No more overfilled cans
The pay-back period for the investment in a fully automatic packing system may be as short as one year When a manufacturer promises a specific minimum product weight in the cans, he will often overfill the cans to keep this promise. By doing so the manufacturer gives away part of his product for free.
This problem, however, can be reduced to a minimum by using Cabinplant’s filling system. Read more in the next In-Side.
World-wide sales representation EUROPE
B FLAMINEX S.A. T. +32 5733 3102 F. +32 5733 2248 E. [email protected]
GR INTEKO REPRESENTATIONS . IMPORTS LTD. T. +30 2 10 81 01196 /01130 F. +30 2 10 81 01279 E. [email protected]
BG DATRA BELGIUM B.V.B.A. T. + 359 2 974 05 48 F. + 359 2 974 08 22 E. [email protected]
I TECNOPARMA S.R.L. T. +39 0521 304346 F. +39 0521 334204 E. [email protected]
D CABINPLANT DEUTSCHLAND GMBH T. +49 36601 92803 F. +49 36601 92804 E. [email protected]
IS MR. ÁSGEIR HJÖRLEIFSSON T. +354 588 8550 F. +354 588 8552 E. [email protected]
D BOHSTEDT INDUSTRIEVERTRETUNGEN T. +49 4123 2534 F. +49 4123 4714 E. [email protected]
N CABINPLANT ÅRSTAD NORGE AS T. +47 5531 0059 F. +47 5531 5158 E. [email protected]
ES KELAPACK S.A. T. +34 93 635 7070 F. +34 93 637 6884 E. [email protected]
PL SVEDAN-POLSKA SPÓLKA Z O.O. T. +48 61 8420 738 F. +48 61 8485 837 E. [email protected]
F CABINPLANT SARL T. +33 1 4840 7050 F. +33 1 4840 0246 E. [email protected]
S CABINPLANT SVENSKA AB T. +46 8795 8095 F. +46 8795 8008 E. [email protected]
FIN TRADOXA OY T. +358 2435 1425 F. +358 2435 1424 E. [email protected]
RU EIGNELINE CENTER T. +7 095 292 10 40 F. +7 095 292 10 28 E. [email protected]
USA CABINPLANT INC. T. +1 207 781 7621 F. +1 207 781 7622 E. [email protected]
PH JCD METALFABRIK CORPORATION T. +63 2 936 0157 F. +63 2 936 3527 E. [email protected]
ID P.T. SABINDO REFRIGERATION TECHNOLOGIES T. +62 21 3500 130 F. +62 21 3501 570 E. [email protected]
THE MIDDLE EAST IR INDUSTRIALS SGC LTD. T. +98218725434 - 8 F. +98218725446
LK . MV COLUMBUS TRADING (PVT) LTD. T. +94 112 69 7779 F. +94 112 69 9371 E. [email protected]
AFRICA ZA K F ALBRECHT & CO SOUTH AFRICA (PTY) LTD T. +27 21 5084 800 F. +27 21 5084 888 E. [email protected]
ET PROMOTING INTERNATIONAL CO. (P.I.C.) T. +20 2762 0097 F. +20 2762 0417 E. [email protected]
CABINPLANT INTERNATIONAL A/S Roesbjergvej 9 DK-5683 Haarby T. +45 6373 2020 F. +45 6373 2000 E. [email protected]
Accurate product mixing in cold store
With the new step motor-driven multihead weigher, accurate mixing of up to four different products is possible.
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30 tons state-of-the-art shrimp in 8 hours
Fast and precise cheese cutting
Cabinplant has built a complete
Cabinplant ensures optimum
processing line for white shrimp in
handling of yellow cheese and
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Gentle weighing and packing of fragile products . . . . . . . . . . . . . . . . . Step motors optimize the multihead weigher
. . . . . . . . . . . . page 04
No more biting off more than you can chew . . . . . . . . . . . . . . . . . . . . .
Processing system encourages Greeks to new investments . . . . . . . . page 07 Shrimp processing plant in Belize, Central America . . . . . . . . . . . . . . . . . . .
Fast and precise cheese cutting . . . .
It is Cabinplant’s declared goal to strengthen its position on the global market. One of the means for achieving this will be to increase focus on the international exhibitions. We look forward to meeting you.
EXHIBITIONS Year 2004
8 - 11 Sep.
World Food Moscow
21 - 24 Sep.
21 - 24 Sep.
22 - 26 Nov.
Boston Seafood Show
13 - 15 Mar.
21 - 27 Apr.
Seafood Processing Europe
26 - 28 Apr.
15 - 17 Nov.
24 - 27 Oct.
Stand Hall 1, A630 2, H50
8 - 11 June
Cabinplant Inside is published by Cabinplant International A/S, Denmark, Distribution: Cabinplant customers, agents, subsidiaries, co-operation partners, etc. Editor: Lars Kops, Languages: English, German, French and Russian, Graphics and layout: Pernille Bæk.
Gentle weighing and packing of fragile products
Cabinplant’s engineers have designed a weighing machine on which fall heights and product handling are reduced to a minimum and the product infeed is supported by vibration. By removing the assembling pans from the multihead weighing machine and replacing them by chutes the first fall that the product normally undergoes has been eliminated. At the same time, the angle of the subsequent assembling hoppers has been levelled as much as possible. To prevent product from accumulating in the flat-angled assembling hoppers, vibrators have
been installed to ensure that the product moves gently through the assembling hoppers without being damaged.
C AB I N P L ANT I N SI DE 03
Automatic weighing of fragile products such as shrimp and mushroom has always been a tricky business – particularly when accuracy is a must. However, Cabinplant has now developed a series of solutions that make it possible to automatically weigh and pack fragile products just as gently as if handled manually.
The angle of the timing hoppers has also been reduced, and product is conveyed through these hoppers in the same way as in the assembling hoppers, i.e. by means of vibration. By means of flat angles, vibratory infeed and a reduced number of falls, Cabinplant’s new weighing machine is the gentlest machine to date for packing of fragile product. Actually, the machine is so gentle that it packs frozen whole shrimp (head-on) without damaging their delicate antennae, eyes and legs. The packing speed depends on the fragility of the product concerned, the weight and volume for each batch, and the special requirements for the packing.
:: Using vibration means that the drop slope can be reduced thereby ensuring a gentle “fall” through the assembling hopper.
Step motors optimize the multihead weigher The French frozen food producer, Boiron, introduces a new Seafood Mix packed on Cabinplant’s new step motor-driven multihead weigher.
C AB I N P L ANT I N SI DE 04
In January 2004, Boiron extended its range of frozen food products with a completely new Seafood Mix. As the name indicates, this is a mix consisting of four different seafood products – two types of mussels plus shrimp and squid. The four products are weighed individually in their own product zones on Cabinplant’s new multihead weigher, and subsequently they are mixed in the timing hopper. The recipe is monitored from and easily changed on the control panel. Cabinplant has optimized the multihead weigher by replacing pneumatic components by electrically driven step motors, which open and close the 28 assembling pans and 28 weighing pans. The step motors ensure optimum machine functioning down to minus 20°C. At the same time, the motoractuated control ensures a high degree of continuity and reliability as the software constantly monitors all
weighing pans. In the event of production breakdown, e.g. if product is stuck in the weighing pan, an alarm automatically starts. In addition, the step motors use less energy than the pneumatic control system. All mechanical parts are enclosed making the machine very easy to clean. In addition, the unit has no flat areas where water and product residue may accumulate during cleaning. The entire multihead weigher is designed in modules. Motor, gearbox and load cell, for example, have been constructed as one independent module, enabling the operator to exchange the modules himself, thus reducing production stops to an absolute minimum. Such modules can be replaced in less than ten minutes – an important cost saving factor.
:: 4 product zones
TECHNICAL SPECIFICATION From 10 to 32 weighing channels.
100 cc, 300 cc and 500 cc
Up to 325 dumps per minute
25 g to 6,000 g per dump
Weighing Accuracy: +/- 0.5 g
C AB I N P L ANT I N SI DE 05
:: Multihead weigher with platform – design and construction of platform facilitates cleaning
Boiron’s new multihead weigher with 28 weighing heads doses the Seafood Mix into 500 g and 1000 g bags. The multihead weigher is capable of weighing approx. 55 small or 40 large bags per minute. The accuracy is very high – Boiron’s Seafood Mix bags are portioned within a tolerance of plus/minus 2.5 g.
:: Motor, gearbox and load cell are incorporated into one module which can easily be replaced.
No more biting off more than you can chew Bread producers expect to cut dough consumption considerably by reducing unnecessary overweight.
C AB I N P L ANT I N SI DE 06
No matter how much accuracy industrial bread producers aim at in their production, it is impossible to achieve the exact bread weight each time. Ambient temperature, air humidity and raw material are factors which affect the process, and consequently bread producers tend to oversize their breads. A costly error when bread bags promise a specific number of breads and a minimum net weight. Because of its considerable expertise within the construction of multihead weighers taking the required number of bread rolls into account, Cabinplant has been able to supply a filling line which can help a Danish bread producer cut down dough consumption substantially. A prescribed number of bread rolls are packed into bags, but since the breads vary in size there is a risk of not achieving the required minimum weight. Consequently, the producer is forced to oversize the breads to ensure that the correct weight is achieved. Cabinplant’s multihead weigher gives the producer instant raw material savings as well as other production advantages. Featuring a high degree of flexibility, the multihead weigher is capable of handling most bread types. Bread rolls are packed in small bags of 10-20 each, large bags containing 60 bread rolls, and even larger quantities for the catering industry. As the bread rolls may also be sprinkled with poppy seeds, grain flakes, etc., which may easily fall off if the bread rolls are subjected to bumps and blows, one of the challenges Cabinplant faced was to ensure gentle handling of the bread rolls. Consequently, Cabinplant’s machine designers created gentle transitions and reduced the fall heights in the weighing/packing process. The plant features a very high capacity and distributes 32,000 bread rolls per hour, thus feeding two vertical form/fill/seal machines continuously. The multihead weigher is of the type 50-14 with 14 weighing pans and a 5 l assembling hopper. The small bags are filled in one discharge sequence while two
sequences are required when filling large bags. Even more sequences are required for catering packages. Cabinplant’s multihead weigher is incorporated completely into the existing production equipment and streamlines the entire process by reducing dough consumption and ensuring a more flexible packing process. With a view to optimising the production, Cabinplant develops individual PLC controls in cooperation with the customer. In addition, everything is controlled by means of a simple, user-friendly recipe control. As an extra facility, the machine design allows for the special cleaning methods used in industrial bakeries.
Agricultural Center’s technological production venture is a success.
Five years ago, Agricultural Center – a company in the northern part of Greece – was producing 3 tons of peas and 1.5 tons of beans per hour on their processing system. Now, 8 tons of frozen peas and 4.5 tons of frozen beans are conveyed through the system every hour during the season, as a direct result of the company’s successful technological venture in which Cabinplant has been engaged to design the processing line layout and deliver the equipment. The new system – which has been incorporated into the company’s original pre-cleaning system – consists of a bulk feeder, air cleaning and washing of vegetables, pod removal (peas) and de-stringing (beans), quality control, draining, freezing and size grading after freezing. The short pea season has a production period of only 25 days, so line capacity and operational reliability are crucial. Even though the bean season is twice as long as the pea season, the line’s operational reliability is also vital for the return on the invested capital. In addition, Agricultural Center is so pleased with the processing system from Cabinplant that the company has already contacted Cabinplant again to have the system
expanded for processing other types of vegetables. The aim is to have Cabinplant develop and design a multi-purpose line that will extend the utilization of the equipment beyond the processing of peas and beans.
C AB I N P L ANT I N SI DE 07
Processing system encourages Greeks to new investments
The photo shows some of the production ponds. At the bottom of the photo, the new processing plant is under construction just next to the warehouse – the blue building.
:: At the bottom left-hand corner and in the middle: The two receiving/storage tanks which can hold a total of 30,000 kgs shrimp corresponding to the harvest from one pond.
:: The conveyors conveying the shrimp from the receiving/storage tanks and into the factory.
Shrimp processing plant in Belize, Central America C AB I N P L ANT I N SI DE 09
Cabinplant has just installed and commissioned a complete processing line for white shrimp (Penaeus Vannamei) in the Central American state of Belize.
Over the past years the customer, Belize Aquaculture LTD, has developed an innovative state-of-the-art shrimp farming method thus obtaining a higher yield per hectare pond than achieved anywhere else in the world. At the same time, the method poses no threat to the surrounding aquatic environment as no waste water is returned to the ocean. Instead, all water is purified and reused.
Weigher, and finally packed on a form, fill and seal machine.
The processing plant is probably the most advanced of its kind today and is capable of supplying shrimp products of superior quality. As soon as the shrimps are harvested, they are transported to the factory in insulated containers filled with liquid ice, which cools them down close to 0°C almost immediately.
The factory layout allows for the subsequent installation of additional equipment, such as a cooking line for manufacturing different kinds of value-added products. The objective for the future is to install equipment for the drying and grinding of the shrimp waste as well.
At the factory, the shrimps are loaded into two large receiving tanks filled with a mixture of liquid ice and chilled water. From here the shrimps are conveyed into the processing area where they are de-headed, graded by size and sorted by quality. The shrimps are then either block-packed in 2 kg cartons and frozen in plate freezers or IQF-frozen in a Frigoscandia spiral freezer. After freezing, the IQF shrimps are glazed and afterfrozen, then portion-weighed on a Cabinplant Multihead
Throughout the entire process the shrimps are either stored in ice water or covered by flake ice. At present, the line makes three types of products, i.e. HO (whole shrimp), HLSO (headless shell-on), and peeled shrimp, which are either block-frozen or IQF-frozen.
White shrimp (Penaeus Vannamei)
3,600 kg per hour
IQF and Block-Frozen Head-on, headless and peeled shrimp
Fast and precise cheese cutting Cabinplant ensures optimum handling of yellow cheese and feta cheese.
C AB I N P L ANT I N SI DE 10
Cabinplant has gained considerable expertise in handling both yellow cheese and feta cheese. The major part of the large, yellow cheese is cut into smaller blocks that are further processed into grated cheese for pizza, etc. Others are processed into small cheese cubes to be used in salads and cooking in general. Feta cheese is cut into blocks precisely fitting the selected packaging. Another type of production using Cabinplant equipment is the small feta cheese cubes packed in small tubs with strainer and brine that consumers find in the refrigerated counter in the supermarket. The yellow cheese blocks are usually 30 x 30 x 40 cm, before dicing. The cube sizes vary from 15 mm square to 70 mm square. Two cuttings are usually required to achieve the preferred cube size. The hardness of the cheese determines whether steel strings or knives are required for the cutting process. Stainless steel knives are often used for hard cheese or alternatively normal
steel cutting strings, which have a tensile strength twice that of stainless steel cutting strings. Soft cheese is cut using stainless steel cutting strings. The cutting capacity depends on the hardness of the cheese. A Cabinplant cutting system for relatively hard cheese such as many yellow cheeses usually processes one ton per hour whereas twice as much cheese is processed by cutting systems designed for soft cheese. Feta cheese cut with knives Despite their soft texture, feta cheeses are cut using knives that minimise operational breakdowns in case of broken cutting strings. The cheese is conveyed to the cutting area on a trolley holding more than 100 cheeses at a time. Cabinplant’s system automatically ensures that the cheese is emptied from the moulds and correctly positioned on the conveyor belt. Here it is sorted according to weight and size before being cut into blocks directly for packaging. Control weighing and measuring are continuously performed to optimise the process at all times. The system is extremely accurate and flexible and reduces the consumption of resources. Knives are easily changed to accommodate different block sizes or packagings. Despite the system’s high precision – a deviation of ± 3 grams per block – the cutting capacity is up to 2.5 tons of feta cheese blocks per hour.
:: Dicing and grating of yellow cheese
:: Dicing of feta cheese
:: Pre-cutting of cheese
TECHNICAL SPECIFICATION Capacity - Grated cheese:
Cap./h: Approx. 2,500 kg Cube size: 25 - 75 mm
Capacity - Feta cheese:
Cap./h: Approx. 1,500 kg Cube size: 8 - 25 mm
Capacity - Block cheese/pieces: Cap./h: Approx. 1,500 kg Block/Piece size: 25x25x25 mm -150x150x150 mm