Why IMA is the right choice for bakery manufacturing companies who have their eyes on the future

E.S.

15 September 2023

IMA Ilapak bread line Vision 3000 and Vegatronic 2600 vision and vertical bagging.

Ramping up to IBA 2023, the world’s most important event in the bakery sector, IMA FLX presents the solutions to be showcased in October at the Münich venue – Stand B1.310.

Already a familiar name supplying turnkey processing and packaging solutions to several industries,IMAfocuses on the food sector through one of its best-established clusters known asIMA Flexible Packaging hub, whose expertise in flexible packaging solutions covers the current and future needs of the bakery sector.

Focus on the future of the bakery sector

However, being a well-known player is far from the objective IMA has set itself in order to keep pace with a market that evolves rapidly from one year to the next. In fact,IMA FLXis investing substantial resources into cutting-edge technologies and new machines that will attract the forward-looking manufacturers, those who intend being the key players in this industry over the next decade and more.

Today, IMA FLX is made up of different brands whose integrated experience and variety of solutions have given rise to the most comprehensive flexible packaging hub serving the bakery sector. Driven by IMA Group’s company culture that pioneers sustainability in every aspect of business or technology, IMA FLX represents a one-stop supplier that is best-placed to support bakery manufacturers looking to deal with tomorrow’s trends as leaders in their own market. IMA FLX is developing numerous technical solutions to handle a wide range of eco-friendly materials that pose different processing challenges, but are likely to become the preferred packaging films in the near future.

At a glance, IMA FLX is a kaleidoscope of specialist companies

IMA FLX’s team of specialists take great pride in their many years of hands-on experience in the bakery industry. This field-tested know-how is expertly applied to the wide range of reliable, flexible and innovative packaging machinery and complete automatic lines designed and manufactured with bakery industry requirements in mind. IMA manages your product from the oven/freezer exit to handling, feeding, dosing, primary, secondary and end-of-line packaging.

From fresh cakes, bread and pizza to biscuits, frozen dough and prebaked products, each application has its own unique packaging requirements and theIMA FLXhub companies–IMA Ilapak, IMA Record, IMA Delta Systems and IMA Eurosicma– offer the best solution for each of these applications, customised when needed. With such an array of competences, the bakery sector can rely on this cluster of expert brands to deliver a turnkey solution which will enhance performance and bring the customer a competitive edge.

Completing the process with the latest end-of-line solutions

No line would be turnkey in the true sense of the word without the necessary technologies to complete the packaging process. TheIMA End-of-Linehubrepresents a strategic asset for all the divisions within the IMA Group and a unique solution provider of secondary packaging technologies for a broad spectrum of industries, including those in the bakery sector.

Each company within the hub brings a specific expertise.IMA BFB is a leading brand in end-of-line technologies ranging from robotic handling to overwrapping, case packing and palletizing. IMA Ciemme is an expert manufacturer of carton packaging machinery, closing, forming and automatic loading technologies. IMA Mespic specialises in tailor-made machines, from conveyors to wrapping, from case packers to palletizers and offers complete turnkey end-of-line systems. IMA Phoenix is a leading manufacturer of print&apply and modular labellers for self-adhesive labels, delivering labelling solutions to distributors, system integrators and OEMs.

Focusing on thebakery industry,无论产品——面包、蛋糕、甜甜圈,muffins in pillow bags, doypacks and block bottom bags – the end-of-line equipment preserves the contents and container while providing packaging solutions of all types. These includedisplay packagingsuch as display boxes, wraparound cases, trays with internal or external lids, orsolutions for transport: RSC cases, wraparound cases, palletizers.

A closer look at the machines and technologies on show at IBA.

IBA 2023 will be running from October 22-26 in Münich and IMA will be showcasing a number of solutions on Stand B1.310. Visitors will be able to examine the technologies close up and illustrate any specific requirements with IMA FLX staff. The IMA FLX team is always available to discuss a customer’s goals and adapt each solution technically to achieve or exceed those specific targets. All aspects are considered: from increasing output to reducing operating costs, handling innovative packaging materials or minimising human intervention, even ultrasonic sealing and M.A.P. systems as required.

COMPLETE BAGGING LINE FOR BREAD ROLLS WITH VISION SYSTEM AND VERTICAL FORM-FILL-SEAL EQUIPMENT.

Vision 3000is a vision system using laser technology and will be running in line with an intermittent vertical form-fill-seal machine, theVegatronic 2600．贝克在一起,作为一个完全集成的解决方案eries, these machines will be displayed as a complete bagging line for bread rolls.

By means of a combination of laser and line scan cameras, Vision 3000 guarantees accurate checking and counting operations to verify product height, length, width and surface. Feeding products at high speed, Vision 3000 is so flexible it will handle fresh, par-baked, frozen and raw dough products, whether baguettes, pretzels, rolls, bagels, donuts or croissants.

Based around a 2.5D laser and line scan camera combination, which generates real-time, overlaid images of the product flow, the software calculates when the target number per pack has been reached. Currently the fastest available camera technology on the market, Vision 3000 also provides quality control capabilities, screening for deformed or damaged products, such as bent or broken baguettes. Furthermore, the system can be integrated with a metal detector, sharing a reject system with the quality control module. IMA Ilapak makes sure that whatever needs to go from freezer to box or bag is exactly what the customer wants.

Vision 3000 will be seen feeding theVegatronic 2600with a film buffer, an exclusive feature to avoid downtime. According to product and gentle handling requirements, Vegatronic 2600 can operate with 30, 45 or 60-degree inclination. Bag width is up to 580mm with a maximum film width of 1200 mm. Small or large bags can be used to pack fresh or frozen rolls, croissants, bagels, muffins and more. Flexibility is enhanced thanks to solutions increasing line efficiency and features designed to facilitate changeover procedures and minimise downtime, such as thefilm buffering function allowing the film roll to be changed without stopping the machine．

Completing the benefits of Vegatronic 2600, the open-frame design offers easy access for fast servicing and maintenance, and boasting the highest seal pressure on the market, gas tight seals are fully guaranteed.

IMA Ilapak DELTA 3000 flow wrapping HFFS MAP.

FLOW WRAPPING SOLUTIONS AND LONG-DWELL SEALING USING NEW SUSTAINABLE MATERIALS.

On show at IBA 2023,Delta 3000is one of the market’s best-known flow wrapping machines offeringM.A.P,hermetic sealingandhygienic design．

A key feature available on Delta 3000 will be demonstrated at IBA and regardslong-dwell sealingtechnology toensure hermetic seals for products processed in a modified atmosphere．In view of a growing trend towardssustainable packaging materials, typically hard to handle, containing high proportions ofpaperorrecyclable mono-material, plastic based on PE or PP, at the show, the Delta 3000 will demonstrate its long-dwell sealing capabilities which cover severalnew materialsand enable companies to be well prepared for thefuture．

TheDelta 3000, whencoupled with the VACMAP™system,ensures the same shelf-life standards as thermoforming solutions, but with considerablylower costs．Film is less expensive and minimal operator intervention keepslabour costs to a minimum, even when changeover is performed.

Furthermore, less material is used by a flow wrapping platform than a thermoforming solution, thus placing less wrapping film/material on the market and consequently in the environment.

Higher throughput and exceptional flexibility are hallmarks of the Delta 3000 combined with VACMAP™as it easily handles multiple sizes compared to thermoforming technology. By switching off the vacuum function and reverting to a normal gas flushing system, wrapping speed can be further increased. And to make the fresh bakery products appealing to customers, unlike thermoformed packaging solutions, the entire package can be printed to enhance the perceived quality.

IMA flow wrappers, integrated with the VACMAP™system, represent a valid and cost-effective alternative to thermoforming solutions, combining vacuum and modified atmosphere packaging (M.A.P.) in a single solution.

Moreover, longitudinal sealing of packages using ultrasonic sealing technology is available on most IMA flow wrappers. This system enables you to work with different film structures, maintenance is minimal, and no hardware adjustments are required. Product contamination does not pose a threat to sealing capability, which is fully air-tight, and the limited sealing size saves significant quantities of film and related costs.

IMA记录熊猫BS RS FLOWPOCKET弗洛w wrapping for buns.

HORIZONTAL FORM-FILL-SEAL MACHINE COMBINED WITH AN AUTOMATIC LOADING SYSTEM PROCESSING BUNS.

Synchronising the stages of a production line improves efficiency and this is one of the key benefits seen when usingFLOWPOCKETby IMA Record to automatically load buns onto the BS RS (Bottom Seal / Rotating Seal) version of the PANDA flow wrapping machine.

Perfect for a broad range of regular, small and medium-sized products,PANDA BS RSreaches an output of up to 300 ppm. At IBA 2023, the line will be equipped to seal mono-material plastic PE film as well as compostable barrier material. Sealing packets of buns with a rotating jaw, PANDA is fed using the extremely flexible FLOWPOCKET. Featuring 3 pocket trains, FLOWPOCKET channels the buns into independent pockets, so that the process can be synched more precisely along the line. In the exhibited solution, groups of 2 buns are assembled, one pair above the other. A perfect alternative to pick&place systems, FLOWPOCKET is easy to set up, quick to implement changeover and synchronised to perfection.

Insight into future trends and technologies at IBA 2023. Satisfying the need for tangible answers.

Sustainabilityis a common topic across a broad variety of industries, even more so when it comes to the food packaging sector. In an effort to support companies needing to achieve ambitious targets and lay claim to a sustainable approach, IMA has dedicated significant resources to researching innovative packaging solutions.

Originally established in 2016 at the IMA Ilapak facility,IMA OPENLabis now a network of laboratories and testing areas with different locations within the IMA Group:new materials are first investigated in a high-tech laboratory and then tested on fully working packaging lines. Extensive trials are enabling IMA to help industry players and prepare tangible solutions to meet current and future needs in terms of sustainable packaging materials, continually influenced by an evolving legislative scenario.

Focusing on flexibility as a rewarding strategy, IMA has been able to adapt its packaging solutions and give its customers a competitive advantage．Long-dwell sealing solutions是目前最有趣的未来the sector, even if not all of today’s regulations insist on sustainable packaging materials. Such sealing technologies will undoubtedly be essential within a few years, making the investment a sensible option today.

As the need to eliminate preservatives in advanced markets increases, replacing standard technologies with M.A.P. systems, IMA FLX is well placed to offer a variety of alternative packaging solutions, from simple and essential machines to sophisticated, customised lines.

Be sure to visit IMA at IBA 2023. Stand B1.310 in Münich, Germany, from October 22 – 26, 2023.

Plant cleaning and sanitation

E.S.

28 August 2023

To prevent the spread and development of altering or pathogenic micro-organisms. The food industry is required to comply with high hygiene standards. One of the most feared events is biofilm formation. Research is focussed on the development of technologies to prevent it or mitigate its consequences.

A clean working environment is critical to preventing prevent food-borne diseases. Processing residues contain the nutrients that microorganisms use to grow. The most classic among the sanitization procedures involves a first step with alkaline product to attack organic compounds such as fat and protein residues, a second step with acid to remove inorganic residues, and, finally, the use of a sanitizer. By doing so, and respecting time and temperatures, good results are obtained in terms of cleaning, descaling, sanitization and prevention of biofilm formation, a layer of organic matter, i.e. organic polymer agglomerates (proteins, polysaccharides, glycoproteins and nucleic acids) and micro-organisms adhering to surfaces that come into contact with food.

When the biofilm is in its initial state (a few microns thick), it is easily removed with a sanitizer. Far more difficult is its treatment when it is well rooted and of considerable thickness. In this case, the thickness hinders the diffusion of the sanitizer, which loses its effectiveness because its active substance is neutralized by the organic matrix surrounding the micro-organisms. Cleaning and sanitization make hygienically safe the environments and processing plants, hence also the food produced there.

There are many variables to consider when setting up these tasks. In the food industry, plants are large and complex, and production is usually long and significant in quantity; many of the raw materials used have not undergone previous processing and may therefore have high microbial loads or be contaminated by micro-organisms that are potentially pathogenic to the consumer. The parts of the plant that need to be monitored with particular attention are those that are most difficult to reach in the usual cleaning and sanitization procedures.

The formation of biofilm

Biofilm is formed in several stages. Some microbial cells, found in free form in raw materials, adhere with weak bonds to the surface of the processing plant. Most come off and are dragged away from the product flow, the rest sticks to the surface with weak bonds. Above this first layer, new microbial cells are deposited, in addition to other organic substances derived partly from the foodstuff and partly from the cells that split themselves and integrate with the new micro-organisms, also from other species. This forms a small ecosystem protected by a matrix of polymeric compounds (polysaccharides, exogenous proteins or DNA). Its structure facilitates communication between cells, in particular the diffusion of nutrients and signal molecules, and conveys waste substances and any microbial exotoxins to the outside.

The Plant Configuration

The possibility of biofilm formation and the effectiveness of sanitization depend on a number of factors, such as plant layout and material, more or less rough food-contact surfaces, and the absence of dead spots. Stainless steel is the most widely used material in food processing industry because it is chemically inert, easy to clean, corrosion resistant at different processing temperatures. However, it is subject to wear, especially when the processed product contains hard or abrasive particles that flow or are forced along the pipe walls. Wear leads to the formation of surface irregularities that facilitate the adhesion of biofilm.

The nature of the processed food may promote or hinder its formation, and residues of foods rich in fat, proteins and carbohydrates, facilitate microbial development. Equally important are the morphological characteristics of microbial cells, the components of their cell membranes, their appendages (pili, flagella, fimbriae), the biopolymers produced by bacterial secretion. In addition, different biofilm-forming abilities between species of strains of different genotypes and serotypes have been identified.

Lipases and proteases released by micro-organisms in the biofilm may promote the alteration of the organoleptic characteristics of the products. Biofilm can be an indirect source of food-borne diseases when its constituent micro-organisms produce toxins that pass easily into the food. This complexity makes sanitization difficult, and facilitates the development of microbial resistance to sanitizers, rarely attributable to genetic mutations of micro-organisms, but due to multicellular strategies and/or the ability of individual cells – residing in the biofilm – to differentiate into a phenotypic state tolerant to the action of disinfectants. Other mechanisms responsible for resistance may be the delayed penetration of the antimicrobial agent into the biofilm matrix, a slower growth rate of the constituent micro-organisms, or physiological changes of those micro-organisms in response to environmental conditions.

Sanitization

Sanitizing principles are divided into two broad categories: Highly rinseable products (e.g. hydrogen peroxide) and products with residual effect (e.g. quaternary ammonium salts). Non-foaming, completely rinseable detergents and disinfectants are to be preferred, suitable for water with different hardness, effective at low concentration. The food industry tends to use specially formulated products. According to the environments and equipment to be treated, classical sanitization involves the use of hypochlorites, quaternary ammonium compounds, amphoteric compounds, peroxides (peracetic acid and hydrogen peroxide), aldehydes (formaldehyde, glutaraldehyde, paraformaldehyde), alkyl amines, chlorine dioxide, alcohols, phenolic compounds.

The lack of product rotation facilitates the development of bacterial resistances. Sodium hypochlorite (NaOCI) is still used. Its efficacy derives from the production of hypochlorous acid (HOCl) and hypochlorite ion (Ocl), strong oxidising agents that kill cells by crossing the cell membrane and oxidising the cell membrane and oxidizing the sulfhydryl groups of certain enzymes. Under physiological pH conditions, the sanitizer reacts with proteins, amino acids, lipids, peptides and DNA. On the other hand, its effectiveness is mitigated by the presence of organic matter that compose food residues. Free chlorine reacts with these molecules, transforms into inorganic chloramines that generate trihalomethanes. Chlorine dioxide in aqueous solution is sometimes more effective than sodium hypochlorite, especially when the plant is dried immediately after sanitization.

Hydrogen peroxide is oxidizing. In contact with biofilm it generates free radicals that destroy it without toxic side effects. Peracetic acid is a powerful oxidizer and is often used against biofilms, because it does not interact with organic matter residues and acts at low temperatures. Quaternary ammonium salts (benzalkonium chloride, cetrimide, didecyldimethylammonium chloride, cetylpyridinium chloride) are cationic surfactants. They reduce the surface tension between biofilm and metal and form micellae that disperse in a liquid. They interact with the cytoplasmic membrane of bacteria and yeasts and are also effective against viruses containing lipids. Ozone is a toxic gas with a powerful oxidizing activity; it destroys different types of microorganisms, biofilms, viruses and protozoa, by intervening on cell membranes.

Enzymes

Enzymes are chosen because of their low environmental impact; in fact, they are biodegradable and not toxic. As mentioned above, the biofilm matrix consists of organic macromolecules (mainly proteins and polysaccharides), which can be attacked by protease (e.g. serine protease, proteinase K, pepsin, and trypsin) and glycosidase (e.g. amylase, dextranase, and pectinase), which facilitate the removal of the biofilm. Pectin methylesterase is an enzyme used for preventive purposes as pretreatment in bioreactors, pipes and other plant parts. Cellulase, lyase, glycosidase (such as dispersin B) and DNase are often components of industrial detergents and can be used both as routine detergents and for more drastic biofilm removal.

Alpha-amylase is effective in the degradation of biofilms containingS.aureus,whereas proteases are less specific and are therefore useful in the treatment of organic-based biofilms. When the matrix is partially degraded, the biofilm is removed mechanically and its micro-organisms become more sensitive to the action of disinfectants. Subtilisins counteract biofilm formation fromP.Aeruginosa orL. monocytogenes.The widespread implementation of these enzymatic alternatives is slowed down by the high treatment costs, mainly due to patent protections.

Pre-treatments of steel surfaces
Among the alternative approaches, nanotechnologies are the most promising. Nanomaterials have two possible functions in sanitization: They are bactericides or they improve the efficiency of other sanitization treatments. Many nanoparticles are effective by direct contact with microbial cell walls. Their action is therefore not reduced by the protection mechanisms described above, and specific microbial resistances are unlikely to be established. Among the most studied nanoparticles there are carbon-based nanoparticles (fullerenes and carbon nanotubes).

They act as dendrimeres with cavities hosting other organic nanocompounds or metals (silver, gold, copper oxides, zinc iron). They are used to reduce bacterial adhesiveness by intervening in factors that promote it, such as tendency to repel water, presence of electric charges, functional groups. Antibacterial surfaces are usually composed of inert materials where the repelling property is provided by hydrogel coatings, coatings with intrinsically antibacterial materials and antibiofilms. Thus, functionalized surfaces are obtained, for example by using lysozyme-functionalized polymers.

Biosurfactants are natural compounds, usually of microbial origin, that modify the hydrophobic characteristics of the bacterial surface. One of the most studied molecules is lichenisin, a cyclic nonribosomal lipopeptide produced byB. licheniformis.Fengycin, iturin and surfactin are lipopeptides similar to lichenisine but are produced byB.amyloliquefaciens andB.subtilisin the case of surfactin. These compounds act on the surface of the corresponding target micro-organism, altering its binding capacity surface. These molecules insert themselves into microbial cell membranes, altering their permeability, disrupting it and causing cell death.

New tools for the identification of adulteration phenomena and the traceability of tomato derivatives

E.S.

28 August 2023

Use of the electronic nose to detect adulteration in tomato concentrate.

Food adulteration is a phenomenon that can have several consequences for the health of consumers. In this context, a recent study, carried out by a team of Iranian researchers (Sadriyan et al.,2022), aimed to evaluate the performance of an electronic nose, equipped with 10 gas sensors, for assessing the adulteration in samples of tomato concentrates at different levels (0, 0.05 and 0.1 %) of sodium benzoate and potassium sorbate.

The effect of these preservatives on some physical-chemical properties of tomato paste, such as pH, total soluble solid (TSS), precipitate weight ratio, and acidity, was also investigated. The results indicate that both preservatives significantly affect the physical-chemical properties of the concentrate. The data collected with the electronic nose were processed with statistical tools.

This showed that both the LDA (linear discriminant analysis) and SVM (support vector machine) methods can accurately classify samples according to the concentration of sodium benzoate and potassium sorbate. In particular, the LDA method offers a 100% accuracy. Finally, it was possible to identify the 3 most sensitive gas sensors in the system, which is critical information for its optimization. In summary, the results of this study show that the developed tool is not only reliable in detecting adulteration in tomato derivatives, but also rapid and non-destructive for this purpose.

Use of gas chromatography in combination with asymmetric flow field-flow fractionation for the traceability of tomato sauce.

Despite defined standards regulating the production of tomato derivatives, the market suffers from fraud such as product adulteration, origin mislabelling and counterfeiting. In this context, the aim of a recent study, carried out by a group of Italian researchers (Zappi et al.,2022), was to develop a faster, cheaper, andgreeneranalytical procedure for the analysis of these phenomena in tomato sauce.

In particular, the procedure involves the analysis of volatile organic compounds (VOCs) by means of gas chromatography couples to flame ionisation (GC-FID) and to ion mobility spectrometry (GC-IMS). In addition, the colloidal fraction was analysed by asymmetric flow field-fractionation (AF4). According to the results, the GC and AF4 data showed promising for the characterization and classification of the product, and offered complementary information.

In particular, the AF4 method has been shown to detect small changes in the food matrix, providing meaningful information on critical product parameters such as its shelf-life. Finally, the authors point out that the proposed method is suitable for analysis in saline conditions, with easy pre-treatment (or no pre-treatment) and no chemical waste: a huge environmental advantage with respect to other traditional methods.

References:Sadriyan et al．, Research Square, 2022;Zappi et al．, Molecules, 27, 2022, 1-19.

Influence of micro-aeration on the thermal properties of chocolate and identification of a new quality indicator

E.S.

28 August 2023

Numerical modeling on the effect of micro-aeration on the thermal properties of chocolate.

The thermal properties, such as thermal conductivity, specific heat capacity and latent heat, strongly influence the melting and solidification of chocolate. Accurate prediction of these properties in micro-aerated products, with varying levels of porosity, is beneficial for understanding and control of heat transfer mechanisms during their manufacturing and oral processing. The former process is important for the final quality of chocolate, and the latter is associated with sensorial attributes.

This study, carried out by a group of British researchers (Bikos et al., 2022), focused on the development of a novel multiscale finite element model (FEM) to accurately predict the temporal and spatial evolution of temperature across chocolate samples with a porosity ranging from 0% to 15%. The model is evaluated via heat transfer experiments at temperatures varying from 16°C to 45°C.

结果表明,传热率within the micro-aerated chocolate decreases significantly as the porosity of the product increases. More specifically, the thermal conductivity decreases by 20%, while the specific heat capacity increases by 10% for 15% micro-aerated chocolate, suggesting that micro-pores act as thermal barriers to heat flow. In conclusion, the authors argue that the latter result is rather unexpected and must be considered for the development of micro-aerated chocolate products with specific structural and sensory characteristics.

Use of 2.5-diketopiperazines in chocolates as a marker of the variety and quality of cocoa beans.

2.5-diketopiperazines are cyclic dipeptides found in a wide variety of food products. The aim of a recent study, carried out by a group of Swiss researchers (André et al.,2022), was to evaluate the use of these compounds in chocolate as a marker of the variety and post-harvest treatments of cocoa beans. For this purpose, a set of 33 dark chocolates from different cocoa varieties were processed by liquid chromatography and tandem mass spectrometry (HPLC-MS/MS); the spectral data were then analyzed using a computational strategy known asmolecular networking．

With this approach 18 different diketopiperazine were identified and quantified (some of which were identified and quantified for the first time). The molecular network allowed the clear visualization of differences between samples. The developed method is a valuable tool to visualize the chemical diversity between craft and industrial chocolates: in fact, the presence of two particular diastereoisomers in classic chocolates indicates that the industrial processing of beans was conducted under higher roasting conditions. In conclusion, the authors argue that further insights are needed to improve the performance of this tool, for example, by analysing cocoa beans all along the transformation process of beans to chocolate bar.

References:Bikos et al.,Food & Function, 13, 2022, 4993-5010;André et al.,Heliyon, 8, 2022, e10770.

Development of innovative cooking processes and new formulations for the production of pizza

E.S.

28 August 2023

New technology for the production of yeast-free pizza.

披萨是一个面包店产品主要包括窟er, flour, salt and yeast. The latter is a bio-chemical blowing agent that releases carbon dioxide as a product of a fermentation reaction during the proofing step. The leavening is a rather slow process that may take up to several hours, depending on yeast concentration and external conditions of temperature and relative humidity.

In this context, the aim of a recent study, carried out by a group of Italian researchers (Avallone et al.,2022), was to develop an innovative technology to produce yeast-free pizza, making use of a gaseous blowing agent (carbon dioxide or helium) and a pressurized oven. The evolution of the viscoelastic moduli of the dough at cooking temperatures has made it possible to define the time window for agent absorption under pressure and the depressurization stage to allow bubbles formation and growth.

It has also been observed that 6 bar and 145°C were required to bake and foam the product in 4 minutes. The authors point out that the proposed technology makes it possible to obtain a well-foamed pizza with densities and morphologies similar to the ones of a traditional dough with yeast. Finally, the process parameters (i.e. temperature, maximum pressure, time at constant pressure, pressurization and depressurization speeds) can be easily varied to modulate the latter characteristics, depending on the quality required for the final product.

Quality evaluation of gluten-free pizza made from legume flour.

Celiac disease is one of the autoimmune genetic disorders triggered by the ingestion of gluten that affects mucosal damage of the small intestine. The only treatment for CD is lifelong strict adherence to a gluten-free (GF) diet. Therefore, a recent study, carried out by a team of Indian researchers (Kumar et a., 2022), focused on the formulation and processing of gluten-free variants of pizza base using different legume flours (chickpeas [BNG], black Indian beans [BLG], soya bean [SB] and fenugreek seeds [FS]).

In particular, a variant was prepared by blending these grains (BNG, BLG, SB and FS) at 33:33:33:1 ratio. The results show that the samples thus prepared have lower water-absorbency, viscosity, development time and dough stability than the control values (based on wheat flour). It was also noted that the latter have lower hardness and gumminess compared to gluten-free dough.

The introduction into the formulation of a blend of additional components (CA: Guar gum+glycerol monostearate+stearoyl sodium lactylate+fungal alpha-amylase) significantly improves the rheological, structural, physical and sensory properties of the gluten-free pizza base. In conclusion, the authors point out that the resulting product not only has a lower digestibility of starchin vitro, but also has a significantly higher protein and dietary fiber content compared to the values measured in the conventional wheat flour product.

References

P.R. Avallone et al.,Physics of Fluids, 34, 2022, 033109;Kumar et al.,《食品加工和保藏,46岁,2022, e16239.

Starch-based films incorporated with anthocyanin as cholorimetric pH-sensors

E.S.

25 August 2023

Natural polymers such as polysaccharides, are the preferred choice for plastic replacement due to their abundance, non-toxicity, biodegradability, high stability, compatibility, and easy control of physico-chemical properties through blending with other biopolymers.

Starch is already used for food packaging purposes as starch is more compatible with some biopolymers, natural antioxidants and nanofillers, facilitating the development of a wide range of active edible films for various food packaging applications. There are many sources of starch available: corn, potato, cassava and wheat.

Sago starch

In addition to these, there is also sago starch produced from the sago palm, native to South-East Asia; there are still relatively few publications on this starch. Sago starch has distinctive qualities all its own, including high viscosity and ease of moulding; it is also simple to gelatinise. Due to its low cost and wide availability, sago starch has become a valuable source for foodstuff and industrial raw materials.N. H. C. Hamzah et al., of the University of Putra Malaysia (Malaysia), have developed new sago starch films incorporating red cabbage (Brassica oleracea), to serve as pH sensor for smart packaging systems.

This study sought to respond to the growing consumer demand for accurate information on the quality of packaged food. In fact, the quality and freshness of food is not always linked to the expiry dates on the containers, because they can also be impacted by incorrect handling and temperature. Therefore, there is a growing demand for smart packages that recognise, sense, track, record, and display food quality. Spoilage indicators detecting pH are very important: fresh milk, for example, starts showing signs of spoilage when the pH decreases to 5.98 from the initial value of 6.21, signalling the formation of lactic acid.

此外,新鲜的肉开始破坏when the pH increases to 6.47 from the initial pH of 5.72 due to the decomposition of several substances, which consequently produce ammonia. In summary, food spoilage can be indicated by modifications in pH as a response to the growth and metabolism of microorganisms or the development of organic acids and/or volatile amines. Natural dyes are preferred as pH sensors, as they are biodegradable and non-toxic, as opposed to synthetic colourants. In particular, anthocyanins belong to the family of flavonoids from plants, fruits, and cereals and are particularly sensitive to different ranges of pH, and easily change their colour in response to pH solutions.

Anthocyanin

Anthocyanin extracted from red cabbage (Brassica oleracea) can be considered an excellent candidate for natural indicators due to its high stability and its chemical properties. In addition, there is wide availability of this anthocyanin variant, because red cabbage originated from Europe, but nowadays it is produced and harvested all over the world. There already are several studies about the use of red cabbage as a pH indicator for smart packaging systems. However, the novelty of the study published in Membranes is that it considered how the integration of sago starch film affects its ability to respond to different pHs.

此外,对f的性质的影响inal film of different concentrations of anthocyanin has also been investigated: 8, 10, 12 e 14% (w/v). The films were prepared using the solvent casting process: the red cabbage powder was first dissolved in distilled water; then the solution was heated until mild boiling, and then starch powder and glycerol, the latter acting as plasticizer, were added. The properties of anthocyanin which is hydrophilic and soluble in water make it a suitable candidate to be integrated in starch.

The solution was then poured into a casting plate and dried in an oven at 60°◦C for 3 hours. After that, the dried film was peeled off the casting plate and sealed in a plastic container for further testing. The films thus obtained had a translucent purple colour due to the presence of anthocyanin. As the concentration of anthocyanin increased, the translucency of the films decreased. This was not a problem, because only a small strip of film will be used on top of the food packaging to indicate the spoilage of the food.

Buffer solutions

The colour response of the films to pH changes was determined by immersing the films in a series of buffer solutions at different pHs, chosen as the model systems of aqueous food. The colour response was measured with the Colour Reader cR10 (Konica Minolta, Japan) as numerical values corresponding to the different color parameters on the CIELAB scale. Red cabbage anthocyanin films prepared in this study showed a significant colour change after one hour of food contact:

In particular, the chromatic response was pink under acidic conditions (pH 3–5), greenish under basic conditions (pH 9–11), and yellowish under very basic conditions (pH 13). In addition, with a high concentration of anthocyanin (14 %) the films coloured after detecting the pH change and maintained the colour change for a longer time than the other concentrations, making them certainly preferable to indicate the quality of the food.

The anthocyanin concentration affects film thickness, with values ranging from 0.12 mm to 0.23 mm. Furthermore, a higher thermal stability and improved mechanical properties of the indicator films were observed compared to anthocyanin-free films. Unfortunately, a certain release of anthocyanin has also been observed over time from the material, which is minimized for higher concentrations.

In conclusion, anthocyanin extracted red cabbage and integrated in sago starch films exhibits a significant colour change between acidic and alkaline conditions and is therefore suitable to be applied as smart food packaging. These sensors respond quickly to pH changes and inform customers about the condition and quality of the packaged food. So far their effectiveness has been tested at laboratory scale; the next step will be thescale upof their production.

References:H. C. Hamzah et al., Membranes, 12, 2022, 913. https://doi.org/10.3390/membranes12100913

Pumping: aseptically and gently

E.S.

21 August 2023

OMAC lobe pumps with external pressure relief valve.

From liquid food products to more viscous ones, even abrasive ones or containing parts, the application range of OMAC volumetric lobe pumps is very wide.

With its B series,OMAC提供AISI 316 l不锈钢的体积叶pumps assembled on a cast iron gear box which has a protective coating in epoxy paint finish. These pumps prevent the contamination between the pumped fluid and the gearbox lubricant thanks to the chamber separating the rotor case and gear box. The base of the gearbox is designed to make installation easier for connecting into pipelines. The lobe pump is modular in design so that the main parts (rotors, seals) can be added or exchanged according to application needs.

Mechanical parts are in oil bath, rigid and compact, with double pre-assembled tapered roller bearings, oversized shafts, gears and support, to achieve tighter tolerances and ensure the pump performance and reliability. The rotors rotate in the opposite direction without touching. This feature prevents metal particles from polluting the product, minimizes mistreatment (lamination, cutting) of the product itself. There are many special executions derived from the standard one, to meet the multiple needs of the food industry.

B series model 100: Trolley pump with stainless steel panel, complete with inverter and remote control.

Special executions

Lobe pumps in aseptic versions provide sterile, steam or liquid barriers on the end cover, shaft seals and suction/discharge ports. This type of pump is used in the food and pharmaceutical sterilised product packaging areas where it is important that the product is not contaminated by bacteria or micro-organisms during transfer. The pump with enlarged mouth allows highly viscous products such as semi-solid pastes or mixtures containing semi-solid pieces to be pumped, In these cases the pump is generally positioned with the port on a vertical axis in order to allow the entry of the product under gravity directly beneath the hopper.

For processing products that need to be pumped at a constant temperature (glucose, chocolate, melted fats, butter), the B series provides pumps with inter-spaced body for the circulation of heating or cooling liquid. Even the lid can be heated or cooled with the same jacket on the body. For the transfer of very corrosive liquids, the pumps can be manufactured with wetted parts in Titanium, Monel or Hastelloy. Models B325, B330 and B390 can be installed on road tankers thanks to the flanged gear cover directly coupled to hydraulic motor. These pumps are available with bare shaft or complete with motor, power station and control system.

Motorization and by-pass

Omac体积叶泵可以提供沪元gienic by-pass or pressure relief valves. This device protects the pump from pressure peaks or restrictions in the discharge and assures excess liquid deviation during CIP and SIP. The by-pass can be manually selected as a flow regulator in order to pass product without changing the pump speed. This valve can be incorporated in the end cover that replaces the standard cover, or it can be incorporated in the discharge pipework, relieving excess pressure by by-passing product through a loop back to the suction side.

The bypass on the lid is sanitary, works in both directions of rotation without intervention and is available on models B100 to B550. All models of the B series can be fitted with an external pressure relief valve in order to recycle the whole pumped product (sensitive products). Motorized ready-to-use pumps feature an AISI 304 stainless steel or painted iron base with elastic coupling, joint cover and various accessories.

Power transmission can be variable speed via mechanical, hydraulic or inverter integrated into the motor; alternatively, it can be fixed speed via reduction geared motor. The motorized lobe pumps can be completed with the following equipment: magneto-thermal inverter; variable-speed power transmission integrated in the motor; IP65 inverter, electric panel with IP21 inverter for automatic operation in response to filler’s remote control signal.

A roundup of B series pumps with bypass on the cover.

Wide range of seals

The shaft sealing system can be equipped with three different seals: lip seals, packing, or mechanical rotary seals. Steel, graphite, silicon or tungsten carbide, ceramics, Rulon: These are the materials to choose from according to the fluid to be pumped. The lip seal is the most economical and is ideal for low speeds and pressures, with Viton ring for products such as vegetable fats and creams, or polymer ring for chocolate, for example. The balanced mechanical rotary seal is the most popular.

This hygienic-sanitary seal does not need adjustment and maintenance except the classic replacement in case of wear. Pump seals used for the transfer of products which in contact with air crystallize or leave solid deposits, shall be flushed with water or compatible liquid at low pressure. Flushing is also useful to prevent the sliding faces from working dry (vacuum operation, for example). When a polluting or dangerous fluid is used for flushing, or if its pressure is higher than that of process fluids, the pump may be made of double mechanical flushed seals that prevent any leakage.

Drying, innovation in pre-treatment and process control

E.S.

20 August 2023

Drying is an ancient food preservation technique, perfected and adapted to contemporary conditions. The treatment is aimed at removing most of the water from food, which is the basic medium in which all the most important chemical, enzymatic and microbiological reactions take place and, therefore, compromise its shelf-life and quality.

During the drying process, food undergoes structural and chemical-physical changes, which influence the quality and the organoleptic, nutritional, and functional properties of the finished product, and, consequently, affect consumer’s opinion. Traditional drying is done by a high-temperature stream of air that provides the necessary heat for water to evaporate. The high temperatures characterizing this process allow to speed up the drying kinetics; however, they cause thermal damages by deteriorating the physical-chemical and nutritional properties of the product and involve a high energy expenditure.

Innovative pre-treatments

In order to improve the drying process, preserve the organoleptic properties and nutrients and reduce the microbial load of the dried products, preliminary treatments are widely applied, prior to the actual drying. Based on the growing consumer interest in proper nutrition and its health benefits, the possibility of obtaining healthy foods with high nutritional and functional properties has increased the efforts of scientists and food industries in this field of research. Many researchers have conducted studies and trials on the treatment of products prior to drying, validating techniques to be applied at an industrial level. Appropriate pre-treatments can reduce the initial water content and alter tissue properties, thereby increasing the drying speed, improving product quality, inhibiting enzymes, and thus minimizing possible deterioration reactions during drying and subsequent storage.

传统的热水和蒸汽加热预处理s effectively inactivate degrading enzymes, reduce microbial load and soften tissues. However, they cause the loss of water-soluble nutrients, texture, pigments and aroma. To overcome the limitations of these treatments, innovative techniques have been developed with high heating speed, high energy efficiency, effective enzyme and microbial inactivation, reduced nutrient loss and improved quality.

高湿热空气冲击漂白(HHAIB)is a technology that impinge jets of high-humidity hot air on the product surface at high velocity to achieve a high rate of heat transfer. It is a uniform, rapid and energy-efficient blanching process that results in minimum loss of water-soluble nutrients.

Microwave, radio-frequency and infra-red burnsare heat treatments based on the dissipation of electromagnetic energy converted into heat within the product being treated. The heat penetration depth decreases as the frequency increases. The wavelength range, which is inversely proportional to the frequency, differentiates three types of burns. Microwave and infra-red energies, having shorter wavelengths, have less penetration capacity than radiofrequencies. Therefore, these technologies are more suitable for application to small and thin products and pieces, for which external agitation or a conveyor belt is also useful to expose all parts of the food to uniform radiation and avoid uneven heating.

With longer wavelengths, radio frequencies can penetrate deeper into the product, resulting in more uniform heating, and can heat even dense products of any size. Radio-frequencies heat up more slowly than microwaves, and thus allow for the processing of more delicate products that require slower heating. Microwaves, having a very short wavelength, are particularly difficult to shield, whereas radiofrequencies with much longer wavelengths are significantly less aggressive and easier to shield easy to shield them below internationally accepted emission values.

Ohmic heatingis a process that generates heat by passage of electrical current through food which resists the flow of electricity. Heat is generated rapidly and uniformly, and for this reason this process is an alternative technique to conventional heating of fruits and vegetables, particularly for whole and large products, with shorter processing time, irrespective of the product size and shape. It reduces deterioration and the loss of thermolabile nutrients, preserves colour and texture and inactivates degrading enzymes and micro-organisms.

Non-thermal pre-treatments, i.e.ultrasound,pulsed electric fieldandhigh hydrostatic pressure, are a valid alternative to heat treatments to limit the degradation of heat-sensitive compounds. In addition, by modifying the cell structure, they improve the permeability of cell membranes, resulting in improved mass transfer during drying.

Chemical pretreatments, in general, effectively improve drying kinetics and help improve food quality. However, less innovative techniques in liquid phase result in the loss of water-soluble nutrients, and chemical residues in food can cause food-safety issues, as well as major issues with solution disposal. One of the most innovative treatments of particular importance isedible coatings: thin edible layers applied to the surface of the food before drying, that contribute to reducing the loss of aroma, colour, and nutrients, while maintaining the physical integrity of the product.

In thevacuum impregnation机械技术,压差是developed that allows the infusion of an external solution into the capillaries and free spaces of the food tissue. Thus, it is possible to introduce anti-browning compounds, antimicrobials, antioxidants, nutrients, functional ingredients, to improve the final quality of dried food and extend the shelf-life.

Theozone treatmentis an innovative technique in gas-phase: the ozone treatment is applied at low concentrations and is particularly effective in inactivating micro-organisms without changing the nutritional, chemical and physical properties of food.

Process control

The drying process is a dynamic, non-linear operation, where process and product parameters undergo continuous changes during processing: The quality of food products should therefore be verified not only at the end, but on the way.Smart dryingis one of the latest and most promising dehydration technologies, based on real-time information on product quality parameters (humidity, colour, shape, taste, odour) and process conditions (speed, temperature, humidity, pressure), to simultaneously modulate the drying process. It is a smart control system that uses sensors, transducers and processing systems that transform information into quantifiable variables to make adaptive decisions.

The result is a high-quality, standardised dried product, obtained with optimum energy consumption and minimal environmental impact. Smart drying uses different technologies.Biomimetic systemsare a monitoring method that uses human-inspired sensor technologies, including odour (electronic noses) and taste detection systems (electronic tongues). Theelectronic noseis a tool capable of creating digital odour discrimination maps. Its key elements are chemical sensors that, working as mini-transducers, respond selectively and reversibly to volatile chemicals, generating electrical signals according to real-time concentration.

Theelectronic tonguealso uses miniature receptors. Activated by the different compounds of the food, these receptors transmit electrical signals which are then analysed by a computer, obtaining a qualitative and quantitative description of the substances that contribute to create the taste. Thus, it is a tool that can identify the taste of a product quickly and reliably, without having to resort to the work of the tasters, with all their subjective limitations.Computer vision technologyallows the real-time determination of physical properties (size, colour, shape) and quality attributes of products, using on-line image analysis, which correlates image attributes (area, colour, texture) with physical drying parameters (humidity, temperature, etc.).

Other technologies used in smart drying aremicrowave and near-infrared (NIR) dielectric spectroscopy, monitoring techniques based on the absorption of radiation by the food matrix which, by reading and analysing the obtained spectrum, make it possible to determine the content of proteins, fats, moisture and density of materials during the drying process. They are non-destructive technologies, characterized by great precision, accuracy, and speed.Magnetic resonanceimaging uses radio waves and magnets to generate images of food samples. It is a powerful tool that, through the analysis of information obtained with high spatial resolution, allows to determine the content, distribution, and mobility of water in the food, during the processing processes, for the optimization of operational parameters and for the monitoring of microbiological, physical and chemical quality of different varieties of food matrices.

The ultrasound technique应用于低功率(高频),是一种高速rging, non-invasive, economical, simple and energy-efficient on-line acoustic measurement technique that can be used to estimate the composition of foods, monitor physical- chemical and structural properties and also detect contamination from metals and other foreign materials during processing to ensure high quality and safety.Electrostatic sensorscan record the electrostatic charge carried by dry solids in a pneumatic conveyor and can be efficiently applied in the dryer for real-time measurements of the moisture content of solids in fluidized beds, i.e. for the direct control of the process and fluidization regime.

This technique offers precision, high-temperature tolerance, implementation on a laboratory or industrial scale, rapid measurement, simple structure and installation, high sensitivity, cost-effectiveness and suitability for qualitative measurements. Smart drying involves not only the monitoring of product quality parameters, but alsocontrol systems for the drying environmentthat monitor operating parameters (such as pressure, temperature, and humidity) and adjust them consistently with the product’s quality requirements. In the coming years, smart drying technology is expected to be increasingly used in the food industry, also as a result of further academic and marketing research aimed at system optimization. Social-demographic and lifestyle changes, the increase in food-related diseases, allergies, and intolerances, are driving an increasingly differentiated demand for food products.

To address the new emerging needs of the food sector, both for consumers and producers operating in an increasingly globalized market, researchers and food industry are studying and implementing new food processing technologies, with the aim of providing consumers with food tailored to their needs, through processes that are sustainable, economic and environmental-friendly. The objectives are to maximize nutrient retention, preserve organoleptic properties, process sustainability and energy efficiency to produce safe and high-quality products. To achieve these goals, it is not possible to apply only one of these technologies; therefore, the focus has been on hybrid methods, combining different technologies, and making positive use of the synergy of their main characteristics.

According to data, hybrid technologies can reduce non-renewable energy consumption by up to 80%. The drying process is one of the most energy-intensive processes in the food industry: In the EU, drying methods account for between 10% and 25% of industrial energy consumption. Energy and food consumption are expected to increase by 40% by 2030. It will therefore be necessary to obtain energy from renewable sources, minimizing the use of fossil fuels, and to increase the use of innovative technologies and systems capable of making a real qualitative leap forward in the field of process efficiency, in terms of energy and overall performance.

By Alex Maggiore, Roberta Dordoni, DiSTAS – Department of Food Science and Technology for a sustainable agri-food supply chain – Università Cattolica del Sacro Cuore (Catholic University of the Sacred Heart)

Tecno Pack, Made in Italy packaging machines

E.S.

18 August 2023

Evolution of Tecno Pack horizontal packaging machines, FP 021 S achieves a performance of 150 packages/min.

Since 1985, Tecno Pack’s mission is to provide packaging machines for any type of food product, with any type of wrapping material and a wide choice of packaging technologies.

Located in Schio, province of Vicenza, an area of the Veneto region rich in factories and large industries,Tecno Packbuilt its first packaging machines in 1985. The company’s facilities today occupy more than 6000 sq.m. space for the design and manufacture of machines to meet the packaging needs of the entire food industry. Over the years, the Company has acquired, and relaunched, Euroimpianti (palletizing systems for packaged products, laser and automated guided vehicles), General System Pack (automatic packaging machines and plants) and IFP Packaging (from entry-level packaging machines to end-of-line systems).

Thanks also to these acquisitions, the current Tecno Pack Group can propose a global technological offer: from product production to packaging, from primary packaging to palletization through secondary and tertiary phases, always in total automation. The industries that turn to the Group can benefit from the experience developed over the decades with the world’s major food groups, in the certainty of having complete plants that are sustainable because they can use both paper and organic and compostable films, with components and automations that reduce energy consumption. The extensive catalogue includes best-selling machines, customizable thanks to a wide range of options and functions, and new entries that consider market and technological developments.

The latest addition to the Tecno Pack range, the FP 100 E Dual Lane is a concentrate of technology for the most demanding applications.

Modified atmosphere packaging

The FP210 E is an electronic machine specifically designed for modified atmosphere packaging that guarantees perfectly sealed packages thanks to the “box motion” sealing system. The combined use of motors and linear actuators in the handling of the cross-sealing unit results in aesthetically good-looking packages with high quality side gussets. Its cantilevered frame and easy access for cleaning and maintenance, reduce to the minimum the need for maintenance and cleaning interventions.

The wide range of optional devices allows to satisfy a wide range of needs: Automatic roll change; photocell for printing registration; web width 760/920 mm; gas intake; coder; powered feed roll; gusseting devices; pack deflating devices; second sealing head; no product-no bag; product phase check before sealing head; color touchscreen; easy-opening package; outfeed packs control; outfeed conveyor extension; stainless steel version. Basic technical specifications make it a first-class machine: Performance up to 100 packs/min; product size 400×180 mm; reel o.d. 350 mm and i.d. 70 to 76 mm; machine weight 1300 kg approximately; machine size 5400x1320x1750 mm; motion control with integrated PLC; installed power 8 kW; compressed air supply 6 bar (dry and filtered air); compressed air consumption 50 NL/cycle. The packaging machine can handle heat-sealable films as wrapping materials.

The wrapping materials used on Tecno Pack packaging machines include both paper and organic and compostable films.

Horizontal Wrappers

The horizontal packaging machine FP 021 S is the result of the evolution of Tecno Pack machines and of many years of experience in the field of horizontal products’ packaging. Featuring a flexible and electronic format change-over, this machine is extremely versatile, suitable for food and non-food products, both for single-dose or multiple packages. Its cantilever design and easy accessibility simplify maintenance, and its total sanitization provide the necessary safety required for food products.

The machine provides top technical features: Performance up to 150 packages/min; machine size 4860x1190x1500 mm; weight 650 kg; reel dimensions 520/720/920 mm; outside diameter 350 mm and inside diameter 68 to 75 mm. The product dimensions are variable: Width from 10 to 250 mm; height from 1 to 120 mm; length from 60 to 600 mm. The usable wrapping materials are heat-sealable, coated, cold-sealable polyethylene films. FP 100 E box motion is a concentrate of technology for the most demanding food industries. It operates at high speed and is built on the technological evolution pursued over the years by Tecno Pack.

Motion control via PLC, brushless motors with integrated electronics and touch-screen operator interface characterize the latest generation of Tecno Pack packaging machines.

This flow-pack a fully electronic packaging machine, featuring cantilever frame to be easily sanitized, motorized film unwinding calender, side-sealing unit with two independent motors, transversal sealing units, both long-dwell (with the innovative fast change-over system) and high-speed box motion. The box motion version is presently the fastest prolonged sealing system of this type to date. In fact, it can combine the versatility of traditional D-like motion cut-seal machines, also known as long-dwell, with the versatility of translating cut-seal machines, aptly known as box motion.

The new packaging machine FP 100 E is suitable for integration into automatic lines thanks to its ultimate operational precision, design and solutions studied for high sanitization, ergonomics, mechanic and electronic stability, high-speed for prolonged sealing; controlled atmosphere (MAP); micrometric dosing of liquids (alcohol, anti-mold); integration into advanced print systems, upstream and downstream interaction with any integrated systems; easy and user-friendly touch screen; reliability and long service life.

The added value of conveyor belts

E.S.

15 August 2023

One commonplace in the world of industrial automation is that conveyor belts don’t add value to the manufacturing or packaging process; it is an ancient legacy that I have been confronted with since the first day I started doing this job and, for obvious reasons, it has always bothered be tremendously. The truth couldn’t be further away. Even if we simply consider the conveyor belt as an object that only serves to connect point A to point B, a well-designed conveyor system can be a great help.

In this case, the aim is obviously to have the most efficient system at the lowest possible cost, but that is not the point worth dwelling on. The purpose of this article is not to go looking for every single application where conveyor belts represent an added value. Rather, it is about highlighting some typical cases where these competitive advantages actually exist, and making project managers and plant operators aware that they should not underestimate their design and procurement.

Efficiency, convenience, and optimization

There are three basic ways in which conveyor belts add value: They increase the line efficiency; replace robotic manipulators at a fraction of the cost; and, ultimately, contribute to the optimization of plant space and processes. Increased efficiency: Any production line needs storage space, when productivity grows and, due to its characteristics, the processing cannot be stopped immediately if the packaging machines stop. Accumulation or buffer systems (they are not the same thing, but this is not the place to go into more detail) perform multiple functions: Efficiency recovery during micro-stops of the machines; adjustment of the production flow allowing intermittent machines to be connected with continuous machines; reduction of the mechanical stress on the machines and the relevant impact on the work of operators, in order to solve standstills.

Product Handling: Simply using conveyor belts, it is possible to carry out any kind of product handling, provided there is the necessary layout space. While it is obvious that a robotic system can perform any positioning in an extremely confined space, when production rates are high with very tight cycle times, performing this type of operation with belt systems – even at the expense of positioning accuracy – ensures continuous operation and speed with a lower investment. Space and process optimization: Although examples could be wasted here, competitive advantages are more difficult to measure and are often overlooked, not least because some solutions are now well established and taken for granted. Think of spiral conveyors, which free-up floor space, open passages for operators and packaging materials, increasing safety and ergonomics of lines.

To conclude with a case of particular importance in recent years: When dealing with conveyor belts in direct contact with food, a design that meets the highest construction standards allows sanitization operations to be carried out without using tools. This saves time, and reduces the consumption of water, detergents, and energy. Other examples came to mind as I wrote these few lines, but I want to stop there, in the hope that I have contributed, as far as I can, to a cultural change that I consider essential for the future of our industry.

Luca Fontana, CMO M.H. Material Handling Spa

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