October 8–11, 2019    McCormick Place    Chicago, IL USA    Pure Processing. Proven Results.

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PROCESS EXPO University Session Descriptions

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Tuesday, Sept. 19

 9:30am

Eat it, Don’t Treat it!
Speaker: Robert Price, Seiberling Associates, Inc.
Theater: FSS

Identify cost savings in existing food processing facilities. Over 85% of currently operating facilities have areas of product loss, excessive water consumption, and downtime related to inefficient cleaning, causing hundreds of thousands of dollars in annual losses. Learn how to identify and correct these problems and how to create an operation that produces a quality product at the lowest per-unit cost.

Remove the Fat from Your Operations to Improve Efficiency and Reduce Costs
Speakers: Philip Lyman, PhD and Niranjan Kulkarni, PhD, CRB
Theater: 2

The modern food and beverage industry continues to be highly competitive and cost conscious. Continuous improvement for efficiency and reduction of operating expenses are important in this environment. Simply identifying improvement opportunities without quantifying the benefits of those changes will not convince management to make the necessary investments. This can be accomplished using a combination of Value Stream Mapping (VSM) and Discrete Event Simulation (DES). VSM is a lean technique used to identify non-value-added activities and find operational improvements. Though VSM can quantify certain improvements, it may fail to capture the impact of change at a holistic level. Furthermore, it does not help characterize the variability and uncertainty inherent in your operations. This shortcoming can be addressed by employing DES. Process modeling describes the dynamics (time-dependent behavior) of operations while providing a rigorous evaluation of inventory, scheduling, and relevant stochastic events.

Increased Productivity with Environmentally Responsible Non-Destructive Cleaning
Speaker: Tyson Marlowe, Cold Jet
Theater: 1

This presentation serves as an introduction to the dry ice cleaning process and its benefits specifically to the food processing and packaging industries. It will also provide details for attacking and reducing the costs associated with cleaning and will help participants position their companies for increased profitability.

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11:00am

Turning Waste Streams into Value Streams in Dairy Processing Facilities
Speaker: Jeff Tocio, Pentair
Theater: 1

Turning waste into energy is a hot topic in any industry. Food processing waste streams such as condensate of whey and wastewater can be treated (anaerobic digestion or fermentation) in such a way that they generate biogas.

The biogas emitted from the digesters is composed primarily of methane (CH4) and carbon dioxide (CO2), with small amounts of hydrogen sulphide (H2S) and other components completing the list. Traditionally, the generated biogas is fed to (steam) boilers (low efficiency) and Combined Heat and Power Plants (CHPs). However, a more efficient usage is to upgrade the biogas. Biogas upgrading is the process of CO2 separation from the biogas. This generates two value streams: high-caloric biomethane and food-grade CO2. Through the application of membrane and cryogenic technology, 100% CH4 can be recovered with minimal CO2 emission. The high-caloric biomethane is either buffered (in the national gas grid) or consumed on site (boiler fed with clean high-caloric gas for optimal efficiency). The filtered CO2 is ready for food-grade application. This technology won a 2016 best in class award from the U.K. Anaerobic Digestion and Biogas Association (ADBA). In addition, stand-alone CO2 recovery plants are solutions for existing sites that may already be recovering biomethane from anaerobic digester biogas but that also want to be able to recover and use the CO2 emitted from their existing system back in their operation or for sale to a third party. This presentation will include case studies of current installations.

Considerations for Validation of Thermal Processes Used in the Manufacture of Low Moisture Foods
Speakers: Nathan Anderson, U.S. Food and Drug Administration; Elizabeth Grasso, Illinois Institute of Technology; Bradley Marks, Michigan State University; Jeyam Subbiah, University of Nebraska-Lincoln
Theater: 2

Recent outbreaks and recalls due both to Salmonella in low-moisture foods and to pending FSMA Preventive Controls rules make processing interventions imperative to ensuring product safety. Legacy technologies previously designed to achieve quality outcomes but not designed as kill steps (e.g., drying or baking) must now be validated for this purpose. This session will also cover critical factors to address when completing a validation of thermal processing for low-moisture foods.

The Food Safety Revolution: Shifting Landscape of Civil, Regulatory, and Criminal Exposure
Food Safety Program

Speaker: Shawn K. Stevens, Food Industry Counsel LLC
Theater: FSS

Learn about new regulatory requirements for the production of safe food and new federal regulatory initiatives and policies which increase processor regulatory risk and exposure. Shawn Stevens will also explain how a link between your product and a foodborne illness outbreak can now trigger broader investigations and potential criminal exposure

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12:30pm

Processor Spotlight: Richard Thompson — Breaking the Mold with Freshpet
Speaker: Richard Thompson, Freshpet
Theater: FSS

Former CEO of Freshpet Richard Thompson joins PROCESS EXPO attendees to share his experiences in transforming a niche of the pet food industry into one of its most innovative and talked-about categories.

Business is Better at the Speed of the Cloud
Speaker: Turner Foster, Columbus
Theater: 2

Moving to the Cloud is big news. There is much discussion about what the Cloud means for food businesses and what you need to do to take advantage of it. In this session, we’ll share some of the top ways the Cloud can benefit your business and why you should consider it.

FSMA Update for Processors
Speaker: Allen Sayler, EAS Consulting Group
Theater: 1

By September 2017, the U.S. Food and Drug Administration (FDA) will likely have met its internal FSMA training obligations, and it is likely there will be significant focus on processing equipment by investigators regardless of their knowledge, training, or experience. This presentation will cover FSMA
equipment requirements, how to comply with those requirements, and “war stories” from recent FDA field inspections that identified equipment shortcomings.

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2:00pm

Aseptic Processing and Packaging
Speaker: Steve Smith, Purdue University
Theater: 2

This session will be an overview of some of the more recent advancements as they apply to aseptic processing and packaging and will cover the following: processing advancements such as particulate validation, hold tube flow control, laminar or turbulent flow, pumping methods, heat exchangers, non-thermal processing, and aseptic dosing. We’ll also discuss packaging advancements such as recyclable and renewable packaging, filler speeds, package design, and fitments.

Milk Pricing 101
Speaker: Brian Gould, University of Wisconsin
Theater: 1

Have you ever wondered what determines the price you pay for your milk-based products? In this session, we review the fundamentals of the systems used to determine milk prices for most of the milk produced in the U.S. A simple spreadsheet of milk price determination under the Federal Milk Marketing Order (FMMO) system will be introduced and made available for your own use in determining future milk costs. The relationship between cash and future market prices for milk-based products will also be introduced, and the availability of additional resources will be identified.

Constructing an Equipment Hygienic Design Program
Food Safety Program

Speaker: James Davis, OSI Group, LLC
Theater: FSS

The presentation would begin by briefly covering a high level overview of hygienic design of equipment, importance and implications for food processing with emphasis on the meat industry. The presentation would then shift to a discussion on elements for constructing an equipment design program and various aspects related to the program – standards, guidance and risk.

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3:30pm

Dairy Facility Contamination Case Study
Speaker: Mike Byron, Seiberling Associates, Inc.
Theater: 1

This case study focuses on a fluid milk producer that had high bacteria counts in the final product. Multiple changes were implemented to fix the issue, but none of them got to the root cause. An examination of highlighted paths during CIP through the equipment helped identify the root cause and resolve the issue.

How Do We Protect Food Processing Equipment from Potential Hazards?
Speaker: Ramakrishnan Narasimhan, Perry Johnson Registrar Food Safety, Inc.
Theater: 2

The presenter will explain the chemistry of materials commonly used in food processing equipment as well as the potential biological hazards associated with poorly designed and poorly maintained
production/processing equipment. You’ll learn the importance of design characteristics such as smoothness and finish, internal angles, joints, connections, and attachments in maintaining food safety. And we’ll cover what biofilms are, how they develop, and ways to prevent them from occurring, which may contribute to food production and safety. The presenter will also explain the differences in behavior of allergens with various food product contact surfaces.

Futuristic Concepts for the Design of Pet Food Facilities
Speaker: Sean Corkins, Graintec
Theater: FSS

What will pet food–producing facilities of the future look like? Futuristic design concepts showcase and incorporate innovative ideas and initiatives for facility design, production processes, equipment, and intelligent instrumentation. The areas of logistics and energy also have to be considered. Facilities that are optimally designed with regard to technology and production while taking the necessary environmental precautions can change the way pet food is handled and production is maximized. Concepts of modern pet food plant design will be presented with a vision of how fast-developing technology will impact the process, design, and operation of a pet food facility.

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Wednesday, Sept. 20

9:30am

Utilizing Advanced Cleaning Chemistry Applications for Food and Dairy Equipment Sanitation
Speaker: Rick Rector, Seiberling Associates, Inc.
Theater: 1

Participants will learn from real-world experience how the application of advanced chemical treatments can reduce the risk of post-sanitation microbiological contamination from the food processing stream.

The Path to IIoT: Effective Change Management Tips
Speaker: Chris Lebeau, Advanced Technology Services
Theater: FSS

Join our discussion on how operational technology and information technology will need to cooperate to successfully implement IIoT.

Essentials of Robust Food Processing and Packing Equipment Design from a Food Safety Expert
Speaker: Ramakrishnan Narasimhan, Perry Johnson Registrar Food Safety, Inc.
Theater: FSS

In the recent past, inadequate equipment design was cited as the culprit in a few major food safety incidents. Therefore there has been an increased focus on understanding the importance of designing, fabricating, and constructing food processing and handling equipment according to sound sanitary design principles. Some regulatory bodies have an approval process in place, respectively, for meat, poultry, egg, and dairy processing facilities in the U.S. The U.S. FDA does not have such an approval process; however, it regularly inspects equipment according to the current Good Manufacturing Practices. Additionally, standards organizations such as 3-A Sanitary Standards, Underwriters Laboratories, and the National Sanitation Foundation (NSF) have developed standards to guide equipment manufacturers in the hygienic design of food processing and handling equipment.

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11:00am

Processor Spotlight: South American Meat Industry in a Nutshell
Speaker: Fabio Nunes, Latin American Poultry Processing Consultant
Theater: 2

Join Fabio Nunes, industry-renowned expert, who will discuss the vibrant poultry industry in Latin America. In this enlightening session, Nunes will share the challenges and technological advances in this key industry with a look to how these trends might affect the U.S. market in the future.

Understanding and Implementing Foreign Material Controls
Speaker: Robert Rogers, Mettler Toledo
Theater: 1

We will discuss various foreign material control methods and identify their capabilities and limitations. Join a discussion on the value of early detection and removal of foreign materials from the process. In addition, we’ll discuss the importance of developing good practices and programs
around the equipment.

Implementing Mitigation (Risk-Reducing) Strategies in Food Processing to Achieve Food Defense in Human Food Manufacturing
Food Safety Program

Speaker: Hal King, Public Health Innovation
Theater: FSS

The FDA Mitigation Strategies to Protect Food Against Intentional Adulteration (in the Food Safety Modernization Act (FSMA)) is aimed at preventing intentional adulteration (IA) of the food supply from acts (including due to terrorism) intended to cause wide-scale harm to public health. The methods to prevent IA differ from the Preventive Controls rule of FSMA in that they require mitigation (risk-reducing) strategies implemented during food manufacturing processes in certain registered food facilities rather than targeting specific foods or hazards. This session will discuss these differences, and how to start an IA Plan based on risk reduction.

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12:30pm

Processor Spotlight: Ted Wampler — Plant Innovations Fueling Success at Wampler
Speaker: Ted Wampler, Wampler Sausage
Theater: FSS

Join President and COO of Wampler Sausage Ted Wampler, who will speak to the PROCESS EXPO audience about twenty-first century innovation in his plant. From solar energy to biofuels, Wampler provides an innovative look into what “makes the sausage.”

Using Cloud Technology for Plant Floor Efficiency at West Liberty Foods
Speaker: Bob Argyle, Leading2Lean
Theater: 1

Executives at turkey processor West Liberty Foods felt they could improve operations but needed a way to identify and solve inefficiencies stemming from a complex, manual data-entry system and from lag time in understanding maintenance issues. Hear how the company is using cloud technology to achieve measurable improvements in efficiency and to meet the demands of growth without adding workers. It has simplified USDA compliance and is seeing significant cost savings.

Current Structures, Challenges, and Opportunities in German Butcheries
Speaker: Eckhart Neun, Deutscher Fleischer-Verband
Theater: 2

PROCESS EXPO is honored to welcome Eckhart Neun, vice president of Deutscher Fleischer-Verband, Germany’s largest trade association for the meat industry, to discuss the challenges that German butchers face on a regular basis and the solutions they employ to provide a consistently high-quality product for consumers. Meat processors in attendance on day two would be wise to participate in this session to see what innovative ideas they can take back to their plant

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2:00pm

Processor Spotlight: Aaron Merrell and Plato Pet Treats
Speaker: Aaron Merrell, Plato Pet Treats
Theater: 2

The CEO of Plato Pet Treats joins the PROCESS EXPO program to share his company’s challenges operating in the competitive pet food industry. From the careful selection of responsibly sourced, all-natural ingredients to efficient in-house production and conscientious distribution, Plato’s sky-high standards are never compromised, ensuring steady growth and solidifying its position as one of the up-and-coming players in pet foods.

Prepare Your Plant, the Future Demands It
Speaker: John Sbraga, Nu-Meat Technology, Inc.
Theater: 1

When going forward in your decisions of equipping your plant, it is imperative to assess up front who you want to be and what you want to look like. Your plant will be subjected to third-party auditors and customer impressions when they visit with you. And your most valued asset, your staff, will care about the workplace environment. You should know what you want to look like.

The State of Food Safety in Meat and Poultry
Food Safety Program

Speakers: Andrew Lorenz, We R Food Safety and moderated by Andy Hanacek, The National Provisioner
Theater: FSS

Myriad food-safety issues and challenges keep processors of meat and poultry up at night — Andrew Lorenz will offer his perspective on the primary issues that require immediate focus from processors, and the approaches they should be taking to mitigate risk and keep their consumers and products safe and secure.

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3:15pm

Pasteurized Equivalent Water by Ultraviolet Light
Speaker: Ismail Gobulukoglu, Aquafine
Theater: 2

UV light disinfection of water can be used in place of pasteurization for meeting Grade A. Low-pressure (LP) UV lamp technology has advantages over medium-pressure (MP) UV lamp technology for disinfection of water.

Processor Spotlight: Tremendous Growth in Meal Kit Delivery with PeachDish
Speaker: Judith Winfrey, PeachDish
Theater: FSS

Judith Winfrey, CEO of PeachDish, shares this story of an underdog upstart in one of the industry’s fastest-growing niches — meal kit delivery. Join Winfrey as she discusses the challenges of this business and how PeachDish expects consumer trends to affect t and the rest of the dynamic food industry.

Value Streams from FOG in Industrial Wastewater
Speaker: Todd Blase, Alfa Laval
Theater: 1

This presentation will detail how processing plants are successfully managing their FOG wastewater treatment — as well as optimizing the process before product, water, and waste “hit the drain.” By implementing the system that will be included in this presentation, plants are able to turn what used to be a heavy cost into what is now a value stream.

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Thursday, Sept. 21

9:30am

Engineering Adaptive Food Safety Systems
Speakers: Pablo M. Coronel and Niranjan S. Kulkarni, PhD, CRB Engineers
Theater: 2

Food safety systems must be re-engineered to make them adaptive and self-organizing. They must be able to detect and correct or to prevent operational deviations, which affect efficiency and compromise safety. The presenter will discuss how process systems engineering, simulations, and data-mining techniques can be used within these food safety systems to improve safety and overall operational or supply chain efficiencies.

Best Practices in Compressed Air and Vacuum Systems
Speakers: Wayne Perry, Kaeser Compressors, Inc.; Troy Bridges, Busch Vacuum Pumps & Systems
Theater: FSS

Compressed air is a key utility supporting automated food packaging machinery and pneumatic conveying processes. Compressed air expert Wayne Perry will cover best practices for improving productivity and reducing operating costs, including compressed air quality, system controls, compressed air storage, and more.

Vacuum systems play a vital role in food packaging and food processing. Vacuum system expert, Troy Bridges, will give an overview of sizing and selection for meeting food application requirements including vacuum fundamentals, different types of mechanical vacuum pumps and appropriate maintenance and service.

Processor Spotlight: People — Still Our Most Valuable Resource? Challenges to and Opportunities
for Increasing Engagement

Speakers: Mike Bartikoski, SVP Operations, Land O’Frost
Theater: 1

The need for a qualified, motivated workforce is an issue that all food processors face, especially as the baby-boomer generation continues to retire. Mike Bartikoski will speak to the PROCESS EXPO audience to highlight what Land O’Frost is doing to address this critical topic.

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11:00am

Processor Spotlight: Justin Shimek and Mattson Food Development
Speaker: Justin Shimek, Mattson Food Development
Theater: 1

It’s all about new ideas! Join Justin Shimek, CEO of Mattson Food Development, to hear about how Mattson works with food processors both large and small across all of the industry segments to bring
together consumer food behavior and food trends to transform ideas into viable business concepts.

Novel Processing Technologies Merge with Nutrition and Chemistry: Maximizing the Health Benefits of Fruit-Based Beverages
Speakers: Indika Edirisinghe, PhD, Illinois Institute of Technology; Britt Burton-Freeman, PhD, Illinois Institute of Technology; Amandeep Sandhu, PhD, Illinois Institute of Technology
Theater: 2

Fruit-based beverages have received much attention among researchers and consumers due to their potential health-promoting effects. The beneficial effects of fruit-based beverages have been attributed to their essential nutrients and non-essential phytochemical composition. In order to impart health benefits, nutrients and phytochemicals should be biocaccessible and bioavailable. Determination of nutrients and phytochemical content directly from beverages is not enough for the prediction of potential health benefits in humans, as metabolites reaching the blood system may be different from the original compounds found in food as a result of an intensive metabolism that takes place during absorption. The bioaccessibility/bioavailability of the nutrients and phytochemicals is often changed in fruit-based beverages due to many factors, such as processing and matrix effects. Therefore, this session will address the factors that impact the bioaccessibility and bioavailability of health-promoting compounds in fruit-based beverages. Processing technologies used to enhance those factors will also be discussed.

Regulatory Transformation in the Food and Beverage Industry
Food Safety Program

Speakers: Megan Cox, Deloitte Consulting and moderated by Barbara VanRenterghem, Food Safety Magazine
Theater: FSS

The Food Safety Modernization Act (FSMA) is the largest regulatory change for the food and beverage industry in decades. FSMA not only impacts FDA regulated facilities, but also impacts facilities that are dual regulated by both the USDA FSIS and FDA. The FDA is working to provide guidance to the industry on the new requirements and companies are working to implement the required food safety programs to be compliant by the required dates. Get the latest, first-hand updates from federal regulators and industry experts who will discuss the rules, the progress of implementation, and identified gaps and needs to gain a perspective on what to expect as the process continues to evolve.

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12:30pm

The Coming of Age of Industrial Automation in the Food Processing World
Speaker: Matthew Hartman, Blentech Corporation
Theater: 2

The presentation will start with a brief history of automation and its evolution. The conversation will move into sensors and technology found on the plant floor. Come discuss the Programmable Logic Controller (PLC) and its functions in a modern control structure, as well as the use of Human Machine Interfaces (HMIs) to communicate status and alarm conditions. In addition, we’ll cover the high-level use of batching along with track and trace software.

What’s Driving the Expansion of HPP in New Product Categories
Speaker: Dr. Errol Raghubeer, Avure Technologies
Theater: 1

High-pressure pasteurization (HPP) is cold pasteurization in pure water; it uses ultra-high-pressure purified water to keep packaged food free of pathogens to stay fresh longer. At very high pressures, bacteria such as Listeria, E. coli, and Salmonella are inactivated. Foods using HPP include ready-to-eat and ready-to-cook meats, ready-made meals, fruits and vegetables, juices and smoothies, soups and sauces, wet salads and dips, dairy products, and seafood and shellfish. HPP helps producers increase
food safety and extend shelf life while providing consumers with nutritious, natural, flavorful food. Join colleagues to learn more about this important alternative form of production and how to get started using it.

Processor Spotlight: Leveraging R&D for Growth — How Science, Research, and Data Can Drive Brand Growth
Speaker: Tulin Tuzel, Sabra
Theater: FSS

Join Tulin Tuzel from Sabra, one of the leading food processors in the prepared foods segment, who will share Sabra’s use of R&D to gain a competitive advantage and take hummus from niche status to one of the more commonly used foods in the United States.

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2:00pm

Challenges and Solutions of Commercial Validation of UV Preservation to Address Shelf Life and Safety Issues of Premium Cold Pressed Juices and Beverages
Speaker: Tatiana Koutchma, AAFC
Theater: 1

Come discuss the results of validation studies of innovative commercial UV systems for preservation of cold-pressed juices and beverages. The tested products included fresh fruit juice (apple and orange), leafy vegetable juice, and coconut beverages. The impact of pH, juice composition, and vitamin content on efficiency of UV inactivation of inoculated organisms and natural juice microflora will be presented. The new approaches of UV dose evaluation and verification using chemical actinometry and process control instrumentation will be discussed.

Technology Developments that Impact your Environmental Monitoring Program
Speaker: Anthony Saitta, Commercial Food Sanitation
Theater: 2

The key to developing a robust environmental monitoring (EM) program is knowing your product and any micro-risks associated with it. The objective of an EM program is to seek and eliminate harborage sites. Don’t be afraid to find pathogens; you should be looking for them! Make a habit of trending positives over long periods of time, as it will help you in discovering and solving the source of your sporadic finds. How does new technology such as whole genome sequencing (WGS) impact food processors? And how can you always be prepared for an FDA visit without having to worry about their “swabathons”?

Overlooking Physical Hazards in a Hazard Analysis
Food Safety Program

Speakers: Patricia Wester, PA Wester Consulting and Chirag Bhatt, CHB Consulting
Theater: FSS

There are many aspects to food safety but the leading cause of consumer complaints relates to the discovery of foreign objects in food products. Although the number of occurrences is becoming less frequent, food manufacturers are well-advised to be vigilant and not overlook physical hazards that extend beyond metal detection. Today’s food safety management systems strive to identify and prevent hazards, rather than just simply react to the contaminant after it’s been identified.

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3:30pm

Making the Invisible Visible — Novel Solutions to Ensure Soft Components Are No Longer the Weakest Link in the Process
Speaker: Stephen F Doherty, Garlock Sealing Technologies
Theater: 1

Physical contamination remains a significant challenge to the food processing industry, with many contaminants, such as rubber and polymer fragments, coming from within the processing system and the manufacturing environment. This session aims to educate the audience that novel materials are now available that facilitate detection and removal or quarantine without compromising physical performance, process efficiency, or industry compliance.

Essentials of Robust Food Processing and Packing Equipment Design from a Food Safety Expert
Speaker: Ramakrishnan Narasimhan, Perry Johnson Registrar Food Safety
Theater: 2

In the recent past, inadequate equipment design was cited as the culprit in a few major food safety incidents. Therefore there has been an increased focus on understanding the importance of designing, fabricating, and constructing food processing and handling equipment according to sound sanitary design principles. Some regulatory bodies have an approval process in place, respectively, for meat, poultry, egg, and dairy processing facilities in the U.S. The U.S. FDA does not have such an approval process; however, it regularly inspects equipment according to the current Good Manufacturing Practices. Additionally, standards organizations such as 3-A Sanitary Standards, Underwriters Laboratories, and the National Sanitation Foundation (NSF) have developed standards to guide equipment manufacturers in the hygienic design of food processing and handling equipment.

Optimize Plant Productivity and Food Safety by Using Tensionless Belt System
Speaker: Jim Honeycutt, Intralox
Theater: 2

Food processors want peak performance within their plants. Conveyance systems are to a plant what arteries are to a human being. Because conveyance systems connect all pieces of equipment and carry sometimes naked food products from receiving to ready-to-eat and packaging, they play a crucial role in optimal productivity. This session explains what benefits you may expect to find once you get rid of tension in your plant conveyance systems. Jim Honeycutt outlines the value a tensionless belt system brings and how it allows food processors to have reliable, predictable, and safe conveyance systems while creating unique opportunities in hygienic conveyance design.

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