Ultrasonic Technology & Innovative Automation Concepts Drive Continued Growth In Food Portioning

There are a number of factors driving what seems to be an ever-increasing demand for pre-portioned products in recent years. These include a greater tendency to eat-on-the-go, convenience for the consumer at home, time savings for retailers and the obvious hygiene benefits of foodstuffs being handled and portioned within a tightly controlled and clean environment.

Initially however, keeping pace with the demand for pre-portioned products did pose some problems for manufacturers. Although the mechanical cutting systems traditionally used for slicing, dicing, and portioning worked perfectly well in many applications, when used on soft, sticky, or delicate products, their restrictions often became clear.

The tendency for these types of products to adhere to a traditional mechanical blade could cause a number of issues, including smearing and cross contamination, plus there is also a risk of crushing on the softer and more delicate products. Clearly an alternative technology would be needed to match the increasing number of applications for portioning and cutting.

The ongoing application of Telsonic’s field proven ultrasonic technology has not only addressed many of the the challenges relating to soft and delicate products, but also played a key role in driving efficiencies, greater productivity, higher yields, and improved product quality when used for food cutting and portioning.

Realising the broad potential for this technology, food manufacturers across the UK have been quick to turn the UK’s industry specialists to evaluate both new opportunities for the technology, and also areas where it could be used to replace more traditional cutting methods.

As one of the leading pioneers in the application of ultrasonics for food cutting and portioning, Telsonic UK plays a key role with both end users and system integrators to deliver the benefits of ultrasonic cutting for a diverse range of products and applications across the UK.

(Telsonic’s ultrasonic technology is being adopted by an increasing number of end users for cutting and portioning food products)

As one might imagine, each application is different and requires its own tailored solution. Concepts range from dedicated automation systems, perhaps incorporating one or more ultrasonic blades, to highly flexible multi-robot systems, capable of producing cuts in different positions and orientations. The many benefits of the ultrasonic process, together with these innovative automated production solutions, mean that a growing number of items such as sandwiches, cheesecake, gateaux, cheeses, and a host of other products, are now being successfully cut and portioned automatically using this efficient and clean process.

Using the ultrasonic process also allows food manufacturers to consider new products or ingredient combinations, which may have been extremely difficult or impossible to cut and portion successfully using traditional methods. The clean cutting nature of the process also improves product aesthetics by providing consistent portion control and eliminating crumbs, important considerations for customers viewing products on the shelf. Manufacturers also realise increases in yield, due to the consistency in cut, and the ability to cut very thinly. All of these attributes can also have a positive impact on downstream packaging operations by eliminating issues related to product inconsistency.

Significant productivity gains are achieved through the speed of the process, and as the cutting sonotrodes do not suffer from the same contamination problems as traditional cutting blades, uptimes are much higher. It is also possible to introduce automated cleaning cycles on dedicated cutting systems or robot-based systems if desired, either by dipping the sonotrodes in a cleaning bath and activating the ultrasonics, or by jet washing within the machine.

The relatively simple configuration of the ultrasonic process means that the sonotrode and its associated converter can easily be mounted to multi-axis robot systems, which has definitely had a positive impact on the uptake of the technology. The increase in the number of systems being integrated to robots can in part be attributed to Telsonic’s development of special extra wide sonotrodes, up to 800mm. These can also incorporate IP rated booster-less systems and special double length yet lightweight “T“ sonotrodes for deeper products, all driven by Telsonic’s flexible compact 20 and 35kHz MAG – S type generators. The relatively low-weight of these sonotrodes make it possible to use smaller robots, which in turn makes for a more compact system, taking up less valuable floor-space.  The flexibility of the process, especially when combined with a robot, makes it simple to change the portion size or shape as required for different customers.

Telsonic’s Martin Frost commented: “We work closely with both end users and system integrators throughout the UK to ensure that we can deliver the optimum solution for any specific application which they may have. The combination of our expertise in ultrasonic technology and the technical innovation, in terms of the solutions which can be offered, has led to the development of a comprehensive range of ultrasonic based food cutting and portioning solutions.”

Telsonic UK offer a comprehensive range of ultrasonic modules and systems for a variety of plastic and metal welding, cutting, sealing, cut’n’seal, food cutting and cleaning applications within a wide range of industries.

More information on Telsonic products and systems for food cutting and portioning can be found HERE.