Production

New factory set to boost supplies of gold standard whey protein

Arla Foods Ingredients is investing €38 million in a new factory in Denmark to meet booming demand for whey protein hydrolysates.

The investment will further strengthen the company’s position as a global leader in natural whey ingredients.

The manufacturing plant is to be located next to Arla Foods Ingredients’ existing whey protein facility in Videbæk, Denmark, where the company is also in the process of building a new lactose factory. The whey protein factory is scheduled to be fully operational towards the end of 2016.

The new factory will increase three-fold Arla Foods Ingredients’ capacity to produce whey protein hydrolysates, a ‘gold standard’ form of whey that offers superior benefits compared with intact proteins, and has applications in the infant, sports and clinical nutrition categories.

Henrik Andersen, CEO of Arla Foods Ingredients, says: “When we speak with our customers they make it clear that whey protein hydrolysates are a very big part of their future plans and they are keen to work with companies who can guarantee ongoing security of supply. The investment in this factory sends out a strong signal that Arla Foods Ingredients will continue to be at the vanguard of the hydrolysates sector and that we will be able to satisfy demand while adhering to the strictest quality and safety standards.”

The new factory in Videbæk will further the commitments made by Arla Foods Ingredients through its ‘Quality starts here’ brand platform.

Henrik Andersen adds: “There are five cornerstones to Quality starts here, including promising our customers security of supply backed by adequate capacity, logistics and documentation. Our new hydrolysates factory in Videbæk will ensure we can meet this pledge and maintain our position as the world’s leading supplier of high quality whey protein ingredients.”

New production site in Indonesia for Schütz

The official opening of the company’s own production facility in Indonesia sees Schütz continuing the sustainable development of the company’s network in South East Asia.

Schütz has been operating in Jakarta since 2005 with a distribution company. In Karawang, 50km east of the island-nation’s capital city, a new factory was built fitted with state-of-the-art manufacturing lines in 2013.

The production of IBCs started at the new site at the end of last year and has since then been further optimised to meet customer demands. The site has now been officially inaugurated in an opening ceremony, which featured traditional dance performances and the symbolic cutting of a ribbon. Gertjan Boom, Business Unit Manager Asia/Pacific, and Ricky Lie, General Manager of PT. Schütz Container Systems Indonesia, welcomed numerous guests from industry, business and politics, including Governor representative Ir Dedi Mulyadia and Dr. Cellica Nurrachadiana, Vice Regent of Karawang. Many customers from the food, pharmaceuticals and chemical industry also attended the event. In a tour of the factory, guests were shown how Schütz’s packaging solutions are produced with the highest degree of energy efficiency thanks to modern technology.

The new subsidiary further strengthens delivery security and shortens transport distances in the South East Asian market. In terms of population, Indonesia is the fourth biggest country in the world and its specific geography poses special challenges - the country is spread over more than 17,000 islands, of which only around 6000 are inhabited. Accordingly, optimised logistics combined with a close proximity to customers are Schütz’s primary goals. The advantages are reduced use of fuels, a better eco balance and higher cost efficiency.

The packaging products manufactured in Karawang also offer customers solutions for a wide range of applications. In order to address the special needs of the food industry the site is presently undergoing the FSSC 22000 certification process, which after completion will ensure and document the highest safety and purity standards in materials, the production process and the end product. For all guests, the key statement at the inauguration event was that Schütz is committed to continually building its position in South East Asia, and that its wide portfolio offers innovative, sustainable and secure transport packaging for a wide range of filling goods including acids, varnishes, paints or concentrates, foods and cosmetics.

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HERMA two-side labelling system is virtual shake-up for ketchup

In order to create an unmistakable look for its ketchup, mustard and salad dressing bottles, Meira is placing its trust in the high-precision two-side labelling system 362M built by HERMA.

The labels for the Finnish company's redesigned products present a special challenge for two reasons. First, their tapered shape and size can easily give rise to inconsistencies during the dispensing operation. And second, they have to be applied exactly in the envisaged recess on the tapered bottles, which also have an oval cross-section.

"Ours is a demanding situation, but the HERMA system offers compelling accuracy. Our products' new look has precisely the desired impact, and the labelling is performed very consistently and efficiently. Despite the complexity of the labelling solution, we are achieving an output of 60 bottles a minute," says Meira Factory Director Juha Suikkanen.

"We also much appreciated HERMA's input before the system was installed; its technical advice related not only to the machine, but also to the development of appropriate labels."

Meira is Finland's leading supplier of herbs and spices, seasonings, dressings and coffee. It is a member of the Italian Massimo Zanetti Beverage Group (Segafredo brand).

The HERMA two-side labeller 362M is predestined for highly accurate front and back labelling applications. Its special centring device exactly positions the labels on the fly, and the product itself is arrested and centred during the labelling operation.

Conventional practice is to align the product accurately and apply the label in discrete operations, but in HERMA's case, the centring device is synchronised with the conveyor belt. With many labelling systems, in contrast to HERMA's solution, the product's position can change in the event of even minimal misalignment between the centring and labelling operations – with a visible impact on the correct seating of the label.

For Meira's application, the centring device plays a crucial role with the large ketchup (930 ml) and mustard (500 ml) bottles in particular. A pre-centring unit is sufficient, however, for the smaller bottles of salad dressing.

Fairburn is egg-static about Co-op deal

The family company, L J Fairburn and Son Limited, is ecstatic with a deal to supply all 77 Lincolnshire Co-op stores with Fairburn’s Lincolnshire Free Range Eggs.

Fairburns are very proud to be going back to their roots, after a long history supplying co-operative societies. In the early 1960s Leslie James Fairburn supplied co-operative shops in the county with his freshly produced free range eggs. 53 years on technology and production methods may have changed but the retail partnership and family values haven’t.

Forming part of Lincolnshire Co-op’s Love Local Range, Fairburn’s Lincolnshire Free Range eggs only travel a maximum of 25 miles, ensuring the freshest eggs are packed for the Love Local Range. Fairburn’s are in control of every process from day old chick to the family fridge. This means that each great tasting egg is full of freshness and very local.

Lincolnshire Co-op’s Supply Chain Manager Nicola Berry says: "We’re delighted to have added large Lincolnshire Free Range Eggs to our growing Love Local range as it gives our shoppers another choice when it comes to buying produce from the county.

“Supporting local family firms like L J Fairburn and Son is also really important to us and because the chickens live on farms in Lincolnshire, it means our customers can really identify with where the eggs are coming from.”

Sarah Louise Fairburn, Brand Director of L J Fairburn and Son Limited, says: “We take great pride in our family business and our eggs, just like our Grandfather did all those years ago. We are delighted that he is alive today to see us rekindle the relationship with the Co-op.

“Our Fairburn’s Lincolnshire Free Range Egg brand is proving really popular and we are so pleased to be supplying all Lincolnshire Co-op stores in the county. The Co-op is an amazing retailer to work with and we look forward to adding future additions to our range to support such a great sponsor of local produce.”

Fast response from UK company to help save lives in Iraq

UK engineering firm Olympus Automation were recently approached by the president of Azersun, the leading food producer in Azerbaijan, for a rapid cooking system to feed refugees in Northern Iraq.

The president was so appalled by the plight of the refugees stuck on mount Sinjar he has chosen to fund the equipment himself.

Time is clearly of the essence and managing director, Harry Norman, of OAL has been quick to respond and a system will be shipped in record time next week. Norman, says: “Normally systems take 24 weeks to manufacture, but this is clearly not a normal situation, lives are at stake and we will be able to deliver a Steam Infusion cooking system in a week. Steam Infusion is 4 times faster than traditional processes making the equipment ideal for feeding lots of people, hence the call from the president.”

OAL will be flying application specialist Stuart Rigby to an undisclosed location in Turkey to provide training on the system before it is deployed in Northern Iraq.

OAL are supplying a simple cooking system based on its revolutionary Steam Infusion technology to make lentil soups, rice and provide a clean source for drinking and washing water. The cooking system uses will use Steam Infusion, OAL’s revolutionary heating and mixing process to make 4,000 portions of hot food an hour.

Gin set to flow from new Caithness micro distillery

Work has now finished at the most northerly gin distillery on mainland Britain with the final piece of equipment – a new still called ‘Elizabeth’ – installed in the new custom-built distillery at Dunnet, Caithness.

Husband and wife team Martin and Claire Murray, the founders of Dunnet Bay Distillers have distilled and tested the first batches of Rock Rose gin and full production will be under way in time for the launch of the new micro distillery on 21st August. Over the next three years, the company will receive support of £83,990 from Highlands and Islands Enterprise which the owners say have put a huge amount of effort into helping them develop their Rock Rose gin. Claire has been working with experts in Caithness to research local botanicals which can be used to flavour the gin.

Martin currently works in the oil and gas industry in Aberdeen and has a master’s degree in process engineering. He is now studying for a pHd in brewing and distillation at Heriot Watt University. As part of this study, he worked with the Centre on a number of research projects to assist with product development.

Located in the Bay of Dunnet where fresh air and pure water is in abundance, Martin and Claire’s goal is to create a spirit which reflects the Caithness way, carefully and slowly distilling by hand to create the product.

Claire says, “Each year we will create a new vintage. Our Caithness botanicals are dependent on our climate resulting in a truly hand crafted gin that will change year on year, but is still undeniably Rock Rose.

“Rock Rose gin was named after our first botanical forage along our Caithness cliffs, where local herbalist Brian Lamb introduced us to Rhodiola Rosea, a rose in the rocks. Hundreds of years ago, the Vikings would pillage these wild exposed cliffs to gather this precious plant, which was thought to give them extra strength to continue with their long, arduous journeys. Our gin uses this ‘Rock Rose’ and a blend of local and traditional botanicals to create a unique taste of Caithness in the Highlands.”

Martin says, “Since the new still arrived, we have been making some trials and we look forward to launching Rock Rose at the end of August. We aim to make about 700 bottles in every batch, producing about 10,000 bottles a year. The first batch sold out by pre-orders within 48 hours and the second batch is expected to be released in early September. We are incredibly proud of what we have achieved in the last year, but we realise that a lot of hard work is ahead of us. We really cannot wait for people to taste the gin!”

Laura Gunn, account manager from HIE, says, “We are very excited about having the most northerly distillery in mainland Scotland opening in Caithness. Martin and Claire have put a huge amount of time and effort into ensuring the product they are creating is of an extremely high quality, and we look forward to working with them in the months and years to come as they take the product into markets at home and abroad.”

Fourth generation family bakery celebrates 80th year in business

A family-run bakery business is celebrating its 80th year with rising orders for the likes of John Lewis and Asda as well as sandwich shops, secondary schools and London cafes.

Barnsley-based White’s Bakery manufactures a wide range of cakes, cookies and bread products for wholesale and retail customers.

The fourth generation business has seen a steep increase in orders in the last four years and now has a turnover of £2.6 million and employs 56 people at its Worsbrough Bridge bakery and four South Yorkshire shops.

White’s has now launched a new marketing drive to build on success and attract more customers in its 80th anniversary year.

Managing director David White says: “We are always handling fresh enquiries and repeat orders and have an excellent relationship with our existing customers whether they are the local corner shop or a national food production company.

“We’ve had four straight years of growth, following the quieter years of recession, and what we’d like to do now is expand our customer base further. We have the capacity to expand so we are stepping up our marketing drive.”

Whites’ business growth strategy is being supported by Enterprising Barnsley, a European-funded programme delivered by Barnsley Metropolitan Borough Council.

The family bakery business was established in 1934 by David’s grandparents Albert and Elsie White. David’s dad and uncle, Jack and Colin, then joined the company and David took over as MD in 1996. His son Mathew is leading on the new marketing initiative to boost their expanding order books.

Recent new orders include a contract to design and bake Victorian gingerbread figures – gentlemen and ladies - to celebrate John Lewis’ 150th anniversary. This is not the first time White’s has baked for the department store as they also produced ‘The Bear and the Hare’ decorated biscuits which accompanied John Lewis’ huge Christmas campaign in 2013.

Another order will see more than 200,000 Madeira cakes baked by White’s on the shelves of Asda stores in Scotland and Northern Ireland in the run up to Christmas this year. The sponge cakes are a particular festive favourite in these parts of the UK and this sale represents a repeat order for White’s via a wholesale supplier.

Fairtrade cookies - made from ethically-sourced ingredients including chocolate, spices, raisins and sugar – are an increasingly significant product for White’s. Sales of these premium cookies have quadrupled in the last two years. Most of the cookies are delivered to London’s universities, colleges and coffee shops again via a large wholesale supplier.

Whites’ customers also include a growing number of schools across Yorkshire and the East Midlands, to whom they deliver flapjacks, cookies and shortbreads.

David says: “Our schools are very important customers to us. Their goods have to be baked and delivered daily and they have to meet all Government required low fat, low sugar and low salt content levels. We are committed to our schools and have doubled the number we supply across the region in the last two years.”

Whites also delivers bread and confectionery direct to small grocers, sandwich shops and chip shops as well its own four retail outlets in Worsbrough, Darfield, Conisbrough and Barnsley market.

Large wholesale orders are transported to food preparation and sandwich-making companies and niche goods are developed for customers too. For example, Whites’ bakers are currently developing a mini Eccles cake for a catering company which supplies big name airlines like Emirates.

David says: “We are responsive to our customers’ needs – whether that means creating bespoke novelty biscuits, following regulated ingredient guidelines for schools or fulfilling bulk orders of cakes.”

White’s Bakery in Charles Street routinely bakes from 6am – 6pm and packs and delivers through the early hours of the morning. The company used to operate a chain of its own small local shops, but when David took over as MD he steered the business towards more manufacture, when he realised the bakery’s equipment was standing idle most of the day.

Enterprising Barnsley is now supporting White’s with intensive specialist coaching to develop robust sales and marketing techniques and improved IT systems.

Enterprising Barnsley business development manager Shaun Higginbottom says: “This is an exciting time for White’s Bakery as it puts fresh impetus into its drive to seek new customers and explore new markets.

“White’s is a perfect example of a family firm which understands the value of its heritage but looks to the future too. We look forward to seeing the business expand and in the next few years, building on its first 80 years.”

Enterprising Barnsley is supported financially by the European Union and has attracted £2,259,511 investment from the European Regional Development Fund as part of Europe’s support for the region’s economic development, through the Yorkshire and Humber ERDF Programme.

Whey and lactose production gets underway at new ArNoCo joint-venture factory

Production has begun at a new whey and lactose production facility that is a joint venture between Denmark’s Arla Foods Ingredients and German dairy co-operative Deutsches Milchkontor.

The factory, which cost more than €50 million to build, is operated by ArNoCo, an organisation created by the two companies specifically to produce high quality ingredients for the food and beverage industry. Located in Nordhackstedt in Germany, just 22km south of the Danish border, the new facility is adjacent to an existing 60,000 tonnes-a-year cheese factory owned by DMK. This site produces Mozzarella and semi-hard cheeses such as Gouda.

ArNoCo will use the whey by-product from DMK’s cheese-making operations to produce whey protein concentrate ready to be converted into value-added ingredients for the bakery, dairy and nutrition sectors.

The new site will also produce 25,000 tonnes of lactose annually, which will be processed and sold as Arla Foods Ingredients’ premium quality Dry Blend lactose for infant formula.

Hans Jørgen Lauridsen, ArNoCo’s Project Director, says: “This new joint venture will enhance Arla Foods Ingredients’ position as one of the world’s leading suppliers of the highest quality whey protein and lactose ingredients. The market for these products is growing faster than the ingredients industry can supply them, so the establishment of ArNoCo in co-operation with DMK is a significant development.”

Following a test production phase in July, the ArNoCo factory is now running at 80% capacity and is on track to be at full capacity in September.

Hans Jørgen Lauridsen adds: “The construction of the new ArNoCo factory in Nordhackstedt is part of our quest to fulfill the pledges we make under our ‘Quality starts here’ brand platform, which promises to offer our customers security of supply backed by adequate capacity, logistics and documentation, along with uniform high product quality, supported by strong traceability.”

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