APPLICATIONS FOOD PROCESSING & PACKAGING INTUITIVE WEIGHING
An Ishida multihead weigher is helping Irish vegetable grower Leo Dunne expand its operation into the supply of processed carrots. After winning a major contract with one of Ireland’s largest multiples, the company needed to develop a carrot processing facility in less than two months. The Ishida CCW-RS Series 10-head
waterproof model with 3l hoppers is delivering accuracy and reliability for Leo Dunne, achieving around 55 packs per minute on 500g bags of carrots with an overall accuracy rate of 98%. Equally important, the machine’s
ease of operation, including fast start- up using the simple-to-use remote control unit (RCU), gives it the flexibility to cope with varying production demands. In addition to reliability and accuracy,
the multi-head weigher was specified for its flexibility, Ishida’s established reputation in the marketplace and the after-sales service on offer.
Ishida
www.ishidaeurope.com Enter 224
35th Anniversary AD PLANT EXCHANGES WASTE FOR EFFICIENCY
The £5.4m on-site anaerobic digestion (AD) plant at malted ingredients company Muntons,
will help reduce the firm’s CO2 emissions from 27,264 to 26,605 tonnes pa. Integral to the success of the 499kW facility is a 3 Tank Batch Sludge Pasteuriser System with Energy Recovery from HRS Heat Exchangers, which will help convert up-to 80,000 tonnes of Muntons’ liquid malt waste into quality organic fertiliser (known as digestate). This will be used on local farmland, helping the company’s network of growers to produce some of the 250,000 tonnes of barley needed to make Muntons’ malt, around 180,000 tonnes pa. With sustainability at its core,
Munton’s realised that using its liquid malt waste as feedstock for an on-site AD plant would not only produce a high quality digestate for its farmers to use instead of artificial fertiliser, it would also cut 3,000 tanker movements per year and generate 25% of the site’s electricity demand.
To satisfy growers’ need for a
high quality fertiliser, the digestate will be pasteurised to meet stringent PAS 110 standards
using the 3 Tank Batch system. The HRS system can save up to 70% of heat required, as well as run at a half flow rate, should the volume of digestate stock reduce. Its monitoring feature enables Muntons to track every batch of digestate back to the feedstock from which it was produced. “The fact that the HRS system offers batch reporting was also a big draw; traceability is very important to us,” said Lawrence Howes, project engineer at Muntons. Matt Hale, International sales
manager at HRS, said: “For Muntons, this whole project has been about maximising efficiency. Although they have an abundance of heat, they still wanted to recapture what they could - our heat exchangers will provide at least 40% heat regeneration.” The HRS system works on a three tank principle; while one tank is being filled, the second tank holds the sludge at 70°C at the same time as the third tank is being emptied (each process lasts one hour). Waste cooling water
STREAMLINED INSPECTION SLIMS DOWN RISKS
Product trust is important for any food manufacturer and Northants- based Cambridge Weight Plan is slimming down risk of contamination in its weight management snacks following the installation of three metal detectors from Fortress Technology. The company produces branded shakes, bars, soups and porridge. Over the years, Cambridge
Weight Plan has safeguarded its products using metal detectors from various manufacturers, but three years ago took the logical step of streamlining its inspection suppliers. “We decided to start buying all
our metal detection kit from one company – Fortress Technology
came highly recommended. This would make it easier for our operators, who wouldn’t have to learn how to use five different systems, and would make more sense for servicing and maintenance. For us, it is imperative that we are confident that the food we are sending out to consumers is safe for consumption,” said Colin Webb, engineering manager at Cambridge Weight Plan.
To kick-start the rationalisation programme, in 2012 Cambridge Weight Plan replaced an old head on one of its recipe blending lines with a Fortress Stealth detector. The Stealth inspection system features FM software which helps achieve better sensitivities, in some applications by at least 40%, satisfying FSMA or customer specification requirements. This increased sensitivity is
especially beneficial for bulk loose product, such as milk powder, a mainstream ingredient in the company’s shakes. The powder blend is
26 JUNE 2015 | PROCESS & CONTROL
sieved and transported via a 45˚ flighted conveyor belt where it is scanned for any metallic contamination before flowing into a bulk container. Reasons for the switch to Fortress also included features like automatic calibration - enabling detector set-up within seconds. Fortress’ ‘never obsolete’ commitment protects customer’s investments by offering performance upgrades to existing Fortress detectors, without having to purchase an entirely new machine. Plus access to a UK based courtesy product testing service gives assurance and validation that the equipment will deliver the sensitivity levels required as product ranges grow. Webb added: “We hold a high degree of confidence in the Fortress equipment, service and company ethos. They have successfully responded to all of our requests and a strong relationship has resulted.”
Fortress Technology Enter 226
www.fortresstechnology.co.uk
from the CHP engine is used to heat the sludge in corrugated tube-in-tube heat exchangers, which is more efficient than heating an entire tank of digestate. HRS has also incorporated an energy recovery section into the process, which reduces energy consumption by up to 70% compared to normal systems and uses heat which would otherwise be wasted. Howes said: “Not only does the
tube-in-tube technique deliver improved performance, they’re also more resistant to fouling, which means less downtime and maintenance. In addition, we had a short deadline – just 16 weeks – which HRS was able to meet easily.”
HRS Heat Exchangers Enter 225 T: 01923 232335
www.hrs-heatexchangers.com
EXPANDED BREWING
FMA Process Engineering has just begun the process of converting a former warehouse at Cork docks into a state-of-the-art craft brewery for Franciscan Well’s lagers, ales, stouts and wheat beer. The project is part of a £2million investment by Molson Coors, and will increase production from 7HL daily to 50HL brews – at up to 6 brews per day – six days per week. Demand for Franciscan Well’s beers has grown over recent years, and with the Cork brewpub already operating at capacity, any increase in production meant finding a suitable new location. FMA’s scope of works includes the
detailed design and installation of all mechanical, electrical, instrumentation and automation aspects of the new microbrewery; the sourcing, delivery and installation of all process equipment; start-up, commissioning and staff training. The design is centred upon a three-vessel brewhouse system, a beer cellar with 10-off, 100HL unitanks and an automated keg washer/filler plant for the filling of circa 90 30l kegs per hour.
FMA Process Engineering
www.fma.uk.com
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