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automation in food packaging

Automation Is Driving American Industry

Virtually every business is looking for ways to utilize automation to improve effectiveness and cut costs. The food packaging and pharmaceutical packaging industries are among those finding solutions in custom designed machinery to meet their specific needs.

Along with government mandated regulations for safety, the fiscal need for efficiency and cost-saving are driving increased demand for labor-saving automation to address specific market trends.

Consumer demand for convenience drives most markets but the main concerns in food processing remain the same; maximizing yield, reducing waste, enhancing reliability and ensuring hygiene and safety.

The rising demand for ready-to-cook meals and prepared cuts of meat are driving developments in modified atmosphere packaging and skin pack formats with extended shelf-life.

Quality control is another important factor driving the automation boom and industries are relying more on robotic QC mechanisms to ensure that their product is as good as it can be when it reaches the market.

Workplace safety is of course a major driver in the shift to automated systems. Injuries in any production line are more than just an inconvenient byproduct of manufacturing, they serve to drive insurance premiums up as well.

ORICS Industries has been designing and manufacturing custom solutions for packaging since 1990 and is the leader in modified atmosphere packaging systems worldwide. With a focus on solving specific the challenges faced by individual industries, ORICS provides technological answers to maximizing yield, reducing waste, extending shelf life, and quality control, while delivering hassle free systems that are reliable and forward thinking so they last for years, even decades.

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ORICS PRODUCT SAMPLES
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Farmingdale, NY 11735

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Orics

What is Modified Atmosphere Packaging?

Orics Rotary tray cup filler sealer

Modified Atmosphere Packaging is the combination of an optimal blend of Nitrogen and/or Carbon Dioxide with in a high-barrier or Permeable package. A finely adjusted and carefully controlled gas blend is created to meet the specific respiration need for each packaged food product.

To package a product in a modified atmosphere requires sophisticated machinery, to flush out air from the packaging chamber and replace it with a different gas or precisely defined mixture of gases, then seal the product in the packaging so that only the modified atmosphere surrounds the product and not any other unwanted gas.

Trays and Packaging films are selected to match the characteristics and needs of each food product. For instance, meat and fish require very low gas permeability films so, For non-respiring products (meat, fish,cheese, Etc..) high barrier films are used. The initial flushed gas mixture will be maintained inside the package. Fruit and Vegetables, However, are respiring (breathing) products where the interaction of the packaging material with the product is important. In this instance, the permeability of the packaging film is adapted to the products respiration. The goal is to establish an equilibrium between the O2 and the CO2 inside the package and this balance results in extended shelf life. in nearly all instances, a M.A.P gas mix slows down the product deterioration, spoilage and rancidity caused by mold and other aerobic organisms.

WHY  M.A.P  SEAL ?

Longer shelf life M.A.P packages allow food processors, food manufacturers, food distributors and food retailers to better control product quality, availability and costs. Longer freshness cycles permit grocers to eliminate frequent product rotation, removal and restocking; thereby reducing labor and waste disposal cost. Distributors can extend distribution territories or offer a greater variety of product line to the retailer, Since less frequent product replacement requirements permits growth in other areas. Food Manufacturers are able to take advantage of extended replacement cycles to reduce production replacement demands. Manufacturing capacity can be more profitably utilized by developing and offering new products.

call us at Orics 718-461-8613 or visit our  site www.orics.com

Orics Guacamole filling sealing trays

Mashed Vegetables Tray Filling for the Elderly

Orics Mashed vegetables Tray filling for the elderly community.

ORICS S 30 2×6 tray Packaging Machine, mashed vegetables for the elderly. machine is US made by ORICS at 240 smith street, Farmingdale NY 11735 . 718-461-8613.

Foods in pureed and mechanical soft diets have a smoother consistency than regular foods. They require very little or no chewing at all to swallow. You may need to be on a pureed or mechanical soft diet if you:

  • Have trouble chewing or swallowing
  • Had mouth surgery
  • Have trouble moving or have lost feeling in parts of your mouth, such as your lips or tongue

A pureed diet is made up of foods that require no chewing, such as mashed potatoes and pudding. Other foods may be blended or strained to make them the right consistency. Liquids, such as broth, milk, juice, or water may be added to foods to make them the right consistency. Soft foods help elderly people who have difficulty chewing or swallowing continue to eat balanced, nutritious meals. Doctors also may recommend softer foods following head, neck or abdominal surgery, and for patients undergoing treatments such as chemotherapy or radiation. Tender or soft foods help ease the amount of chewing and swallowing needed to ingest food. You can also modify tougher foods in texture and consistency for better tolerance.

 

Orics falafel machine

Falafel Balls Forming Machine

ORICS FRM-8 FALAFEL BALLS FORMING MACHINE.

When ORICS received an Inquiry From Haggai Lavi, C.E.O and Founder of “FALAFAPITA GLUTEN FREE”, Located in Brooklyn, NY,  To Engineer and construct a Machine that will form Falafel balls at a rate of 240 balls per minute, ORICS welcomed the challenge with open arms.
Falafel is made primarily from over night soaked chickpeas and onion. after grinding the chickpeas and the vegetables, the Falafel viscosity is thick and sticky, Traditional Falafel machines are work on the assumption that as long as you extrude the right amount of batter, the falafel will achieve its round shape in the hot oil as it being cooked. In contrast Falafapita wanted ORICS to design and manufacture a Falafel ball Forming Machine that would create a beautiful uniform shape with the falafel batter without having to drop the ball into oil, instead Falafapita wanted to collect the formed balls on a pan where they can then be frozen at their peak of freshness. The frozen falafel balls are then packed and sold as a solution for restaurants who want a ready-made Falafel and for consumers whom prefer their Falafel baked rather than fried.

Orics ffm-8 falafel forming

Orics ffm-8 falafel forming

The results of ORICS engineering and manufacturing is the FFM-8 Falafel forming machine. Forming Falafel Balls at 8 balls per cycle and a maximum of 30 cycle per minute, the FFM-8 is capable of producing240 perfectly formed Falafel Balls per minute. By way of comparison, even the most experienced and skilled person forming falafel balls by hand could only produce 20-30 balls per minute. Additional configurations are available to produce as many, or as few, balls per minute as a manufacturer’s needs may require.

Today, only two years later, the Falafapita Gluten free frozen Falafel product can be found in many fine restaurants in the new york, Tri-state area and for retail, nationally at Restaurant Depot and Jetro.

falafel Orics Industries

Orics Falafel Machine

 

pomegranate seeds filling sealing

Pomegranate Seeds Cup Filling Sealing Packaging Machine

Pomegranate Seeds Cup Filling Sealing Packaging Machine

Fresh pomegranates may be incredibly heart healthy, but could nature have invented a more annoyingly inaccessible fruit? Find out how to get the goods—without the hassle.

Our S-30 Pomegranate Seeds cup filling sealing machine is a perfect solution for the new hot item on the shelves (pomegranate Seeds) in a cup.
watch how this machine package Pomegranate seeds in a clean and outstanding way.
One of the oldest known fruits, found in writings and artifacts of many cultures and religions, the pomegranate is an original native of Persia. This nutrient dense, antioxidant rich fruit has been revered as a symbol of health, fertility and eternal life. As with many fruits, pomegranate seeds are low in calories and rich in fiber, providing only 83 calories and 4 g of dietary fiber per 100 g serving. A 100-g serving is equivalent to about 3/4 cup. According to the U.S. Department of Agriculture Dietary Guidelines for Americans, for optimal health with a 2000-calorie diet, you should consume 2 cups of fruit and 2½ cups of vegetables per day. Pomegranate seeds and other fiber-rich foods, such as whole grains, may reduce your risk of developing chronic disease and aid in weight management.

Orics Feta cheese fill and seal

Cheese Packaging Machine

Orics S-50

Orics S-50

  Watch our video of  Cheese packaging machine.

 

ORICS Cheese Packaging Machine.

There is an ORICS packaging solution to match every way people like to enjoy cheese, yogurt, and other dairy products.

From easy-peel yogurt lids to deep-drawn cheese packaging, ORICS Machines help keep dairy products fresh, flavorful and extend shelf life, by preventing mold and dehydration.

Shelf Life  Water vapor, light, and oxygen all affect the quality of cheese. Light and residual oxygen lead to the oxidation of fats, which contributes to bad flavors in the cheese.                      Reducing head-space volume and minimizing residual oxygen are both important to increasing the shelf life of cheese.

Our Machines portfolio and proven technical expertise help dairy brand manufacturers create innovative dairy and cheese packaging solutions that:

  • Deliver high hot tack strength
  • Provide leak-free durability to reduce Damages in-store and at home.
  • Control gas exchanges to promote specific barrier properties needed to keep cheese and yogurt fresh.
  • Prevent mold, dehydration, and off-odor absorption.
  • It might at first seem a little strange that cheese needs protecting from microbes – after all, microorganisms have a crucial role to play in cheese making. Nevertheless, while some microbes are ‘good’ and useful in cheese making, others are not and can cause cheese to become spoiled. In general, hard cheeses that do not have a high water content are susceptible to attack by moulds, while moister cheeses can be affected by bacteria. Also the fats of some cheeses are prone to oxidation by oxygen in the air, which can make the cheese become rancid.The main gas that is used in modified atmosphere packaging (MAP) to prolong the freshness of hard cheese is carbon dioxide. Hard cheese can be packaged in an atmosphere of total carbon dioxide, while for soft cheeses the proportion is typically between 20 and 40 per cent, with the remainder being usually nitrogen. The main reason for this approach with softer cheeses is that over time the carbon dioxide can dissolve in the water that is within the cheese, and this reduces the volume of gas in the package, eventually causing the packaging to collapse. The presence of the nitrogen prevents the packaging from collapsing.

    Yogurt fill seal Rotary machine

    Orics tub filler sealer and caper

 

 

 

Orics tray sealing machines

ORICS-Food Packaging Machines

ORICS Equipment Gallery

ORICS – Equipment for every application

How to Buy a Filling Machine

If you are looking to move forward with your food packaging machines
Before you make a purchase, let ORICS do the hard part. Submit a free request for quotes using this site, and we’ll Get you the layout plan and the machine you need.
1. What are you filling?
While some fillers are suited to fill containers with dry goods (pills, powders, coffee),. It’s a far different task to ask a machine to pump out units of water (low viscosity) than it is to fill jars of molasses (high viscosity). And while some machines can handle them all, you want to make sure the machine you buy can handle the product you’re filling and sealing.

2. What type of container are you filling?
There are many types of containers that fillers can fill. For purposes of this page we will often refer to them as bottles, but you can fill cans, jars, jugs, cups, tubs or Trays etc. Some machines work well with certain containers, while other machines will destroy your chosen container. For instance, some automated machines will grab a bottle from the top, others from the side. If your bottle has a unique top, it might not work with a top-grabber, same if your bottle is too wide, it might not work with a side-grabber. So, it’s important for us to know the size of the container you’re using (ounces, liters, gallons) as well as its height, diameter or shape if you can tell us. Also, what type of opening does the container have (large lid, small cap, peel back)? For instance, if you are filling aluminum cans, that top requires a special machine.
3. How many are you going to fill and how fast do you need them? CPM or containers per minute.
There are many different speeds to fillers, and the speeds differ for many reasons. Often smaller machines are measured by the amount of containers they produce per hour (CPH), while larger, faster machines are measured by cups or containers per minute (CPM). For purposes of this site, we will use CPM.
4. How automated do you want your machine?
A manual machine may be a great investment for a small company or brewing enthusiast, but it might not meet the demands of a large or growing company. A semi-automatic machine is going to take a little more manpower to feed bottles into it, but a little less money to purchase and it’s not as big. Automatic machines take up more space, but require less hands as they pull bottles from bulk with a conveyor system. Use this chart to help determine your desired speed and automation:
Speed Automation Target Buyer
1 – 6 CPM Manual Small Business
6 – 20 CPM Manual or Semi-Automatic Small or Medium Business
20 – 50 CPM Semi-Automatic or Automatic Medium or Large Business
50 CPM or Higher Automatic Large Business
5. Do you want a Liquid Level or Volumetric filling machine?
Liquid Level machines fill bottles so they appear to be filled to the same line on every bottle. Many companies, including cleaning products, soft drinks, beverage companies, breweries, wineries and distilleries prefer their customers see a uniform product and chose Liquid Level fillers. Liquid Level fillers also help achieve higher speeds of production and, in most cases, a lower cost per machine, which is sometimes a difference in the tens of thousands of dollars.
Volumetric Filling machines fill each bottle with exactly the same amount every time, sometimes resulting in bottles not looking as full as others. They require special instruments for balance, calibration, timing, etc., so they tend to cost more. But if every drop of your product comes at a high cost, (like gold or oil) the extra money for the machine will be necessary to save money in the long run. Machines cannot be converted from Liquid Level to Volumetric or visa versa.
6. Do you want an overflow pressure, piston, pump, or gravity machine?
Overflow Pressure Fillers are the most popular machines with beverage makers (beer, wine, juice, etc.). Although they are limited to low viscosities, they are a great value to any business owner attempting to produce a lot of bottles quickly. The liquid enters the bottle fast under pressure, while the machine catches spillage overflow or over-bubbling and sends it back to the bulk source. These machines are built for speed, and the one pictured below has 12 heads. Heads, or spouts, are the nozzles that deliver the product directly into the bottle. The more heads a machine has, the more bottles it can fill at one time.

Piston filling machines use pistons to pump from one source to another with accuracy and some speed. Piston fillers are basically divided into two methods: Check Valve Pistons and Rotary Valve Pistons. Check Valve Piston fillers work well with low viscosity and are great for drawing your product from a large container, then transferring it to the container easily and accurately. Rotary Valve Pistons are better for transferring thicker and chunky material, as the valve allows for chucks to pass through undamaged. Rotary Piston Filling machines are most notably recognized by the existence of a large funnel, or Hopper, used to pour the material into from a large container. Both Rotary and Check Valve Piston bottle fillers are available as manual, semi-automatic and automatic machines.
Pump filling machines are great for a wide variety of applications with different viscosities, but not so great with chunks. Pump filling machines can pump liquids, pastes, creams, Hummus, Yogurt (wine, syrup, toothpaste, ketchup, moisturizers) from your bulk container then deliver the product into the bottles. Pump fillers are popular, common and made many different ways including with volumetric filling instruments and multiple heads. we at ORICS make small tabletop size pump fillers with a single head and we make them large with 10-foot, inline conveyor systems and 12 or more heads.
Gravity filling machines can be a cost effective way to achieve volumetric filling. They can be built and modified for a wide variety of products including pharmaceutical, beverage, chemical, flammable and hazardous materials. When the product needs to be dispensed more precisely, gravity fillers can be the way to go, especially if the product has a low viscosity. They make them simple, like this small siphon filler:
And they make large, automatic gravity fillers like the one below, which is a Timed Fill Gravity Machine. This machine places the product bulk above the bottles and times its release through the heads, achieving equal and accurate outputs each time. Be mindful when switching from filling one product to the next with these machines because the system will need to be rebalanced and/or recalibrated with each product change.
7. Do you want an inline or rotary filling machine?
Inline filling machines fill containers just as they suggest, in a line. Inline machines are popular, cost effective and easy to adjust with your needs. Small to medium-sized companies often use inline-filling machines because if a problem occurs during production, the machine can be stopped, fixed and put back into production faster than you can a rotary machine. This also results in fewer bottles wasted.
Rotary filling machines are usually much smaller, specialized machines. Rotary machines are fast and will help your company produce CPM in a much smaller facility than your average inline machine. whereas inline machines tend to allow easier access to fix problems on the fly.

You can find piston, pump, and gravity or overflow pressure machines made as inline or rotary fillers.
8. Are there any other special features or requirements you think we should know about the bottle filler you need?
Do you need additional machinery such as capper, or labeler?. When you make your request, please let us know what else you need.

Always A Place For Innovation In Yogurt packaging.

Watch Orics MR-35 Rotary Cup Yogurt Filling Sealing Machine.

 

Watch Orics S-50 Yogurt Filling and Sealing Machine.

Yogurt is a food celebrity. Not only has the cultured dairy delicacy conquered increasing real estate at retail, in refrigerators and lunch bags, it’s now a double-digit growth category for many food service operations, according to The NPD Group, Port Washington, N.Y.

Now is the time to join this booming category. Consumption of yogurt is up an astounding 400% and there’s still a lot of room for manufacturer’s to profit here with the right innovation. Let us give you some ideas in yogurt packaging.

In the wake of the Greek yogurt craze, yogurt remains a superfood with significant upside, according to a recently released report from Packaged Facts, The Yogurt Market and Yogurt Innovation: Greek Yogurt and Beyond. Packaged Facts forecasts that U.S. retail sales of yogurt will approach $9.3 billion by 2017, up from $7.3 billion in 2012. Even with its recent market growth, yogurt continues to be consumed at a much lower per capita rate in the U.S. than in other countries where yogurt is a staple. Moreover, yogurt is spreading beyond the breakfast daypart, reflecting the “breakfast-all-day” culinary and menu trend.

In the U.S. market, retail dollar sales of Greek yogurt increased more than 50% in 2012 to reach $1.6 billion, with significant gains in the mass-market as well as natural and specialty retail channels. At the same time, non-Greek yogurt saw its sales decrease. According to David Sprinkle, publisher of Packaged Facts, “Greek yogurt has raised its share of the refrigerated yogurt market to 35%, up from only 1% in 2007.” Even though it is unlikely that Greek yogurt can keep up its growth marathon, Greek yogurt has continued to increase market sales and share through first quarter 2013.

Private label controls a large share of the market in refrigerated yogurt, in aggregate ranking as the number two brand overall, with growth outpacing the market. In frozen yogurt, private label ranks as the number one brand, although it is a far less important player in yogurt drinks. The restaurant and foodservice industry also is getting in on the action, with Chobani and Dannon opening up their own yogurt shops, and yogurt appearing on more restaurant menus.

The Packaged Facts report also shows how innovative marketers are driving the yogurt and especially Greek yogurt bandwagon into other food categories. Yogurt’s popularity and “healthy halo” have propelled a spill-over over into product categories such as smoothies, frozen yogurt and novelties, cream cheese and butter, salad dressings, dips and spreads, and granola bars, among others.

At Orics we will engineer and fabricate your packaging fill and seal machine for any of your dairy or non dairy applications.

we will built the machine to suit your plant needs as far as speed filling sealing per minute and as far as space and machine size.

we will accommodate you with your every need in packaging filling and sealing machines for cream cheese, smoothie, butter, yogurt, greek yogurt, or salads and fruits fresh from the farm.

check our equipment page or just follow us on our you tube channel for best view video clips of our machines and decide whice one fits your needs.

http://orics.com/cup-fill-and-seal-machines/.

Customers Purchase ORICS equipment at Pack Expo, Las Vegas 2007

Revisiting Las Vegas: Vistors Purchase ORICS Equipment

Their 2005 visit to Pack Expo Las Vegas yielded big dividends, so these two packaging professionals plan a return to Vegas for another look-see.

By Pat Reynolds, VP Editor, Packaging World

A. Duda & Sons increased productivity by 70%. Kona Joe Coffee boosted production even more dramatically. How? By purchasing new equipment seen at Pack Expo Las Vegas 2005. Needless to say, principals from both firms will return to Las Vegas for this year’s edition of Pack Expo Las Vegas, sponsored, as always, by the Packaging Machinery Manufacturers Institute (www.pmmi.org).

A. Duda & Sons, out of Oviedo, FL, is one of the world’s largest producers of celery products. It also serves both retail and foodservice markets, selling its products under the Dandy brand name. Products in addition to celery include mandarins, red grapefruits, red and white onions, broccoli, and cauliflower.

With operation centers as far-flung as Michigan, South Africa, and Spain, the firm found it increasingly difficult to maintain necessary production speeds while relying on a manual packaging process.

“Having been to Pack Expo on numerous occasions, I knew it would be a good opportunity to investigate ways we could improve efficiency,” says Steve Bocchino, vice president of procurement and packaging at Duda.

After extensive research, Bocchino purchased a linear-motion S-30-DX Heat Seal Machine from [ORICS]. (www.orics.com) to help increase the value of the company’s Dandy Microwaveable Sweet Corn brand. The sweet corn is fully-husked and tray-packed into individual packages that can go right into the microwave. Both three- and four-count packages are available.

Prior to the purchase of the Orics S-30, Duda depended heavily on a smaller table-top steam sealing machine. “Microwavable corn trays were filled by hand and manually steam pressed closed, requiring excess film and increased labor time as well as low productivity,” says Bocchino.

The sleek design of the S-30 proved to be a perfect fit for A. Duda & Sons. Orics customized the system to include an extended frame and registered film slice-cut mechanism to handle the specially vented printed film that adorns the top of each Dandy Microwaveable Sweet Corn pack.

The S-30’s film feeder technology offers additional benefits. Film is cut in between each container, leaving no wasted film and saving the company more than $35,000 a year. The approach also minimizes environmental impact by decreasing the amount of material discarded.

Installation proved to be an easy, hassle-free process. Orics also offered off-site training, which “was invaluable for our employees,” recalls Bocchino. “They were able to learn first hand from trained instructors how to operate the system.”

The S-30 packs two trays per cycle for A. Duda & Sons and has increased productivity by 70%. In addition, by eliminating the manual packing process, the S-30 has also helped free up employees to handle more strategic tasks within the organization.

Original Article: Packaging World, August 9, 2007

Pack Expo 2015

Pack Expo 2015