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FoodTech Report

Volume 6 Issue 2

Conserve and Control: Part 2 — Extract, Extend, Enhance

This two-part series on conservation will discuss the ways that food processors can reduce the consumption of natural resources, ingredients and maintenance products while reducing overall operating costs. Part 2 discusses opportunities for waste reduction and materials savings.

Part 1,
 which appeared in the last issue of FoodTech Report, addressed how processors can conserve utility usage. JBT FoodTech can help companies address these issues with innovative food processing solutions that have been developed in response to worldwide natural resource consumption concerns and increasing operating costs.

CitrusWaste not, want not. The saying is a reminder that people should value what they have, while inferring that the more conscientious they are in using resources, the longer those resources will last. In food processing, less waste can mean more product output, less unplanned downtime and a cost-effective processing environment.

Making use of every part of an ingredient by finding ways to use what would normally be waste, extending the life of cooking oils and cutting down maintenance needs are just a few ways food processors are reducing waste and achieving cost savings.

One process, multiple benefits

Citrus processors cut down on waste by utilizing every part of the fruit. Orange oil and pulp wash — by-products of orange juice processing — are common ingredients in food, beauty and cleaning products; rind and seed waste from the extraction process is sold for livestock feed production. The JBT FoodTech Citrus Juice Extractor aids processors in oil collection by simultaneously conducting juicing and oil recovery during the same extraction cycle.

The cold-press oil recovery system uses a fine water spray to collect oil droplets that are expelled from the

Citrus Juice Extractor.

orange peel at the extractor. The citrus oil is separated from the water through centrifuging, and the water is returned to a decanter tank, which separates remaining fine particles and solids. The water is then sent through a series of filters and returned to the extractor for reuse.

“By using a decanter tank designed and manufactured by JBT FoodTech specifically for the citrus industry, processors can achieve 75 percent water reuse without negatively impacting oil recovery,” says Michael Mas , product manager, citrus processing technologies for JBT FoodTech .

Preserving quality and cost

A similar centrifuge and filtering technology can be used to extend the life of trans-fat-free cooking oils, which tend to be more susceptible to degradation than partially hydrogenated oils. Processors are increasingly turning to these high-quality oils as consumers opt for trans-fat-free foods.

“The widespread prior use of partially hydrogenated oils by food processors stemmed from the oil’s ability to fry multiple batches of product while maintaining its quality. Trans-fat-free oils have a lower heat threshold,” says Ramesh Gunawardena, technology and process development manager at the JBT FoodTech Food Processing Technology and Training Center in Sandusky, Ohio, U.S.A.

JBT FoodTech combats the high cost and short life of high-end cooking oils with the MX-Series MicroMax™ hot oil filtration system, which can minimize oxidation, polymerization and sedimentation, extending the life of cooking oils and preserving food product quality. 

Studies have shown that the MicroMax hot oil centrifugal filter extracts about 50 percent more filtrate, or oil from the sediment filtered, in relation to a conventional mesh filter. Clean oil is returned to the fryer through a continuous system.

The MX-Series MicroMax is a high-speed decanter centrifuge hot oil filtration system that creates continuous filtration and extends the frying life of trans-fat-free oils.

Waste reduction means more production

New freezer technologies run more efficiently and require 50 percent less lubrication, which translates to decreased waste from lubrication and increased production uptime. The FRIGoDRIVE® M drive system, available on larger-size GYRoCOMPACT spiral freezers, chillers and proofers, is an ultra-low friction, third-generation FRIGoDRIVE featuring a patented roller-bearing system.
“The roller-bearing eliminates the internal friction caused by traditional ball bearing systems, resulting in a reduction in lubrication use,” said Ingmar Pahlsson, freezer product line manager for JBT FoodTech .

In addition to product improvements, food processors can reduce lubrication efforts by ensuring the proper type of lubrication is used and applied correctly on equipment. The Ask the Expert article in the last issue of FoodTech Report explains proper lubrication techniques.

The challenging costs of ingredients, energy and environmental compliance have food processors looking at their operations from a 360-degree view. Efficiency is at the core of the solution to operating facilities using smarter, more manageable methods.

To learn more about JBT FoodTech, visit the JBT FoodTech Web site or contact a JBT FoodTech Specialist.

FRIGoDRIVE® is a registered trademark and MicroMAX™ is a trademark of JBT FoodTech.
©2008 JBT FoodTech. All rights reserved.

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