< Previous20 Food & Drink Internationalwww.fdiforum.netHYGIENIC WALLS, FLOORS & DOORSHigh-profile cases of bacteria andinfection in recent times have illustratedthe immense importance of ensuring cleanand secure production facilities and foodpreparation areas. The productionhardware itself requires intensive cleaningto avoid any potential contamination, butthe surrounding areas are equallyimportant – not just for consumer safetybut for employees as well.The new breed of coverings for walls,doors and floors offer extremely highlevels of hygiene – providing greaterstrength and durability and provingresistant to chemicals, scratches andabrasions. They have other values as well,thanks to new technology which allowsthe coverings to be laid in a totallyseamless fashion, avoiding joins andcrevices, while their colourful designprovides an effective way to differentiatevarious production areas and highlightpotential flashpoints.Those who attended the recent AGMheld by FeRFA, the Resin FlooringAssociation, certainly got to see the hugestrides that are being taken in innovationby the industry – not least when theassociation presented its annual awardsfor best practice through the sector. Aswell as highlighting this, FeRFA plays avital role in developing talent in theindustry, alerting the various companiesto changes in the law and providing ahost of training and apprenticeshipschemes.As Helen McGachie, FeRFA’s ChiefExecutive Officer, tells Food and DrinkInternational, “The key objective ofFeRFA is the qualification of a specialistworkforce. We’re very keen on promotingspecialist skills and we believe that resinflooring should be installed by a skilledand qualified contractor, in accordancewith the latest standards.“FeRFA is the training provider forthe industry, because the sector is sospecialised the training can’t be offeredfrom traditional colleges. We’ve beenworking closely with CITB and withthem have developed the NVQqualification for both resin flooring andsurface preparation. Since 2007 we’vealso been delivering apprenticeshipschemes.“Historically, if you look at resinflooring, it was originally developed forindustrial environments – particularly inthe food industry. However, because thesector is so niche people who get involvedhad generally been friends or family ofthose already involved in the industry.Since the introduction of theapprenticeship schemes, we’ve now put inplace a route to attract newcomers intothe industry. They can gain a qualificationand there is an ongoing career path sothey can move up from being skilledoperatives to a qualified supervisor andultimately a contract manager. Althoughit’s a small, specialised sector, there isnow a recognised way to gainPHOTO: SHUTTERSTOCK.COM/REDTCManya slip...Hygienic floors, doors and walls are ensuring improvedefficiency and security across the food and drink sector20-25:Layout 1 12/12/13 14:36 Page 1Food & Drink International 21www.fdiforum.netHYGIENIC WALLS, FLOORS & DOORSCommercial & Industrial Seamless Flooring Solutions – GUARANTEED!Tel: 01925 740400www.industrialflooring.co.uk qualifications and upskill.”A more qualified and specialised groupof flooring specialists is obviously of hugebenefit to those looking to benefit fromhigh quality flooring, given the stringenthealth and safety regulations that nowhave to be followed in manufacturing anddistribution sites. As Helen McGachiepoints out, “One of the key factors isalways going to be slip resistance, andparamount with the food and drink sectoris of course hygiene – so companies are22 The newbreed of coveringsfor walls, doors andfloors offer extremely highlevels of hygiene – providinggreater strength and durabilityand proving resistant tochemicals, scratchesand abrasions20-25:Layout 1 12/12/13 14:36 Page 222 Food & Drink Internationalwww.fdiforum.netHYGIENIC WALLS, FLOORS & DOORSlooking for flooring that is extremely durable, fit forpurpose, can give a hygienic, seamless surface and isgoing to be excellent value for money.“Manufacturers are looking at new methods to makeflooring much more environmentally friendly, such asusing water-based materials and minimising use ofsolvents, as well as making it simpler in terms of packsizes and how they’re mixed. Because resin flooring ismixed and laid in situ, there’s no material wastecreated.“The key to the success of any flooring is inunderstanding the client’s needs. If you look at themajority of applications for resin flooring, they’reactually in refurbishments, rather than new builds.You’re going into a situation where you may havecontamination in substrates, weak substrates, weakjoints, so you need the skill and expertise to be able tosurvey the substrates and thoroughly discuss with theclient how that area is going to be used and theactivities that are going to take place.Kemtile are a one source contractor of hygienic floors in seamless resin polyurethane, Argelith tiles,Wiedemann-Technik stainless steel channels and drains as well as Protectorseal wall and ceiling systems. We specialise in the food and drink industry where the very highest standards are demanded and haveworked for most of the food companies in the UK, both large and small, with many letters ofcommendation on our work. Visit our website for more information.HYGIENIC FLOOR & WALL SYSTEMSKemtile Ltd, Unit C3, Taylor Business Park, Risley, Warrington, Cheshire WA3 6BL. UK. Tel: +44 (0)1925 763045 Fax: +44 (0)1925 763381Email: all@kemtile.co.uk www.kemtile.co.ukSee us atFoodex 2014Stand M288Birmingham NEC 24-26 March 2014 20-25:Layout 1 12/12/13 14:36 Page 3Food & Drink International 23www.fdiforum.netHYGIENIC WALLS, FLOORS & DOORSCall 0161 483 1232 to speak to our teamfood and drink innovationCampden BRIMADE IN THE UKHygienic surfaces for food & drink environmentsFoodsafeImprovedhygieneSeamlesssurfaceCampden BRIapproved“The slip resistance value will have to be discussed, too,depending on whether the area will be used for dry or wetprocessing, for example, and how it will be maintainedthrough the cleaning process, and how the client will beensuring it remains effective through the choice of footwear.You also have to look at the aesthetics – a lot of clients nowwant colours that meet with their brand image. They wanttheir clients to see that while their food productionenvironments are extremely functional, they’re also very niceplaces to work in.”The result of using qualified and specialist flooring suppliersis a bespoke process that can meet all the customers’ needs –from initial consultation, product specification, productmanufacture and logistics management, through to productinstallation from a trained and approved contractor.As well as in manufacturing and distribution sectors,catering operations have obvious requirements when it comesto hygienic flooring. One example of this in action comes fromthe restaurant kitchens of IKEA’s new store in Sydney, wherethe flooring had to comply with the legislation which means itmust provide an anti-slip rating of R12, so this was a majorfactor when specifying the floor.EpiMax have been using products from their partner RSL fora number of years and, when engaged to offer a solution,approached them about IKEA’s exacting requirements to helpspecify the right product. Polyurethane resin Resuthane SL45incorporating a high grade non-slip aggregate was chosen forthe 640m area.Mike Thelwell Flooring specialisein seamless hygienic flooringsurfaces that can be laid fromfloor to ceiling in a range of boldand contrasting coloursDiversey have launched EnduroPower, a range of cleaningfoams that demonstrates up to50% less water usage24 Companies are looking for flooring that is extremelydurable, fit for purpose, can give a hygienic, seamlesssurface and is going to be excellent value for money.Helen McGachie, FeRFA’s Chief Executive Officer20-25:Layout 1 12/12/13 14:36 Page 4HYGIENIC WALLS, FLOORS & DOORS24 Food & Drink Internationalwww.fdiforum.netCatering facilities demand high qualitysolutions, such as RSL’s Resutile & Resusealwhich has been used by FeRFA contractorResmax to create hygienic coated wallsurfaces at a commercial kitchen clientResuthane SL45 isa self-smoothingwater-based,seamless, resin floorfinish which isusually laid from3mm to 5mm. Thisproduct is the idealchoice for commercialkitchens because it’sseamless, non-dusting surfacedoes not harbour bacteria, making it easy toclean. Furthermore, the Resuthane range ofproducts are Campden BRI approved – whichgives customers an independent stamp ofapproval for using Resuthane in foodproduction areas. It’s not just flooring where hygiene is a majoraspect – doors and walls can also harbourcontaminants and prove obvious flashpoints forproblems to arise. Effective cleaningprogrammes must therefore be planned andnew technology is allowing for a more efficientprocess than ever before. Diversey, for example,have launched Enduro Power, a range ofcleaning foams that demonstrates up to 50%less water usage, a reduction of up to 33% inchemical levels and a rinse time up to 50%shorter than standard foams.In addition, many companies make useof specialist cleaning providers given theneed to avoid downtime at any point inthe production process. Some can makeuse of scissor lifts and extended booms toclean the ceilings, girders, walls andpipework throughout the facilities.Hygiene Group, for example, make use ofa dedicated team of cleaners that haveundertaken specialist training in workingat height – allowing them to reach partsthat other cleaners cannot.FeRFA’s recent awards are an exampleof the exceptional standards that nowexist in the industry and mean thatmanufacturers, distributors and catererscan be assured that when they seek asolution for their hygiene needs, the resultwill be hugely cost-effective, secure andattractive.Effectivecleaning programmesmust be planned andnew technology isallowing for a moreefficient process thanever before20-25:Layout 1 12/12/13 14:36 Page 5Food & Drink International 25www.fdiforum.netHYGIENIC WALLS, FLOORS & DOORSBespoke solutions fromMike Thelwell FlooringMike Thelwell Flooring aim to deliver high quality flooringsolutions tailored to the needs of businesses in all parts of thefood and drink industry. They can help with all aspects of anew build construction, refurbishment or facility maintenance.Effective flooring plays avital role in ensuring food anddrink companies meetstringent hygiene regulations.Mike Thelwell Flooringspecialise in seamless hygienicflooring surfaces that can belaid from floor to ceiling in a range of decorative, bold andcontrasting colours. These offer the look and feel of vinyl flooringbut deliver greater strength, durability and chemical, scratch andabrasion resistance.Bonded directly to the concrete slab eliminating weak separatinglayers, the system is laid with no joints, welds, grout or any crevicesthat could potentially harbour dirt, dust or germs. With uniqueadded anti-microbial additives, their seamless synthetic vinyl surfaceprotects against a number of bacteria, yeast and mould and has beenscientifically proven to inhibit bacterial growth by up to 99.9%.With the added benefit of easiness to clean and maintain syntheticvinyl, many food production environments can reduce E-coli,listeria and other food-borne diseases.The company’s high performance resin flooring finishes also focuson key criteria such as mechanical and thermal shock protection,excellent resistance to aggressive chemicals, and the need towithstand heavy impact and abrasion – in addition to meetingbudget and time constraints.Mike Thelwell Flooring can provide flooring suitable for* food production areas * washdown areas* packaging and storage areas * cold storesand many other aspects of the food and drink supply chain.For more information on how they can help your business,contact Mike Thelwell Flooring on 0151 200 1038 or visit www.mikethelwellflooring.co.uk.The ResuthanelegacyWith so many new flooring products being launched,what does it take to create something contractors canrely on? Martin Wroe, Commercial Director at RSL,explains how the Resuthane legacy developedWhen we launchedResuthane theproduct developmentprocess had takentwelve months. AtRSL all productsundergo rigoroustesting – it’s vital torefine the formulaand test in differentenvironments, usingdifferent installationtechniques.After launch wegot feedback fromcontractors thatResuthane was easyto apply which helpsto reduce installationtimes and increasestheir confidence in the product finish. The production is tightlycontrolled and monitored, high quality raw materials sourcedthrough consistent suppliers and efficient production methodsensure contractors can rely on the product finish.Building on from this early success we worked with contractorson prestigious and complex installations including Cadburys, AstraZeneca and Pepsi where we developed Resuthane for specific needs.These customer-led product development projects helped RSL tocreate the Resuthane Series which incorporates five productssuitable for use across a wide range of environments Resuthane is chosen time and time again as a proven product.Most manufacturers offer a product guarantee of sorts but the factwe have customer sites where Resuthane has been installed over tenyears ago and is still functioning is testament to the capability of theproduct and the value of the guarantee. Resuthane as a brand is developing to be a market leader inpolyurethane screed systems. There is a lot more planned to takeResuthane to even greater heights.For more information on RSL and Resuthane, call 0161 483 1232 or visit www.resinsurfaces.co.uk.20-25:Layout 1 12/12/13 14:36 Page 626 Food & Drink Internationalwww.fdiforum.netLABORATORY / TESTING SHOWCASEAll Laboratories are notthe SameFood safety has never been such a high priority so why take risks withyour testing? Find out why so many manufacturers trust their work to ALS for a complete testing service.A ‘one-stop shop’ of analytical tests and services (Micro, Nutritional, Allergens, Meat speciation)Modern, well equipped laboratories; UKAS accredited to ISO 17025Unrivalled industry expertise ensures that every test is delivered with accuracy and integrityAn industry-leading web-based portal provides quick and easy access to your test resultsT:01354 697028 E:sales.uk@alsglobal.com W:www.als-testing.co.ukSpecies testing using PCRWidespread reports of food adulteration and mislabelling in 2013 highlighted major failures infood traceability, with numerous cases of horsemeat contamination reported to have been found ina range of processed food products. The Techne Prime thermal cyclers can be used to detect contamination in meat samples usingcommercial PCR-based species identification kits. First the DNA must be extracted from thesamples to be tested. The yield of DNA from each extraction can be measured using the JenwayGenova Nano micro volume spectrophotometer. Once extracted the DNA samples are amplified inthe Prime thermal cycler. Following amplification, positive and negative samples can be identified by comparing with the positive controls includedwith each test kit. In order to quantify how much contamination is present, quantitative PCR assays can be performed using Techne’s PrimeQ real-time PCR system.Bibby Scientific brands Techne, Jenway, Stuart and Electrothermal provide laboratories with a choice of instrumentation and equipment tosupport rapid testing and the delivery of consistent, reliable results in the food testing environment.Tel: +44 (0) 1785 812121 Email: info@bibby-scientific.com www.bibby-scientific.comRapid 12 Minute Meat Species KitKnow what you’re eating with a rapid species identification kit from Trafalgar Scientific.Surpasses current testing capabilities with no lab required: UNIQUE - On site testing for horse, pig and cow at less than 1%SIMPLE - Easy to use and everything included in the kitRAPID - Reduces technician time and overall costsRELIABLE - Validated with LGC Reference MaterialsROBUST - Improves supply chain traceabilityTel: 0116 2719010 Email: Care@trafalgarscientific.co.uk www.trafalgarscientific.co.uk Combating a confidence crisisOne of the major problems to hit the food and drink industry in 2013 was the horsemeat scandal, where the integrity and quality of thesupply chain came under fire and consumers lost confidence in many brands. It’ll take some time until this confidence is won back, which canonly happen by ensuring consumers that products are of the highest standards at every step of the supply chain. In the light of the scandal, the UK Government commissioned Professor Chris Elliott, Professor of Food Safety and Director of the Institutefor Global Food Security at Queen’s University Belfast, to review the food system, and one of the recommendations in his interim report is thatthose involved with audit, inspection and enforcement have access to resilient, sustainable laboratory services that use standardised, validatedmethodologies.The laboratories and testing services available for the food and drink industry, some of which we highlight on this page, are well placed toensure that recommendation becomes a reality for every single company. Food safety is, in the words of Professor Elliott, an absolute priority forthe industry – and 2013 illustrated what can happen if consumers think that isn’t the case.26:Layout 1 13/12/13 12:34 Page 1Food & Drink International 27www.fdiforum.netSOUPS & SAUCESWith the world now a smaller placethanks to improved supply chains,global distribution and a more openmarket, soups and sauces have seen asurge in creativity and innovation resultin a crowded industry. That said,there’s enough happening in theindustry to allow room for manoeuvreand changing tastes across differentcountries helping create new areas inwhich to do business.Exotic and spicy tastes are provingpopular across Europe and with morepeople seeking out unusual and healthyoptions, the more canny soup and sauceproviders are making good inroads.For example, during the past sixmonths EHL Ingredients, a leadingA soupconof successSoups and sauces have theirown issues in production bytheir very nature. With suchdiverse ingredients andmethods of creation as well asuniversal changing tastes, howare companies meeting thischallenge?29 PHOTO: INGREDIONA soupconof success27-31:Layout 1 12/12/13 14:33 Page 128 Food & Drink Internationalwww.fdiforum.netSOUPS & SAUCESPenn PackagingHarkstead Hall BarnHarksteadIpswichIP9 1DBTel: +44 (0)1473 893990Email: email@penn-packaging.co.ukwww.penn-packaging.co.ukWith the model FBM20 machine (100-120stand-up pouches perminute), SNMaschinenbau offers ahighly efficient andinnovative machineconcept to pack freshsauces into pouches.In order to optimisesterility and shelf-life ofthe product filling, the film can be sterilized by UV-radiation during thepouch making process. The product filling is supplied via CIP-compatiblepumps which can completely be cleaned without dismantling.Conductive product filling is dosed precisely by means ofelectromagnetic flow meter. A major advantage is that the servo-drivenfilling valves guarantee exact and reproducible behaviour of the product(spilling and splashing).Like with all other SN machines, a recipe control is integrated and allfilling parameters are reproducible at the push of a button. Thisguarantees an easy and quick change of product. Further advantages ofthe FBM 20 machine are its flexibility concerning pouch formats and thesmall footprint.PHOTO: WWW.VOM-HOFE.DEBCHTelephone: +44 (0)1706 852122Email: info@bchltd.comwww.bchltd.comCompany ProfileBCH are processengineers for the foodand confectioneryindustries, providing aone stop shop combiningmechanical engineering,automation and foodscience. Established in1835, BCH hasdeveloped a worldwidereputation specialising inturnkey systems for the manufacture of soups, sauces, pie fillings,desert toppings, ready meals and much more.Product ProfileBCH provide a range of flexible solutions in up to 3000kg batch size.This can be a simple stand alone cooking kettle for integration into anexisting production line, up to a fully integrated cooking and coolingsystem feeding directly into an automated filling system. By usingvacuum cooling technology, BCH can achieve very fast cooling rates,typically achieving below 5°C within 45 minutes. Another alternative isthe BCH RotaChill system, a tumble chiller capable of cooling sealedpouches to below 5°C within 60-90 minutes.The process equipment is supported by a comprehensive range ofPLC based control options using HMIs, SCADA and data processingsystems. Trial equipment is available in the Innovation Centre.May Products18 Heathfield RoadHalesowen B63 1ADTel: 0121 550 7872Email:mayproducts@btconnect.comCompany ProfileMay Products Ltd is a smallindependent supplier of a comprehensiverange of ingredients to the food industry,based in the West Midlands. MayProducts deals direct with UK-basedmanufacturers and sourcing houses onthe continent or in the UK with in-houseQC, with whom they have developed along-term relationship based on mutualtrust.Product ProfilePersonnel involved in the company haveover fifty years combined experience in the industry. With long termconnections developed throughout the food sector, they offer acomprehensive range of both natural and artificial ingredients includingseasonings, colourings, flavourings, sweeteners, baking powders andvitamins, as well as the usual range of chemical additives andpreservatives. They don’t have minimum order quantities and they don’tbelieve in delivery charges.May Products are determined to be a pleasant, honest company todeal with – a friendly, familiar voice on the other end of the phone, givingyou a straight answer.Soup in sleeves –from KliklokTel: + 44 (0)1275 836131 Email: m.newman@kliklok-int.comwww.kliklok-int.comRecent trendshave been to packfresh ready-madesoups in plastictubs, which arethen wrapped in acardboard sleeve.“Wraparound”cartoning isbecoming apopular packagingmethod, enablingproducers use less packaging materials, and enabling the customer tosee the product when displayed on the ‘chilled foods’ supermarketshelf.Kliklok’s CERTIWRAP range of wraparound sleeving machines hasbrought a solution to the needs of this fast moving food sector. With thebenefits of icon-based HMI touch screen controls, patented rotary cartonfeeder, powered carton hopper, and quick size change facility asstandard – the Certiwrap range provides reliability and flexibility plusreassurance of continual production efficiency, with minimal downtime,reduced maintenance and low running costs – all essential requirementsfor a busy production line.27-31:Layout 1 12/12/13 14:33 Page 2Food & Drink International 29www.fdiforum.netSOUPS & SAUCESpacker, blender and importer ofnatural food ingredients, hasreported a surge in demandfor arrowroot powder fromfood manufacturers looking totap into to the burgeoning ‘ free-from’ foods market.During 2013, sales of EHL’snatural arrowroot powder havesoared by 20%, with the surge inpopularity of the product beingattributed to its properties as agluten-free thickening agent. The white, flavourless powder is astarch extracted from the roots ofvarious tropical tuber plants, typicallygrown in the West Indies. It hastwice the thickening power of wheatflour and can be used as areplacement for corn or wheat flourin both sweet and savoury foods.Available in conventional andorganic formats, EHL’s arrowroot isideal for thickening soups, sauces,stews, sweet gels or fruit sauces. Tasneem Backhouse, sales directorat EHL Ingredients, says, “Free-fromfoods have been a key area of growthfor us, as an increasing number offood manufacturers look to includefree-from items alongside theirconventional products. “At EHL, we have noticed anincreasing demand for arrowrootpowder which can be attributed to itsuse as a gluten-free alternative tocornflour. Its high starch content,and the fact that it does not hinderthe flavour of foods, unlike someother thickening products, makes itideal for food manufacturers to use insweet or savoury sauces, glazes andjellies, as well as soups, stews, brothsand baked goods. “The medicinal benefits ofarrowroot also make it suitable forpeople with digestive disorders, andwith gluten-free foods increasinglybeing associated with wellbeing andweight loss, retailers are also seeing agrowing demand for gluten-free foodproducts as consumers look toadopt a healthier lifestyle.”This trend for different flavourshas meant that even long-established brands have been ableto gear their products to newaudiences. One example of this issoy sauce manufacturer Kikkoman.The company has recentlyrelaunched its main stir-fry saucewith a complete redesign and namechange. Kikkoman’s new premium Stir-fry Sauce replaces Sukiyaki Sauceand is positioned for everydaycooking. Stir-frying in the UK hasgrown in popularity in recentyears, not least because it’s quickand easy but also due to itsassociation with healthy eating.Kikkoman’s Stir-Fry Saucebalances the savoury flavour(Umami) with a hint of sweetness,resulting in a unique taste. Bing-yu Lee, manager ofKikkoman UK says, “In line withthe UK’s love of Oriental cuisinewe are confident that our newly re-launched Stir-fry Sauce will be asuccess. Consumers don’t havemuch time to read the labels so30 This trend for differentflavours has meant that evenlong-established brands have beenable to gear their products tonew audiencesEven established brands arehaving to rethink their strategyas tastes and consumerbehaviour have changedPHOTO: KIKKOMAN27-31:Layout 1 12/12/13 14:33 Page 3Next >