Bibby Distribution slashes carbon footprint for Tayto

Snack manufacturer Tayto expects to take up to 250 tonnes of CO2 emissions out of its supply chain by July, thanks to a pioneering ‘virtual warehouse’ system developed jointly by Bibby Distribution and Tayto’s Supply Chain & Commercial Teams.

New figures show the system has already saved 160 tonnes of CO2 emissions since the system was implemented in July 2014, with a further 90 tonnes expected to be taken out by the first anniversary of the system’s implementation. This figure will potentially increase as Bibby Distribution plans to introduce two new 15.6m longer semi-trailers onto the contract in May, meaning fewer runs will be required for deliveries. These new trailers will also be used as mobile advertising for Real Crisps and Mr Porky, two of Tayto’s premium brands.

Furthermore, in addition to generating crucial environmental savings, this joint Bibby Distribution and Tayto virtual warehouse approach has improved on-shelf availability for retailers and provided a platform on which to establish a home delivery market for the largest British-owned snack manufacturer in the UK.

Nigel Smith, Tayto’s Group Supply Chain Director, says, “The virtual warehouse system has been extremely beneficial for our business. It has slashed our annual food miles by around 40,000 a year, plus there are now three thousand fewer pallet touches which means the risk of damage to our stock is far, far lower.”

The partnership team developed the virtual warehouse system to provide Tayto with the benefits of consolidation, but without the outlay required for a physical warehouse or the logistical costs of transporting goods from two production lines to an additional facility.

A software system provides a single ordering point for customers which then builds multi-sku loads from stock in Tayto’s two major warehouses, and calculates the most cost-effective way of consolidating the load based on other orders in the system, transfer costs and warehousing expenses. This then provides the cheapest possible route to market, while also making it easier for customers to order, as previously they would have had to place two separate orders depending on whether they were ordering snacks, stored in Corby, or crisps, stored in Scunthorpe.

The virtual warehouse system is also scalable, with Tayto now evaluating the prospect of using it to provide home delivery direct to consumers.

Scott Cooper, Tayto Impulse and B2B Sales Director, says, “The virtual warehouse solution has been a notable success – one which has satisfied our customers’ ordering expectations and greatly improved their overall experience."

Rail now keeping urgent deliveries on the move

Freight trains are now carrying more intermodal traffic, mainly fast-moving consumer goods, around the UK than coal. But more work is needed if rail operators are to wean more customers off road transport and “green” the supply chain, according to a seminar at the Multimodal exhibition in Birmingham.

Julian Worth, Director of Transworth Rail and Chairman of the Rail Freight Forum at the Chartered Institute of Transport & Logistics, said that when UK rail services were privatised fifteen years ago, the main freight flows comprised heavy, low-value goods and FMCG was barely on the radar. He highlighted the “three Cs”, cost, carbon and convenience, as the reasons for rail’s change of direction.

He claimed goods could be transported from deep-sea ports to the so-called Golden Triangle in the West Midlands up to 40% more cheaply by rail than by road – “an order of cost saving for which most people would bite your hand off”. Every tonne moved by rail would generate 76% lower carbon emissions. “If you’re looking to de-carbonise your supply chain, there’s nothing more effective you can do."

Julian Worth said the convenience aspect was that a truck driver would have to offload and turn around inside two hours to pay his way. “With a rail box, within reason, you can call it in when you want it.”

Andrew Hemmings, Secretary of the Rail Freight Forum and a contributor to Network Rail’s freight utilisation strategy, said, “We weren’t far-sighted enough to see the decline in coal, or may have thought that biomass would be going [by rail] into the power stations instead. But the economics of the supermarkets have dictated the rise of boxes into national and regional distribution centres.”

From the customer perspective, Tim Wray, General Manager of Multimodal Logistics, said he “struggled” to accept that rail transport to the Midlands could save him 40%. With the merchanthaulage market offering him such low rates, rail was “not a cost-effective option. Capacity when you need it is the issue. Huge vessels all arrive at same time, and coping with the volumes is difficult.”

Tim Wray said rail infrastructure must improve and more lines should be electrified. Shippers would make “huge savings” if electric trains didn’t have to switch to diesel on route to Felixstowe, for example. The East Coast Main Line was not cleared for high-cube containers and transport was therefore cheaper by road. Better wagon configurations were vital to a more efficient rail service, and Tim Wray was unhappy about operators’ continued use of 60ft wagons. “We need 45ft units, but you take it because you need the capacity.”

Julian Worth pointed out that the biggest cost of intermodal transport “isn’t the rail bit, it’s the on-cost of going the final 30 or 40 miles by road.” By using a DC at Daventry - Tesco has already put in place, with Sainsbury set to follow – a container load of goods could be put on a dock loader for £30 or £40 against a cost of up to £100 “just to get out of the gate” by truck.

Tesco had taken out a further tranche of cost by using rail outbound from a national distribution centre to regional facilities in Barking and Tilbury, from where stores across the UK south-east are supplied.

Julian Worth noted a generational shift in attitudes to rail. A former generation of transport managers were actively migrating to road, then came distribution directors who were “agnostic”. Incoming supply chain managers now more aware of the need for sustainability and saw rail as a genuine option, though he could recall only one customer who had ever offered to pay more to be green.

Andrew Hemmings said freight facility grants had helped pump prime rail projects over a 20-year period but were currently only available in Scotland and Wales, not in England. However, EU funding was available to incentivise small and medium enterprises in eastern England to try rail, and 70 had converted some of their traffic.

Welcoming the informative debate on rail freight, Multimodal Director Robert Jervis says, “We’re looking forward to a lively three days of networking for visitors and exhibitors.”

Faster and safer logistics with Dynamic Mast Control

Leading global industrial truck manufacturer Linde Material Handling is announcing a new intelligent operator-assist system for reach trucks. Set to transform the way that material is handled in retail and food & drink warehouses and distribution centres, this unique Linde system is currently completing its final field test phase and will be available for the existing reach truck series Linde R14 – R20.

There is a growing demand to working at height in warehouses and distribution centres.

Alexander Schmidt, Head of Reach Trucks & Tractors Linde Material Handling, said: “The market trend for ever higher storage racks in warehouses and distribution centers is continuing apace. This means there is an increasing demand for reach trucks with lift heights of over eight meters. While only 38 percent of all Linde reach trucks sold in 2005 were designed for such heights, this increased to 52 percent last year.”

However, higher lift heights place more demands on the skill of the operator. With the mast fully raised, the dynamic mast oscillations during reach movements are more pronounced particularly when laden. Furthermore, with the pallet load fully raised, the forward deflection of the mast increases.

When placing pallet loads onto a rack, the operator must first wait until the dynamic mast oscillations have ceased, because even with small oscillations it is difficult to position the load accurately into the rack location. This makes the operator’s task much more challenging and in the worst-case scenario, the load could damage the rack or displace the load stored behind. This eventuality could happen because the bigger the mast deflection, the more likely it is that the pallet load will be placed too deeply into the rack space and the load/pallet faces in the racking will therefore not be uniform along the aisles – the “chimney-effect” occurs.

Linde's new sensor-controlled "Dynamic Mast Control" operator-assist system for reach trucks provides highly effective support for the operator, providing a stress-free, and highly efficient working environment. Key to the system is a very precise electric linear actuator sytem in the reach truck’s motor compartment.

Ports “at the heart of the economy”

Speaking to a packed Drapers’ Hall in the City of London at its AGM lunch, British Ports Association Chairman Andrew Moffat set out the ports industry priorities for the next Government. He said, "Ports are at the heart of the economy, and we will work with the next government to build on the successes we have achieved.

"We are an independent sector, which uses its own resources to invest and grow. Nevertheless we depend on the right national policies. These include improving road and rail links, a planning system that underpins growth, support for investment in people that also enhances safety, and a well protected border which does not impede travel and trade. We also want the EU to promote fair and unsubsidised competition."

Andrew Moffat said a new ‘ports policy blueprint’ had been jointly produced by the Association with the UK Major Ports Group and would be used in first briefings with new Ministers. He also referred to the challenges presented by devolution to UK organisations such as the BPA.

"With ports policy coming from four directions following the Silk Commission recommendations, as an Association we will have to be extremely light on our feet in representing our members to the various devolved governments. I am proud of the progress we have made in creating the right structures to do this."

Embarking on the second year of his two year term, the Chairman said that his main theme would continue to be collaboration "in telling our story and building our brand, with stakeholders and between the port associations."

In response the guest speaker, CBI Director General John Cridland, praised the remarkable transformation of ports and their contribution to transport and the economy. He saud ports and business formed a successful partnership and better recent economic figures showed the need for infrastructure investment, both private and public. Increasing exports was a major objective, particularly beyond the borders of the EU.

Andrew Moffat also took the opportunity to launch an updated BPA Member Guide showing the wide variety of ports and organisations that the BPA represents.

Hunt’s Foodservice loading investment pays for itself

Ice cream and frozen food wholesaler Hunt’s Foodservice has been reaping the rewards of its recently installed Thorworld loading bay - a solution which, when combined with a double-deck trailer, has proved pivotal in reducing delivery trips, fuel consumption and working man hours.

The company’s Cornish hub, situated in Redruth, has long been supplying retailers across Cornwall with a wide range of frozen consumables, despatched from Hunt’s headquarters in Dorset. Historically, the deliveries leaving Hunt’s Foodservice for Cornwall were prepared and packed for their intended end retailer at source, which meant small shipments of mixed items were loaded onto lorries without fully utilising the space available.

While the method ensured that retailers conveniently received all their frozen goods in one instalment, it did leave room for improvements in efficiency. Will Harvey, Operations Manager at Hunt’s Foodservice, says, “The nature of our business means delivery quantities are relatively small, which is convenient, but not necessarily productive, and would lead to us having to choose between filling a trailer too small for the delivery, or under-filling one the right size.”

Will and the team wanted to improve delivery function and streamline the overall logistics process, so opted to have double-deck racks installed within the vans. “Double racking the vehicles was more conducive to delivering smaller pallet loads, however to effectively load and unload, you need a forklift, and for that, you ideally need a loading bay – which is why we contacted Thorworld.”

Having experienced positive customer service in the past, Will felt confident that returning to Thorworld with its niche product line, was the right solution. By creating a mobile working environment in which the forklift could operate - with adequate space to load, unload and manoeuvre, Thorworld Industries gave Hunt’s a bespoke piece of equipment, which combined both yard ramp and platform. As space was at a premium, Thorworld designed its loading bay for outdoor use and storage, and fitted it with integral dock lights.

Will says, “The installation process was fantastic, and was performed on time and with minimal disruption. We started using the equipment as soon as possible, filling vans appropriately, and improving efficiency. Since installation, we’ve saved a fortune in delivery costs, as our journeys take an average of three hours each way - for which we must pay labour and fuel.”

Swannay Brewery to export beer in new international markets

An award winning brewery in Orkney is to expand production and create new jobs amid growing demand for its independently brewed beers. The Highland Brewing Co’s Swannay Brewery on Orkney’s west mainland, has seen sales of its varieties of craft beers in cask, bottle and keg beer soar in recent years.

With £123,300 financial support from Highlands and Islands Enterprise, developments at the brewery will involve rebranding of the product range and significant international marketing to build sales activity in new countries including North America, Japan and Scandinavia.

The family-run Highland Brewing Co was established in 2005 by Rob Hill who was joined by his son Lewis in 2011 and now employs a further four people. The brewery has seen increasing demand for its award-winning range which includes Scapa Special, Dark Munro, Orkney IPA, Orkney Blast and Island Hopping and Duke IPA. Several Highland Brewing Co beers are national champions and have won the brewery a string of top international prizes worldwide.

The main development at the brewery will involve the installation of increased capacity enabling the company to produce more cask beers and will put more focus on keg products to complement sending bottled beers to the new export markets, both in the UK and around the world.

Harvey Stevenson, head of strategic project at HIE in Orkney, says, “This is an exciting business that we have been closely involved with over the years. We are delighted to be able to help again now that the company is moving up a gear and expanding into international markets.

“With its award-winning and highly regarded products, Highland Brewing Co has the potential to achieve a significant level of international business as sales have been steadily growing and there has been substantial interest from overseas, particularly the Far East and North America. This expansion will ensure that the business is well placed to cope with increasing demand whichever part of the globe it comes from."

Lewis Hill, who runs the Swannay Brewery, says, “The craft beer market is thriving locally and globally and we are looking forward to engaging our UK customers more as well as doing Orkney, Scotland and the UK proud as we share our wares with beer-lovers in exciting new markets. The ongoing support provided by HIE is invaluable.”

The project is also receiving support from Clydesdale Bank.

New roadmaps for sustainable fisheries

Seafish, the industry authority on seafood, alongside the Marine Stewardship Council, has announced its findings from a three year project which, for the first time, has mapped all English inshore fisheries and developed sustainability ‘roadmaps' for them to help secure seafood supplies from these traditional inshore fleets.

Named ‘Project Inshore’ and the first exercise of its kind on this scale in the world, the project has produced bespoke reports for each of the English Inshore Fisheries & Conservation Authorities, and will now enable these inshore fisheries managers to come together to co-ordinate efforts. Project Inshore will also provide an evidence-base for IFCAs that do not have sufficient resources to approach funders.

Project Inshore has been split into three stages. Stage one mapped over 450 different fisheries within the English inshore sector,out to six nautical miles. Stage two assessed all of the fisheries within each IFCA district using the MSC standard as a gap analysis tool to score how each fishery was performing.

In total, around fifty fisheries were found to be performing at a level that could be considered in the short to medium term to move on to full MSC assessment. The remaining inshore fisheries require a longer term programme of work to be undertaken to get them to perform at this level.

Dr Tom Pickerell, Technical Director from Seafish, and one of Project Inshore’s instigators explains, “Before we started Project Inshore we knew that for many fisheries there was insufficient information available to determine stock status and ecosystem impacts. These ‘data deficient’ fisheries are a result of limited funding being available to support research into all fisheries, often resulting in a necessary focus on those of most economic importance.

“This therefore led us fittingly to stage three of the project which aimed to provide a plan or roadmap for each IFCA. These plans provide information and guidance for the IFCAs on what to do, and how to do it, to move fisheries towards higher levels of performance, ultimately reaching a standard that could go forward for MSC certification. Once at that level, it would be up to the fishermen themselves whether they wish to attempt certification.”

Claire Pescod, Chair of the Project Inshore Advisory Group and Fisheries Outreach Manager from the MSC, says, “Project Inshore started with a grand ambition: it was a ground-breaking project using the MSC Pre-Assessment process as a gap analysis of current management of the English inshore fisheries.

“The past two and half years’ work, mapping and examining the inshore fleet, culminates in these reports and a publicly-available database incorporating a wealth of information. Together, they allow us to use the results to work toward an environmentally sustainable future for English inshore fisheries. I believe there will be a strong legacy from this project, both in the UK and further afield, feeding the results into management to help inform priorities and develop improvements as well as highlighting current best practice.”

Dr Pickerell says, “Working in partnership we see real long term benefits for the entire supply chain starting with the small coastal vessels that fish in these waters. By working to demonstrate sustainability and this level of credibility can only help inshore fisheries in opening new routes to market for its seafood.

“The Project Inshore approach is now being recognised internationally. Seafish has been contacted by organisations in the US interested in the feasibility of the approach in California inshore fisheries and we understand there is interest in repeating Project Inshore in the Baltic and Mediterranean Seas, so we can see real potential for other bodies and countries to adopt this as a blueprint for their own data-deficient fisheries management.”

Seafish receives backing to develop new apprenticeship for fishermen

Seafish, the industry authority on seafood, has been given the green light by the Department of Business Innovation & Skills to develop a new Trailblazer Apprenticeship for new entrant fishermen in England following an announcement by the Skills Minister Nick Boles.

A Sea Fishing Apprenticeship has been delivered successfully in Whitby for many years and has proved immensely popular. Indeed it is considered the flagship qualification for aspiring young fishermen and competition for places is tough. However, the Richard Review in 2013 called for improvements in Apprenticeships to better reflect the needs of employers and as a result all Apprenticeships have to be re-written as Trailblazers by 2017.

This announcement gives Seafish the opportunity to secure the ongoing availability of an Apprenticeship for commercial fishermen and ensure its ongoing suitability for attracting and training high calibre new entrants - helping to safeguard the future viability of the fishing industry.

In taking forward this new development Seafish will work with fishing vessel owners, skippers and organisations including the National Federation of Fishermen’s Organisations and the Maritime & Coastguard Agency, all of whom are committed to keeping the Apprenticeship route open for new entrants to the fishing industry.

Apprenticeships provide a route into commercial fishing for aspiring young men and women. They combine classroom training with on-the-job learning, giving trainees valuable experience and a nationally recognised qualification. The training covers all the duties expected of a deckhand including preparing the deck, including the use, storage and maintenance of fishing gear, engine room support, handling and stowing the catch, and keeping watch. Successful trainees must be physically fit, have good eyesight, and be able to communicate well with others.

Simon Potten, Head of Safety Training and Services at Seafish, says, “We welcome this backing from the Minister and are really enthusiastic to re-develop the Sea Fishing Apprenticeship as a Trailblazer, so it is fit-for-purpose for the next generation of fishermen.

“Commercial fishing is a challenging occupation. An Apprenticeship provides the best possible route into the fishing industry for new entrants as it combines comprehensive training with work experience. Over a twelve month period it produces competent deckhands with transferable maritime skills. Many Apprentices go on to develop long and successful careers in the fishing industry.”

Anne Hornigold, Chief Executive of the Whitby & District Fishing Industry Training School says, “It’s fantastic to see apprenticeships in maritime occupations going from strength to strength. This backing from the Government underlines the importance of investing in the future generation of fishermen.

“The Whitby Fishing School has run a Sea Fishing Apprenticeship for many years and has successfully achieved national recognition for our innovative high quality training methods. It’s exciting to see so many enthusiastic young people coming into the industry and a real pleasure to train them in a number of important roles.”

New ThermoBarScan offers instant feedback on temperature measurements

Food manufacturers looking for high accuracy temperature equipment at fantastic prices should pay a visit to UK thermometer manufacturer TME’s stand at the Anuga FoodTec exhibition.

TME will be launching their new Barcode scanning logging thermometer, the MM7100 ThermoBarScan, at the show. Representing the next generation in handheld food temperature measurement, the MM7100 uses its own integral Barcode reader to provide users with high level, HACCP-compatible information on each scan, including temperature, time, date and identifying details of the product or test point from the unique, user-set Barcode.

The instrument stores up to a thousand measurements before downloading to PC via Bluetooth or USB using free open-source software for a surprisingly cost-effective solution.

The user is offered the choice of programming alarm limits for individual food items and locations, global alarms, or legionella-safe alarm limits. The user can also choose their own remedial action recommendations, which display when an alarm limit is exceeded.

Visit TME at Stand D060 at Anuga FoodTec or at www.tmethermometers.com.

DUO PLAST presents German Technology Centre for Load Unit & Cargo...

DUO PLAST are presenting their German Technology Centre for Load Unit & Cargo Security - ensuring maximum safety troughout the supply chain.

Slipped packaged goods, crooked pallets and damaged products are often caused by the transport of goods. With their unique testing technologies, the Technology Centre can simulate horizontal and vertical influences in combination with pitch & roll movements on the load unit realistically. Based on these “field-to-lab” simulations holistic optimisation concepts can be developed, which improve the load unit security sustainably and ensure the customer maximum safety during the transportation.

As a result of the increasing global transport volume, security in the movement of goods becomes more and more important. This development also can be seen in the raised appearance of legal regulations, which obligate the companies to a proper securing of the cargo. But load security already starts with a secure and stable load unit. A stable load unit is already the foundation for a secure transport. Certainly in practice, the real effects on a load unit during the transport process were underestimated the most. Such a neglect leads to accidents, which provoke personal injuries or material damages and as a result cost-intensive legal consequence for the company's management team.

To reduce the cost-intensive consequences of an insufficient load unit security and to secure a transport for all participants a proper load securing has to start with load unit security. This is the starting point for the German Technology Centre for Load Unit & Cargo Security. The Technology Centre checks, develops and audits load security concepts for dispatchers, logistics companies and institutions. By using the unique testing technology of the Technology Centre neutral and individual optimisation concepts for a single load unit can be developed. These concepts assure the customers a legal load unit packaging and maximum safety.

The German Technology Centre for Load Unit & Cargo Security is officially accredited as Laboratory for Packaging Tests by the German accreditation body DAkkS. The accreditation is an official seal of quality which assures the operations according to national and international auditing standards. Furthermore, the accreditation guarantees independent operations with objective results. This sign of quality ensures validated testing results towards the customers, which also can be issued as recognised certificates. Due to the authorisation of the Technology Centre the certificates were recognised by international authorities.

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