IBIE 2016 is said to be the biggest, most comprehensive event in the United States for the grain-based food industry.

Produced by the American Bakers Association (ABA), Washington, D.C., and the Baking Equipment Manufacturers and Allied (BEMA), Overland Park, Kan., IBIE 2016, which took place Oct. 8-11 in Las Vegas, brought together more than 20,000 baking professionals from 100 different countries and every segment of the business.

New to this year’s show was an expanded Innovation Showcase, which was 15% larger than the 2013 IBIE show, featuring 56 participants representing a range of categories from ingredients and equipment to packaging and services.

“People come to our show to see what’s new, and it’s our job to make it easy for them to find what they’re looking for,” says Michael Cornelis, chair of IBIE. “This year we’re really delivering on our promise. It’s a record-breaking show with the largest show floor, largest number of exhibitors, largest innovation showcase and largest education program in IBIE’s history. That’s something we’re really proud of and something that will create tremendous value for attending companies.”

Here is a rundown of new equipment and solutions (in alphabetical order by company name) introduced and/or showcased at the show:

CLOSED-LOOP WASTE ENERGY SYSTEM

Air Management Technologies, Lewisburg, Pa., debuted the Closed-Loop Waste Energy System (CLWES), which capitalizes on the synergies that exist between various production load processes to power cold and hot thermal energy. 

Typical baking processes require various thermal heat exchanges – heating or cooling – used in sequence or simultaneously. CLWES is said to greatly enhance facility sustainability by providing both energy and carbon footprint reductions.

Implementation empowers food processing facilities to recycle multiple utilities’ waste streams significantly reducing water, natural gas and electrical input requirements while delivering a positive return on investment. 

Benefits include:

• Significantly reduce energy consumption by utilizing waste heat to power thermal processes. Electrical, gas and city water savings can provide a rapid return on investment depending on geographic region, hours of operation and process load requirements.
• System utilizes waste heat from large industrial ovens, oxidizers or other waste heat sources currently being discharged directly to atmosphere. As part of intelligent facility architecture and waste heat streams, systems have the capability of satisfying both hot and cold thermal process requirements from makeup to the freezers.
• Many organizations currently purchase—or will be required to do so in the future—carbon offset credits. The amount of credits purchased is directly correlated with facility energy usage and carbon “footprint.” Recovering existing thermal waste energy and reducing energy consumption lowers carbon credits purchase requirements by reducing facility electricity usage, which may be generated by coal, oil or natural gas.
• Immediate returns are possible in most new facility installations. Energy savings provide positive cash flow in most retrofit applications depending on full-time process load requirements. Additional utility or government incentives may be available to offset initial capital investment.

Properly utilizing this “recycling” of process waste provides an immediate energy savings. Waste heat can be used to create low-temperature refrigeration, process heating to eliminate steam boiler requirements or even generate on-site electricity.

Air Management Technologies, Inc.
570-523-4822
www.airmanagement.com

PASTEURIZER FOR ICE CREAM INDUSTRY

Bakon USA, Torrance, Calif., debuted the Pasto-Cooker, available in 25-, 110- and 220-quart capacities.

This range of pasto-cookers heat, stir and cool down various preparations for the production of creams and ganaches (custard cream, lemon cream, fruit pastes, liquid caramel, jams, glazes and more), sugar syrup, bavarois, pâte à choux (choux, eclairs, chouquettes, profiteroles) savory sauces, gelato and ice cream.

Additional features include:

• Works well in a wide range of temperatures (from 32°F up to 392°F).
• Is fully programmable with larger color touchscreen.
• Allows minimum loads (20% of maximum capacity).
• Patented outlet tap for easy unloading.
• Reduced water consumption thanks to double air/water cooling condenser.

Bakon USA Food Equipment
800-779-2256
www.bakonusa.com

FLOW WRAPPING TECHNOLOGY
Bradman Lake, Rock Hill, S.C., showcased the FT120, a fully automatic horizontal form-fill-seal flow wrapping machine.

Features include:

• Operates at the highest level of efficiency and seal integrity, even for difficult heat seal applications.
• Can be connected to the exit of the process cooling tunnel and supply the product delivery belt, product removal stations, product orientation systems such as bar turning unit and in-line or shuttle phase infeed conveyors to the wrapper. All the equipment is integrated into one system with one supplier. 
• Can be integrated with complete range of product-specific handling systems for semi and full automation.
• Handles a wide range of products, formats and sizes.
• Quick and simple changeover parts.
• Robust and well-built to the latest safety and hygiene standards required in the bakery, confectionery and frozen food industries.
• High standard of machine specification, which can include twin film reel holders, automatic film reel to reel splice, splice detection and rejection, print registration, automatic film web alignment, film printing, empty and deformed pack identification and rejection, 4 pairs of longitudinal seal crimp rollers to provide heat or cold seal options and robust end crimp sealing.
• Latest Allen Bradley/Rockwell electronic component and software platform.
• Upgraded machine construction to handle washdown applications.

Bradman Lake, Inc.
704-588-3301
www.bradmanlake.com

METRIC-SIZED CONVEYOR BELT

Cambridge Engineered Solutions, Cambridge, Md., unveiled Cam-Grid GP, a new metric-sized product for use on spiral cage systems and other low-tension food processing applications. Cam-Grid GP is designed for OEMs and end-users in international and domestic markets with spiral cage systems used for proofing, cooling and freezing processes in bakeries as well as conveyors that move meat, poultry and prepared foods within processing plants. With a 35-mm pitch and 90.7-kg tension rating, Cam-Grid GP provides excellent strength-to-weight ratio, allows product loading from link to link and is fully collapsible for easy cleaning.

Cambridge Engineered Solutions also unveiled Variable Cambri-Link and Variable DuraLite, highly customizable conveyor belts for spiral cage applications to proof, cool and freeze baked goods such as bagels, breads and pizza shells as well as packaged foods, including ice cream and frozen entrées. The two patented products allow end users to specify desired opening widths to achieve the correct support, airflow and strength-to-weight ratio for specific products. Variable DuraLite was originally designed in cooperation with I.J. White Systems, Farmingdale, N.J.

Cambridge Engineered Solutions
877-649-7492
http://cambridge-es.com

STRUCTURE-SUPPORTED SPIRAL FREEZERS, FOOD PROCESSING EQUIPMENT

JBT Corp., Chicago, and Intralox, New Orleans, partnered together to offer structure-supported spiral systems equipped with conveyor belting features such as Intralox’ patented DirectDrive System. Additionally, JBT will offer upgrades for Northfield low-tension freezers already in use.

Intralox’s DirectDrive technology offers reliable, consistent performance, improved efficiency and eliminates product orientation issues, thus dramatically reducing unscheduled downtime and maintenance costs and increasing belt life.

JBT also provides a series of food processing equipment for “thaw-and-serve” and “bake-off” products. For example, its Stein ProBake continuously applies heat to the bottom surface of food via conduction, and generates the desired under-sole for any type of dough-based bakery item. When coupled with JBT’s Frigoscandia GYRoCOMPACT self-stacking spiral proofer, the ProBake provides a reliable and consistent solution for panless processing.

The DSI J-Scan inspection system delivers high-speed precision sorting by providing corrective feedback to the operator using upstream processing. It also provides the ability to simulate runs and make adjustments in seconds, while achieving greater yield. The scanning system provides added quality control and off-site access to plant production.

JBT’s JayBoT AGV (automated guided vehicle) is ideal for operations currently using manual forklift trucks or that are just starting to automate.

With newly acquired A&B Process Systems, JBT continues to expand its portfolio of services and expertise. For instance, A&B’s melt tank systems combine inline to offer uninterrupted production for lines utilizing ingredients such as melted butter, lard and chocolate. Novus X-Ray inspection systems, including the CCPX series of pack units, aren’t affected by temperature variations common with delays in production flow, making them ideal for breads, cakes, cookies, pastries and pies.

JBT Corp.
312-861-5900
www.jbtcorporation.com

Intralox
504-733-0463
www.intralox.com

CASE LOADING SYSTEM

KLEENLine, a Newburyport, Mass., unit of Pro Mach, presented its innovative case loading system, equipped to count the amount of pre-determined product required per case, thus providing an effective way for manufacturers to count and collate singulated products.

This new system offers the latest in robotic product handling design to accommodate high-speed and fragile baked goods.

Utilizing speed-up conveyors and high-speed sensors, the product is separated and counted before being deposited into a holding chamber. Once a count is reached, the system indexes to a second holding chamber while the first chamber releases the product into a waiting case or bagger infeed.

KLEENline, powered by Pro Mach
800-259-5973
www.kleenline.com

CRYOGENIC SOLUTIONS FOR BAKERIES
Linde LLC, Bridgewater, N.J., highlighted proprietary cryogenic solutions developed to improve product quality and help extend shelf life for a range of baked goods, including par-baked artisan breads, chilled cookie dough and quick-frozen pizzas.

For example, the ACCU-CHILL dry ingredient chilling system rapidly chills dry ingredients as they flow from the storage silo to the mixer. The in-line system controls ingredient temperature within 1^oF of the set-point at the mixer for more consistent cycle times and high-process repeatability.

CRYOLINE MT modular tunnel freezers are in-line cryogenic tunnel freezers designed for flexibility, efficiency and cleanability. Modules can be added to expand capacity. They’re ideal for pizzas, cookies, dough, par-baked breads and other items.
 

CRYOLINE XF cross-flow spiral freezers feature patented cross-flow design, producing more uniform temperatures across the width of the conveyor belt for high-quality output at high production rates. Ideal for par-baked goods, artisan breads, rolls, pastries, cookies, dough products, pizzas, trayed foods and ready meals.
 

The Linde impingement freezer is a patented freezer that can typically process about 30% more than a cryogenic tunnel freezer in the same linear space. The process uses an initial blast of N₂ to crust freeze the surface, then impinges food items with a controlled flow of N₂ from above and below the conveyor belt. It’s ideal for pizzas, cookie dough, waffles, pancakes, garlic bread and other baked items.

Linde North America
908-771-1491
www.lindeus.com 

CO₂ TECHNOLOGY

M&M Refrigeration, Federalsburg, Md., exhibited spiral freezers that are powered by CO₂ Cascade System technology. Vigorous circulation of cold air is used to enable freezing at a rapid rate. Spiral freezers are ideal for products requiring a long freezing time, such as raw or cooked meat, fish fillets, chicken and pizza. The M&M CO₂ Cascade Refrigeration System also helps lower suction temperatures down to -60°F, bringing the air temperature to approximately -50°F. This ensures faster freezing and quick product preservation, increased production and lower energy expenditure.

This CO₂/NH₃ cascade system combines the advantages of CO₂ in the lower-temperature side and ammonia on the higher-temperature side.

Key benefits include:

• Increases throughput by up to 50% and decreases operation costs up to 40%.
• Dramatically reduces ammonia charge.
• Smaller first-stage compressors.
• Smaller suction and discharge piping.
• Smaller control valves and liquid separating vessels.
• Requires less material to build the system.
• Less insulation required for valves and piping.
• Does not contribute to global warming.
• Does not deplete the ozone layer.

M&M Refrigeration
410-754-8005
www.mmrefrigeration.com

AUTOMATION PRODUCTION LINE SOLUTIONS

MECATHERM, France, introduced a slew of automation production line solutions.

Unveiled for the first time at IBIE 2016 is the FTA, a new modular single deck tunnel oven that is accurate, flexible and controllable throughout the line. The FTA is said to more closely control the delicate baking process from the first to the last minute, precisely adjusting each parameter (type of baking, intensity of energy transfer, steam management, etc.). The FTA oven also boasts several independent modules through which each baking phase can be independently adjusted to one-degree accuracy. Plus, MECATHERM’s unique patented technology now allows bottom radiant heat. With one and the same piece of equipment, bakers can accurately bake a wide range of products, including pizzas, hot dogs, buns, bagels, muffins, pies and more. The FTA oven is also equipped with the new e-connect pack that optimizes control and maintenance operations such as sensors that detect vibration, motorization and the actuators. A thermal camera determines the temperature of the products leaving the oven, thus overcoming the possibility of fire. A supervision camera reduces the need for the line operator to move. A dual system for event traceability and employees maximizes line productivity.

The MVS (modular vertical system) is a line automation system that combines modularity, quality and intelligence. Its FIFO (first-in/first-out) mechanism provides storage capacity or standing time for proofing, cooling, freezing and storage operations. The MVS is constructed with approved food-grade materials such as tropicalized IP66 motor, stainless-steel shaft, galvanized or stainless-steel frame and aluminum grating around the module. Intended to operate, optimize and develop the production units, the MVS packs feature a traceability pack, which accurately identifies all users to anticipate events and process them. Operators have access to a comprehensive log of all actions and the users involved. MVS also features an e-maintenance pack, which preserves capital assets and optimizes equipment availability.

This pack comes equipped with standard and specific sensors and actuators, which provide the operating status of every main technical operation, including trays detection, vibration, motorization, jack etc. And, the energy and exhaust packs ensure users optimize operational costs by monitoring use and waste over specific periods (daily, weekly, monthly).

MECATHERM also developed the high-quality process, which removes the hurdles associated with producing artisan quality bread under the same practicality and cost conditions as those of convenience bread (high speed, cost reduction, simplification of the line, etc.).

MECATHERM
+33 (0)3 88 47 43 00
www.mecatherm.fr

BAKERY CART PROVIDES END-TO-END SUPPLY CHAIN VERSATILITY

ORBIS Corp., Oconomowoc, Wis., featured its Pally bakery cart, designed to offer the mobility of a dolly with the functionality of a static pallet, all in one.

When mobile, the Pally converts to static mode with a press of the pedal. When static, the rubber braking stabilizers ensure the Pally withstands lateral force, allowing it to be safely stored, displayed and transported, resulting in greater end-to-end supply chain versatility for increased efficiency.

The Pally can be used with plastic trays and a metal racking system to create a shopper-ready, mobile solution. The optional locking handle allows it to be pushed or pulled, and the contoured deck handles and lightweight structure enable ergonomic handling.

ORBIS Corp.
800-890-7292     
www.orbiscorporation.com

LIQUID-BASED COOLING SOLUTIONS

For the first time, Pfannenberg Inc., Lancaster, N.Y., showcased its liquid-based cooling solutions designed to cool in harsh ambient conditions.

Solutions include:

• The air/water heat exchangers, designed for trouble-free cooling of electrical enclosures, are suitable where ambient temperatures are high or the atmosphere proves to be particularly oily or aggressive.
• The stainless-steel CC Series packaged chillers, ideal for machine cooling applications, combines the economy of the rack series with the full-featured design of the company’s EB chillers. These compact chillers (CC) boast quick set-up and trouble-free operation. 
• The DTS 3000 Series cooling units meet the needs of indoor NEMA Type 12 applications, NEMA 3R/4 outdoor applications and NEMA 4/4x stainless steel for washdown applications.
• The company’s visual and acoustic signaling devices satisfy numerous alarm, warning and indication requirements, including machinery operating status, process monitoring, system startup and building or area evacuation due to fire, toxic gas leak, chemical spill or intruder alert. These solutions feature rugged construction and the ability to withstand severe environments.

• Filterfans are designed for forced convective cooling to circulate and cool the air in cabinets. For example, the Filterfan 4.0 reaches a particularly high airflow while providing an IP 55, Type 12 system of protection. The flat-profile, uni-colored design complements modern machines and plants.

Pfannenberg Inc.
716-685-6866
www.pfannenbergusa.com

SPIRAL MIXER WITH 3-ZONE KNEADING PROCESS
WP Bakery, Shelton, Conn., introduced the new Kronos spiral mixer, said to be the best mixer for gluten development of a variety of doughs.

The mixer’s 3-zone kneading process produces quick, intensive mixing with higher oxygenation and the ability to mix 10% of the dough capacity.

Plus, it’s a universal mixing tool for wheat, rye and whole grain dough in pretzels and bagels, and is ideal for the production of cake and crumble dough as well as salads, mixtures and fillings.

WP Bakery Group USA
203-929-6530
www.wpbakerygroupusa.com

COMPACT TRANSFER PUMP FOR AUTOMATING PRODUCTION

Unifiller, Canada, launched the iPump, which is a transfer pump that uses gentle pumping technology to quickly transfer a product without compromising quality or production space.

The iPump is particularly useful for operators looking to automate production, but retain a small footprint.

The iPump is compact, can control production levels to ensure consistency and efficiency and gently pumps products like buttercreams, batters, fruit fillings and sauces.

Consisting of a stainless-steel construction frame, key features include a 1.5-inch-diameter flexible outlet hose, flow control to adjust pump speed according to the products being pumped and an optical product sensor to ensure hoppers remain filled at a consistent level.

And, the tool-free disassembly makes for quick and easy cleanup.

Unifiller
888-733-8444
www.unifiller.com