtesy of Marel) Stelton Road, Ste B4, Piscataway, NJ 08854.

International Meat Topics • Volume 7 Number 3 3

The targeted technical publication for progressive meat professionals world focus seeking the latest information from around the world An executive summary of key international issues

SUBSCRIPTIONS International Meat Topics is published 6 Canada times a year and your subscription Do not doubt the vegan influence! includes a free digital edition In Canada so-called ‘extreme vegans’ are promoting the case that not eating animals is a Subscription rate morally superior lifestyle. One restaurant with a vegan-or-nothing attitude is not putting off 1 year – £UK60 diners but is, in fact, attracting them! "I want someone who isn't vegan to say, 'That's a good 2 years – £UK90 burger,' not 'That's a good vegan burger," the chef says. The owner is quite evangelical about veganism and is unapologetically vegan. He says that people confuse vegan as a diet but it is inclusive of airmail more than that, it is a moral stance people take to end the suffering of animals! Vegan restaurants are now popping up all over Canada and in Toronto the first all-vegan mobile Group & multiple title restaurant will soon be opening. discounts available

Subscribe online today @ www.positiveaction.co.uk Britain or contact Antibiotic success story from the British poultry sector! Sally Walker The antibiotic usage data collected by the British Poultry Council (BPC) for 2015 reflects well [email protected] on their poultry meat sector as it shows they have continued to make significant progress. Their 2015 data showed a 28% drop in overall usage of antibiotics compared to 2014. The For details of our digital edition contact: BPC believes that the industry will continue to make further improvements following on [email protected] from analysis of the data. The poultry sector has led the way in the UK with real progress seen since the formation of the BPC Chicken Antibiotic Stewardship Scheme in 2011. The PO Box 4, Driffield, British poultry meat sector is currently the only sector that collects and shares its antibiotic East Yorkshire YO25 9DJ, usage with the UK’s Veterinary Medicines Directorate. England. Tel: +44 1377 241724 Fax: +44 1377 253640

OUR FULL RANGE OF TITLES Britain We have six titles covering the No defence for beefing up lamb burgers! pig, poultry, hatchery, dairy, food hygiene & meat processing sectors A Manchester based halal butchers has been hit with a bill for more than £18,000 (£15,000 Contact us for more information fine and £3,300 costs) after being caught marketing ‘lamb’ mince laced with cheap beef. They [email protected] were found guilty of food fraud after being investigated by local environmental health officers. They were prosecuted after tests showed that the ‘lamb’ mince was being bulked up with cheap cuts of beef before being sold on. Samples were taken in April and a follow up sample in May. This last sample was shown to contain 50% beef. Magistrates found the butchers guilty of two offences of selling food not of the nature demanded by the purchaser and commented that ‘practices like this are unacceptable and cannot be tolerated’.

International Meat Topics • Volume 7 Number 3 5 Control of foreign bodies and contamination within the meat supply chain

hroughout the meat supply chain there exist contamination risks and, as Conventional Dual energy Tthese supply chains become longer and more complex, technology is playing a vital role in minimising the real and potentially costly threat of contaminated product reaching the end consumer. It also enables full transparency to determine liability in the event of a complaint or incident.

False detection Better bone detection by Adrian Sunter, Technical Director, Ishida Europe. Chicken example: conventional vs dual energy. ishida.com

supermarket chain in the UK last year and into millions, especially when you factor in This article examines the role that X-ray small balls of plastic resulted in a recall of labour, production, logistics and disposal plays in helping to eliminate physical con- 4,500lb of chicken nuggets in the US in costs. They also impact on reputation not tamination risks, product recalls and the March. A failed bearing prompted a recall just for the supplier but, in the case of own- potential for brand damage and business loss. of more than 75,000lb of fresh beef label brands, the retailer, resulting in products because of the risk of it being potential loss of custom and damage to contaminated by metal, while wire found in brand reputation. A perennial problem a sukijaki beef product prompted the recall Physical hazards in finished products can of more than 48,000 ready-to-eat frozen arise from several sources, such as ‘Foreign body’ is a term that applies to beef and pork products. Glass fragments contaminated raw materials, poorly anything physical, chemical or biological resulted in a recall of more than 200,000lb designed or maintained facilities and that is found in food and renders it unfit for of chicken pizzas and lasagnes in the US in equipment, faulty procedures during human consumption. Physical March. These are just a few examples, but processing and improper employee training contamination generally refers to any they often involve high volumes of product. and practices. Food hygiene legislation contamination that is not microbial and Indeed, the Food Safety Inspection emphasises every food business operator’s includes a diverse range of items from Service has requested millions of dollars responsibility to produce food safely by metal, plastics, and glass through to hair, from Congress to improve its meat applying good hygienic practices and food insect parts, bones, paper and paint. inspection capabilities. Of the 18 meat safety management procedures based on While many recalls affecting meat are due recalls in the US already identified in 2016, hazard analysis and critical control point to poor labelling or bacterial contamination, 33% were attributed to foreign matter (HACCP) principles. a piece of plastic found in mince beef contamination. In common with other food businesses, all prompted an investigation by a leading Around the world, the cost of recalls runs meat plant operators have an obligation to keep supplier and customer records. Indeed, traceability has become a major Sausage example: conventional vs dual energy. factor in reassuring customers that the meat products that reach the table have been handled and processed responsibly. Conventional Dual energy

Advancing the performance of quality control systems

The range of options for X-ray inspection systems is growing year on year, offering entry level solutions for smaller companies through to sophisticated solutions for high volume and complex final meal delivery. False detection Better bone detection Different products and processes require dedicated solutions. While regulation and

6 International Meat Topics • Volume 7 Number 3 compliance are important, the main driver for investing in X-ray inspection systems is High kV Single sensor to reassure the customer, often the Light & shade supermarket, that the supplier is doing edge extraction everything it can to protect its customers’ brand reputation by ensuring that it delivers a consistently high quality product, day after day, month after month, year after year. It demonstrates a commitment to quality and, for many businesses, is the foundation on which long-term relationships are built. Low kV Dual sensor And, if things do go wrong, full traceability and data mean that investigations can start promptly and remedies found, helping to Comparison maintain customer satisfaction and ultimately, brand equity. One advantage of X-ray over other inspection systems is its ability to monitor consistency of the product. Used as an end of line check, X-ray inspection can detect cracks in burgers, can identify broken Single vs dual energy X-ray diagram. Conventional image processing technology finds sausage casings, can count the correct contaminants by checking contrast variance on the image, where the high X-ray pene - numbers of pieces in the pack, can ensure tration area appears bright and the low X-ray penetration area appears dark. However that clips on products are present and in this principle tends to cause false detection where the X-ray penetration rate is low, the right place, can see if there is anything due to the effects of product overlapping or product edges. trapped in packaging seals and can even reject products that do not conform to weight parameters. low-density contaminants such as metal an ingredient in ready meals or products X-ray systems cannot see absolutely every foil, thin glass, bone or shell. such as pies, burgers, and sausages. physical contaminant that may be present Conventional image processing Where processing is more complex, risk in a product, such as paper, insects or hair. technology finds contaminants by checking factors increase and need to be managed As a guide, X-ray systems can only see contrast variance on the image, where high more carefully. products with a density higher than water. X-ray penetration area appears bright and Typical poultry processes can be easily That means that, generally speaking, if it the low X-ray penetration area appears accommodated by the X-ray system. In floats, X-ray can not see it. Despite this, dark. However the identification of low X- order to minimise waste, a trimming station X-ray machines are proven to be more ray penetration areas, due to the effects of will often be placed after the X-ray system effective than metal detectors, vision products overlapping, can lead to false so that when bones are identified, the systems and laser sorters at identifying and rejects. product can be re-trimmed rather than rejecting contaminated products at high Energy analysis makes use of the principle discarded, ensuring optimal output and speed. What they can see is dense plastics, that different products have different X-ray productivity. rubber, metal, bone, shell, stones or glass, penetration characteristics at different With poultry and burgers, the fast food which critically, are the physical energies, with the darkness of the image industry is becoming increasingly insistent contaminants most likely to cause injury or depending on the atomic mass. By that X-ray forms part of a supplier’s quality harm if swallowed. cancelling the image of product control systems and that the system The introduction of Genetic Algorithm characteristics, the contaminant is more provides accurate records of all processed (GA) technology to image processing has easily identified and the number of false products leaving a facility. taken the sensitivity of X-ray to a new level, detections is reduced. In fact, X-ray images can be stored along improving detection rates by rapidly and with a unique number that appears on the automatically finding the optimal image pack, making it easy to trace the product settings to detect known, expected Four key production points and pull off all of the data and images contaminants or impurities at very low should a complaint arise. levels. X-ray systems are typically installed at four An in-depth audit of the process line For example, a 3mm glass ball without GA key points in production and where works helps to identify which system will deliver technology would only be spotted two out best will very much depend on the type of optimal results for a customer. Factors that of 10 times for different parameters, but product and the amount of processing could affect this include an assessment of with GA processing, this would improve to involved. sensitivity to determine the level of 10 out of 10. It would also be able to see Often they will be installed to inspect contaminant that can be seen, on-site and smaller balls of 2mm diameter. This saves loose bulk products such as chicken off-site testing, consideration of speed, size manufacturers time and money by nuggets or on separated fillets prior to and weight of product feeding through the removing the need for them to send the packing, or compacted cooked cut meat system and packaging options on the line. product away to a laboratory. It also products. By removing contaminated Ultimately, X-ray is designed to give peace ensures that users have the best algorithm product at the start of the process, X-ray of mind to both suppliers and customers possible, since it was created on the actual inspection systems are helping to minimise that a quality product has left the factory product in the actual environment. waste in energy and packaging, as well as and all the documentation is there to prove Numerous manufacturers of poultry protecting process-line equipment from it. A lot of customers are surprised to find products are benefitting from the advanced damage from bone, metal, stones and glass, that there are many additional cost-saving bone detection capabilities of specialist thereby helping to reduce maintenance and benefits in terms of minimising waste, dual energy X-ray inspection systems. These down-time costs. performance and productivity, beyond the machines use two X-ray line sensors Meat usually undergoes some form of enhanced quality control that X-ray offers simultaneously, which analyse different processing before it reaches the processor. to support their own and their customers’ energies, to improve detection rates of It can be sold fresh, or frozen or be used as brands. n

International Meat Topics • Volume 7 Number 3 7 8 International Meat Topics • Volume 7 Number 3 Do casings with transfer functions really make business sense?

alue-added casings have been around 100% in, 100% out? Not with a Key benefits include a significant for a number of years now. While manual spice coating reduction in manual workload and a faster Vthey have become well established production process – with zero investment with many large-scale sausage The entire production process is fully in additional equipment. Value-added manufacturers, there is still some automated – except for the four stages casings can be used with standard filling reluctance among small to medium-sized where the spice coating is applied. This and clipping machines in exactly the same firms. In this article, we examine a typical manual procedure conflicts with the aim of way as conventional casings. mid-sized plant producing 70 metric tons ‘100% in, 100% out’, full automation, which per day, and assess the quality and cost is key to achieving maximum safety and benefits of using value-added casings. efficiency in the food industry. Ideally, the Less processing, lower costs filling should be fully encased at every stage from filling through to heating, The benefits in terms of hygiene and food by the Kalle Group, Germany. cooling, slicing and packaging. The safety are obvious. But what impact do kalle.de application of a spice coating is the only value-added casings have on our sample point after the cooking process where company’s overheads? After all, value- production staff comes into direct contact added casings are considerably more Our mid-sized manufacturer in this with the unpacked filling. Our sample expensive than conventional products that example produces a range of pork products company looked at several different ways have no transfer function. Fig. 2 provides a that are particularly popular with of eliminating this risk to food safety. comparison of production costs before and consumers on account of their spice Despite numerous attempts, it was unable after the introduction of value-added coating. to find a mechanised means of applying the casings. With a daily output of 70,000kg of The manufacturing process consists of spice coating – the right equipment is cased products, the cost of production nine individual steps, four of which are simply not available. with conventional sausage casings was required solely for application of the spice Eventually, the company found the ideal €47,657. With value-added casings, the cost coating (Fig. 1). solution: the new NaloPro Spice shirred for the same volume was €42,085. After the sausage has been cooked and value-added casing from Kalle. The interior In short, the company is now saving cooled, it is peeled in preparation for the of this casing is pre-coated with the €5,572 a day. With annual production of coating stages. A layer of gelatine is then selected spice mixture, which is 14,000 tonnes, that amounts to a saving of applied as a carrier medium, and the automatically transferred to the filling around €1.1 million a year. sausage is manually coated by pulling it during the cooking process. It is no longer The majority of that saving is due to lower through the relevant spice mixtures. necessary to peel the sausage, apply the processing costs, which value-added Next, the sausage is cleaned and repacked gelatine and spice coating, clean the coated casings reduce to almost zero. Added to in another packaging, before being peeled sausage and then repack it in another that are the savings in spices and gelatine, for a second time and finally sliced. packaging. Continued on page 10

Fig. 1. Value-added casings eliminate four stages in the produc - Fig. 2. Using value-added casings, the manufacturing costs in our tion process, resulting in significant cost savings. sample company fell by 12%. This reflects the average potential saving across the industry. Filling Filling

Cooking Cooking Cost in €/70,000kg (excluding protein)

Cooling Cooling 47,657 11.7% Gelatine 6,045 42,085 Peeling Peeling

Spices 13,390 Spice coating Spice coating Casing 2,971 NaloPro Cleaning Cleaning 41,591 Spice

Packing Packing Processing 25,251 Peeling Peeling 495 Processing Slicing Slicing Traditional process Value-added casing process

International Meat Topics • Volume 7 Number 3 9 Continued from page 9 surface of the filling. In other words, these which are already included in each casing. casings fulfil all the functions of the Thus, despite costing more than traditional smoke house. The smoking conventional products, the NaloPro Spice process can therefore be eliminated in its casing has a clear cost advantage of 11.7%. It entirety. Although the low water-vapour also has one other benefit not included in barrier restricts the storability of cooked the cost analysis: since the sausage is only meat products, the drying losses which peeled once rather than twice during occur during the cooking process production, less filling is lost in the process. undoubtedly have a positive effect in terms of the taste of the finished product and ensuring the desired colour. Spices, colouring, aroma, flavour: Apart from cost savings and product consistent quality standards safety, a major benefit of value-added casings for many manufacturers is In addition to applying spices, value-added standardisation, the ability to ensure that casings can be used to transfer colour, every product meets the same high aroma and flavour components to the standards with regard to both flavour and

NaloPro Spice sausages.

colour. Even when the same type of product is produced at multiple locations, the manufacturer can guarantee that each sausage has exactly the same appearance, flavour and aroma. This is a key selling point for manufacturers who supply global food- retailing brands. When products are coated manually, the coating can vary significantly from one employee or location to the next.

Value-added casings are fully customisable

Of course, standardisation does not mean homogeneity. Kalle is able to provide value- added casings with customer-specific aromas and spice mixtures. Manufacturers can thus continue to create their own flavour blends to set themselves apart from competitors. In addition, Kalle has already established a wide range of ready-to-use value-added casings. Its clean-label casings, for example, cater for more discerning and health- conscious consumers. By using natural smoke types and plant- based colouring agents, it is possible to create attractive products with no unwanted ingredients. The casings are suitable not only for the classic round-slice form, but also for shaping in metal moulds. They can also be used for D-shaped products, which are not produced in a metal press. Instead, the casing is simply under-filled, and the ‘D’ shape is formed during the cooking process. Value-added casings are an attractive and easy to implement solution for all manufacturers who want to reduce their overheads and increase product safety. There is no need for investment in special plant and equipment, and the quality and cost benefits are immediate. n

10 International Meat Topics • Volume 7 Number 3 Good vibrations – tuning into food metal detection frequencies

etallic inclusions are the number airborne electrical interference – static, contaminant. So the solution is to change one contaminant in food radio, earth loops – vibration and the frequency of operation to minimise the Mproducts, causing product quality temperature fluctuation may also affect effect of the product. The downside is this and consumer safety issues. This article performance. can impact your ability to find different looks at the technologies behind effective metals. When you drop frequency you tend metal detection, the three key frequency to enhance your ability to find ferrous options and why it is essential to select the Identifying optimum frequency metals but you really limit your correct frequency for your food performance when it comes to non-ferrous application. In order to reduce metal contaminant risks metals, because the lower end of the it is essential to identify the optimum frequency is more responsive to magnetic frequency for any product. Many products effects of the contamination. By the same by Phil Brown, Sales Director, inspected inherently have electrical token, if you take the frequency higher, the Fortress Technology, UK. conductivity and/or magnetic permeability reverse happens – you start to limit your fortresstechnology.co.uk within their makeup. ferrous detection capability but enhance For example, any product that is iron- your non-ferrous detection. Running enriched, such as cereals, creates a large product samples and tests is advisable. The most widely used type of metal magnetic signal that the detector must Experts will tend to know what the detector in the food industry functions on overcome in order to detect small pieces of frequency bands are likely to be, but it is the principle known as the ‘balanced coil’. metal. These are referred to as ‘dry’ always dangerous to be too presumptuous With a general-purpose search head, these products. Conversely, wet’ products with because sometimes different types of the can detect ferrous and non-ferrous metals, high moisture and salt content, such as same product can behave in different ways. as well as stainless steels in fresh and frozen meat, are electrically conductive. It is really important to choose the right products – either unwrapped or wrapped, Dry products tend to be a lot easier in frequency for the product. The process even in metallised films. Yet, they are still terms of detection capability, because you typically takes specialists an hour or two. unable to detect every particle of metal do not have to worry about the product passing through them. effect. Equally, you suffer with the Many factors will determine the sensitivity level on the wet products, Evolution of metal detection theoretical sensitivity of a metal detector. because you have to deal with the signature Among them the aperture size (the smaller of the product. Even amongst wet products In the last decade, metal detection the aperture, the smaller the piece of metal bread is very different to meat. They are technology has progressed significantly. that can be detected), the type of metal, both conductive but meat has more water Nowadays, a food manufacturer generally product effect, and the type and so, consequently, the two exhibit very has three technology options – fixed orientation of the contaminant as it passes different product effects. frequency, multi-frequency and through the detector. The detector must remove or reduce this simultaneous frequency. With a single Environmental conditions, such as ‘product effect’ in order to identify a metal Continued on page 12

The Interceptor range carries out real time analysis of low and A multi-aperture system that spans a number of lanes offers high frequency signals in parallel making it possible to identify greater sensitivity and detects smaller metal particles, as conductive product effect, such as high moisture levels in meat. products are inspected individually.

International Meat Topics • Volume 7 Number 3 11 Receiver 1 Transmitter coil

Receiver 2

Most metal detectors use a balanced coil system to detect As metal passes through the aperture, and again as it leaves the ferrous, non-ferrous and stainless steel contaminants. exit side, the coils act like a radio transmitter to signal disturbance.

Continued from page 11 detectors. This means it can pick up metal food production environments? A machine tuned-frequency device, the operating contaminants half the dimensional size with a fixed frequency is good if you are frequency has to be picked to suit the previously identifiable. consistently inspecting the same product product. With a difficult conductive Like other metal detectors, the day in day out, but there are obvious product like meat, or a larger product, the Interceptor also reliably detects the full limitations if your product range is more frequency has to be set low to deal with range of ferrous and non-ferrous metals, expansive. Multi-frequency systems the product effect. That makes the system including stainless steel, which continues to perform well on range of products passing less sensitive to the detection of stainless pose the highest metal contaminant risks in down the same production line, although steel and non-ferrous metals. the food industry. Significant engineering the sensitivity and performance may be About 15 years ago, the introduction of and other challenges have had to be compromised, increasing the risk of metal selectable frequency made life a little bit overcome to make the system more contaminants going undetected. easier, but the metal detector still had to affordable for smaller-sized food Machine operatives may still have to be set to run at a specific frequency. In a manufacturers. Adding more electronics select the frequency, and this raises the worst-case scenario, that would be a low, and a new coil structure enabled new cost issue of what they are basing their decision less sensitive frequency. efficiencies to bring the Interceptor on. If its not tuned in exactly right, like a To solve this, Fortress built a system that system’s costs to only slightly more than a radio station, they might not select the had two frequencies for simultaneous standard metal detector. frequency that delivers perfect clarity and inspection at a high and a low frequency. The new technology works by carrying sensitivity. The high frequency could detect stainless out a real-time analysis of a low frequency Automatic product learning does, steel, while the low frequency was able to and a high frequency signal in parallel. Using however, reduce the possibility of human meet specs on ferrous metals. It worked an advanced algorithm, the Interceptor error. With simultaneous frequency it is really well, but it was quite expensive and splits the product and metal detection more sensitive as you can ignore the difficult to build. signals and then links the readings back product effect, making it ideal for wet together. products that vary in size and density, like Compared to the traditional approach of cuts of meat or fish. Critically, with any Advance in technology tuning into specific frequencies, this new metal detector, there’s no ‘best’ frequency. method makes it possible to identify the There are only ranges of frequencies, each The Interceptor range that Fortress product effect (most noticeable at lower better for different purposes. unveiled last year built further on this frequencies) and eliminate it from the Understanding how these frequency technology and improves stainless steel higher-frequency signal, where the options work and differ is fundamental to metal detection capability on ‘wet’ potential effect of the metal is more selecting the right inspection machine for products by a further 100%, compared to prominent. your application. If in doubt, seek impartial the most recent generations of metal So, what technology is best in today’s and professional advice. n

12 International Meat Topics • Volume 7 Number 3 Effective and reliable vacuum supply for cooked sausage products

or more than 50 years Salzbrenner sausages have been a byword for Fquality, especially in the greater Hamburg area. Founder Karlheinz Salzbrenner explains the company philosophy: “We want to make high-quality sausages from locally produced meat and natural ingredients. A simple idea that has been successful to the present day.”

by Uli Merkle, Busch Dienste GmbH, Germany. buschvacuum.com

Initially Salzbrenner sold products to restaurants and snack bars, but now it also supplies retail and wholesale companies throughout northern Germany. The company focuses on cooked products such as Krakauer (polish sausage), Bratwurst (frying sausage), Currywurst (sausage with One of four packaging lines supplied by the central vacuum system. curry sauce), and Kohlwurst (smoked sausage for cabbage dishes). Salzbrenner’s concept is to bring high- on the day of delivery, and to ship the The success of Salzbrenner products made quality fresh products to the market. No finished sausage products the following it necessary to continuously increase pasteurising processes are involved, limiting day. On delivery, fresh meat is subjected to production capacity, although the the shelf life of the products to three or quality control checks, stored in a cold production area of the site at the old four weeks. room for a short time then weighed and Hamburg Abattoir could not be expanded. A sophisticated logistics system is minced according to recipe. Some 95% of therefore necessary to process fresh meat the meat processed is cut boneless pork. The mincing process is carried out in a Production capacity increased shredder or colloid mill, after which the Busch central vacuum system, supplying mixture is filled into skins. Bratwurst In 2006 a new building making optimal use four thermoforming machines and a dual sausages are boiled immediately, whereas of the available space was inaugurated at chamber packaging machine. other varieties such as Knackwurst, Wiener the site. The original vacuum supply for the Würstchen and Krakauer are reddened, four thermoforming machines and a dual dried and smoked before boiling. All chamber machine included the pumps for varieties are cooled immediately after the rough vacuum located in a separate room boiling process, then separated and packed. above the production area. The traditional company Salzbrenner KG This was done to prevent waste heat from manufactures 15-30 tons of boiled sausage the pumps entering the cooled production products daily. Production focuses on area, causing increased air conditioning proven recipes, natural spices and locally costs. sourced fresh meat. In contrast, the The rotary lobe vacuum pumps remained processing technology used by Salzbrenner as boosters beside the thermoforming is highly modern. machines, as did the smaller rotary vane Vacuum for the packaging machines is vacuum pumps used for forming foil into supplied by an efficient centralised vacuum trays. However, this arrangement proved to system made by Busch. have a disadvantage: the vacuum pumps Salzbrenner uses the latest technology to were started with the packaging machines, manufacture and pack top quality products and ran almost continuously throughout economically and to the highest hygiene the working day. standards. Continued on page 14

International Meat Topics • Volume 7 Number 3 13 Continued from page 13 reservoirs to maintain a permanent vacuum In order to reduce energy costs and of 30-40 mbar. improve system reliability, production This arrangement has the advantage that manager Christian Heitmann decided last vacuum is available immediately at the start year to centralise the vacuum supply. of the evacuation cycle. The rotary lobe Busch vacuum specialists were contacted, boosters installed directly to the packaging who designed a central vacuum system for machines increase the rough vacuum installation in the same room as the instantly to the level required for previously used rotary vane vacuum pumps. packaging, permitting extremely short cycle This centralised system now generates times. vacuum for the four thermoforming Part of the central vacuum system runs machines, and supplies the pre-vacuum to independently to supply vacuum for tray evacuate the packaging in these machines forming at about 150 mbar. and the dual chamber machine. After a year of operation, the central Between the central vacuum system and vacuum system has met production the packaging machines three vacuum manager Christian Heitmann’s expectations containers are installed, which act as in full: the operating hours of individual

vacuum pumps have been reduced by 20%, as the pumps only run if required by current demand. In addition, only four rotary vane vacuum pumps and two rotary lobe boosters are installed in the central system. A fifth rotary vane vacuum pump acts as a reserve, and can also be connected to the system if production is expanded and another packaging machine added. The previous decentralised system had a rotary vane vacuum pump for each of the four thermoforming machines and the dual chamber packaging machine, and a smaller rotary vane pump for each of the tray thermoformers. The new system creates substantial energy savings by reducing: l The operating hours of individual vacuum pumps. l The number of vacuum pumps in operation. l Air conditioning energy consumption by eliminating waste heat emissions in the packaging room. Christian Heitmann regards the improved system reliability as another significant advantage. In the event of a vacuum pump failure, the reserve pump will activate automatically without production interruptions or downtime. In addition, maintenance personnel no longer need to enter the production area. Stoppages due to maintenance have been eliminated, as service staff have unrestricted access to the individual vacuum modules during production. Christian also relies on Busch to carry out maintenance work. A service contract guarantees the availability of the entire vacuum system over a five year period for a fixed annual payment. This contract allows Salzbrenner to plan operating costs in advance, and provides professional and punctual execution of all maintenance work by a Busch service technician. n

14 International Meat Topics • Volume 7 Number 3 processing systems

Award for best innovation in food processing technology

In addition to its well-known distance it travels under pressure RevoPortioner family, Marel has into the smoothly rotating drum of introduced the V-Pump. This V- the RevoPortioner is only 30cm. shaped piston pump produces, The meat passageway is com - together with the RevoPortioner pletely auger-free. The width of the 700, up to 5,000kg high quality red piston is as wide as the forming The RM 400 DDM. The RM 2000 S. meat convenience products per drum. Meat does not have to be hour. The new pump has been spread horizontally in a manifold awarded the ‘best innovation in and vacuum is not needed. Friction New developments showcased to food processing technology’ and is and shear are avoided. The pressure proving its success daily to various applied is low. All these features the meat sector worldwide customers that deliver products to help retain the original meat struc - demanding global QRS companies. ture. The latest IFFA 2016 was definitely a for poultry, pork or fish, but also marel.com record breaking year for Lima. The showcased their new developments number of visitors, all professionals such as: Core of the new technology are from the meat industry with individ - l Their Lima RM 700 BSP, a separa - two alternating belt-wide pistons, ual needs and projects, was unsur - tor specifically designed for beef delivering a uniform pressure to the passed. bones, which can also be used for forming unit, moving the meat mass pork bones to produce an excellent over a small distance with a mini - lima-france.com quality fibrous structured meat. mum of pressure. This retains the l A Lima RM 400 DDSM with spe - original meat structure and texture Lima’s stand attracted many inter - cific hopper and anti-bridging arm as much as possible, an important A production process including ested meat processors from the as the latest equipment developed factor for a good bite and attractive the V-Pump and RevoPortioner is pork, beef, lamb, poultry and fish in their range of Lima DDM/DDSM mouth feel. very stable, clean and consistent. sectors worldwide. deboners/desinewers. Traditional pumping of meat with There is virtually no loss of raw Lima exhibited not only the now l The Lima RM 2000 S, the biggest an auger, via piping and/or using product (less than 0.3%), no down - traditional MSM/Lima ‘S’ separators meat bone separator in their range. vacuum and higher pressures, leads grades and no rework. All valuable to more shear and friction, more raw materials are used. Reducing ‘damage’ to the natural meat struc - waste is attractive not just from a ture. In the V-Pump meat mass is financial point of view; it also makes Software maximises high levels of gathered by gravity only, right on the best use of scarce natural top of the Marel RevoPortioner. The resources. overall equipment effectiveness

Food and drink IT specialist CSB- In addition, CSB Linecontrol helps Extensive stabilising systems for System International has developed companies to reduce rejects and a new software program that pro - the incorrect labelling of products. sausage products vides optimal planning, control and An optional component, CSB eco - monitoring of production and pack - control, can also be specified for ing systems in order to ensure con - the capture of environmental infor - Hydrosol are specialists in stabilisa - ising systems for the special require - sistently high levels of overall mation. This provides details of ele - tion systems for the simple and ments of halal products. equipment effectiveness (OEE). ments such as energy consumption economical manufacture of meat Another focus is the manufacture on the line. and sausage product. of cooked ham specialities, ranging csb.com CSB says its Linecontrol system from cost-optimised to premium ideally supports long-term multi- hydrosol.de quality recipes. These stabilising sys - The CSB Linecontrol software shift operations by automating tems improve water binding, shap - establishes an online link with all planning and monitoring so that Hydrosol also offers a wide range ing and sliceability. Even at higher equipment on the line. This enables these tasks are not affected by fre - of stabilising systems for poultry yields, the final products have mini - it to provide real-time information quent changes in staff on duty. products like cold cuts, sausages, mal syneresis and an on current capacity utilisation and As a result, individual machines nuggets and similar items. appetising appearance. the performance of individual are fully integrated to ensure the This includes functional Hydrosol’s functional machines. line constantly operates at maxi - systems that reduce systems for the cost- This data can be accessed on the mum efficiency. the production cost optimised production production line or delivered of poultry sausages. of wieners and hot dogs remotely to a specific computer. Their ingredient com - are likewise centred on The software can identify binations create economy. potential bottlenecks or other recipes that give high They let manufacturers adjust stoppages on the line. Any prob - quality final products the protein, fat and water phase to lems can be pinpointed to the with reduced meat content. suit, resulting in firm sausages that exact machine for fast targeted Hydrosol develops individual have a stable structure even after troubleshooting that minimises solutions to customer order. For heating, with individual meat, fat unplanned system shutdowns or example, the company offers stabil - and water content. downtime.

International Meat Topics • Volume 7 Number 3 15 Ultra-sensitive detection systems offer the safest solutions

Safeguarding consumers from con- nies such as Anritsu Infivis Ltd is taminants in the food chain is para - playing an important role in food mount to protect both the retailer safety. and supplier alike – finding the Anritsu, an award-winning supplier smallest foreign body or bone frag - of food safety solutions, is confi - ment in processed poultry or cuts dent that the latest ultra-sensitive of meat can be seriously damaging technology now available on the both financially and to a company’s market can offer peace of mind to reputation. the meat and poultry sectors by detecting the most minuscule con- anritsu-infivis.com taminant, whether bone, metal or other foreign bodies. The food industry is under Suppliers like Anritsu are always increasing pressure from both regu - responding with innovative solu - latory authorities and consumers to tions to the drive from food manu - implement reliable methods of facturers for new products so that inspection to ensure product they can be totally confident that security and quality. their products are free from foreign Continuing advances in detection bodies and safe for consumption by technology available from compa - consumers.

Innovations enhance product quality and operator efficiency

Provisur Technologies Inc offers l New advanced rotary and slide- solutions for grinding, mixing, sepa - plate forming technologies (VerTex rating, forming, coating, heat treat - 660 and the NovaMax 660). ment, freezing, slicing and l A new deboning and desinewing autoloading that help processors machine that allows for greater optimise plant efficiencies, increase flexibility and ease of use (Beluga throughput and deliver high quality Systems – pictured). products at the lowest cost of own - l A grinding system that increases ership. productivity and quality (VersaGrind Pump Grinding provisur.com System). PRE specialize in the maintenance and repair of all Rotary dryers l A new slicing and Cooling. With over 30 years of experience in this field, PRE With corporate headquarters in machine that can problem solve, engineer and execute a solution tailored to Chicago, Illinois, USA and your specific needs. facilities in Asia Pacific, China, Europe, Middle East, Africa Ask us about our programmed maintenance service and South America, Provisur continues to enhance its offers up to PRE works in Canada, Precision Rotary Equipment food processing equipment, four individual USA, Mexico & South PO Box 586 Council Bluffs, IA 51502 including more integrated product drives America. processing solutions for meat, for higher Tel: 1-712-352-3509 • Fax: 1-712-352-3511 poultry and seafood applications. slicing yields Email: [email protected] • Web: www.precisionrotary.com Its recent innovations include: (PowerMax 4500).

16 International Meat Topics • Volume 7 Number 3 processing systems

Product inspection experts at your fingertips

The food manufacturing landscape today’s world of online communica - is constantly evolving. Trends and tion,” Daniela Verhaeg, Marketing regulatory and technological devel - Manager SBU X-ray Inspection at opments are areas which must be Mettler-Toledo Safeline X-ray, told followed closely, and the ability to International Meat Topics. access high quality updates quickly “By offering a range of online is essential. resources we want to further meet the needs of our readers by giving mt-product-inspection.com them the chance to interact with us and our experts and to find out In order to enable manufacturers what the market is looking for. As to make informed choices when innovation is one of the corner - selecting in-line technologies and to stones at Mettler-Toledo we will furnish them with up-to-the-minute also use the blog for new product information at their fingertips, announcements.” Thermoforming line is compact, Mettler-Toledo has launched its Product Inspection Blog. flexible, rapid and cost efficient This resource has been designed to inform the food industry on trends, news and the latest devel - The successful thermoforming line more rapid than a chamber machine opments within X-ray inspection, ‘Sprinter’ made by Komet is now and thus it lives up to its name. metal detection, checkweighing and available to process film width of It is not only speed that distin - vision inspection technologies on a 322mm and 422mm as well as with a guishes the Sprinter from other regular basis. Manufacturers can variable cut off length of 200mm up machines. Due to a new hydraulic subscribe to the blog by visiting the to 300mm. lifting system, the compressed air website. Thus, users can create larger pack - consumption is very low, which “We recognise that fast, accessible aging in the future and respond makes the price of the thermoform - information is key to success in even more rapidly and ing machine unbeatable compared variably to different requirements. to conventional systems, not only regarding the purchase, but also vakuumverpacken.de during operation. This information New X-ray range provides solution gourmet-thermalisierer.de and facts should absolutely be taken into consideration when mak - for all food applications The Sprinter is unique in many ing a decision on new investments. aspects. It is much smaller and more This new system enables not only compact than similar machines of a high contact pressure but reflects Ishida Europe has launched a new The entry-level Ishida IX-EN series its kind – without having to forego also in a low maintenance forming range of X-ray systems, with a provides an excellent cost effective operating comfort. and sealing station as well as cross choice of three models which cover introduction to X-ray technology. To the contrary. With its length of cutting. the entire needs of the market, from The higher specification IX-GN 2.7m it also fits into small rooms. The used hydraulic oil is water- an entry level, low cost machine for series offers even greater sensitivity But in spite of the little external clear, has no smell and is tasteless, simple tasks to a high performance and is able to monitor the widest dimensions, three complete uses to food-safe and has no harmful system that is able to detect very range of packed and unpacked infeed the products are available effects on health. It complies with low density natural objects such as products including ready meals and due to the extremely long infeed the FDA and USDA directives. The bones and bone fragments in meat meat. area. Therefore, it is possible to machines are delivered fully wired, and poultry. The top-of-the-range Ishida IX-G2 work extremely efficiently – and so that production can be started offers the most effective detection with several persons at a time. after a short heating-up time. ishidaeurope.com of low density contaminants such as The implementation of the Vario- The Sprinter represents its great bones, glass, shells, and rubber, tool enables and contributes to a combined attributes ‘compact, flexi - All deliver a fast return on invest - while maintaining high substantial flexibility to process dif - ble, rapid and cost-efficient’ in one ment through effective foreign inspection speeds. ferent products. It ensures a very machine. body detection which helps to rapid format change and even the It is a strong thermoforming avoid customer complaints and the film can be replaced in no time. machine for medium-sized compa - risk of product recalls in order to The Sprinter is up to five times nies. protect brand reputation and meet the stringent quality standards of leading retailers. To feature your products As well as spotting contaminants including metal up to 0.3mm, glass, rubber, hard plastic and bones, the machines can also perform a variety of additional quality control proce - dures such as detecting product flaws and missing items, and carry - Contact: +44 1377 241724 ing out weight estimation.

International Meat Topics • Volume 7 Number 3 17 processing systems

New sausage casing detection guarantees optimal food safety

ViskoTeepak and TOMRA Sorting “The biggest advantage is the fact Food decided to join forces in order that this casing allows for full to develop a casing solution that automation of the detection and would make it easier for sausage eventually the separation process producers to detect pieces of cas - with the correct sorting equip - ing in peeling operations, while still ment,” Marc Vrijsen, Business Line being able to track the colour for - Director at ViskoTeepak, told mation of the sausage during pro - International Meat Topics. cessing. The result of this synergy is “Combining TOMRA ’s Genius a completely new patent pending sorter with ViskoTeepak’s D-Tech innovation in the world of casing development, not only allows for and casing detection. casing detection but it is also possi - ble to sort on size and other quality tomra.com/meat deviations such as colour,” added Manufacturing technology for high Bjorn Thumas, Director Business In the production of skinless Development at TOMRA Sorting quality meat products sausages, it is essential to guarantee Food. that all fragments of the casing are TOMRA ’s Genius sorter can removed from the surface of the process up to five tons per hour and The Mauting company is currently kettles. The perfect construction of sausages after peeling. ViskoTeepak is equipped with high-end technol - among the largest and most suc - Mauting machines ensures excellent has therefore developed a special ogy to detect good sausages and cessful companies worldwide who isolation without heat leaks, stiff - casing type ‘Wienie-Pak D-Tech’ hotdogs from bad ones, including manufacture technology for the ness and a long lifetime. that allows producers to verify that defects such as too light, too long, meat processing and food industry. The technological process of heat the casings are completely too short, attached and loose cas - treatment is operated by a micro - removed. ing. mauting.com processor control unit in accor - This type of casing contains a spe - The requirements in food safety dance with a chosen program. cial component in the full body of will continue to increase. TOMRA Mauting machines enable produc - Mauting chambers are equipped the casing. This component leaves can now, together with Visko- ers to carry out the automatic with a highly efficient air circulation the casing fully transparent in nor - Teepak, provide the most complete thermal processing of products, system, which guarantees uniform mal conditions, but becomes range of cellulose casing detection reddening, warming-through, drying, temperature and smoke distribution detectable in combination with to help reduce the exposure of smoking, cooking, baking, chilling to any place inside the chamber. TOMRA ’s Genius optical sorting manufacturers. They take these con - and storage. In particular, they Heating can be by request of the machine. cerns seriously and, by doing so, specialise in equipment for thermal client – electricity, gas, oil, steam or During the processing of the provide support for a long term sus - processing of meat, smoking cham - combined heating. sausages, the colour formation of tainable business. Another benefit is bers, cooking chambers, chilling With 25 years of operation in the the sausages can be followed as in the labour cost saving, since less chambers for intensive chilling of market, the Mauting company has regular clear casing and at the same workers are needed in the peel - smoked products, air conditioned captured the leading position as an time becomes detectable while ing/packaging section. The innova - cold smoke pre-ripening and curing important supplier of quality implementing TOMRA ’s special tion was thoroughly tested at a units for production of fermented machines and equipment of meat optical module. major German producer of salami thermally unprocessed products, air processing industry over almost all The innovation can be used to snacks and the results were con - conditioned post-ripening and dry - of the world. Yearly the company produce skinless type sausages of vincing. Shortly after, the customer ing units for maturing and drying of presents numerous innovations and all types, including frankfurters, hot decided to switch to D-Tech casing thermally unprocessed and news items at international trade dogs, mini-salamis and much more. and TOMRA sorting technology. processed products and boiling fairs worldwide.

18 International Meat Topics • Volume 7 Number 3 processing systems

Second Queen’s Award for Enterprise

Mettler-Toledo Safeline Ltd has The development effort to been awarded a second Queen’s achieve this has been significant, Award for Enterprise, this time in with five granted patents and five the Innovation category, for devel - further disclosures going through oping its family of Profile metal the patenting process. The company detection products. The 2016 award collaborates closely with the follows The Queen's Award for University of Manchester, sponsor - Enterprise: International Trade pre - ing several PhDs to underpin its sented to the company in 2012. technology. “This Award recognises the deep mt.com expertise of the Safeline team and its reputation for design and manu - The industry standard is to use facture of technologically advanced detectors tuned to a single radio metal detectors,” Alan Purvis, frequency; Safeline has developed Managing Director, Mettler-Toledo Intelligent portion cutter uses signal generation and processing Safeline Ltd, told International Meat techniques to deploy tuned, vari - Topics. “With over 100,000 systems proven technology able and dual frequency detectors. installed globally, we have accumu - lated thousands of man-years of experience, which allows us to con - Marelec Food Technologies has friendly software allows fast fine tinuously improve our products and become a world player with its tuning of the programs. Options processes. On behalf of the global Portio range. The Marelec Portio is exist to calculate the density and to network of Mettler-Toledo employ - an intelligent portion cutter which hold the products in place when ees, I am proud that the company cuts fresh meat or fish into portions cutting. The Portio can be placed in has received this prestigious award of fixed weight and/or fixed thick - line with a grader, to maximise the in recognition of its high perfor - ness. The machines use the proven yields. In this case, the machine mance products and commitment technology of laser guided cameras selects the optimal cutting pattern to innovation.” to scan the volume. to reduce trim. The Portio range also includes machines that cut marelec.com under an angle as well as dual lanes Agitation is the energy efficient for high capacity portioning. All Marelec Portios are designed Recent innovations include the key to rapid cooling for optimum cleaning and hygiene. option for external lasers on the The machines can be opened com - infeed belt to position the product pletely for easy access. They are at the right angle and a new perpen - The laws of physics tell us that hole perforated skin sheets. That equipped with a cleaning in place dicular straight knife to cut large cooling products in a static tank of assembly resides in water to the on all modular belts. The user and soft products more precisely. water, on a belt conveyor with centre line. Product is fed into the water sprays or on a spiral belt cylinder to a water cushioned entry freezer is a very inefficient way to and moves through the machine by cool anything. the auger with gentle water and or High pressure processing solutions air agitation along the way. lycomfg.com Agitation is the key to rapid cool - for meat and shellfish ing. At the end of the cylinder prod - Lyco Manufacturing has 50 years uct is gently fed to a belt conveyor. of experience cooling raw foods or Avure Technologies created the increased demand. With Avure HPP, pouched products and they believe first commercial high pressure producers are manufacturing in their submerged and agitated processing system more than 60 record volumes, reducing shrinkage method of cooling is far years ago. and growing their distribution more energy efficient overnight. than any other avure-hpp-foods.com Avure also manufactures a vertical known method. machine, the AV-S, developed What’s the Today, Avure features multiple specifically to allow seafood pro - proof? They HPP systems, including the AV-X, ducers to more efficiently process cool hot dogs with expandable, energy efficient shellfish, removing 100% of the or sausages in and space saving designs, worldwide meat from the shell, increasing half the time it tolling centres and partnerships yields by up to 30%. can be done on a belt with more major food brands than Avure operates an in-house which is a huge increase in pro - every other HPP manufacturer. research and development facility ductivity. Product also passes Avure’s expandable machines to help partners perfect their HPP- through the bacterial danger zone enable a producer to buy the friendly recipes plus maintains ser - (130-80˚F) in half the time. machine that best suits current vice centres around the globe to The machine shown here is their needs, and as the company grows answer questions, provide on-site Rotary Drum Design which is a 60” and volume expands, the machine maintenance and spare parts fulfill - diameter auger covered in round can be upgraded to keep up with ment.

International Meat Topics • Volume 7 Number 3 19 20 International Meat Topics • Volume 7 Number 3 French success story in continuous analysis of meat composition

alaisons Jouvin is a French com - analyser in order to automate the Spany specialising in the pro - quality control and analytics duction of cold meats, and is processes. This has allowed the recognised in the market for the facility to improve product quality quality of its products and its high while saving on costs and time. level of customer satisfaction. According to Jean-Louis Jouvin, The company’s production facili - Salaisons Jouvin’s founder, president ties in Nogent-sur-Oise, Picardy, and general manager: “Our goal is to France, have a total area of 3,500m 2, improve quality control of the fin - employ 60 workers, and produce ished product and the quality of 2,700 tons of pork cold meats annu - raw materials. These are intimately ally. Its star product, without a linked and affect costs as well as doubt, is its chorizo, which consti - consumer satisfaction. In this sense, tutes 95% of production and is mar - the QVision analyser is a good tool keted in several varieties. to reach our goal.”

by Marijke Bellemans, Uniform, consistent quality TOMRA Sorting Solutions Food, 3001 Leuven, Belgium. Large retailers and other distribu - tomra.com tors have very specific needs and erally be evaluated visually, the The QVision unit was installed at requirements and Salaisons Jouvin’s same is not true of other factors, the front of the factory’s produc - first goal is to adequately respond such as collagen,” Jouvin indicates. tion line. After going through a With more than 25 years of expe - to these. “What is most important is what slicer, a thick cut of meat is rience, tradition and innovation go In order to do so, ensuring consis - can not be seen! And the fat and obtained initially, as this is the best hand in hand at Salaisons Jouvin in tent quality is important, which is collagen levels are clearly notice - way of maintaining traceability of the ongoing search for the best much easier for the company since able to the consumer. Both must be suppliers’ products. product quality. they began using the TOMRA inspected in the interest of product The QVision analyser has a recipe The company has jealously QVision analyser. uniformity and quality. In addition, editor which guides the machine guarded the secret of its traditional “One of our priorities is to main - uniformity also allows us to control operator when adding certain quan - recipes in order to offer a unique tain consistency in our products the curing parameters.” tities of raw materials to batches. flavour, while at the same time throughout the year, from January 1 QVision does not just ensure con - The QVision performs continuous, evolving technologically in its pro - through December 31. sistency in the quality, content and analysis and provides the operator duction methods. Having raw materials sorted and taste of their products through the with information about the cumula - A good example of the company’s batches analysed allows us to cor - year. tive weight of the current batch. passion for continuous innovation is rect our recipes and adjust our According to Jouvin, another Afterwards, the operator must the installation of machines at any point in time so advantage is undoubtedly “the pos - normally take corrective action to TOMRA’s QVision that the consumer’s percep - sibility of inspecting raw materials reach the target fat level for the tion of the quality from our suppliers to ensure that batch (normally 1,000kg). remains consistent,” they scrupulously comply with our To facilitate, or rather, to auto - explains Jouvin. requirements.” mate this task, the QVision has a Thanks to QVision’s personalised application, ‘Intouch’ precise measurement of which can make recommendations fat, moisture, Ease of use and integration or guide operators, provided the proteins and in the production line selected recipe has been entered collagen beforehand with the proportions of the manu - Initially the company engaged in the individual ingredients. facturer can manual production, using estab - “This function is an excellent aid precisely combine lished recipes, which frequently for operators. They feel freer different suppliers in required them to make corrections because they know that the order to ensure product and discard a lot of the product. selected recipe will produce exactly conformance, and “Before using QVision, we regu - the desired result,” says Jouvin. can correctly assign larly had to carry out numerous Apart from being easy to use different suppli - time-consuming manual inspections. thanks to its intuitive interface and ers to different This involved a greater investment touchscreen, the QVision has an products to of time and diminished our open and light design and is also consistently response capacity. easy to move and clean, which achieve the desired With automation, the checks are allows users to maintain standards quality even though different mix - ongoing and dynamic. All materials for quality, cleanliness and general tures are used. from all suppliers are analysed all hygiene. “Although raw materials can gen - the time,” Jouvin explains. Continued on page 22

International Meat Topics • Volume 7 Number 3 21 sensors to measure fat, collagen, reports, thereby simplifying all of protein and moisture content in the processes. meat, whether fresh or frozen, as The Qvision’s high capacity, sim - well as in different shapes and sizes ple handling, easy cleaning and low (small cuts of meat, diced meat, energy consumption make it the ground meat). best alternative for analysis and The QVision analyser uses interac - process control in the meat indus - tance spectroscopy technology to try. The system also generates analyse light in the VIS-near infrared important cost savings by reducing range, penetrating deep into the lean giveaway, thereby increasing meat and measuring products and profits. In addition, the QVision production in real time. The equip - allows complete traceability, higher ment is able to analyse 30 tons of productivity, consistent quality in Continued from page 21 tions or local regulations. Regarding meat per hour and allows data the finished product, a reduction in the expected return on investment, access and management, generating human error and smarter purchasing Complete satisfaction Jouvin insists that “in any food busi - daily integrated or exportable of raw materials. n with results ness, the quality of the finished product is a crucial intangible. The first contact Salaisons Jouvin “Our decision to purchase the had with TOMRA technologies QVision was based on our sense and About TOMRA Sorting Food occurred at the French agri-food conviction that this tool would play expo CFIA in Rennes.The company an important part in our return on had become aware of a need and investment due to the positive TOMRA Sorting Food, formerly Best and Odenberg, designs and manufac - TOMRA had the solution. Today, image it conveys to our customers. tures sensor-based sorting systems for the food industry. The company after experience with the new Both our suppliers and customers has more than 7,500 systems installed at food growers, packers and equipment, Jouvin considers the are satisfied and trust the new processors worldwide. QVision to be a “natural tool to QVision analyser: the former manage our resources, stock and because of the objectivity of the The company offers high-performance automatic sorters, graders and curing chambers.” analytical method and the latter peeling and process analytics systems for meat, fish and seafood. The sys - The decision to purchase the because of the consistency in qual - tems ensure optimal quality and yield, resulting in increased productivity QVision analyser, as Jouvin himself ity that it affords,” concludes Jouvin. and efficient use of resources. acknowledges, was determined by TOMRA Sorting Food is part of TOMRA Sorting Solutions, which also the level of the technology, develops sensor-based systems for recycling, mining and other industries. TOMRA’s accessibility and quick Cutting edge vision This powerful combination of technologies makes TOMRA Sorting one of response times, as well as the ease the most advanced suppliers of sensor-based sorting solutions in the with which the equipment can be TOMRA’s QVision system is a con - world, with more than 11,200 systems installed worldwide. installed, without technical limita - tinuous analysis solution which uses

22 International Meat Topics • Volume 7 Number 3 Preventing pneumatic component failure in the meat processing industry

any pneumatic component struction and manufacturing facili - failures can be traced back ties around the world. Mto the source of com - The product is more than the pressed air. For reliable operation highest quality USP white mineral and long tool life, the components oil that meets NSF H1 and FDA of process equipment require clean, requirements for materials that may moisture free air at the proper pres - have incidental contact with food sure and flow rate. as defined under Title 21 CFR, 178.3570. It is Kosher and Pareve approved, by Sam Hall, OMA 1, MLT 1, as well as Halal certified. It is Industrial Technical Service below a designed and formulated to max - Manager, Bel-Ray Company LLC. baffle collect - When imise air tool life and optimise belray.com ing at the bottom of the hydraulic oil, food grade pneumatic system performance. bowl. Many times during or not, is being used as an air - The advantages and benefits plant surveys I have seen dis - line lubricant, moisture is denser include: How do you protect compressed coloured filter bowls full of rusty than the hydraulic oil thereby pene - l Excellent film strength. air processing equipment, such as air water and sludge from the lack of trating the hydraulic oil and attack - l Anti-wear properties. driven knives, saws and deboners, maintenance beyond the compres - ing metal surfaces. l The unique feature of emulsifying that are used in meat and poultry sor or down line and/or from using The moisture stays below the with water. processing plants. a poor quality airline lubricant. hydraulic oil film settling in and l Bacteriological protection. Pneumatic tool and airline protec - One very noticeable clue is the attacking the metal surface of the tion is easy, use an NSF H1 food discolouration of the filter bowl, airlines, the moving components of grade airline oil, designed with air usually an indication of rusty/ pneumatic tools, all while inducing Moisture absorption line and pneumatic tools in mind, contaminated standing water. rust, gum, sludge, and power rob - not hydraulics. A properly formu - This has always been a clue to me bing deposits. The emulsifying feature of No-Tox lated, versatile, colourless ISO VG that little or no service has been The regulator (R) is used to main - Food Grade Air Line Lubricant aids 22 airline lubricant maximises air performed and it is definitely an tain/regulate constant air supply in absorbing a significant amount of tool life while optimising pneumatic indication that a premium perfor - pressure to the pneumatic compo - moisture present in all airlines. The system performance. mance food grade air line lubricant nents of the processing equipment. moisture is generated by the expan - First and foremost, it is very is long overdue for this system. It is There is usually a pressure gauge sion and cooling of compressed air. important to install and take care of quite simple to drain the water out installed for at a glance monitoring. Thus, rust and oxidation, tool stick - an FRL (Filter, Regulator, Lubricator), of the filter bowl on a regular basis. The lubricator (L) which looks sim - ing and line clogging is eliminated available in modular or conven - Filter bowls have a drain valve. All ilar to the filter canister is the third optimising tool and system perfor - tional mode. you have to do is turn the valve a piece of the FRL puzzle or the end mance. There are different sizes, styles quarter turn and the water drains of the line for the compressed, fil - In fact, the moisture absorption and flow-rates available. You can out. In fact, there is even an auto - tered and regulated air to mix with properties (water in oil emulsion) assemble and plumb the three com - matic drain type available. the proper amount of food grade means that instead of moisture ponents, or install a pre-designed Sometimes the drain valve is or airline lubricant. interfacing with the oil creating set up. will become plugged up with a The oil to air volume ratio can be acids that form rust, gum, and gooey slime. You will need a pipe adjusted on the lubricator prevent - sludge, especially on tools not in cleaner and, time permitting, take it ing over or under lubrication of the use, the oil wets out due to its How does an FRL work? apart, clean the bowl and flush it pneumatic tools. polarity with metal, protecting out. The outlet air, which is an atom - against the formation of acids that An FRL is a device that conditions When walking through a process - ised mixture of oil and air, not only can form rust, gum and sludge, air for use in pneumatic systems. ing plant and you see the FRL, take a lubricates the tools, it protects the especially when air operated tools Let’s start with the filter (F) which moment to look at the filter bowl air lines and all components of the are not in use. doubles as a water separator and fil - which is usually clear plastic and air tool system. The superior bacteriological pro - ter. If the compressed air has not when you see brown rusty water in tection effectively inhibits the been de-hydrated, a considerable the bowl, point this out to the growth of certain bacteria, yeast amount of water will be collected maintenance department and Food processing and more and mould in the lubricant which in the filter. enquire as to the type of oil used can also be a contributing factor to The filter will hold back most of for airline lubrication. There is a Bel-Ray No-Tox Food Grade Air Line the gooey slime found in the filter the physical contaminants. The good chance you will hear ‘ISO VG Lubricant (62050) is not only used bowl/drain valve and infrequently standard filter is rated at five 32 hydraulic oil’, which is a problem. for meat and poultry processing used air tools and systems. microns. When we survey/audit industrial equipment, it is also used in phar - Bel-Ray No-Tox Food Grade Air As the air enters the filter with process plant equipment and the maceutical, beverage, and other Line Lubricant is at the head of the great velocity there is a centrifugal lubricants used, it is quite common ‘clean’ industries. pack when it comes to the mainte - air rotation created throwing the to uncover the use of an ISO VG 32 Not limited to the clean industry, nance and care of FRLs, airline water to the outside of the filter hydraulic oil used as an airline lubri - it is also recommended and used in systems and the lubrication of bowl where it runs downward cant. This is not acceptable. the mining industry, general con - pneumatic tools. n

International Meat Topics • Volume 7 Number 3 23 Age related carcase changes Microbiological count (cfu per g) Breast Thigh This Polish study (Euro. Poult. Sci. 79 103) looked at age related changes in the Total mesophilic aerobic bacteria 8.50x10 4-9.70x10 8 2.70x10 5-4.84x10 8 tissue composition of carcase parts and the distribution of lean meat, fat with skin and bones in turkey carcases from BUT Big 6 turkeys between two Total psychotrophic bacteria 1.70x10 4-9.35x10 8 1.74x10 5-2.06x10 8 and 20 weeks (males) and two and 16 weeks (females). In the males between two and 20 weeks of age the percentage lean meat Yeasts and moulds 2.50x10 3-3.20x10 4 2.50x10 3-1.35x10 5 in breast and legs rose by 3.4 and 1.8% respectively, whereas similar figures Total coliforms 4.30x10 1-2.30x10 6 2.30x10 1-9.30x10 5 for wings, back and neck saw decreases of 2.8, 1.5 and 1.0%. Similar figures were seen in the females. Faecal coliforms 0.36x10 1-9.30x10 3 2.30x10 1-2.30x10 4 The content of skin with subcutaneous fat decreased considerably in neck Staphylococcus aureus <10 2-5.52x10 5 <10 2-2.02x10 5 and wing, especially in males over 16 weeks and females over 12 weeks of age. The smallest changes seen related to bones. Bacillus cereus 1.10x10 1-1.10x10 5 2.20x10 3-7.40x10 4

Clostridium perfringens 1.90x10 3-4.90x10 3 2.00x10 3-5.70x10 3

Positive samples (%) Packaging gas and lactic final product. Where a product acid bacteria l o o k s l i k e a c u t or joint of meat and Listeria monocytogenes 12 16 This Finnish study (J. of Appl. Micro. if there is more than 5% added 119 1310-1316) looked at the effect of water this also has to be declared Salmonella spp. 44 76 different CO 2-rich packaging atmos - on the label. pheres on the composition of the lactic acid bacterial communities Chicken microbiology in Turkey There was no interaction between proliferating on raw pork. -lipoic acid and broiler In this Turkish study (Akad. Gidya 13 sex and slaughter weight for any of Raw pork was inoculated with a αthigh meat 3 0 4 - 3 1 6 ) 2 5 c h i c k e n b r e a s ts and 25 the evaluated parameters. Ham, mixture of 14 lactic acid bacteria This Korean study (J. of Chem. 2015 chicken thighs were screened. The shoulder and loin weights increased and then packed in one of four gas 406894) assessed the antioxidant results are shown in the table above. linearly with increasing slaughter atmospheres (100% CO 2, 80% N 2 + activity of broiler thigh meat and weight which had little effect on 20% CO 2, 80% N 2 + 20% CO 2 + 0.4% meat products enriched with nat - primal cuts’ weight yield. CO and 80% O 2 + 20% CO 2). These ural antioxidants ( α-lipoic acid and Muscle type and volatile Increasing slaughter weight products were then monitored α-tocopherol acetate). compounds p r o d u c e d m e a t w i t h a more intense through 14 days of storage at +6°C. At 21 days of age broilers were This Spanish study (Food Sci. and red colour, the same intramuscular It was shown that a high concen - supplemented with varying levels of Tech. Int. 21 581-592) looked at the fat content and had a marginal tration of CO 2 favoured α-lipoic acid and a constant level of effect of muscle type on volatile effect on tenderness. Lactobacillus sp., high concentration α-tocopherol acetate for three compounds throughout the manu - of O 2 favoured Leuconostoc spp. weeks. The birds were slaughtered facture of Celta dry cured ham. and atmospheres of 80% N 2 + 20% and processed at 42 days of age. Samples of the semimembranosus New rapid method for CO 2 favoured Lactococcus spp. Broilers receiving 100mg α-lipoic and biceps femoris muscles were Campylobacter spp. detection acid and 200mg of α-tocopherol collected after salting, at 120 days This British paper (J. of Appl. acetate per kg feed possessed the after salting, after the end of the Microbiol. 120 469-477) describes Labelling requirements h i g h e s t a n t i o x i d a n t a c t i v it y . T B A R s drying ripening stage and after 165 the development of a rapid test for In the UK (Analytical Methods 7 and peroxide levels were highest in and 330 days of ‘bogeda’ step and the detection of thermotolerant 8997-9004) labelling rules require these birds. It was concluded that these were tested for volatile com - campylobacter in poultry faeces. ingredients that are highlighted in α-lipoic acid supplementation in pounds. This method is based on immuno - the name of a food should be feed enhances the antioxidant Some 55 volatile compounds were magnetic separation and loop medi - declared as a percentage of the capacity of thigh meat. identified and quantified. The ated isothermal DNA amplification number of volatile compounds (IMS/LAMP). increased as the processing This LAMP method is specific, as progressed and reached 39 and 40 demonstrated by using 10 campy - respectively in the semimembra - lobacter strains and 13 non-campy - nosus and biceps femoris respec - lobacter bacterial species, and tively at 550 days. sensitive (95% probability of detect - FREE Editorial Library The most common compounds ing 22 genome copies). were esters followed by aliphatic A competitive internal amplifica - hydrocarbons and aldehydes. The tion control has been incorporated muscle type showed significant to give unambiguous determination differences for four esters, two of negative results. Our extensive article library allows alcohols, one aldehyde, one ketone Immunoseparation of campy - you to download previous articles and four aliphatic hydrocarbons. lobacter allows direct LAMP detection from poultry boot swabs from all of our titles (sampling material is placed on the Meat quality and cut yield of boots and then walked around the heavy pigs shed to sample the litter) in 90 It is fully searchable and available FREE This Brazilian study (Arq. Brasil. de minutes without enrichment or Med. Vet. e Zootec. 67 1166-1174) DNA purification (74% probability www.positiveaction.co.uk looked at meat quality and cut yield of detecting 100 cfu per ml of boot The global technical leader in pigs slaughtered between 100 and swab suspension). 150kg live weight. The analysis of 17 samples from a

24 International Meat Topics • Volume 7 Number 3 commercial turkey farm showed a 100% correla - pork pressurised at 200, 400, 600 and 800 MPa Furthermore, the soluble proteins were tion with (10 minutes, 5 or 20°C). A pressure of 400 MPa exposed to remarkable structural changes already traditional microbiological culture. was found to be the threshold for loss of solubil - at 200 MPa and lost their native functionality. It was considered that a rapid test had been ity and the structural proteins, myosin and actin The modification of proteins in pressurised meat developed for the direct detection of thermo- lost their native solubility due to aggregation. affected the water binding sites of the myo- tolerant campylobacter from boot swabs. It is suggested that this pressure induced fibrillar proteins and, therefore, the interactions aggregation was mainly caused by hydrogen between proteins and water molecules and dis - bonding during pasteurisation and not hydro- tribution between myofibrillar and extra-myo- Lipid peroxidation in pork meatballs p h o b i c i n t e r a c t i o n s o r d i s u l p h i d e c r o s s l i n ks. fibrillar compartments. To retard or avoid lipid peroxidation of meat products, antioxidants are commonly added. Consumers prefer natural antioxidants rather than synthetic ones. Gentisic acid and epicate - chin from litchi flowers are such antioxidants. In this Taiwanese study (J. Food and Drug Anal. 23 501-508) physicochemical pork meat with and without dried litchi flower powder was analysed during a four week frozen storage period. The addition decreased TBARs but increased thiol group contents in the meatballs. The addition also improved texture and water holding capacity of the meatballs as well as making them redder and darker in colour. The meat balls containing the added litchi flower powder had the best overall sensory scores on taste panel assessment.

Quality of fresh and frozen pork This American study (Meat Sci. 111 110-115) com - pared the quality and sensory characteristics of pork from gilts, physical castrates, entire males and immunological castrates. The meat was aged for 10 days and then cut into chops and roasts and some of these were frozen for between 14 and 30 days. The evaluated pork characteristics showed no differences between the sexes except for marbling in the frozen samples and all but the entire males were similar in terms of boar odour and pork flavour. These results suggest no differences in the pork of traditional and immunological castrates.

Reducing salt content of cooked ham The partial substitution of salt (sodium chloride) by potassium chloride appears to be a promising way of reducing sodium, and hence, salt content. This Norwegian study (PLoS ONE 10 e0137805) looked at the sensory changes in cooked ham with a reduced sodium content. The salt content was reduced from 3.4 to 1.4% and 25% sodium content was replaced by potassium. The salt reduction had the greatest effect on salty taste, after taste, tenderness, hardness and colour hue. There were no significant changes in WHC, moisture, pH, expressed moisture, sensory profile attributes or surface lightness and shininess.

High pressure effects on meat In this Danish work with pork (Food Chem. 196 1005-1015) complementary methodologies were used to analyse pressure induced modification and functionality of myofibrillar proteins from

International Meat Topics • Volume 7 Number 3 25 Food Grade Lubricants is a new feature, to be published twice a year, that provides a key reference for those seeking to source suppliers of This feature will next appear in the lubricants that protect against wear, friction, corrosion, oxidisation, heat December 2016 issue of International Meat Topics dissipitation and power transfer. To fi nd out how to be listed contact Claire Fussey It will be seen by at least 20,000 meat professionals worldwide making it [email protected] or Tel: +44 1377 241724 an excellent opportunity to promote your business.

More than just lubricants Food-grade lubricants Worldwide service SFK LeBlanc ROCOL Lubricants Bel-Ray Company, LLC Albuen 37 Rocol House, Wakefield Road, PO Box 526 6000 Kolding, Denmark Swillington, Leeds, UK. Farmingdale, Tel: +45 7634 2703 Tel: +44 113 232 2600 NJ 07727, USA Email: [email protected] Email: [email protected] Tel: +1 732 938 2421 Web: www.sfkleblanc.com Web: www.rocol.com/foodlube Web: www.belray.com

ROCOL Lubricants manufactures and Bel-Ray Company, LLC was founded in SFK LeBlanc aim to address maintenance supplies Foodlube NSF H1 registered, and lubricants issues at the initiating 1946 and serves the lubrication needs of food-grade lubricants featuring DETEX industrial customers worldwide. discussion of a project or acquisition of metal detectable components to help a machine, because when knowledge is meat processors improve safety, reduce the base, the odds of prolonging the downtime and meet performance of the stringent audit equipment is higher. requirements.

26 International Meat Topics • Volume 7 Number 3 meat processing news from around the world Simple panel control

With the introduction nated ring key. The user will receive of its new panel gen - a sensory and visual confirmation of eration, K+G Wetter the commands for the best possible satisfies the growing demand for degree of control. self-explanatory control units which As an alternative, these commands can be simply and quickly under - can also be entered on the touch stood. panel, such as different knife speeds, The new panel solution creates which are well visible on the screen new possibilities in the world of and can be selected directly. meat processing. This progressive Each user can customise the panel control unit combines modern in accordance with his own wishes operation via touch screen with and requirements. That includes set - push button technology. ting up the most important shut- The user can execute the most down functions for the user, such as frequently used machine commands temperature, time or bowl revolu - Included in the many products displayed by Frey at the for hydraulic or mechanical tions, on a separate large area of the recent IFFA exhibition, their WK98 grinding head system is processes. panel. designed for the use as an attachment in connection with Processes such as hydraulic load - All data can be viewed and con - a Frey vacuum stuffer. This opens a new dimension in the production of ing and unloading, closing and trolled through the menu, such as raw and coarse products. Due to the Frey rotor pump system the prod - opening of the knife lid, start and various machine and operating data. uct is evacuated and continually led to the cutting set of the grinding stop functions or speed changes can But it also enables updating recipes head. The ripening process and production time can be shortened be simply controlled using an illumi - and recipe management via hereby. Before the product is led into the filling tube it is grinded to the CutControl. The latter will lead the size of the end granulation. An obviously higher product quality can be user through the production achieved regarding the finish and hygienic standard. The usual heating process for each recipe step by step. and contamination during the standing times is reduced. One to two The CutVision software also working steps can be saved due to the integration of the filling and enables the user to record and read grinding process. The transport ways are shortened. The grinding head is out all production steps with the simply installed in place of the linking gear. Four or five part cutting sets measurable quantities, such as of 98mm can be used. For the production of minced meat a cutting set times, temperature progression etc. for Freeflow is optionally available. This ensures the most important frey-online.com cornerstone for quality manage - ment in the cutting production step. kgwetter.de tinuous and quick heavy loads han - Joint venture dling, for long distances and large in China spaces; with Tecsal’ s MACH system Innovative overhead ideal partner for the meat process - all these difficult manual operations The Freund machine factory is now rail solutions ing industries, with thousands of are no longer necessary. represented by a new sales, service installations worldwide in Europe, tecsal.com and production site in China. Tecsal, founded in 1982 in Parma, USA, South America and China. Together with the Chinese partner offers innovative solutions for the MACH is the next-generation sys - Mado (Beijing) Machinery handling of processed meat prod - tem developed by Tecsal for the Production Co Ltd, Freund has ucts such as bacon, cooked ham, automatic transportation of frames New office in established a joint venture under prosciutto, salami, peperoni and along the rail system. The whole Malaysia for BRF the name of Freund-Mado Food sausages. handling is managed by touch- Machinery & Technology China Co. The consolidated experience and screen configurable terminals to BRF’s new office in Asia, located in Ltd, headquartered in Beijing. continuous research into technolo - easily set up all the operating para - Kuala Lumpur, Malaysia, will acceler - Freund is reinforcing its position in gies have allowed Tecsal to develop meters (speed, time, stopping space) ate the company’s international the critical Chinese market and extremely versatile and cutting edge according to the specifications of expansion, especially in Southeast strategically expanding its own applications, such as its own over - each system and the particular stage Asia and the Middle East. made-in-Germany product range head rail systems, rack and frames, of the process; a mimic external “We see a big opportunity in with stationary table band saws for bacon hooks and sliding units to monitor also allows real-time con - Malaysia as a global platform for worldwide distribution. move the racks, that can be installed trol of all the operations. supplying Halal consumer markets Freund has already been active in in any kind of environment, process Compared to traditional systems, around the globe,” Simon Cheng, the Chinese market for over 20 or production. MACH presents many advantages: it BRF’s general director in Asia, told years with a sales and service repre - Careful and meticulous project drastically reduces manual opera - International Meat Topics. sentative. planning, a thorough knowledge of tions, it guarantees fast, safe and BRF already operates four plants freund.com food processes, reliable technology efficient handling in any environ - on the continent. The new office and high quality materials, continu - ment and conditions (such as salt - will enable the company to compile Please mention ous and direct technical support, ing, refrigerating, freezing cells), an relevant information more rapidly International and a modern and dynamic organi - advanced process management, low and to accelerate the mapping of sation have allowed Tecsal to operating costs and greatest pro - new investment opportunities in Meat Topics become a leading company in han - ductivity index. the region. when sourcing further information dling solutions and rail systems; the Wherever there is a need for con - brf-global.com

International Meat Topics • Volume 7 Number 3 27 New leak testing system

A new, fully auto - placed into cases or shipping crates. mated, leak testing Solving the problem at that stage system has been becomes more labour intensive and developed to help food processors costly. ensure that individual modified Dansensor’s LeakProtego uses a atmosphere packages (MAP) are not patent-pending sensing system with going out the door with undetected CO 2 as a trace gas to detect leaks micro leaks. To answer processor down to 50 microns. The technol - demands for improved package ogy relies on modular units, each of integrity and shelf life monitoring, which can test up to 12 packages per Dansensor, a Mocon Inc company, minute. Multiple modules can be has introduced LeakProtego. combined so that individual pack - The first-of-its-kind online system age testing can keep up with MAP has been engineered to test for equipment output. The modules The GEA CookStar’s ability to use steam, hot air, roasting, potential leaks at levels lower than provide processors with critical smoking and drying in any combination makes it a true previously possible. This is of partic - information such as individual leak master of industrial cooking. Launched 25 years ago as the ular significance for processors who size and rate so that production line world’s first double-spiral industrial oven, the GEA CookStar has are pushing the shelf life envelope. modifications can be made quickly. incrementally evolved into today’s three-phase cooking solution. This “Leaks degrade shelf life, compro - mocon.com unique configuration – patented by GEA – includes a booster/turbo mise product safety and negatively impingement zone between the main oven sections. This extra zone uses impact brand image. We wanted to high velocity, vertically flowing air to roast, brown or dry the product’s develop a concept that provides surface. food processors with package gea.com integrity information further upstream to facilitate cost savings,” Karsten Kejlhof, vice president of sales and marketing, told a 2B mill finish. Standard oil-free dri - portation device all in one, eliminat - International Meat Topics. ves, elastomer isolators, scalloped ing the need for single use packag - Currently, most food processors flat bars, internal ground arms and ing. They store between 110-160kg of test for leaks further down the line no laminations maximise equipment meat, either bone in or bone out, when the product has already been hygiene and help meet rising sani - meaning greater efficiencies on the tary standards and regulatory production line as well as in storage requirements. and handling. The monobeam frame is sloped to The FoodCap primal handling sys - New vibratory contamination and maintain food prevent product and moisture build- tem is designed to integrate with conveyors safety. up that can harbour bacteria. automated storage and retrieval sys - The elegant and robust new key.net tems for efficient and accurate han - Key Technology has introduced structural design of Iso-Flo dling and inventory management, their reengineered Iso-Flo with monobeam makes it ideal for a wide although it also has the flexibility to monobeam construction. This new range of food processing and pack - be used without automation if family of vibratory conveyors fea - aging applications. The monobeam Revolutionary new required. tures an innovative frame made of a architecture can be used on distrib - approach The new system has been scientif - single structural member. ution shakers with side discharges as ically verified by independent The monobeam conveyor’s frame well as transfer shakers, collection Innovative New Zealand company, research and development com - and spring arms can be tucked com - shakers, feed shakers and inspection FoodCap has developed a fresh pany, Carne Technologies. pletely under the conveyor bed. The shakers. With the frame and spring approach to chilled meat material foodcap.com narrow frame offers less than half arms located under the conveyor handling. the surface area of other Iso-Flo bed rather than on both sides, The FoodCap primal handling sys - frames, fewer parts to clean and monobeam inspection shakers tem is a reusable bulk chilled meat better access to the conveyor bed. enable operators to get closer to handling system for buffering, stor - The single beam design eases the the bed for improved product visi - age, ageing, and transport of red and sanitation routine and enhances bility and ergonomics. white meat between primal and equipment hygiene to In addition to case-ready processing lines. reduce the risk of the sanitary At the heart of the system is the product enhancements asso - FoodCap, a meat storage capsule. ciated with its simpli - The FoodCap is robust and seals fied frame, the single completely to maintain a modified beam design offers atmosphere where oxygen is the sanitary advantages of excluded, preventing microbial traditional Iso-Flo shakers. growth and product deterioration. The stainless steel conveyor bed FoodCap CEO, Julian Beavis features a standard rotary polish describes the technology as ‘revolu - within the product contact zone, tionary’ for primal chilled meat which resists bacterial attachment processors. The capsule is essen - and biofilm formation compared to tially the vacuum pack and trans -

28 International Meat Topics • Volume 7 Number 3 meat processing news from around the world Tailored packaging

Thanks to its wide For small processors, Multivac range of products, offers the compact R 085 e-concept Multivac, the packag - thermoforming packaging machine, ing machine manufacturer, offers which does not require water and tailored solutions for the packaging compressed air connections, as well of fresh meat, ham and sausage as the entry level model R 105 MF, products of all kinds. which is designed for the produc - Their R 235 thermoforming pack - tion of MultiFresh vacuum skin aging machine is a new economic packaging. model for the packaging of sliced As the smallest fully automatic Metalquimia’s Movistick Triplex, the self-piloted hydraulic products. It is equipped as standard traysealer from Multivac, the T 300 injector, incorporates up to three injection heads. This is, with format sets and sealing dies, is suitable for packing small to without a doubt, the injector for meat products (bone-in or which are specially tailored to pro - medium-sized batches. It has boneless) with the highest injection potential in the global meat sector ducing flat packs of sliced products energy-efficient drive systems and that, equipped with a triple hydraulic piston pump, provides the highest and have an interface for attaching can be washed down. The machine injection and productivity rates on the market and the highest final yields slicers. can be configured with multiple with maximum precision, obtaining spectacular brine distribution and Thanks to a lowered film infeed, tracks, enables quick die changes colour uniformity, thus providing an answer to the demanding exponen - the loading conveyor of the slicer and can be combined with a variety tial challenges to be faced by the meat industry of the future, even sur - can be placed horizontally at the of discharge systems. passing the ‘mythic 150% injection’ in a single pass, thereby eliminating height of the machine frame. This The high-performance traysealer T the need to grind the meat to absorb such large quantities of brine. enables the length of the machine 800 is suitable for packaging large metalquimia.com to be reduced significantly. batches and can be integrated into At the recent IFFA exhibition it automated packaging lines. It has was displayed with the MBS 200 energy-efficient drive systems, can converging system with pack ejec - be washed down and allows for tion and an L 330 conveyor belt quick die changes. The scalable Invisible but essential labeller, which ensures that packs of machine can be operated from both sliced products are perfectly sides and is available with a variety labelled with side-driven toothed of equipment options. Almost no other Thanks to the in-house produc - belt guides. multivac.com achievement has tion, the quality of the starter cul - revolutionised meat tures is not left to chance. technology as the invention of Besides the acidifying and flavour starter cultures for raw sausage forming properties of the starter Lubricants are more initiating discussion of a project or fermentation. cultures, in recent years Meat Cracks than just lubricants acquiring a stand-alone machine, With the traditional process of conducted research on metabolic because when knowledge is the producing raw sausage products, products of micro-organisms. The Every professional, whether a ser - base, the odds of prolonging the using the natural bacterial flora of focus was on Bacteriocin-producing vice technician, the developing performance of the equipment is the meat, it was nearly impossible strains which work against spoilage engineer or operator, knows that in higher. to control the quality and guarantee and pathogenic micro-organisms order to ensure optimal working sfkleblanc.com continuous product quality. such as Listeria monocytogenes and condition for any equipment, you Today, it is possible to achieve the do not have an effect on the fer - need to lubricate with oils or desired aW-values and pH-values mentation activity of the starter greases on a regular basis. very precisely by using the right culture. They worked with the raw Today lubricants are more than Strategic marketing starter cultures and professional sausage directly isolated Listeria just lubricants. A full range of so- alliance control of the fermentation plant. subspecies to achieve best called intelligent lubricants is avail - In 2004 Meat Cracks Technologie results in the finished product. able. Lubricants that consist of Messe Frankfurt and the Food GmbH decided to broaden their As a result of the research activi - chemical technical additives defi - Processing Suppliers Association product portfolio with starter and ties carried out, the protection cul - nitely make the difference between (FPSA), USA, have entered a strategic protection cultures which are pro - tures of the BioPrime Safe range the usable and the excellent food marketing alliance. Both organisa - duced in their in-house class 10 were developed. They ensure grade lubricants. Roughly speaking tions hold leading trade fairs. cleanroom. All used culture strains demonstrably better product safety natural wear is nonsense, as, with With IFFA, Messe Frankfurt has are subject to strict quality controls and make an important contribution the correct additives, you can target been organising the leading interna - in their in-house laboratory. Every to listeria management in products any issue of wear and tear. tional trade fair for the meat indus - batch is analysed for its effective - such as Zwiebelmettwurst. SFK LeBlanc develop and manufac - try in Frankfurt am Main for 45 ness. New strains and strain varia - meatcracks.de ture high-tech equipment and focus years. FPSA launched Process Expo: tions are subject to further practical on maintenance and lubrication sys - the Global Food Equipment and tests in the Meat Cracks technology tems. They have collaborated with Technology Show in Chicago in 2011. centre to determine effectiveness, the best of the best to be able to Both organisations want to co- fermentation activity and the offer a complete range of lubricants operate more closely in the future, effects on the character of the fin - that match the investment in a to lever the potential of the ished product. Meat Cracks takes slaughter project or stand-alone expanding international market of into account that continuous and machine. the food industry and to generate repeatable raw sausage quality can The company address mainte - synergistic effects. only be achieved by high quality nance and lubricants issues at the messefrankfurt.com cultures and maturing compounds.

International Meat Topics • Volume 7 Number 3 29 Diary

Powerful vacuum filler 2016

Vemag Maschinenbau with 12kg of sliced salami product GmbH has introduced on a unit with individual sections. Avi Africa the world's most Rates as high as eight tonnes an 21-23rd June powerful vacuum filler. With a hour are possible for sliced prod - Johannesburg, South Africa power input of 65kW, the XP2 offers ucts when working with a double- www.sapoultry.co.za double the performance of the pre - clipping machine and mincer with vious global market leader, the portions of 12kg and a calibre of 110. HP30E from Vemag. vemag.de The XP2 is primarily designed for Indo Livestock grinding applications in the produc - 27-29th July tion of minced meat, as well as in Jakarta, Indonesia salami production. www.indolivestock.com Guaranteeing safety Delivering some 170 1kg portions and quality in raw of minced meat per minute and 60 and processed meat 2.5kg portions per minute, the XP2 is is essential for manufacturers. To the new benchmark for grinding IAFP USA do so, different parameters are applications. The system processes 31st July-3rd August analysed, such as sugars, sulphites, 12 tonnes of raw pork meat an hour St. Louis, Minnesota, USA nitrites, nitrates, allergens, and on a 2mm hole plate, the equivalent www.foodprotection.org/ veterinary residues or speciation, to a grinding performance of annualmeeting among others. Mycotoxins in 200kg/minute. feed are also a key parameter to Using the mincer, the system por - control, in order to assure trace - tions at a rate of six tonnes an hour ability in the whole food chain at a calibre of 110 when working International Congress of (from farm to fork). Enzymatic Meat Science and and immunoassay methods are a sensitive, reliable and cost effec - cold storage and marine refrigera - over the previous event in 2013 Technology tive way to identify substances in tion. The new lubricant has been (60,509 visitors from 144 countries), 14-19th August food processes. BioSystems pro - formulated using polyol esters (POE) whereby special mention must be Bangkok, Thailand vides a complete system with a to enhance lubricity, wear protec - made of the increased degree of www.icomst2016.org wide range of reagents and dif - tion and chemical and thermal sta - internationality, which rose to a new ferent automatic analysers to bility. It supplements ExxonMobil’s record level of around 66%. identify these substances in the existing range of synthetic lubri - Particularly well represented on best possible way. cants for refrigeration compressors the visitor side were the Russian International Indonesia biosystems.es and systems, the Mobil Gargoyle Federation, Spain, Poland and Italy. Seafood + Meat Expo 2016 Arctic SHC 200 Series and Mobil IFFA 2016 also set a new record on 28-30th September EAL Arctic Series. the exhibitor side with a total of Jakarta, Indonesia The three key three qualities of 1,027 companies taking part (2013: www.iism-expo.com New synthetic Mobil SHC Gargoyle 80 POE are 966). The exhibitors, who came from oil developed excellent low-temperature fluidity, 51 different countries, presented in-service viscosity control and innovations for the entire meat pro - ExxonMobil has developed a syn - potential contribution toward sys - cessing chain. SIAL thetic oil for carbon dioxide-cooled tem efficiency improvements, com - On 110,000m 2 of exhibition space 16-20th October industrial refrigeration applications. pared to mineral oils. (gross), as in 2013, they presented Paris, France Mobil SHC Gargoyle 80 POE has The development of Mobil SHC new products and technologies for www.sialparis.com been designed specifically for the Gargoyle 80 POE was driven by the slaughtering, dismembering, pro - lubrication of compressors and is projected rapid growth of carbon cessing, packaging and sales. particularly suitable for reciprocat - dioxide as an industrial refrigerant iffa.com ing compressors using carbon diox - over the next four years. Vietstock ide as a refrigerant, which are found ExxonMobil predicts that carbon 19-21st October in applications ranging from food dioxide will be one of the main preparation, freezing operations, industrial refrigerants by 2020 and Traceability of Ho Chi Minh City, Vietnam will also feature regularly in light meat products www.vietstock.org commercial refrigeration operations. mobilindustrial.com Espera’s latest software technology for traceability of meat products makes the declaration of the coun - MeatEx try of origin of meat products easier 5-8th November IFFA 2016 sets than ever before. Tehran, Iran new records Their unique software solution www.iranmeatex.com transfers the required information Over 63,000 trade visitors from 143 fast and easily on to a label. Mixing countries recently attended IFFA, up of information is avoided and the world’s leading trade fair for the unnecessary programming and data Gulfood Manufacturing meat sector in Frankfurt am Main. management efforts are reduced. 7-9th November This was an increase of around 5% espera.com Dubai, UAE www.gulfoodmanufacturing.com 30 International Meat Topics • Volume 7 Number 3