http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/RSS.ashxMarel PagesThu, 10 Feb 2011 17:35:10 +0100http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=1http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=1Published by Townsend Further Processing - June 2010 - English IFFA 2010 D E D U L C IN T N E M E SUPPL GLOBAL EDITION Further Processing news In this edition: RevoPortioner product range extended Salm Partners: US sausage giant installs another QX System In dit nummer: IFFA 2010 Bringing youReview successful solutions – Stork delivers… Esca Food Solutions: partner in … een nieuwe generatie RevoPortioner opdeelsysteem: ‘red meat’ innovation ACM-NT iLinker iConveyor: … een & FHF-XB nu ook the innovation JHVFKLNWYRRUUHWDLO¿ OHW in sausage making equipment … in-lijn marineren met de ValueDrum Western Brand: Leading UK andvan Ireland … een combinatie Stork poultry processor en Townsend apparatuur gears up for the future Vital Convenience buys state-of-the-art line for new factory building2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=2http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=2Content 2 A new name and a new face 3 RevoPortioner product range extended 4 Salm Partners installs company’s third QX System 5 through 8 IFFA 2010 PERFECT HARMONY EXHIBITION SUPPLEMENT A new name and a new face In the past year much has changed both within and outside our organization. The economic crisis KDVKDGXVWRR¿UPO\LQLWVJUDVS 'HVSLWHWKLVZHKDYHEHHQVXFFHVVIXO With the integration within Marel you have easier With a strong focus on innovation, Townsend Further Processing offers a complete package of products for all possible steps in the further SURFHVVLQJRISRXOWU\UHGPHDW¿VKQRQPHDWDQG potato products; portioning, marinating, coating, frying, cooking and sausage manufacture. in taking the path to growth. It seems 9 iLinker & iConveyor: the innovation in sausage making equipment 9 Vital Convenience buys state-of-the-art line for new factory building 10 Jensen’s Foods and Townsend Further Processing – a new partnership 10 ‘Angel hair’ burgers to really get your teeth into 11 Fieldale Farms: Superior quality with the RevoPortioner 11 Western Brand invests in complete Townsend Further Processing line 12 B.A. production group meets new food trends on Iranian market The integration within Marel is an important process for us. Until now, we have been known to many of our customers as the ‘Further Processing business unit of Stork Food Systems’ or quite simply as ‘Townsend’. access than before to a wide range of advanced products, which we are now able to offer as in-line concepts as well. These cover the entire process from protein masses preparation right through to an attractive end product presentation. Clear examples of this cooperation and of our innovative strength could be seen at IFFA 2010 in Frankfurt. ,QWKLVQHZVSDSHU\RXZLOO¿QGDVXSSOHPHQWRQ this exhibition. WKDWZHZHUHDEOHWRFRQYLQFH VXI¿FLHQWFXVWRPHUVZLWKRXU innovative, progressive machines DQGV\VWHPV2XUVROXWLRQVKDYH contributed to the improvement of SURGXFWTXDOLW\DQGRIFRXUVHWR SURFHVVLQJHI¿FLHQF\DQGFRVW FRQWUROWRR )RUPHSHUVRQDOO\,))$)UDQNIXUWZDVP\¿UVW comprehensive introduction to the branch, as I only started working for Townsend Further Processing on May 1st this year. With my background in the packaging industry I feel at home in this organization. It is a good basis to work together with my colleagues on more innovative products and a good service provision. With my strong belief in a thriving future I hope and Our new name is Townsend Further Processing. We are now the Further Processing Industry Center worldwide within Marel and form together with the three other Industry Centers (Stork Poultry Processing, Marel Meat Processing and Marel Fish Processing) the pillars of this international organization. look forward to working very closely with you. Colophon Townsend Further Processing Handelstraat 3, 5831 AV Boxmeer P.O. Box 233, 5830 AE Boxmeer The Netherlands T : +31 (0)485 586 122 F: +31 (0)485 586 655 E: info.townsend@marel.com www.marel.com Townsend Further Processing is a trade name of Marel Townsend Further Processing B.V. © Copyright Marel Townsend Further Processing B.V. The Netherlands, 2010: all ULJKWVDUHUHVHUYHG$Q\UHSURGXFWLRQRUPRGL¿FDWLRQRIDOORU part of this brochure, regardless of the method of reproduction RUPRGL¿FDWLRQXVHGDQGUHJDUGOHVVRIWKHFDUULHUXVHGLV strictly prohibited, written authorization by Marel Uitgave van Stork unless Food Systems Townsend Further Processing B.V. has been obtained beforehand. Those acting in breach of this notice expose themselves to criminal and civil prosecution, in accordance Stork Food Systems with the international conventions and copyright laws. Bert Jan Hardenbol, Managing Director of Townsend Further Processing. Postbus 118 The data published herein answer to most recent information 5830 AC Boxmeer, Nederland at the moment of publishing and are subject to future T : (31) 485 586 111 PRGL¿FDWLRQV7RZQVHQG)XUWKHU3URFHVVLQJUHVHUYHVWKHULJKW F modify : (31)the 485 586 222 to construction and the execution of their product2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=3http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=3F u r t h e r P r o c e s s i n g N e w s 3 RevoPortioner product range extended > T E C H N O L O G Y RevoPortioner Small and RevoPortioner Large: ready to conquer their markets The use of air RevoPortioner’s forming drum is made from air-permeable stainless steel. Products are unloaded using air instead of water. This is good for product quality and makes for better control of downstream process such as, for example, ÀRXULQJEDWWHULQJEUHDGLQJIU\LQJFRRNLQJRU packing (fresh) product. To give an example: as water is no longer needed, there is no thinning of batter or proteins. The front and back of the product pick up coating equally and adhesion is better ensuring nicely even coating of the whole product. An even coating which adheres well will also have a positive LQÀXHQFHRQWKHIU\LQJSURFHVV)HZHUSURGXFWVZLOO burst open and the frying oil will age less quickly. The result is a quality end product at lower cost. The Townsend RevoPortioner’s WHFKQRORJ\KDVEHHQDELJVXFFHVV VWRU\IRUVRPH\HDUVQRZ7KHORZ pressure portioning machine uses air WRXQORDGSURGXFWDQGLVNQRZQIRULWV DELOLW\WRSURGXFHORQJWURXEOHIUHH runs of attractive end products of XQLIRUPO\FRQVLVWHQWVKDSHZHLJKW VL]HDQGTXDOLW\5HYR3RUWLRQHUFDQ KDQGOHDYHU\ZLGHUDQJHRIPHDW PL[HVDOVR¿VKQRQPHDWDQGSRWDWR SURGXFWV,WVDLUSHUPHDEOHIRUPLQJ drum, which can be swapped over TXLFNO\DQGHDVLO\DOORZVYLUWXDOO\DQ\ shape to be made. The success of RevoPortioner’s technology and developments in the market were reasons enough to go for a robust expansion of the RevoPortioner family. Townsend Further Processing is therefore proud to present the new RevoPortioner Large and the RevoPortioner Small. Both machines are suitable for the processing of all kinds of meat mixes including lean beef as well. RevoPortioner Large can handle 4,000kg (8,800 lbs) per hour and has a belt width of 700mm. The much smaller RevoPortioner Small uses the same technology and is of the same quality and durability. With its belt width of 400mm it can produce some 1,000kg (2,200 lbs) per hour of end products. With its integrated pump, the machine is compact and easy to move around. Its price level makes it very suitable, indeed, for the smaller further processor. Function A pump unit presses the meat mix at low pressure into the distributor housing. The distributor housing ensures equal distribution of the meat mix over the width of the continuously rotating forming drum. As they pass the distributor house opening, each URZRIIRUPVLV¿OOHGZLWKWKHPHDWPL[$SUHVVXUH VHQVRUPHDVXUHVWKH¿OOLQJSUHVVXUHDQGFRQWUROV WKHPHDWSXPSWRJLYHDFRQVWDQW¿OOLQJSUHVVXUH 7KHSUHVVXUL]HGVOLGHSODWHNHHSVWKH¿OOHGIRUP under pressure. This ensures the integrity of the shape of the product. At the blow off position, formed products are blown from the forming drum by air. After they have been blown off, formed products move on a transport belt to the next process step – for example, breading, frying, cooking or just freezing. Strong technology RevoPortioner’s strength is its technology. Whilst maintaining the quality, texture and structure of the raw materials, the machine forms perfectly portioned quality products at low pressure. Central to the technology are a forming drum, which is ÀH[LEOHLQLWVXVHDQGDLUWRXQORDGSURGXFWVIURP the drum. Water is no longer needed. Flexible, three dimensional technology RevoPortioner’s forming drum is quick and easy to VZDSRYHUDOORZLQJÀH[LEOHDQGTXLFNUHDFWLRQWR the market. Examples of “classics”, which can be made on RevoPortioner, are hamburgers, nuggets and schnitzels. With its ability to form three dimensional products such as, for example, WHQGHUORLQVVWHDNVDQG¿OOHWV5HYR3RUWLRQHUVWDQGV out from other forming solutions in the marketplace. To give an example; steakers are often used in beef applications. These prick holes in the product to improve the cooking process. The three dimensional forming technique allows this job to be done during forming. A separate steaker is therefore no longer necessary. Another good example of the three dimen2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=4http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=44 F u r t h e r P r o c e s s i n g N e w s ¿ UVWFODVVVROXWLRQIRUSRUWLRQLQJVPDOORUODUJH volumes of product at low pressure. It is a very À H[LEOHV\VWHPDEOHWRIRUPDOOPHDWPL[HV¿ VK mixes, potato and non-meat into products of virtually any shape, large or small, thick or thin and in 3D or not. There are different RevoPortioner versions and FRQ¿ JXUDWLRQV:KHWKHU\RXZDQWWRPDNHVPDOOHU or very large volumes, whether you want to have WKHÀ H[LELOLW\RIPDNLQJDOONLQGVRIGLIIHUHQW products or just want to turn out continuous runs of perfect hamburgers, RevoPortioner is the perfect portioning solution for you. N N N N Key RevoPortioner features Suitable for all kinds of meat mix: whole muscle meat (chicken), lean beef and meat mixes Keeping raw material texture and structure intact ensures the best possible mouth feel N N N N N N Wide production program. High capacities of up to 4,000kg (8,800 lbs) per hour possible Very low maintenance costs Very low noise level Simple to operate and clean. Consistently high accuracy of shape and weight Product is unloaded using air. Water is not necessary. This enhances quality. Forming drums, quick and easy to swap over, ensure optimal product variety Minimal leakage of the meat mix > M A R K E T S Salm Partners installs company’s third QX System similar results. category volumes are steadily increasing as families add the improved product to their regular meal rotation. Application of QX coextrusion to linked products is steadily increasing as well with The “cook-in-package” technology truly sets the product apart and Salm predicts this technology will permeate the market in all categories. The food safety advantages and the enhanced shelf life of “cook-in-package” products will prove critical in feeding the world’s population in this century. Salm Partners has built their business on the pillars of credibility, transparency and trust. They seek to serve the meat industry by showcasing and proving cutting edge technologies. Their partnership with Townsend Further Processing has allowed them to do that, and there is every indication that this relationship will continue for many years to come. 6DOP3DUWQHUVLVDQLQQRYDWLRQ LPSOHPHQWDWLRQFRPSDQ\ZLWKDFXUUHQW IRFXVRQ³FRRNLQSDFNDJH´UHDG\WRHDW SURFHVVHGPHDWV7KHFRPSDQ\LVORFDWHG in Denmark, Wisconsin. Founded in 2004, 6DOP3DUWQHUVKDVHQMR\HGSDUWQHULQJZLWK Townsend Further Processing to VXFFHVVIXOO\LPSOHPHQW7RZQVHQG¶V4; TXDOLW\FRH[WUXVLRQIRUVDXVDJHDQGKRW dog production. Recently, the company installed a third QX system, this one for linked sausage and hot dogs. 6DOP3DUWQHU¶V¿ UVW4;V\VWHPLVULQJVDXVDJH VSHFL¿ F7KHVHFRQG4;V\VWHPLVXVHGWRSURGXFH a combination of ring and linked sausage. The three QX systems allow Salm Partners to achieve WKHFDSDFLW\DQGÀ H[LELOLW\WRPHHWYLUWXDOO\DQ\ market demand in the sausage and hot dog markets. “Our goal is to implement new technologies that can change the market for the better,” said Chris Salm, CEO and founder of Salm Partners, LLC. “The Townsend QX technology is appropriate for our business because we can produce a JXDUDQWHHGVDIHPRUHHI¿ FLHQWO\SURGXFHG consumer preferred product.” “In order to serve our customers and their consumers,” Salm added, “our products must have VSHFL¿ FH[DFWLQJFKDUDFWHULVWLFV7KHEHDXW\RIWKH Townsend QX system is being able to change variables by dialing in lengths, weights and other characteristics to get the desired products.” Salm Partners’ mission is to be a proving ground for new technologies in food processing. “We come alongside our supplier partners and help them to prove and improve their new systems and processes in a full manufacturing setting,” Salm H[SODLQHG,QWKHODVW¿ YH\HDUVWKHFRPSDQ\KDV opened their doors to visitors from around the world who want to learn more about the Townsend QX systems. The retail shelf and meat counter in the US have changed markedly with the introduction of the QX systems. Though coextrusion has been used in Europe for nearly three decades, its use in the ring VDXVDJHFDWHJRU2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=5http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=5IFFA 2010 Perfect harmony EXHIBITION SUPPLEMENT2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=6http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=6Bert Jan Hardenbol, Managing Director of Townsend Further Processing new possibilities to develop their processes further. The large number of leads and the various commercial successes, to which we were able to raise a glass of champagne at the exhibition, are an excellent illustration of this. I am also proud of how our Townsend Further Processing brand has been presented here. When we combine its product range, eloquent examples of which are the RevoPortioner Large, the RevoPortioner Small and the iLinker and iConveyor, with the various solutions on offer from our colleagues at Marel Meat, then we are able to give excellent support to our customers in achieving their objectives. IFFA 2010 was a big success for both Marel industries; and in my opinion, the theme of the exhibition “Perfect Harmony” endorses perfectly the way in which we appeared here together.” Townsend Further Processing / Marel “As a start-up company we are visiting IFFA for the first time. We got to know Townsend Further Processing during the Gulfood fair and are really curious about equipment such as the RevoPortioner. Besides processing salmon, we focus on producing beefburgers chiefly for markets in the Middle East. We are on the lookout not just for new machines but also for help and advice. Townsend Further Processing could therefore be a first-class partner for us. The company exudes confidence and supplies top quality. This is a very important combination for us and the basis for a good honest deal. The product range on offer from Townsend Further Processing and Marel Fish is an excellent match for our objectives and the products we process.” Jacques Roosenbrand, DemoCenter Manager of Townsend Further Processing “We chose this IFFA to let our customers taste everything we can make with our machines. Between 1600 and 1800 hrs, we served up a generous selection of products. Besides the usual classics such as hamburgers, nuggets and various sausages, we served breaded whole muscle chicken fillet, ‘chicken thigh on a stick’ and ‘angel hair burgers’ (both with and without a rich filling). Certainly, these burgers, made on our MasterFormer, were enthusiastically received by our customers. Their open structure, rich taste and home-made look were really an eye opener for some customers. Our happy hour was a big success; drinks, snacks, live music, good atmosphere, a lot of visitors. Customers could really catch up on the news in an informal atmosphere. As hosts we did an excellent job. It was good for me to be able to make my contribution as chef.” “It’s splendid to see that once again we were able to show our visitors a large number of innovative products at this IFFA. The many machines on our own stand rightly received a lot of attention. The large number of visitors is a sign for us that the market has started to move again. We spoke to many companies looking to expand or for MasterFormer “MasterFormer could be a good solution for producing Cordon Bleu, but those products with a loose structure are particularly attractive. The beefburger filled with cheese which I tasted on the stand was fantastic!” “We are seeing a trend in the Dutch market. There is more and more demand for quality products with an open loose structure, demand for products which have that home-made ‘old-fashioned’ magic. Besides this, we are also concentrating on new, innovative and exciting products. MasterFormer looks to be an excellent solution for these.” TurboVar “The speed and flexibility of this machine appeals to me as well as its small footprint and the fact that we can combine it with our own pump. It is attractive that the machine cuts sausage with no twist, yet your products don’t have an open end.” Townsend RevoPortioner Small “We want to increase our production capacity and to keep offering new products to our customers. Flexibility and quality are really important here. This RevoPortioner Small fits seamlessly into our existing 400mm line. This makes the investment attractive. We on2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=7http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=7Esca Food Solutions GmbH, Germany The OSI group, to which Esca Food Solutions belongs, is worldwide one of the largest manufacturers supplying the various quick food chains and food services. Esca occupies a leading position in the European market and manufactures a total of approximately 55,000 tons per annum of poultry products and approximately 130,000 tons per annum of beef products at ten production sites. Esca Food Solutions is known above all for its hamburgers and chicken nuggets. technique at low pressure has since convinced him. Schulze: “Both me and my team believe in the machine’s technology and have been able to move a lot internally to convince our organization. This led to me being called “Mr RevoPortioner”. Sometimes it was not easy but we see great potential in carrying on with this technology. In the meantime we now have almost ten RevoPortioners in the OSI organisation. Me and my team are currently involved in all RevoPortioner decisions.” “Of course I am enthusiastic about the machine, the long trouble-free runs of perfect products, the reliability, the low maintenance costs, the high degree of flexibility, its rotating production method, clean with low noise levels, little waste, few moving parts and therefore very low wear and tear. But there is scope for more development, for example, the weight and price of the drum. Airpermeable stainless steel is an expensive product and unfortunately the drum cannot yet be made at short Peter Schulze (Business Director Esca Europe, on the left) receives the award from Henri Janssen (Manager Sales & Operations, Townsend Further Processing). Peter Schulze, Business Director Esca Europe: “We would like to improve our efficiency, further develop our products and processes and come up with innovative new products. To develop ideas which are really new you have to think “out of the box”. Many businesses are orientated on price alone, whereas we would like to open up new possibilities with new competitive products and new processes. That is our strength.” “For this, we are looking for partners who are happy to take this occasionally long road and are really in the position of working together as a team on both the products and the best processes for them such that our customers are satisfied and get exactly what they want. Townsend Further Processing is just such a partner. We have very good dialogue both on technical matters and on new products and get competent support.” “Cooperation on the RevoPortioner is a splendid example. Common dialogue enabled us to find solutions, which optimized not just the machine but the whole production process. In the last two years both teams worked closely together on the development of RevoPortioner for beef products. Our customer’s acceptance of the products produced, which we have already received, and the very good test results are witness to the success of this excellent cooperation. Both teams (Esca and Townsend Further Processing) put in an enormous amount of effort to achieve success. I would like to take this opportunity of expressing my thanks to both teams.” First the solution and only then the costs “What is impressive with Townsend Further Processing is that they as good as always look first for a solution and have a positive attitude to our ideas. You never hear “that’s not possible,” they always come with a solution of how it could be possible. Then we can have a look at the “how” and afterwards the costs. “Not possible” doesn’t exist. That’s exactly the attitude we need if we are to make real progress together.” ‘Mr. RevoPortioner’ Schulze has been following RevoPortioner ever since the technology was first introduced. Its rotating portioning From left to right: Theo Bruinsma (member of the Board of Directors, Marel), Mrs and Mr Salm, Bob Damstetter (Vice President Further Processing Industry Center, Marel). Christopher P. Salm, president and CEO: “The Townsend Further Processing/Marel booth is really impressive and is the main att2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=8http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=8Cardinal Meat Specialists, Mississauga, Ontario, Canada Cardinal Meat Specialists Ltd. is a Canadian, familyowned company operating since 1966, with a family commitment to the meat business for over 80 years. One constant factor in their history is a dedication to a “family values” driven philosophy for doing business. Cardinal markets and manufactures the highest quality, portioncontrolled meat products, specializing in burgers at one facility, and a wide range of innovative, fully cooked meats at another. Both facilities are HACCP recognized, utilizing leading technologies and production methods. Roy Amm, Director of Manufacturing: “Satisfying our customers’ needs is what drives us to ensure we make the very best, food safe products. Our commitment to safety, quality and productivity is the cornerstone of how we have maintained our reputation for so many years. Combined with that, we are looking for real partnerships when we select companies to work with. We need good support, supply and service. From that perspective, we have a great start with Townsend Further Processing.” orientate myself on robotic picking and automated packaging. It is great to see that now Townsend and A Unique Burger Experience “We are always looking for technology that can help us create a new, unique burger experience for our customers,” says Roy Amm. Cardinal has added a Townsend MasterFormer with MasterSlice and make up to 75,000 Natural Texture Forming™ burgers per shift. “NTF is our version of the products we make using the ultra low pressure forming technology. It creates a perfect bite for the product, with the ‘look and feel’ of a burger made by a butcher, yet produced in volumes on a machine. The various burgers we make with the MasterFormer can make a huge difference for Cardinal and our ability to lead in the Canadian market.” RevoPortioner “We also work with the RevoPortioner and tried to get the production of lean beef right on the RevoPortioner Medium. Although the equipment wasn’t compatible for use with lean beef, the Townsend team assisted us with troubleshooting and developing a plan to ensure our needs were met. I think the RevoPortioner Large will do a better job with lean beef; there won’t be any fat built up. The construction of the machine and the 700 bandwith makes it suitable for high volume production. The RevoPortioner is a great machine: it is robust, simple to operate and easy to maintain. You have few moving parts and the machine is very quiet.” Partners Roy Amm continues: “I came to IFFA to see the Townsend Marel stand and wanted to visit other companies to Marel are one: I can find these solutions at the very same booth, which will be another great step in us being partners in business. The path of becoming partners was not always easy: we had some struggles and frustrations and some times we were unhappy. Yet this was needed; they were growing pains. Working together toward a common goal, we made it possible. Now Townsend and Marel continue to provide great solutions for the processing of food. and we continue to be a dominant player in the Canadian premium burger market.” Roy Amm Director of Manufacturing of Cardinal Meat Specialists (on the left): “Burgers? We take it back to the old days, when I watched my mother grinding fresh meat …”. BBS Convenience Food BV, Barneveld, the Netherlands BBS Food BV makes its own label deep frozen and chilled fresh convenience chicken and pork meat products for food service, retail and industrial customers in the Netherlands and abroad. They process fresh meat into convenience products and snacks at two establishments in Barneveld. A large range of products is marinated and cooked in an integrated, fully automatic production process, after which products can be deep frozen, weighed and packed. Their way of working is really unique in the industry. They work for all customers following the 1-2-3 concept. Product, production process and type of packing are geared to the individual wish2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=9http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=9F u r t h e r P r o c e s s i n g N e w s 9 > T E C H N O L O G Y iLinker & iConveyor: the innovation in sausage making equipment smokehouse throughput. Processors can keep their tunnels and batch houses full, which means they are able to process and cook the extra links per strand practically for free. Loops are evenly spaced on the smoke stick, eliminating the need for operators to “thread” smoke sticks through the loops. This creates more time to properly tie the front and end links, reducing rework. Compared with conventional systems, the combination of iLinker and iConveyor can load up to 20% more links per stick when longer casings are used. Townsend Further Processing added two new machines to the company’s VDXVDJHOLQNLQJSURGXFWOLQHWKH iLinker and iConveyor. The new hybrid technology of the iLinker Intelligent Sausage Linking and iConveyor Intelligent Stick Management systems represents process LPSURYHPHQWVEH¿ WWLQJ7RZQVHQG¶VORQJVWDQGLQJ reputation for innovation in sausage making equipment. The system takes high speed sausage linking and smoke stick management to a whole new level. The Townsend iLinker maintains weight and length control unmatched in the industry. A link counting feature manages the number of links being produced on a stick-by-stick basis, notifying staff of Thanks to iConveyor’s hook spacing innovation, additional loops per strand enables maximum The Townsend iConveyor is the perfect connection to the iLinker. The system loads smoke sticks automatically according to the “moving drop point” principle. The iConveyor determines optimal positioning of each loop on smoke sticks. any link count shortfalls. The iLinker’s “Quick Jump” feature prevents loss of links due to untwisting, which dramatically reduces rework and provides better casing utilization. The new iLinker and iConveyor system opens the door to previously unimagined opportunities. Ask your Townsend Further Processing sales representative for more information. Townsend Further Processing engineers designed the iLinker and iConveyor system to match the footprint of the NL linker series. Therefore, no redesign of production areas is required when replacing NL linkers and conveyors with new iLinkers and iConveyors. > M A R K E T S Vital Convenience buys state-of-the-art line for new factory building 9LWDO&RQYHQLHQFH*PE+LVSDUWRI %$+2)22'DIDPLO\EXVLQHVVRIWKH %DOYHUVEURWKHUVZLWKEUDQFKHVLQ (PPHULFKDQG0|QFKHQJODGEDFKLQ *HUPDQ\DQG:HXUWDQG:LMFKHQLQWKH 1HWKHUODQGV:LWKLWVUHGPHDWSRXOWU\ DQGYHJHWDEOHSURGXFWVWKHFRQFHUQLV focused on the convenience food market. 8VLQJWUDGLWLRQDOSUHSDUDWLRQPHWKRGVDQG UHFLSHVSHUIHFWO\JHDUHGWRWKHP9LWDO &RQYHQLHQFHGHYHORSVLQQRYDWLYH SURGXFWVZKLFK¿ WLQZLWKWKHFRPIRUWDEOH OLIHVW\OHRIWKHPRGHUQFRQVXPHU7KLV FRQVXPHUZDQWVWRSTXDOLW\SURGXFWV ZKLFKFDQEHSUHSDUHGTXLFNO\EXWZKLFK DERYHDOOWDVWHJRRG7KHFXUUHQW9LWDO UDQJHLQFOXGHVSUHSDFNHGFKHHVHEXUJHUV FKLFNHQQXJJHWV*HUPDQPHDWEDOOVKRW GRJVDQGVFKQLW]HOV 7KH¿ UVWPHHWLQJEHWZHHQ9LWDO&RQYHQLHQFHDQG Townsend Further Processing took place at the IFFA fair in Frankfurt in 2007, where Townsend Further Processing’s equipment caught Vital Convenience’s interest. From that moment on the two parties began to work intensively together and became deeply involved in each other’s products. Lasting commitment from both sides In Mr Balvers’ opinion, what connects both businesses is the way in which the two companies, each in its own market, have created a distinct SUR¿ OHIRUWKHPVHOYHVZLWKWKHLULQQRYDWLYH products. Vital Convenience and Townsend Further New line for new factory building $WWKLVPRPHQWWKH¿ QLVKLQJWRXFKHVDUHEHLQJSXW to a completely new factory building to replace the unit in Mönchengladbach, which was destroyed by ¿ UH7KHQHZEXLOGLQJLQ(UNHOHQ]LQ*HUPDQ\KDV a surface area of some 6000 m2. To equip it, a contract was recently signed for a complete further processing line from Townsend Further Processing. After thorough evaluation of the various potential suppliers Townsend Further Processing was chosen. Accordin2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=10http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=1010 F u r t h e r P r o c e s s i n g N e w s > M A R K E T S Jensen’s Foods and Townsend Further Processing – a new partnership controlled process to retain yield and succulence. A chili glaze is then applied in the Townsend BatterApplicator, after which product temperature is lowered through the Dantech spiral freezer. Mr Mads Mikkelsen, Factory Manager at Jensen’s Foods in Struer, is happy with the new line: “The Townsend Further Processing team has shown huge commitment to make the project a success. 6XSSRUWDQGFRPPXQLFDWLRQKDYHEHHQ¿ UVWUDWH´ Jensen’s Foods is proud of its reputation for high Jensen’s Foods was founded in 1997 to VXSSO\IRRGSURGXFWVWRWKH-HQVHQ¶V Bøfhus chain. In its 10,000 square meter factory at Struer in Denmark, it manufactures a range of beef, pork and SRXOWU\SURGXFWVDVZHOODVDZLGHYDULHW\ RIUHDG\PHDOVVDXFHVDQGGUHVVLQJV both under its own brand name and VXSHUPDUNHWRZQHGODEHOV,WLVSDUWLFXODUO\ ZHOONQRZQIRULWVVSDUHULEVRIZKLFKLW SURGXFHVVRPHWRQVDQQXDOO\,W WXUQVRXWERWWOHVRIVDXFHHDFK week. Since 1997, the company’s business KDVJURZQVWURQJO\ quality at reasonable prices. Townsend Further Processing looks forward to being part of Jensen’s Foods bright future. 7KH¿ QDQFLDOFULVLVKDVDOVREHHQIHOWDW-HQVHQ¶V Foods, but business has been adapted to the market conditions. With excellent prospects for future growth, Jensen’s Foods management decided that the time was ripe to invest in a new line to cook, glaze and freeze pork spare ribs. The line should, however, be able to handle other products such as pork tenderloins and chicken items. The company’s priority was to increase capacity and reduce throughput times, whilst maintaining quality and yields. Jensen’s Foods ZDQWHGDOHDQSURFHVVJLYLQJDQXQLQWHUUXSWHGÀ RZ of the right product at all times, and it was looking to quality equipment to provide this. The company was keen that one supplier should be responsible for the whole project. -HQVHQ¶V)RRGVZDVDOUHDG\DVDWLV¿ HGXVHURI Marel equipment. Townsend Further Processing, however, was an unknown quantity. It was obviously time to invite Jensen’s Food management to visit the DemoCenter in Boxmeer for trials on Townsend equipment using Jensen’s own raw materials. The visit was a success. Spare ribs were cooked to satisfaction, presentation, color and yield exceeded expectations. An order was placed shortly afterwards for a SpiralOven, the ¿ UVWLQ'HQPDUND7RZQVHQG%DWWHU$SSOLFDWRUDQG a Dantech spiral freezer. After marination in existing equipment, pork spare ribs enter the SpiralOven, where they are cooked at low temperature and high humidity in a precisely ‘Angel hair’ burgers to really get your teeth into ideal structure and texture throughout the fully automatic production process. The meat used was beef with additives. MasterFormer processed this meat mix into extremely loosely structured ‘angel KDLU¶EHHIEXUJHUVZLWKDFKHHVH¿ OOLQJ Products made on the RevoPortioner and MasterFormer stood out for their good structure and bite. To round the day off, our very own chef, Jacques Roosenbrand, sprang into action. He cooked and enthusiastic about performance of the MasterFormer that he wanted to buy one there and then. For some years now Townsend Further Processing has been inviting customers to its own DemoCenter in Boxmeer, the 1HWKHUODQGVWRFRPHDQGWDNHDORRNDWWKH ODWHVWIXUWKHUSURFHVVLQJGHYHORSPHQWV 7KH3RUWLRQLQJ(YHQWWRRNSODFHRQ February 9th, 10th and 11th this year, with the use of RevoPortioner and 0DVWHU)RUPHUIRUWKHORZSUHVVXUH portioning of products from red meat, PHDWPL[HVDQGSRXOWU\ZLWKDQGZLWKRXW ¿ OOLQJDVLWVWKHPH A mixer-grinder processed the different meat PDVVHVLQWRDKRPRJHQRXVPHDWPL[7KH¿ UVW demonstration was with a 100% beef mix without additives, which the RevoPortioner processed into lean beef hamburgers. RevoPortioner’s ability to process composite meat masses with ease was shown when a composite red meat and poultry mix was processed into burgers. 0DVWHU)RUPHULVDÀ H[LEOHPDFKLQHVXLWDEOHIRU processing different meat mixes with 2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=11http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=11P o u l t r y P r o c e s s i n g N e w s 11 > M A R K E T S Fieldale Farms: Superior quality with the RevoPortioner Last year, Fieldale Farms installed two Townsend Further Processing RevoPortioners at its further SURFHVVLQJIDFLOLW\LQ*DLQHVYLOOH*HRUJLD7KH RevoPortioner is an advanced low pressure, portioning machine that combines high capacity, exceptionally high product quality and low cost of ownership. Product release without water Up to now forming machines have used water to assist with the release of products from the mould; but the RevoPortioner uses air. The use of air EHQH¿ WVSURGXFWTXDOLW\LQWHUPVRISURFHVVHV further down the line, such as coating and frying. It also reduces the amount of product waste around the machine. Both men went on to comment, “We are pleased Exceeding expectations “The RevoPortioner has exceeded our expectations with its consistency and reliability,” remarks Blake Wikle, Plant Manager. “We are very pleased with the consistency of the meat coming Whole muscle portioning One of the RevoPortioner’s unique capabilities is portioning whole muscle meat into many natural shapes, while maintaining consistent size and weight. The advanced, low-pressure technology utilized by the RevoPortioner retains the original whole muscle properties, such as bite, structure, and visual appeal. The RevoPortioner allows the Blake remarks further, “We are seeing return on investment on meat waste and water usage. We DUHDOVRH[SHULHQFLQJDQLQFUHDVHLQHI¿ FLHQF\DV out of the machines, water reduction, noise reduction, and low meat waste leakage. In addition, the RevoPortioner produces an aesthetically appealing and edible product.” with the service and sales support we have received from Townsend Further Processing, as well as the commitment to our company. Townsend Further Processing is head and shoulders above other companies in the industry.” Installation and Townsend Further Processing experience “The installation of the RevoPortioners was superb. Townsend Further Processing was very good about being at our location when needed, DQGZHDUHVDWLV¿ HGZLWKWKHVHUYLFHZHUHFHLYHG´ state Blake and Dan. food industry to introduce new products with superior attributes to the marketplace, whether it is SRXOWU\UHGPHDW¿ VKRUYHJHWDEOHV well as, reduced labor. Finally, we are seeing an improvement in the reduction of maintenance downtime as compared to other machines.” )LHOGDOH)DUPVSURGXFHVLWVRZQ)LHOGDOH )DUPVEUDQGDQGSULYDWHODEHOEUDQGVRI IUHVKIUR]HQSUHFRRNHGDQGPDULQDWHG ZKROHFKLFNHQVDQGFKLFNHQSDUWVIRUVDOH LQWKH8QLWHG6WDWHVDQGLQWHUQDWLRQDOO\,Q DGGLWLRQWRKDYLQJVHYHUDOSRXOWU\ SURFHVVLQJIDFLOLWLHV)LHOGDOH)DUPVDOVR KDVDIXUWKHUSURFHVVLQJIDFLOLW\GHGLFDWHG WRSURGXFLQJSRUWLRQFRQWUROZKROH PXVFOHSDUIULHGIXOO\FRRNHGEUHDGHG DQGQRQEUHDGHGDVZHOODVUDZ unbreaded products. Superior quality Comments Dan White, Food Safety Quality Assurance Manager,“We chose the RevoPortioner because its quality is superior to any other portioning solution. The process allows for more of a whole muscle bite, as well as providing more of a whole muscle restructuring technology. Performance on waste is also superior to any other machine on the market.” > M A R K E T S Western Brand invests in complete Townsend Further Processing line the money,” said Eugene Lannon, chief executive RIWKH:HVWHUQ%UDQG*URXS³7KH6SLUDO2YHQDQG RevoPortioner are very easy to operate, low cost to run and produce excellent results. We do not use water during the RevoPortioner process, and WKLVKDVEHQH¿ WHGWKHSURFHVVIXUWKHUGRZQWKH production line. In fact, we were so impressed by this machine that we have now purchased a second RevoPortioner. Townsend Further Processing are great to work with, and I am particularly impressed by their excellent after-sales service,” concluded Eugene. Leading UK and Ireland poultry processor, Western Brand Poultry Ltd, has invested in a complete new 7RZQVHQG)XUWKHU3URFHVVLQJOLQHVLJQL¿ FDQWO\ increasing capacity and enabling production of a broader range of new products. T2011-02-10T17:35:10+01:00http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=12http://nozebra.ipapercms.dk/MarelGroup/Newsletter/FurtherProcessing/TownsendFurtherProcessingJune2010/?Page=1212 F u r t h e r P r o c e s s i n g N e w s > M A R K E T S B.A. production group meets new food trends on Iranian market With the present project, despite its short term of activity, the B.A. production group is proud to be able to supply the needs of the most sensitive and accredited consumption centers in the country and it hopes to export products and to become one of the greatest food product exporters of the country. Their main export markets are the countries in the Middle East. B.A. production group aims at serving all different segments in the market. The B.A production group is proud to present The fast food industry in Iran has been GHYHORSLQJTXLFNO\XQGHUWKHSUHVVXUH RIWKHSUHGRPLQDQWO\\RXQJ SRSXODWLRQ7KH%HVW$SSOLFDWLRQ%$ production group in Iran has taken advantage of the new consumer trends RQWKHQDWLRQDOPDUNHWDQGKDV 7KHFRQVWUXFWLRQRSHUDWLRQRIWKH¿ UVWIXUWKHU B.A group to produce products appealing to Iranian taste and complying with superior standards prevalent in the worldwide food industry. Mr. Jamal Razeghi, President AFS Group. healthy food complying with the latest international standards. By using its unique capability in observing physical, chemical, microbiological characteristics and by observing the Iranian taste requirements, it takes a very effective step in promoting the health and nutrition of the consumers. decided to put products on the market WKDWZLOOPHHWWKHQHZFRQVXPHU QHHGV7KH\KDYHGHYHORSHGWKHLURZQ TXDOLW\VWDQGDUGDQGVHOHFWVXSSOLHUV ZKRREVHUYHVLPLODUKLJKTXDOLW\ standards. This has proved to be the basis for a good partnership with Townsend Further Processing. The B.A. production group has purchased WZRIXUWKHUSURFHVVLQJOLQHVIRUWKHLU QHZSODQWRQHOLQHIRUIXOO\FRRNHG products and one for the production of formed products. processing plant in their B.A. production group, Asian Frozen Star (Setareh Yakhie Asia) started at the beginning of 2005. The installation and commissioning operation were completed on $XJXVW6LQFHWKHQDQGIRUWKH¿ UVWWLPH in Iran’s food industry, product design was initiated. Product design in the B.A production group includes a series of product characteristics such as DURPDÀ DYRUWH[WXUHFRORUDQGTXDOLW\7KH product design operations were conducted at the beginning of 2009 under the supervision of accredited European experts and experienced Iranian experts in the food industry and assisted by traditional Iranian chefs. Simultaneously with releasing the products on the market, more market research was conducted and large-scale productions and market availability were initiated. The B.A. production group has also developed their own packaging to provide their end products with a recognizable look. The combination of the world’s latest technology in producing fully cooked frozen dishes and B.A.’s product design, the input of the traditional Iranian FXLVLQHDVZHOODVWKH¿ QHVVHLQWKHSUHSDUDWLRQRI the various meat products (chicken, red meat and ¿ VKDGYDQFHGSURGXFWLRQKDOOVKDYHHQDEOHGWKH Contact details Townsend Further Processing Design, manufacture, worldwide sales and service of further processing systems for portioning, marinating, coating, heat treatment and sausage-making for poultry, red meat, and fish. Townsend Further Processing Handelstraat 3, 5831 AV Boxmeer P.O. Box 233, 5830 AE Boxmeer The Netherlands T: +31 (0)485 586 122 F: +31 (0)485 586 655 E: info.townsend@marel.com www.marel.com2011-02-10T17:35:10+01:00