< PreviousSee us aton stand K241030:Layout 1 16/12/11 09:36 Page 1CARTONING & SLEEVINGwww.fdiforum.net31Cartoning and sleeving are becoming amore common ways of presenting foodon our shelves. There is almost a culturalstigma attached to wasting packaging andthose who use far too much in the way ofcardboard, plastics and films will findthemselves appearing dated, uncaringtowards the environment and ultimately,could see a shift downward in sales.Use of sleeving means you can be asdetailed as you ever were with foodinformation, but also means you aresaving a significant portion of packaging.This, coupled with the cost saving, meansit is a green, cost-effective andaesthetically-pleasing option forpackaging food and drink. Similarly, cartons mean less use ofplastic, the ability to use recycledcardboard and the room to include asFresh, green and fastPackaging is one of the first things consumers look at before considering apurchase, and there needs to be a balance between cost savings, aestheticsand green credentials The V60 Verticalcartoningmachine fromRaupack, whichenablescardboard‘bucket’ designsto be shapedto customspecifications. PHOTO: RAUPACKEven intricateand smallpackaging ispossible, asT Freemantlehave workedwith innocentto produce‘stick packs’PHOTO: INNOCENT32 031-032:Layout 1 16/12/11 09:37 Page 132www.fdiforum.netCARTONING & SLEEVINGmuch design or supplementaryinformation as you wish.When it comes to machinery, thecartooning and sleeving sector has aboutthe same amount of options as traditionalmethods of packaging. From the small,more manual sealing machines, all theway up to fully automated end loadcartoners or sleevers. Many options comewith pre-glued options, so the machinetakes care from the cardboard net all theway to finished product. Other machineswill apply glue during the process.T Freemantle, a long-established playerin the cartoning and sleeving sector havea range of machines that can deal withany kind of carton or sleeve you couldcare to mention. They have worked intandem with several high-profilecompanies to produce the highest-quality,innovative packaging solutions available.Customers include German specialityfood producer Kappa, who have workedthree times with the company to producea preglued sleever for their Antipastiproduct. Running a variety of sleevedesigns and tray sizes, it produces afantastic, secure and aesthetically-pleasing sleeve.Similarly, they have provided readymeal producer Greencore with pre-gluedsleevers for use with their high-qualityready meals as well as cartoning machinesfor use with Kraft’s vast range ofconfectionery products and cartoners forthe successful range of innocentSqueezies. This product is a conveniencefood, with portions of fruit in squeezablesticks.Special requirements are what makepackaging companies stand out, andRaupack are one such company. Recentlytasked with creating a carton that wouldhouse a ready-to-eat pasta salad thecompany came up with an automatedway of producing a design that wouldallow for around base to hold apot of pasta, tapering up toan opening flap at the top. This,combined with an aesthetically-pleasingalmond-like shape in the profile of thepackaging, meant the pot looked pleasingwhen both on the shelf and while beingused. The machine used was a V60vertical cartoning machine, which has apatented ‘bucket’-like mould, meaningshapes can be created from that basicshape into any combination required.This not only gives companies options ofcreating new package designs, but alsomeans the machine is fully-customisable.Security is one aspect of sleeving thatmany firms use it for. The tamper-evident sleeves used on necks of beer,wines and spirits, as well as items thatneed to be kept fresh, are great ways ofensuring an uncontaminated productreaching the consumer. Depending onhow much companies wish to spend, theopportunity for extra information orpromotions is an option on these ‘neck’sleeves or collars, even if it is not aconventionally recognised area for use.For example promotional prices or offerscan be printed on a collar or even acontinuation of the labelling a productmight have, spreading a design all over aproduct. This can be of particular usefor seasonal designs or one-offs wherean unusual or innovative design is beingused.Printing on porous and secondarymaterial such as collars or sleeves in thefood and drink packaging sector can provedifficult, manufacturers always demandthe highest quality of presentationavailable as their products need to standout on retailers’ shelves. Printing of codesis something that coding and printingspecialist Videojetunderstand well - theirlatest product, the V2300, is asingle-unit and compact printer,which marks codes as part of theproduction line. Coupled with its releaseis a series of instructional anddemonstration videos online to letmanufacturers see the printer inoperation and to see what benefits itoffers the food and drink industry.It seems bespoke designs are part ofthe make-up of cartoning and sleeving.No job seems too much and there seemsto be a solution to even the mostseemingly complex requests, as Raupackhave proven. Instead of boxing oroveruse of plastics, why not considersleeving? As shown again and again, itlooks great, saves expense and scant useof raw materials means it is good for theenvironment.Showtime!For those who wish to see the latest incartoning and sleeving technology andinnovations, as well as a host of otherpackaging options, a visit to the NEC inFebruary is a must. The easyFairsPackaging Innovations show takes placeon 29th February and 1st March and willfeatures over four hundred leadingsuppliers, over fifty free seminars and ahost of other inspiring features. It isaimed at both manufacturers and thoseresponsible for sourcing or designingpackaging.Add to this the other big event, thePPMA show which takes place inSeptember, with a focus on the entireproduction line. It includes not only araft of packaging innovators, buteverything that can aid cost savings,quality of product and smooth productionoperations.Keep an eye out for more news onpackaging exhibitions throughout theyear in Food & Drink International.Printingtechnology nowmeans codingand marking isavailable onmost surfacesPHOTO VIDEOJETSimple but effective packaging is one advantage ofsleevingPHOTO: MASH DIRECT031-032:Layout 1 16/12/11 09:37 Page 2CARTONING & SLEEVINGwww.fdiforum.net33“Earlier on this yearI took the Eurostarfrom London’s recentlyrefurbished railwaystation St Pancras. As Iboarded the train under amagnificent Victoriancanopy of steel and glass Idid not know what to expecton my journey to Paris. Asthe buffet car made its waydown the narrow aisles of thehigh speed train, my taste budswere awakened by the smell ofcooking food. It was the smell ofpasta in a box…”French manufacturers Cookinov– short for Cook Innovation – basednear the town of Le Mans, are an IFScertified company who produce foodproducts for retail and internationalbrands including organic foods.Recently Cookinov purchased a CMASV60 Vertical Cartoning Machine toproduce a unique shaped carton.Their customer, Zapetti brand holderRaynal et Roquelaure, was looking for anattractive carton into which to placeplastic pots of their ready meal pasta.The idea was simple – the carton was tobe round at the base and square at theopening. A gentle taper would make thisan easy pot from which to eat. A specialfeature of this carton is the patentedalmond shaped profile running along thevertical creases. The challenge was tofind a cartoner up tothe task.The solution layjust up the road atCMAS. CMAS isrepresented byRaupack in the UK.The Vertical Cartoner,the V60, uses apatented bucket design totransport the cartons.These buckets can bemachined to hold the shape ofthe carton, in this case thespecial Zapetti Box shape. Othershapes include Trapeziums,Ballotins and Pillow packs throughto the standard square box.Once the machine has a firm grip onthe carton it can be automatically loaded,labelled, printed and closed. In the caseof the Zapetti Box, the pots of pasta,cooked in the ovens at Cookinov, receivea cardboard holding ring before beingautomatically loaded into the box. Theresult is a unique but functional shapedcarton.For the V60 and its little sister, theMiniCompact, the possibilities are huge.These vertical cartoners really are shapechangers.Contact Raupack on 01483 736800 to discuss any new shapes you wish to automate.A game changer,a shape changerCookinov are benefiting from the V60 Vertical Cartoning Machine033:Layout 1 16/12/11 09:38 Page 1Let us do thetalking…….www.fdiforum.net the voice of the Food and Drink industryINTERNATIONALFood&DrinkFood&Drink053:Layout 1 16/12/11 09:44 Page 1DUST CONTROLwww.fdiforum.net35You might think that residue or layersof dust are simply an inconvenient by-product of the food and drinkmanufacturing process, but to take thatattitude is naïve. Dust is thrown into the atmosphere infood preparation facilities by any numberof factors, be it delivery of raw materialsin containers that do not fully capture allpossibilities of dust control, processessuch as milling or grinding or use ofequipment that is not airtight or clean.Dust is bound to be something thatoccurs within any preparation area, butmeasures can be put in place.To simply make sure equipment is upto date and not worn is something thatcan make all the difference. If feeds,conveyers or delivery systems are notfully connected or are being filled ordealt with incorrectly, this can lead to abuild-up of dust or dust particles inplaces where they could becomehazardous. As well as the risk ofexplosion from friction or overheating,the risk of machinery getting clogged isalso a concern. This could be asdangerous as an explosion could occur ifany part of a machine cannot movebecause of dust clogging, or a largebuild-up of material occurs. Internal fires could gut not only themachine, but an entire factory. This isof even more concern as productionlines and supply chains become evermore automated. Lack of maintenancecan lead to these situations, but alsocarelessness on operators andmanagements’ parts. One such instance of a devastatingexplosion through lack of dust controlwas in 2008 at the Imperial SugarCompany. A huge explosion rocked thefactory in Georgia, USA, causingfourteen deaths and injuring 38 others.The explosion occurred thanks tomassive accumulations of combustiblesugar dust in the packing department.How to make it safe?One solution many factories andpreparation areas look to is thoroughcleaning, using both the smaller handheldand the larger, centralised vacuumsystems means dust is effectively keptaway from danger areas and is notallowed to build up. Solutions that use acentral vacuum for multiple areas of aproduction line now often come withecological concerns addressed. Variablespeeds and economic cycles of use canmean your energy consumption ismonitored, ensuring both your safety andproduction costs are addressed.Bill Treddenick, Compliance director atLorien Engineering Solutions, argues thatwhen it comes to dust control, whatseparates the good food and drinkfactories from the bad, is the attitude ofoperational staff, from top to bottom hesays, “Food and drink factories are eitheroutstandingly good, or outstandingly poor36 Staying in controlControlling dust is one of the more troublesome tasks those in food and drink sectors have todeal with, but with around 70% of organic materials being combustible, the danger is very realThe Imperial SugarCompany factory, whichwas the site of a majordust explosion aftermass accumulation ofsugar dust.035-037:Layout 1 16/12/11 09:42 Page 136www.fdiforum.netDUST CONTROLat controlling dust in the workplace, andthere are not many in between. “What separates the ‘good’ from the‘not-so-good’? The true difference is theattitude of operational staff, from top tobottom. This often comes from anawareness of the consequences of poordust control, and also from an overall‘good manufacturing practice’ ethos, thatcan also be observed through the settingof targets and clear reporting andmanufacturing controls.“Part of my business’ work is aboutmaking factories productive, a dustyfactory shouts “we are not in controlhere”. For many, dust in the workplace willbe a justifiable cause for concern over thehealth of workers, and for the long termviability of the business.“What may be overlooked is theimmediate and very potent risk of fireand explosion. We should therefore beequally concerned about controlling thesehazards, and complying with regulations.The surprising fact is that manycompanies have factory areas that fallunder regulations that could, withoutactive management and careful design,cause mass injury.“Dust is an everyday part ofmanufacturing, except this part can kill.”This may seem like rather a heavily-worded warning, but rings true in thecontext of safety, what may seem initiallylike a trifling issue can have devastatingconsequences.One health issue not immediatelyobvious to many would be the respiratoryproblems that come from breathing dustin. Occupational asthma and respiratoryirritation from exposure to flour dust forexample can cause you and yourworkforce serious problems. Exposurelimits for flour dust in particular havebeen set since 2002, with a certainconcentration of dust allowed per shift aworker is on duty.One way to combat dust even being inthe atmosphere to these levels is toinstall preventative measures. While thismay seem expensive initially, if dust isprevented from being in the same area asvulnerable machinery at all, then the costsaved through not repairing equipmentdamaged will soon justify itself.Doors that create an effective seal bynot being porous and having almost air-tight closures can prevent dust frombeing blown around a facility. Thismeans areas where dust will be highlylikely to be in the atmosphere can besectioned off where it will not affectmachinery or workers’ health.Taking further measures such as nothaving shelving or ledges in an area youconsider may have a high volume of dust.Build-up not only makes a preparationarea look untidy but also frees uppotential for dust to fall into delicatemachinery or to contaminate a differentproduct. Those on nut-free lines areespecially at risk to contamination as wellas other allergy-sensitive products’ lines.Consider installing sloped window ledgesto ensure the very minimum of dust isleft behind and that adequate cleaningtakes place if dust is an issue.Using vacuums, bothportable and fixed, can reduce the amount ofdust accumulating in a food or drinkpreparation areaDust can take many forms, spices,sugars, active or functionalingredients or simply additives035-037:Layout 1 16/12/11 09:42 Page 2DUST CONTROLwww.fdiforum.net37Fike provideprotectionEverything can be sailing along nicely but itpays to be prepared for the unexpectedMany manufacturingprocesses involveprocessing at elevatedpressures or partialvacuum conditions,some of which can beextreme – and eithercondition can causesevere damage ifunprotected. 70% oforganic dusts arepotentially explosivegiven the correctconditions – whetherthese are part of themanufacturing processor an unwanted by-product.Recently there have been two high profile incidents involvingdust explosions in the food processing sector. One involved onlyplant damage but tragically the other involved the deaths of sixworkers.If a primary explosion emanates from a process then thesecondary explosion can be the order of magnitudes larger.Secondary explosions outside a process can be virtually eliminatedby good housekeeping. However, inside a process this propagationrisk must be countered by some form of mechanical or chemicalisolation system in the line between the connected vessels.For over 65 years, Fike have provided equipment to preventsuch incidents. For protection of process vessels or equipmentagainst excessive over-pressure or vacuum, they can supplysanitary grade bursting discs, such as the innovative Axius SCwhich has no indentations or tool marks on the process side. Forsanitary processes which generate dust the SANI VA explosionvent is the only vent on the market to obtain both 3A andEHEDG approval.If explosion venting is not possible or desirable, Fike’s range ofsanitary grade explosion suppression and isolation equipment willstop a spark in its infancy and prevent it from turning into apotentially life threatening incident.For more information, call +44 (0)1622 677081,email sales@fike.co.uk or visit www.fike.co.uk.A simple andeffective systemfrom Dustcontrol UKDustcontrol was foundedin 1972 on the basis of anidea for creating extractionsystems to capture dust andother pollutants at thesource. They are notsatisfied with just sellingproducts. The companymanufactures industrialextraction systems for directextraction and vacuumcleaning as well as portabledust extractors with veryhigh levels of filtration tosuit customer requirements.Both are available as Atexrated. A Dustcontrolsolution contributes tobetter health, productquality, a cleanerenvironment and more efficient production.Dustcontrol have recently found many food and drinkproduction facilities would like to minimise the use of portablevacuums, but are put off by the idea of installing a centralised vacsystem to cover big areas due to complex and often large capexand installation issues. They have developed the DC11 Module‘plug and play’ vac system which is ideal for individual factorylines or departments. The unit is delivered pre-built on a singlepallet complete with cyclone and cartridge filtration, turbo-pumpand pre-configured PLC based control panel and optionalfrequency drive for energy saving. The unit has apowerful vacuum producer which can easilyrun three to fourvac cleaning pointsat the same time,(spanning e.g. a40mtr main line) andhas proved to be an ideal solution for manyclients. The simple to fit steel pipe andantistatic rubberised bend system results in aquick but professional looking install whichis easy to reconfigure as the factory evolves.Tel: 01327 858001 www.dustcontrol.co.uksales@dustcontrol.co.uk035-037:Layout 1 16/12/11 09:42 Page 3Invaluable advice fromindustry specialistsMeet the expert38www.fdiforum.netT: 0044 1223 243444 E: enquiries@sherwood-scienfic.com www.sherwood-scienfic.com Sherwood Scienfic Ltd, 1 The Paddocks, Cherry Hinton Road, Cambridge - CB1 8DH, UKFlame Photometers forSodium DeterminationChloride Analysersfor Salt DeterminationSherwood Scienfic Ltd is a Development andManufacturing company producing a range of scienfic instruments and apparatus with applicaons in many industries, educaon and research.For more informaon on our instruments & apparatus please contact us on...Established for over ten years with a nationwide service across the UK, The Diverse Cleaning Company are experts in commercialduct cleaning, commercial kitchen deep cleaning, high level and industrial cleaning. We have highly trained staff working to strictprocedures.The Diverse Cleaning Company believe in offering the best possible service for the most economical price based upon the requirements of our clients. As a result we can tailor our service to meet your needs and offer solutions to meet restricted budgets if necessary.Please contact us now for a free quotation02392 668600www.deep-cleaning.comCleaning Services• Commercial Kitchens • Ductwork Cleaning• High Level • Pressure Washing 038-039:Layout 1 19/12/11 08:33 Page 1www.fdiforum.net39High level cleaningReach for the SkyVacThe Diverse Cleaning Company South are an automatic choice when it comes to high level cleaning in food related premises.A family run and owned business, spanning three generations, enjoys a fresh, contemporary approach to business mixed with integrityand reliability. Heavy investment in training enables its staff to tackle almost any high level cleaning problem utilising the safest and mostcost-effective solutions available.Its MEWPs drivers are IPAF trained and qualified and their rope access staff are IRATA trained and qualified. They also boast aSkyVac cleaning system that will allow them to vacuum surfaces up to 35 ft from the ground while an on board camera records theprevailing conditions before and after cleaning!The safety of its staff and clients is uppermost and its RAMS are transparent and unambiguous allowing quick and easy assessment byits clients’ H&S auditors.DCC’s current clients include supermarkets, logistics centres, garden centres, storage and warehouse facilities, hotels and just aboutany premises that require a high level of cleanliness at all levels.For initial survey and free quotations contact info@diverse-cleaning.co.uk or call 02392 668600. Visit www.deep-cleaning.com to view the full range of specialist cleaning services.SAFETYWORKS & Solutionswarn that roof safety systems must not be used without testingLeading manufacturers of roof access and safety systems, SAFETYWORKS & Solutions are also authorised to provide inspection andmaintenance of systems in accordance with the appropriate HSE legislation.In order to ensure the continued safety of operatives and maintenance personnel who have to access roof areas, it is a legalrequirement that the roof safety systems are inspected regularly and re-certified annually. SAFETYWORKS & Solutions personnel are fully trained to undertake inspections, testing, and re-certification, and if so required, cansupply and install replacement systems.To discuss your roof safety systems annual inspection requirements, contact SAFETYWORKS & Solutions on 01487841400, email beth@safetyworksandsolutions.co.uk or visit www.safetyworksandsolutions.co.uk.Sherwood Scientifichelp manufacturers monitor their salt contentSalt content of foods is receiving increasing attention and there is now a move towards a significant reduction in dietary salt.Sherwood Scientific’s Model 926 Chloride Analyser has long been recognised by independent studies as an accurate and preciseinstrument for measuring salt. The latest version, featuring a redesigned PCB, sealed face-plate and a new backlit LCD display, offers thesame usability and high performance specification. Sherwood’s Model 926 Chloride Analyser is widely chosen for its ability to deliverhighly accurate results without the need to make up the fresh reagents required by traditional silver nitrate methods for chloridedetermination.In addition to Salt, Sodium concentrations in food ingredients and final product are becoming increasingly important requirement. Themost sensitive and robust technique has always been flame photometry. Sherwood Scientific has introduced two new products, whichallow the busy analyst to automate the measurement and collection of data on the Model 410 Flame photometer. A new Digital Interfaceand 410 BlueNotes Software can be retrofitted to existing Model 410s already carrying out this analysis. Key innovations allow addition ofthe Model 860 Autosampler and correction for the drift associated with single channel measurements.For more information, visit www.sherwood-scientific.com.038-039:Layout 1 19/12/11 08:33 Page 2Next >