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Feeling Blue

glen@osiminteractive.com (Glen Hall) — Fri, 08 Sep 2023 20:12:08 GMT

The entire Food & Beverage Industry is feeling BLUE. In 2018 less than 10% of Food Processors utilized blue as a visual detection aid for foreign particles. That number has skyrocketed to 70% and is expected to be adopted as an industry standard and will migrate into other Food related sectors.

Is it possible to eradicate Food Recalls? From 2016 – 2021 US food manufacturers recalled an average of 20 million pounds of protein- based products. These recalls directly result from extraneous material contamination, such as bone, wood, metal, plastics, wire, and other impurities.

For Food Manufactures, eliminating contamination is the Holy Grail. Perhaps it is not currently possible to eradicate Food Contamination. Recent technology advancements and increased awareness move this reality into focus. The “how” is blurred, but the vision is crystal clear. Zero tolerance for foreign material recalls.

August 2022, PepsiCo initiated a voluntary product recall for select lots of Starbucks Tripleshot Energy Vanilla over concerns the beverages may contain metal fragments. Some Global food manufacturers can weather the storm of a major recall, but smaller regional food processors cannot. What’s at risk: Brand image, financial consequences, and customer loyalty.

What’s at risk?

Brand image, financial consequences, and customer loyalty.

Food Processors desire consumable components that are identified visually, by X-ray, or using inline metal detection systems. Ports Plastics understands that the risk of component failure increases with time. We offer a complete portfolio of detectable performance plastics.

Food Irradiation

glen@osiminteractive.com (Glen Hall) — Fri, 08 Sep 2023 20:08:45 GMT

Food Irradiation (the application of ionizing radiation to food) is a technology that improves the safety and extends the shelf life of foods by reducing or eliminating microorganisms and insects.

There are three sources of radiation approved for use on foods Gamma rays, X-rays, and Electron beams. Francisco Diez-Gonzalez, Food Safety Director at the University of Georgia Center, said “Irradiation has proven it can reduce the count of salmonella and listeria by more than 99.99 percent. It’s capable of killing viruses. Irradiation also helps to reduce microorganisms that could have an influence in spoilage.”

What does Irradiation do to plastics, rubber, and urethane? Some polymer materials can degrade due to overexposure to radiation sources including protons (alpha), electrons (beta), and photons (gamma, X-rays). This degradation can lead to efficiency lost, down time, and increased power consumption.

Physical properties of polymers can be impacted with repeat exposure to radiation. These impacts are not always visible or understood. For example, a critical component such as a gear may experience a decrease in shear strength or tribological properties. Surface degradation, discoloring, or material shedding are common visual signs that a component is being affected by radiation. The risk of component failure increases with multiple exposure to radiation cycles. Choosing the right material upfront limits conveyor down time.

2022–2028 Global Food Robotics Forecast Food Automation

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 21:07:25 GMT

The global Food Robotics Market is predicted to double in the next six years. Current market size is estimated to be valued at USD $2.4 billion in 2022 and projected to reach USD $5.1billion by 2028, returning an average CAGR of 13.1% during the same time period.

Market Drivers

There are two drivers leading exceptional accelerated growth. Global population growth and the increasing demand for quality food. Food processors must increase the rate of production with enhanced productivity to meet consumer demand.

Segments

Food Sectors such as the dairy and bakery industry are actively minimizing human contact in the production process in order to comply with emerging health regulations.

Expectations

Increased investments in food automation technology provides tremendous growth opportunities for plastics consumable smart parts

How Does This Affect The Choice Of Plastics?

The Food Industry will require polymers that are visual, X-ray, or metal detectable for end effectors in direct contact with food. Additional Engineers will look for suppliers that can integrate emerging smart part technology. Where the part lets you know it is ready for replacement. To achieve this we need materials that are lighter, stronger, resistant to cleaning chemicals, and self lubricating leading to increased component life. The convergence of AI, Industry 4.0, polymer technology will lead design and process engineers to next generation technology.

Plastics Role In Meeting The Ever Increasing Global Food Demand

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 20:58:32 GMT

Food automation equipment is ripe for disruption.

The Food Processing and Handling sector is a critical factor in providing the systems, machinery, and equipment that enable the food industry to feed the global population. With the current global population nearing 8 Billion and expected to reach 10 Billion by 2050, we must increase food production by nearly 60% to adequately feed the world. Think about that; significant innovations will be required to keep up with demand. Plastics will need to play a role in this efficiency gain.

Expectations

Changes in consumer expectations and rapid AI technology transformation are key catalysts for disruption. Increased investments in food automation technology will provide tremendous growth opportunities for plastic consumable parts.

Food Processors will require plastic components that link to Artificial Intelligence, notifying engineers when a part is ready for replacement. These parts can increase efficiency and have the ability to help control the process by being key analytical communication links.

So, What’s Next For Plastics?

The Food Industry will experience an array of new technologies, materials, and food regulations. Polymer manufacturers are actively looking to integrate innovative new technologies into what are today’s traditional polymer solutions. Food Processors desire consumable components integrated directly into the automation software system. This provides huge savings in terms of cost and efficiency as PM cycles are optimized. The challenges are certainly there for the plastics industry to provide the innovation required so that the Food Equipment Industry can stay ahead of the growth curve in feeding the global community.

Sugar... The Silent Killer! - The Risks To Food Automation

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 20:54:11 GMT

What Sugar Does do to your Equipment?

Everyone enjoys a sweet treat, but too much can lead to health issues. Well, sugar is also a silent killer with respect to Food Processing Equipment. Sugar is inherently sticky and is naturally abrasive. The combination of these two properties is severely problematic for processing of confectionary foods. Sugar’s abrasiveness significantly reduces the life of wear components within any type of automation. So how does this affect the choice of plastics?

The Cause: Abrasive Wear

Defined as the volume of material loss caused by abrasive media moving through or over a component. Abrasive wear isn’t just related to sugar other abrasive media such as flour, grains, nuts, and coffee will also cause premature surface wear.

The Solution

Ultra High Molecular Weight Polyethylene (UHMW-PE) is polymer with an extreme resistance to sliding abrasion or slurry abrasion. It is the most commonly used material in critical food processing applications with a focus on abrasive wear resistance. In addition UHMW-PE has low friction, high abrasive resistance, good toughness, high impact strength, high resistance to corrosive chemicals, no moisture absorption, and low cost.

However, not all UHMW-PE are equal in performance. There are two major influences that will determine the performance of UHMW-PE components within Food Processing Equipment.

Molecular Weight

UHMW-PE has a molecular range between 3M – 6M depending on manufacture. Molecular weight influences the performance in terms of wear, izod impact as well as static and dynamic friction.

Fillers

Stock shape manufacturers use a variety of fillers to enhance a particular property. For example, glass might be added to improve stiffness and compressive strength, reduce expansion, and increase operating temperature. Glass does negatively impact Coefficient of Friction and can be abrasive to metals such as Stainless, Aluminum and brass often found within food processing equipment.

Metal Chips or Chocolate Chips! - The Risks of Food Contamination

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 20:48:07 GMT

Despite numerous types of inspection systems and advances in detection technology, metal is still the most common risk for contamination in the food industry.

Traditional materials such as metal and generic polymers just are not good enough anymore. The food

Industry continues to see numerous recalls for foreign particle contamination. In 2015 Kraft Foods recalled 6.5 million boxes of its famous Mac & Cheese. In 2019 Taco Bell recalled 3 million pounds of beef due to concerns over metal shavings and discarded an additional 2 million pounds for fear of safety. In January 2021 Weis Markets recalled nearly 11,000 containers of ice cream.

These are just a few examples of major recalls for Class 1 foreign particle contamination. Even the Pet Food Industry has the same risk of recalls due to contamination. While there is no significant penalty from the government for recalls there is a significant cost to brand reputation often costing millions in direct cost and irreversible reputation damage. Food recalls lead to lost sales, lawsuits, increased compliance cost, and lost production.

While polymer technology has evolved so has the manufacturer of food. The question is, have they evolved together? This answer may not be so obvious. What is obvious is that food manufacturers need material solutions now and polymer manufacturers need to understand the global trends for food compliance. The upfront cost is far less than the cost of lost brand reputation. The right engineered performance polymer can dramatically minimize the risk of contamination. Laird Plastics understands both the food processing industry and the plastics industry to support Food Processing.

Why Polymers Over Metal?

Emerging polymers that are visual, X-ray, or metal detectable hit the mark
Polymers are significantly lighter than metals
Polymers are resistant to chemical wash-downs.
Lower power consumption can be achieved with polymers
Exhibit extreme resistance to sliding abrasion
Outperform metals by 10x
Polymers do not gall like metals
Tri-detectable or ultra-detectable

The Effects Of Friction On Food Processing

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 20:40:13 GMT

FRICTION is a common force that significantly affects the motion of moving objects in a system. Reducing Friction with respect to Food Automation Equipment is a challenge that engineers are constantly faced with. So how do you determine what is the optimum sliding material for your application? To answer this we first define the two types of friction, Static and Dynamic.

Static Friction

Is a force that when applied keeps an object at rest. This means servo motors that drive Food processing equipment must overcome static friction to be automated. Materials with high Static friction require larger servo motors and consume more power.

Dynamic Friction

Is defined as a force acting between two moving surfaces: In food processing equipment this creates frictional heat, surface wear, and static build up. Static and Dynamic friction decrease in performance as temperature increases. This results in the slowing of a moving systems. Engineering plastics minimize frictional forces resulting in faster line speeds and a decrease in power consumption. When choosing a plastic it’s important to understand effects of localized frictional heat, environment temperature, and the materials CoF at operating temperature. Laird Plastics is the one source to bring together the wide range of critical physical properties needed enabling engineers to make optimal material choices and design decisions for their applications. Understanding a few key properties can deliver enhanced performance, increase line speeds, reduce power consumption, and lower maintenance cost.

Three Common Materials Used In Food Processing

UHMW-PE: COF .12 - .20 static with excellent abrasion properties. Excels in cold environments less than 40deg F. UHMW is chemically inert and has zero moisture absorption which minimizes bacteria growth. Very close to PTFE but has better compressive strength over PTFE.

NYLON: COF >.5 static Excels in dry environment, excellent wear properties, and extremely tough especially where shock loading or impact is present.

ACETAL: COF >.25 static. Excels in a wet environment, good Compressive strength and improved dimensional stability.

Plastic Detectability in Food Processing

glen@osiminteractive.com (Glen Hall) — Thu, 07 Sep 2023 20:20:10 GMT

Plastic materials are used throughout the processing and conveyance of food. Materials that have direct contact with food are required to meet the strict requirements of the US Food and Drug Administration (FDA) and/or Regulation 10/2011 EU. In addition to compliance, the materials pose a potential issue in terms of foreign body contamination. This refers to pieces of the plastics that can break off and contaminate the food stuff during usage creating a potentially costly situation for the food end user. Plastic particles are of the most prevalent foreign body contaminants due to the fact that plastic is not inherently able to be identified by the typical metal detection or X-Ray detection systems. For that reason, plastic shape manufacturers have developed technologies to increase the detectability of plastics in food processing environments.

Single Detectable

These plastics simply refer to plastics that are blue in color. A vivid blue color is added to the material to make it more visibly detectable in the event it finds its way into the food stuff. Compliant single detectable materials are available in a wide range of thermal and physical properties to meet the requirements of the application.

Dual Detectable

This category of Food Plastics refers to products having both visible blue detectability as well as Metal Detectability. Metal detectors rely on the magnetic or conductive properties of the foreign body contaminant to be detectable and are designed to pick up ferrous, non ferrous and stainless steel contaminants. Metallic filler can be added to the plastic to allow for it to be detectable by traditional metal detectors yet maintain the physical properties and in many cases remain compliant for food contact.

Tri Detectable

This category includes visible and metal detectable, but adds X-Ray detectable to the level of detectability. In order to detect non-metallic contamination, such as ceramic, bone, glass or stone, food processors utilize x-ray detection systems to screen for foreign body contamination. X-Ray detectors are commonly used in food processing and rely on density difference between the foodstuff and the foreign body contaminant to detect the particle. Plastics have been developed that offer enough deviation from the typical density found in food (usually a specific gravity of 1.0 such as that of water) that they are detectable by X-Ray technology used to detect other foreign contaminants. One cannot assume that an MD food grade plastic is also X-Ray detectable. Tri-detectable materials are perfect for companies that use one detection technology on one line and another technology on another line. Tri Detectable materials use a hybrid of technologies such as metallic additives and high density additives to achieve detectability while maintaining compliance.