The new space brings GEA’s manufacturing, assembly and application teams closer together at Janesville. For clients, this means direct access to experts on site, shorter turnaround between a test result and a production decision, and less time lost moving a process from the lab to the plant floor.

The new infrastructure will focus on solutions from GEA’s Nutrition Plant Engineering portfolio, with drying technologies among the core capabilities. It will also support customer and internal training as well as application-related testing activities.

“Food and beverage producers in North America are looking for partners who can combine process expertise, practical testing and reliable project execution close to their markets,” said Klaus Stojentin, chief executive officer of GEA’s Nutrition Plant Engineering Division and member of the GEA executive board. “Expanding our Janesville campus is a direct response to that. It builds real capability in a region that matters strategically to both our customers and to GEA.”

Building on Existing Capabilities
GEA’s Janesville operation already combines several operational and technology functions. In 2024, the company opened a production, repair, logistics and training facility at the site for equipment such as separators, decanters, valves and pumps. A year later it added a New Food Application & Technology Center, providing food producers access to pilot-scale testing for precision fermentation, cell cultivation and plant-based applications. The planned expansion builds on this foundation.

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“Timing is one factor many manufacturers cannot control, especially in seasonal production or contract packaging. Their production window opens when it opens, and the equipment has to be there and ready to go,” said Tom Koshy, sales director. “LightningBuild lets our customers commit to a schedule instead of working around a lead time. Our team’s decades of experience informed exactly what configurations we could offer and how to assemble them this quickly – from purchase order to the customer’s dock within four weeks.”

LightningBuild is ideal for seasonal processors that may need additional inspection capacity as harvest volumes and timing evolve, as well as for co-packers responding to new customer contracts, package formats and production schedules. Other applications include replacing equipment after an unexpected outage and receiving equipment before a fiscal-year budget deadline.

Mettler Toledo assembles each LightningBuild system to order. The company supports the shortened delivery schedule through standardized engineering processes, targeted inventory management and coordinated production planning. Each system undergoes standard testing and quality checks before shipment.

The X12 LightningBuild is an entry-level x-ray inspection system for small- to medium-sized packages in food and pharmaceutical applications. It detects dense contaminants including metal, glass, stone and bone and can perform package integrity checks. The C31 LightningBuild is an entry-level inline dynamic weighing system for food and non-food manufacturing. It replaces manual spot checks with 100% inline weight control, helping manufacturers reduce product giveaway, comply with net-weight regulations and lower operating costs.

– Reported by Malcolm Cameron

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Over a career spanning more than three decades, Dr. Jaykus has advanced scientific understanding of foodborne viruses while addressing complex food safety challenges.She has served as a trusted scientific advisor to the frozen food industry, helping stakeholders navigate complex enteric virus-related issues in frozen berries and apply science-based approaches to testing, risk assessment, and mitigation. Separately, during the Covid-19 pandemic, she worked closely with food manufacturers to advance scientifically sound strategies to protect essential workers and ensure operational continuity across the industry.

Most recently, Dr. Jaykus led an international panel of experts charged with evaluating the state of the science surrounding enteric virus detection in berries. The resulting publication, “Detection of Foodborne Viruses in Berries – State of the Science and Considerations for the Future,” provides a comprehensive examination of testing methodologies, confirmatory approaches, result interpretation, and future research needs. While prompted by challenges facing the berry supply chain, the work has broad relevance across the food industry by helping inform science-based approaches to enteric virus prevention, control, and supply chain risk management.

“With her scientific expertise and leadership, Dr. Jaykus has provided critical guidance and left a lasting impact on the drive toward continuous improvement in supply chain safety,” said Dr. Sanjay Gummalla, executive director of the American Frozen Food Institute’s (AFFI) Frozen Food Foundation. “Her contributions to food virology research, industry education, and science-based risk management are invaluable for the frozen food industry and the broader food safety community.”

In addition to her research accomplishments, she has demonstrated an unwavering commitment to education and helped translate complex virological concepts into practical guidance for industry applications. Her efforts have equipped food safety professionals with a deeper understanding of risk factors, preventive measures, and control strategies, fostering a culture of science-based decision-making throughout the frozen food sector.

Dr. Jaykus earned her doctorate in environmental sciences and engineering from the University of North Carolina at Chapel Hill and spent more than 30 years on the faculty at North Carolina State University. In addition to her research accomplishments, she has held leadership positions in several leading food safety and scientific organizations, helping advance collaboration, education, and scientific excellence across the food safety community.

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The machine offers greater efficiency, high cut quality, and simplified operation across a range of cheese applications, and helps reduce the need for pre-cutting for a variety of product formats.

“Processors today are under pressure to do more with less — less waste, less downtime, fewer skilled operators and less margin for error. What we see in the field is that cutting is often underestimated, yet it has a direct impact on profitability. With Flexifam.2, we are offering a practical, accessible solution for processors who need reliable cut quality, easy sanitation, and low maintenance without complexity,” said Thijmen Put, product manager (pictured above).

The global cheese market continues to expand, with industry estimates valuing it at US$ 98.0 billion in 2025 and projecting it to reach $154.4 billion by 2034, reflecting sustained demand across retail, foodservice, and convenience sectors. Europe and the United States remain the largest and most mature markets, while countries such as China, Brazil and India are driving new growth, supported by the rapid expansion of foodservice and changing consumption habits. Mozzarella, in particular, has become the most widely processed cheese type worldwide, driven by the global popularity of pizza and ready-to-eat product formats, where consistent portioning and performance are critical.

At the same time, dairy processors are operating under increasing pressure. Rising raw material and energy costs, labor constraints, and market volatility are forcing producers to focus more than ever on operational efficiency and margin protection. According to McKinsey & Company, technology is one of the primary levers identified by industry leaders to address these challenges and improve performance across the value chain. In this context, cutting performance becomes a critical control point in the process, where even small deviations can lead to measurable losses in yield and product quality.

Evolving Cheese Processing Needs
In response to these evolving requirements, Kontich, Antwerp, Belgium-headquartered FAM Stumabo’s Flexifam.2 dicer is built to deliver consistent performance in demanding cheese processing environments, with a capacity of around 1,000 kg/h depending on the cut size.

The new model is an evolution of the Flexifam 55, further refined to meet the needs of small- to medium-sized processors seeking a robust, easy-to-use solution that combines reliable cut quality with improved hygiene, simplified maintenance, and efficient operation in continuous production environments, supported by a 5.5 kW drive system.

Addressing Key Processing Challenges
Cheese processors face a range of operational challenges, from maintaining consistent cut quality across variable products to reducing waste and avoiding unnecessary pre-processing steps. Flexifam.2 addresses these requirements through a combination of design features focused on performance and practicality.

The machine cuts product in three steps — slicing, strip cutting and dicing — using fast-rotating knife spindles rather than forcing product through a cutting grid. A shear plate enables a very small tolerance between the crosscut knives and the shear edge, reducing friction and delivering clean, consistent dice with minimal fines across a wide range of cheese types and textures.

Variations in product size are accommodated by the large drum diameter — one of the largest in its category — enabling processors to feed larger formats without the need for pre-cutting. At the same time, a 5.5 kW drive system and precise knife positioning contribute to stable, repeatable output, even when processing products with varying texture or moisture levels.

The dicer can process products up to 135 mm in diameter and 270 mm in length. It delivers dice sizes ranging from 3 to 15 mm.

Flexifam.2 is particularly well-suited to mozzarella processing, one of the most widely processed cheese types worldwide. Its large drum diameter accommodates the longer logs commonly produced by smaller and artisanal mozzarella makers, reducing or eliminating the need for pre-cutting. Thorough and efficient cleanability — a critical requirement in any dairy processing environment — is also central to the machine’s design.

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The Hybrid Tunnel Freezer features a newly developed, more compact design that delivers up to 60% more production capacity than its predecessor. Despite a reduction in size, the system retains full flexibility and can freeze or chill a wide range of food products, including small and delicate items such as raw minced meat, seafood and cooked proteins.

Performance Meets Efficiency
This redesigned model not only boosts production throughput but also improves overall system performance without increasing energy consumption. The enhanced capacity is achieved through the addition of two extra conveyor belts, enabling high-volume freezing using the same energy consumption and footprint as the previous model.

The Hybrid Tunnel Freezer is built around a “clean-by-design” engineering approach. This design minimizes difficult-to-clean areas and incorporates smooth surfaces and high-grade components, making cleaning simpler and more effective. With a simplified design and smart engineering, the freezer improves cleanability and supports compliance with hygiene standards in food processing environments.

A key feature of the freezer is its multi-belt conveyor system, which crust-freezes products prior to full freezing. This helps retain product shape, structure and appearance while also allowing smoother product transfer between belts. The combination of gentle movement and crust freezing promotes product agitation, reduces clumping and ensures consistently high-quality IQF results.

Understanding the critical need to minimize downtime, Starfrost has engineered the equipment for fast and straightforward installation. Delivered as a pre-assembled package, the system can be fully operational within one week, ensuring minimal disruption and maximum productivity.

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“Interpack draws processors and packers from every major market, and across all of them we’re hearing the same priority: more operational value without added complexity,” said Robert van Dorst, the company’s managing director for EMEA/Asia markets. “Our portfolio is built around exactly that, grounded in decades of application expertise, equipment engineered for minimal operator intervention and a global service team that supports customers wherever they operate.”

At the show, Key will introduce ADR X, its next-generation automatic defect removal system (pictured above) for identifying and precisely trimming defects from wet potato strips to recover more usable product and increase yield. Building upon the field-proven technology of previous-generation ADR designs, the new model features multi-channel sensing with advanced LED lighting and strobing technology, improving the detection of challenging defects and enabling more accurate trimming decisions. A redesigned mechanical architecture eliminates activity above the product stream, integrates clean-in-place capability and positions critical parts for easy access to support sanitation, simplify maintenance and maximize uptime.

Also on display at Interpack will be Key’s Compass belt-fed optical sorter (pictured below).. Featuring multi-channel sensor data and multi-wavelength strobing to generate up to eight channels of inspection data, the equipment boasts detection capabilities comparable to laser-based sorters but without mechanical scanning components, which simplifies day-to-day configuration and adjustments, lowers long-term operating costs and offers a strong return on investment. The horizontal belt configuration ensures gentle product handling even at high throughput. Recipe-driven operation simplified controls and an open sanitary design help processors achieve consistent performance while reducing training requirements, cleaning time and maintenance.

Additionally, Key will present its Impulse vibratory conveyor, designed for processing and packaging lines that require precise product metering with minimal maintenance. Impulse shakers start and stop quickly to deliver accurate flow for mixing, ingredient feeding and scale feeding applications. Magnetic drives eliminate sliding or rotating parts, reducing wear and helping ensure long service life, while oil-free operation and IP65-rated enclosures support food safety and reliable performance in harsh production environments.

PPM Technologies will be showcasing its new Gen 3 FlavorWright All-in-One seasoning system, which combines liquid and dry seasoning in a single plug-and-play unit. Designed for frozen food, snacks, nuts, cereals and more, it achieves consistent coating with fast setup and intuitive operation. New features in the Gen 3 model include enhanced drum magnets for high-capacity applications, improved safety and wiring design, a stainless-steel drum option and additional upgrades that expand flexibility while maintaining safe, reliable operation in continuous production environments.

Multiscan will exhibit its MXV-PACK 4015 X-ray inspection system for products packaged in boxes, trays, bags and other formats. Utilizing high-resolution UHD X-ray technology, the system detects dense contaminants that are difficult to identify with conventional inspection methods. Designed to handle formats up to 400 mm (15.7 in) wide and 150 mm (5.9 in) high, the machine provides accurate inspection across a wide range of product and package types.

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Requiring minimal floor space, the freezing system offers continuous high throughput freezing or chilling for a broad range of food products, It is designed in 10-foot modular sections making it easily field expandable. Couple this advanced machine with Freshline Smart Technology, and Air Products engineers can work with a customer’s team to easily troubleshoot from afar, minimizing downtime.

Air Products operates a state-of-the-art food and grinding lab at its headquarters in Allentown, Pennsylvania. Customers and prospects can utilize the facility to test products on production-scale equipment to help determine the feasibility of using cryogenics in their process.

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Uniform Heat Distribution and Reduced Cooking Times
The machine features a twin-zone spiral configuration with integrated booster impingement. By combining horizontal and vertical airflow, the system achieves more uniform heat transfer across the conveyor belt. According to Düsseldorf, Germany-headquartered GEA, the core temperature variation across the belt is limited to approximately 1°C, compared with deviations of up to 6°C in conventional ovens. This uniformity enables cooking times to be reduced by 10-30% while maintaining consistent product color and internal doneness. Throughput can reach up to 1,700 kg per hour, and more stable thermal conditions contribute to yield improvements of up to three percent.

Focus on Energy Efficiency
Improving energy efficiency in spiral ovens requires a better oven balance. Company engineers introduced a new intelligent active exhaust system, changes to the oven design, and adjustable product gates to the GEA CookStar First to minimize air leakage. These features work together to ensure consistent cooking conditions throughout the oven. More efficient water flow enables water reuse. Together, these features reduce energy and water consumption by up to 12%.

Process Transparency and Digital Connectivity
CookStar First is equipped with GEA SmartControl HMI, providing operators with access to real-time process data, alarm management, and a 24-hour timeline for tracking events and parameter changes. The system supports consistent operation and data-driven optimization and is compatible with GEA Insight Partner technology for remote diagnostics, service intervention, and maintenance planning.

Compact Footprint and Scalability
With an overall height of less than 3.9 meters, the machine is designed for installation in existing facilities, including brownfield sites with limited ceiling height. The oven’s cooking technology supports a wide variety of products and process parameters.

The broader CookStar family range includes the original CookStar model, which adds smoking functionality and higher capacity, as well as the CookStar Turbo for large-scale applications with capacities of up to 12,000 kg per hour and roasting capability. All systems share a common footprint and can be integrated into existing CookStar production lines.

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“More than ever, Bühler has an important role to play in the sustainable transformation of the food, feed and mobility industries. I am excited to lead the company into its next stage of development. Our focus will remain on creating value for our customers, driving meaningful innovation, and growing our business sustainably. Together with our global teams, we will continue to build strong partnerships and deliver solutions that enable our customers’ success,” said Samuel Schär (pictured above).

His appointment stands for continuity and stability for Bühler’s employees, customers and partners. Schär joined Bühler 20 years ago to establish the nanotechnology business unit. He then led the grinding and dispersing business area for several years, before joining the group executive board in 2013 and successfully leading the advanced materials segment for 10 years. He later took over responsibility for the global services and sales organization.

Scheiber (pictured below) will be nominated for election as the new board chairman of the of Bühler Group next month. With a 35-year career at Bühler, he has been a member of group management for 20 years in various areas of responsibility and has held the position of chief executive officer for 10 years.

Calvin Grieder, current chairman of the board, will step down at the annual general meeting after 25 years serving as CEO, as well as member of the board of directors, and chairman of the the board.

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“After successful installations that demonstrated significant yield improvements in chilling poultry in combo bins, we are excited to deploy the high-capacity KwikChiller for freezing applications — expanding our freezing equipment portfolio and its impact across protein processing value chain,” said Don Smiley, director of Food and beverage at Bridgewater, New Jersey-based Messer Americas.

Developed in collaboration with poultry processors, the equipment was designed to eliminate the need for CO₂ pellets when chilling fresh poultry in combo bins. Inside the Innovation Suite at IPPE 2025, Messer showcased how its rapid, uniform temperature control system improved product yield at a leading poultry facility. In addition, the inline chilling system features an integrated exhaust, offering a safer and more efficient alternative to manual CO₂ pellet handling.

“The recurring question from our customers in the 2025 Innovation Suite was, ‘Can the KwikChiller freeze too?’ We were proud to say yes, as we’ve validated that the KwikChiller delivers the high production rates and product quality our customers expect – all within a compact footprint that allows customers of varying scales of production to access this novel technology,” said Smiley.

The KwikChiller removes up to 30% more heat than traditional freezers, making it ideal for high-throughput operations where space is at a premium. This freezing technology increases temperature uniformity throughout the product in both full freezing and cryo-assisted mechanical freezing applications. It even fits through a standard door for easy installation.

Messer’s protein processing team will be at booth #C23149 during IPPE 2026, ready to discuss production line challenges and share proven chilling and freezing solutions that help processors achieve their goals.

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