Applications Insights for Dairy Products
Rick Cash
Product Technology Manager
Pack Expo 2014
The world leader in serving science
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The World Leader in Serving Science
Global Scale
• 50,000 employees in 50 countries
• $17 billion in annual revenues
• Unparalleled commercial reach
• 10,000 employees working with
customers every day
Unmatched Depth
• Innovative technologies
• Applications expertise
• Lab productivity partner
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Premier Brands
A Mission We’re Proud Of
We enable our customers to make the world
healthier, cleaner and safer
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Product Inspection History  One Brand
2007
2002
2000
1998 Thermo Electron acquires Goring Kerr
1994 Thermo Electron purchases Ramsey
1985 Ramsey Purchased ICORE
1947 Goring Kerr founded
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On-Line Inspection Solutions for Food and Pharma
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Dairy Industry
• The dairy industry spans ice cream to cheese sticks, to
yogurts, milk and more. Inspection and measurement
systems in a dairy plant must meet rigorous standards of
hygiene and performance.
• Common packaging types include plastic or glass bottles,
plastic or paperboard tubs, lidstock (transparent, metallized
film, or foil), metalized film and plastic overwraps and a
variety of other material combinations.
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Dairy Industry
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Dairy Industry Selected Applications
Dairy
Product
Application Problem
Solution
Equipment
Cheese
Accurate weighing for
environment
Proper CW selection
Versaweigh PWT, Versa 8120 chain
Solid contaminant detection
MD with IXR ,XR
Apex 500, various XR
Missing slices
Missing wedge
XR
XR
Xpert
Xpert, PowerX
Ice cream
Sticks in novelties
Missing novelties in carton
XR
XR
Nextguard
Xpert
Yogurt
Metalized lid; weighing
XR,CW
Nextguard, Versa 8120
Powdered Milk
Contaminants in baby formula
MD, XR
Apex, Xpert S
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Requirements for Dairy Plant Inspection EquipmentPackaged (IP 65/66)
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Factory Demand
Range or
Frequency
Impact on
Equipment
Specification
Impact on Life of
Equipment
Teardown / Reassembly
Weekly
Ease of access for
service
HI
Chemicals &
cleaners
Chlorine, caustics,
acids, sterilizers
Resistance to
chemical damage
HI
Water wash
Garden hose
pressure
Resistance to
water ingress
HI
Equipment
temperature cycle
Chilled to hot
water wash
Resistance to
thermal cycling
HI
Uptime
100%
Robustness to all
the above
Solutions for Dairy Plant Inspection EquipmentPackaged
• Common requirements for product inspection equipment:
• Sturdy construction for sanitary operation
• Robust design to assure uptime and ease of maintenance for constant operation
• Applications knowledge to handle a broad range of package types
• Broad service footprint to assure uptime of line
• Metal Detection:
• Thermo Scientific™APEX 500 metal detector performance allows smallest ss size
to be found
• CW:
• Thermo Scientific™Versa 8120 chain-portion control, washdown for tubs, ‘stiff’
packages
• Thermo Scientific™ VersaWeigh™ powered weigh table for cups, wheels, bags
• Xray (contaminants and product verification)
• Thermo Scientific Xpert™ or NextGuard™ or POWERx X-raysystem selected to
suit thickness, package style
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Dairy Plant Inspection Equipment-Packaged
Examples
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Solutions for Dairy Products with Inspection
Equipment - Examples
The drop-through metal
detector is suitable for
online detection of bulk milk
powder while the XR
conveyor model is ideal for
the end of the production
line
A checkweigher for weighing cheese, a common
food industry application.
During the production process, a checkweigher
will check the weight frequently because weight
is used to determine the cheese’s stage of
maturity.
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CW Examples
• Cheese: Cut/Wrap operations
• Bags capably measured with Versaweigh Powered weightable design
• Blocks (up to 5 lb): o-ring option- weights can be sent to printer for labelling
• Cheese: Blocks
• Up to 5 lbs; use o-ring transfer and feed back weights to
printer for labelling
• Butter, Sour Cream, Yogurt, Cottage Cheese, Dips, Ice Cream
• Versa 8120 chain with s.s.(+/- 1 g) or nylatron (+/- 0.5 g) chain
• 1 lb blocks, tubs, cartons
• Transfer is critical due to chines on cartons- may require interleaving of infeed
• Yogurt cups can be jam-fed into feedscrew infeed over 8120 chain system at rates up to 550
ppm
• Powdered Products
• Versa 8120 chain: can feed back control to screw auger of filler
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Metal Detector IXR Software
• Conductive and partially frozen products have significant
“Product Effect.” Their dielectric values can mask metal
signals in metal detectors
• IXR technology in APEX MD improves metal contaminant
detection by applying separate thresholds to reactive and
conductive contaminant signal, improving performance by
20% on average
X Detect
Intellitrack XR
R Threshold
7m
m
5m
m4m
m 3m
m 2mm
1mm
R Detect
Threshold
X
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Metal Detector Examples
• Pipeline cheese
• Processed cheese
• Cheese curds
• Packaged cheese: Thermo Scientific™ APEX 500 metal
detector
• Shredded cheese example: 1.5mm ferrous, 2.5mm non-ferrous, 3.0 mm SS
• (100 fpm, PNR filter ON, 5 lb plastic bag)
• Sliced cheese
• Ice Cream
• Cartons example: 5.00 mm ferrous, 5.5 nonferrous, 8.5mm ss
• (4.5 X 7.5 X 13 in)
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X-ray Packaged Product Applications
Box - Yogurt Cups
System used Thermo
Scientific™ EZx 420 X-ray
System
Size: 12 – 6 oz cups
Detection Results:
•Metal 1.5 mm
•Glass 4.5 mm
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Box - Ice Cream Bars
System used EZx 420
Detection Results:
•Metal 1.3 mm
•Glass 4.0 mm
Overwrapped Tray – Formula Cans
System used EZx 520
Detection Results:
•Metal 3.75 mm
X-ray – Packaged Product Applications
Plastic Cup, Foil Top - Pudding
System used PROx C1
Size: 6 Count (3x2 Layer)
Detection Results:
•Metal 2.0 mm
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Box - Parmesan Cheese
Inspected on EZx 420
Plastic Bag - Ice Cream Cone
System used PROx C1
Size/Weight: 200 packets/15 lbs
Detection Results:
•Metal 1.0 mm
•High Density Plastic 1.5 mm
Detection results:
•Metal 2.25 mm
•Glass not tested
Packaged Cheese Applications – X-ray
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Cheese in Plastic
System used PROx C1
Cheese in Plastic
System used PROx C1
Cheese in Plastic
System used PROx C1
Weight: 150g
Weight: 300g
Weight: 500g
Detection Results:
•Metal 0.8 mm
Detection Results:
•Metal 0.8 mm
Detection Results:
•Metal 1.5 mm
POWERx C X-ray System – Packaged Product
Applications
Carton – Yogurt Cups ( 18 ct)
System used POWERx C400
Detection Results:
•Metal 2.5 mm
•Missing cup
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Takeaway Slide: Dairy Applications
• The most important factors for successful contaminant inspection and checkweighing
in dairy products environment are:
• Properly capturing the requirements (clients responsibility to sign off)
• Selecting a cost effective system for total lifecycle that meets requirements
• Most problem installs are the result of:
• Failure to capture the true requirements
• Application of the wrong system to the job
• Changes to the requirements after order is quoted or placed
• Successful product handling is required
• Product motion must be consistent at line speeds
• Reject mechanism must not impact line efficiency through jams or false rejects
• System operation must be simple and effective
• When operators make changes to products or setup, must be easy to ‘get it right’
• Supplier technical support as backup keep lines running
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Questions?
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Thank you
Rick Cash
[email protected]
www.thermoscientific.com/productinspection
Your partner in product and process improvement