INTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netJANUARY 2015£3.50 STERLINGServingthe foodchainDEVELOPING TALENTIMPORT & EXPORTServingthe foodchainEND OF LINE PACKAGING01_Layout 1 18/12/2014 16:24 Page 1Cross + Morsefor all your Power Transmission SolutionsRoller Chain - Gears & Sprockets - Timing Belt DrivesClamping Elements - Inverted Tooth Chain - Inverted Tooth SprocketsSealmaster Bearings - Shaft Couplings - Freewheel ClutchesTorque Limiters - Overload ClutchesShady Lane, Great Barr, Birmingham, West Midlands. B44 9EUTel +44 121 360 0155 Fax +44 121 325 1079sales@crossmorse.com www.crossmorse.com02_Layout 1 18/12/2014 15:47 Page 1ContentsJanuary 2015This magazine is now fully recyclable. By recyclingmagazines, you can help reduce waste and add to the5.5 million tonnes of paper already recycled by the UKpaper industry each year. Before you recycle yourmagazine, please ensure you remove all plasticwrapping, free gifts and samples. FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforumNews 4• General news • On line - production news• On the shelf - new products and initiatives Import and export 12Commitments to automation, recycling andlogistics ensure Germany remains one of theindustry’s most important locationsDeveloping talent 16Food and drink companies can get one stepahead of their rivals via a steady stream of newtalentEnd of line packaging20 End of line packaging is a sector wherecompanies can’t compromiseSorting & weighing 25Weighing in food factory environments is arguablyone of the most important areas of factory floorcontrol – but rarely it is optimised.Hygienic flooring 32Bespoke and hygienic floors, doors and walls canmake all the difference throughout the supplychainLaboratory showcase35Soups & sauces36The range of soups and sauces available hasexpanded massively in recent years – but thisbrings with it new challenges in their productionHospitality Show40The Hospitality Show returns to NEC Birminghamon 19th to 21st January to celebrate the very bestof British hospitalityEditor:Steve Fisher (s.fisher@blmgroup.co.uk)Editor’s PA:Angela SharmanJournalists:Steve Williams (s.williams@blmgroup.co.uk)Michael Fisher (m.fisher@blmgroup.co.uk)Sales Director:Teri CooperSales Manager:Becky DarnellAssistant Sales Manager:Sam TrottSales:Nikki LoganTel: +44 (0) 1472 310302Accounts & Subscriptions:Dawn Cook, John DownesDesign & Production:Gary Jorgensen, Mark Casson, Rachel Green(studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317Email:fdi@blmgroup.co.ukPart of the Business Link Magazine Group:Armstrong House, Armstrong Street,Grimsby, N E Lincs DN31 2QEEnglandAll rights reserved. No part of this publication may bereproduced, transmitted, photocopied, recorded orotherwise without express permission of the copyrightholder, for which application should be addressed firstto the publisher. While every reasonable care is taken,neither the publisher nor its participating agents acceptliability for loss or damage to prints, colourtransparencies, negatives or other material of whatevernature submitted to this publication. The viewsexpressed in this publication are not necessarily theviews of those held by the publisher.COVER PHOTOGRAPHSCOURTESY OFMain:shutterstock.com/Mark SkalnyTop: NylacastMiddle: shutterstock.com/Jens GoepfertBottom: ABBLogiMAT43LogiMAT, the international trade fair fordistribution, materials handling and informationflow, sets new standards as the biggest annualintralogistics exhibition in EuropeProSweets44As the world’s only trade fair for sweets andsnacks, from 1st to 4th February, ProSweetsCologne offers manufacturers a closer look atmanufacturing processes and packagingGulfood45Gulfood, the world’s largest annual food andhospitality trade show, marks its twentiethanniversary in 2015.Events46Your chance to keep abreast of forthcomingexhibitions and food fairs from around the worldClassified 49Food & Drink Diary 5003_Layout 1 19/12/2014 09:01 Page 1Picked to perfection the FANUC wayOver the last twelve months, FANUC has seen enquiries from food manufacturers looking toautomate their food handling and packing operations increaseby 35%. Spurring on the food industry, FANUC aims to inspiremanufacturers with the development of a food picker cell,combining both articulated arm and delta style food graderobots, which performs typical loading and unloading packingscenarios.FANUC’s latest robots have been designed specifically towork in the harshest of environments, and in addition to beingsmaller, stronger and faster, they incorporate the latest visiontechnology to improve the robot’s ‘sight’. John Rainer, RegionalSales Manager of FANUC UK, says, “We’ve strengthened the business case for robot adoption byproviding the necessary functionality that a food producer needs.”The IP67 certified food picker cell is designed to orientate and pack a wide variety ofunpackaged and packaged foods, including confectionery, baked, snack and dairy items.Clondalkin Flexible Packaging Burylaunches unique coding on shrinksleevesClondalkin Flexible Packaging Buryhas launched a shrink sleeveincorporating a unique code. Using aninnovative printing technique, the codeis printed on the inner surface of theshrink sleeve, and only revealed whenthe sleeve is peeled back. This unique solution is ideal forrunning product competitions and isalready used very successfully on itspre-cut lids. Each shrink sleevefeatures its own individual code whichcan be made up of a series ofnumbers and characters.Martin Hardman, Sales andMarketing Director of Clondalkin Flexible Packaging Bury, says, “This latestinnovation will provide customers with added value for very little extra cost.Customers are always looking for new ways to market their products anddifferentiate them from the competition and this new technology will enablethem to do so.”Shrink sleeves offer a sophisticated labelling solution and maximum shelfappeal with a 360 degree print area.A sensor for the newblack?The new SICK W2S family deliverspowerful sub-miniature photoelectricpositioning sensing for today’s most difficultpackaging materials – even matt black. Theslim housing allows convenient mountingwithin tight spaces demanded by compactmachinery.The sensor’s cutting-edge photoelectricsensing promises production efficiency and reliability even with challenging objects to detect inpackaging applications.Phil Dyas, SICK (UK) industrial sensor specialist, says, “The new W2S performance enables highspeed conveying lines to deliver efficiency even with matt black materials. The SICK W2S givesmanufacturers the opportunity to integrate modern photoelectric sensing power where it wasdifficult and expensive before.“The W2S will consistently detect matt black materials with as low as 1% reflectivity, unheard of inthis size and price range. The sophisticated background suppression software ensures highreliability and consistency whether detecting jet black, brightly-coloured, matt, transparent or highlyreflective objects.”New grocery boxreduces waste and keepsproduce freshGoplasticpallets.com has launched the GoBox1210 BBE, which is ideal for the storage andtransportation of fresh produce and other foodingredients. When packaged in corrugated containers, the lackof air speeds up the deterioration of freshlyharvested fruit and vegetables. The GoBox 1210BBE grocery box has a perforated base and sidewalls which aid air circulation, product cooling andventilation. The box’s rigid structure also offersultimate strength and protection, helping preservethe quality of fresh produce for longer.The ability to withstand extreme hot and coldconditions means it is suitable for use in hot andhumid environments as well as cold storage intemperatures as low as -40°C. Jim Hardisty, Managing Director ofGoplasticpallets.com, says, “Our new GoBox 1210BBE grocery box has been specifically designed tomeet the hygiene and environmental requirementsso strictly stipulated by food processors.”4 Food & Drink Internationalwww.fdiforum.netInvestment in ISBM technologyRPC Containers Corby hasinvested in new InjectionStretch Blow Mouldingtechnology that enables it tooffer its established highbarrier PP/EVOH/PP containerswith even greater transparency.The company says thistechnology opens upopportunities in the retailsector, in particular marketssuch as cook-in sauces andready meals, producing packsthat deliver high clarity for apremium on-shelf image alongwith the benefits of plastic. The lighter weight of the plastic jars will helpmeet sustainability targets in terms of packaging and carbon emissionreductions.The development of a special new manufacturing process has allowedRPC Corby to produce containers that incorporate its effective EVOHoxygen barrier for long ambient shelf life, while delivering excellent clarity.The containers are thermally stable to temperatures in excess of 100°C foreffective pasteurisation and sterilisation.A number of popular retail jar sizes are being developed with additionalsizes planned for the future. Caps are supplied by RPC Halstead.04-06_Layout 1 18/12/2014 16:51 Page 1Food & Drink International 5www.fdiforum.netLaunch of specialist cold store providerSteve Prior has launched Cold Store Rentals, a newspecialist food and hospitality refrigeration company he hasformed in partnership with other respected industry figures.Cold Store Rentals provides bespoke cold stores for rental,rent-to-buy, or purchase. The firm has a complete range ofbespoke, modular build, chilled and frozen rooms to suitvirtually any application. All are fully weather-proofed so canbe used outside, either for events or situations where indoorspace is at a premium. Steve says, “My colleagues and I had listened to customerfrustrations for many years, and so created an offer to makelife much easier for busy food industry executives. BetweenCold Store Rental’s founders, we have 125 years of combinedindustry knowledge, and we believe our offer to be unique inthe market.”Cold Store Rentals specialises in quick and easyinstallations for short term, medium term and long-termrentals, as well as equipment leasing and sales. Clondalkin Speciality Packaging acquired by EssentraEssentra has agreed to acquire Clondalkin Group’s Specialist Packaging Division for approximately $455million. This transaction, which is expected to complete in Q1 2015 and represents Essentra’s largest acquisitionto date, significantly extends the company’s existing packaging capabilities.With 24 strategically located facilities, Clondalkin SPD is a leading global provider of a broad suite of specialitysecondary packaging solutions for the pharmaceutical and health industries, and will transform Essentra’sposition in these end-markets. As a leading player in North America, and with strong market positions in Europe,Clondalkin SPD’s range of technologies and capabilities support the high product quality and the versatility todeliver the complex solutions required. The addition of Clondalkin SPD significantly enhances Essentra’s existing geographic presence in healthcarepackaging and, through leveraging the combined footprint of both businesses, will allow the company to furtherexploit both existing, and attractive new growth opportunities. ETI launches TempTest 2food thermometerElectronic Temperature Instruments have launchedthe TempTest 2 food thermometer. It features anautomatic 360° display, which rotates in 90° incrementsenabling the user to read the temperature in anyposition.Additionally, the TempTest 2 features an intelligentbacklit LCD display, illuminating the display whenambient light levels are low, making food temperatureseasier to read whatever the time of day. The case iswaterproof IP67 and includes an ergonomic rubberseal, both of which include Biomaster additive toreduce bacterial growth. In addition, it is one of the fastest reading contact thermometers on themarket – the true temperature of a product can be measured in just three seconds.Supplied with a hand held food penetration probe with a fast response tip, the thermometer willmeasure the true temperature, typically 50% faster than traditional thermometers.The TempTest 2 food thermometer is competitively priced at £60 and available direct fromElectronic Temperature Instruments.Company’s barrierspoint to the future forwarehouse safetyA-SAFE is a world leader in barrier safety inworkplaces. The company offers unbeatableprotection for racking, loading bays, columns,doorways and more. The barriers are made from aninnovative, patented material called Memaplexwhich absorbs and dissipates impacts, savingclients huge costs in replacement barriers, damageprevention to structures and vehicles and reductionin maintenance down-time.New iFlex RackGuards protect rack legs via aseries of modern innovations, Column Protectorsoffer heavy duty, modular protection for vitalstructures and high-vis, flexible Pedestrian Barriersact as protection, guide-way and segregation forpersonnel and equipment. In all, A-SAFE have oversixty products available, covering all aspects ofwarehouse safety and protection.Installing A-SAFE products can offer payback onthe investment in less than a year. Our complete truck range atyour serviceYou can call us for further information on 01844215501 or email sales@atlet.co.ukwww.atlet.co.uk04-06_Layout 1 18/12/2014 16:51 Page 2Starfrost marks anniversary with new HQStarfrost is celebrating three decades atthe forefront of technical innovation infreezing and chilling systems for the globalfood processing industry. Starfrost’s thirtiethanniversary coincides with a significant movefor the company, as it has relocated its UKheadquarters and manufacturing base to apurpose built facility at Oulton Broad, nearLowestoft. At over 1000 square metres, the premises at Craftsmans Way feature office space and meetingrooms, as well as a large engineering workshop and equipment maintenance centre. With furtherspace available on site for future expansion, the new facility looks set to provide Starfrost with anideal base for many years to come.Starfrost’s new headquarters also houses a fully equipped test facility which simulates differentfreezing and chilling processes. This allows Starfrost engineers to calculate the optimumconditions required for each food product.New solvent barrier solution fromRPC MoiransRPC Emballages Moirans hasdeveloped a new barrier solution for itsrange of blow moulded containers upto thirty litres.RPC Protect provides an effectivebarrier against solvent-based products,offering a safe and efficient transportsolution for a wide range of chemical,agrochemical and fuel products. It isalso approved for food use.The barrier does not affect theperformance of the containers in anyway, maintaining their lightweight,robust and shock resistant propertiesand passing all the requirements ofdrop, pressure and stacking tests. Inaddition, containers with RPC Protect are currently undergoing assessmentfor UN approval.RPC Protect can be applied to all types of containers, ensuring flexibilityin design and enabling family ranges containing both barrier and non-barrier packs to be created. Thanks to their mono-material construction,containers incorporating RPC Protect are easy to recycle, while reducedenergy consumption during transportation is a further sustainability benefit.Freshtime gets greenseal of approvalThe green credentials of Freshtime UKhave been given the seal of approval byInvestors in the Environment. Freshtime hasbeen awarded the highest green level ofaccreditation following a thoroughenvironmental audit of the company.To qualify for green accreditation Freshtimehad to meet strict criteria. Freshtime is nowclassed as a green leader by Investors in the Environment and will help to set the standard for theenvironment amongst businesses.The environmental audit covered use of resources such as gas, electricity, water, landfill waste,propane, liquid CO2 and refrigerant. It also considered Freshtime activities such as the Big BostonCleanup, use of paper from sustainably farmed trees and involvement in the South LincolnshireSafety Group.A spokesman for Investors in the Environment says, “It is refreshing to see Freshtime aremotivated and committed to invest in offsetting these impacts in so many ways, whether it isthrough technology or behavioural change.”Givaudan expandsflavour capabilities inMiddle EastGivaudan has opened its new, expandedTechnical Centre and Regional Offices in Dubai.For the first time customers from across the regionwill benefit from local access to Givaudan’s worldclass savoury and snacks flavour creation andapplication capabilities. These are complemented bythe full range of services in sweet goods andbeverages, where Givaudan is now also offeringflavour creation in addition to already existingapplication expertise.Drawing on an in-depth understanding of localtastes and consumer preferences, the expansion ofGivaudan’s facilities in Dubai will bring closercollaboration with customers in creating andapplying flavours for the Middle Eastern markets. The new state-of-the-art facilities are responding togrowing demand for flavours from developingmarkets. The new technical centre in Dubai is part ofthe company’s overall strategy of increasing its salesin developing markets.6 Food & Drink Internationalwww.fdiforum.netEdina Group celebrate triple awardsfrom the CHPAEdina Group pickedup three awards at theannual conference andawards of the CombinedHeat and PowerAssociation.Edina was successfulin the Industrial andCommercial categorywith the turnkeyinstallation at R&R IceCream in Northallerton and the Community, Campus and Residentialcategory as sub-contractor to Vital Energi for the second phase of CHP atLiverpool University.For R&R Ice Cream, installation of a “power island” CHP plant amongexisting buildings was designed and constructed by Edina with twoTCG2020V20s with a combined output of 4MWe and ~4MWth from MWMsupplying all the power for the factory. Previously hampered by grid supplylimitations, the factory can now expand its operations.Tony Fenton, Edina’s Joint Managing Director, says, “This is a greatconclusion to an outstanding year for Edina. These awards demonstratethe engineering skills contributed by all entrants and promotes CHPsolutions to a wide audience”.04-06_Layout 1 18/12/2014 16:51 Page 3All new O6 series photocells optimised for harsh, hot and wet environments such as food production. Superb optical performance even in water spray or with shiny backgrounds and up to 80°C. Compact and robust, IP69K stainless steel housings, with 25.4mm hole centres. Eye-catching innovation from ifm.www.ifm.com/uk/o6Best sensor for wet areasifm Telephone 020 8213 222207_Layout 1 18/12/2014 12:27 Page 18 Food & Drink Internationalwww.fdiforum.netAdditional volume for SIG Combibloc’s combisafecarton packThree Bio Sonne brand vegetablevarieties are now available in Germanyin the heat-resistant combisafe cartonpack from SIG Combibloc.The combisafe carton packs, filledby food manufacturer Jütro, have avolume of 440ml – a majorinnovation as it means productstraditionally in standard metal cans can now be sold in carton packs, packaged exactly the same.Dominik Haug, Global Market Segment Manager Food at SIG Combibloc, says, “More than 200products are now sold in our heat-resistant carton pack. The major strengths of carton packs aretheir convenience, their product protection qualities and their good environmental characteristics.“Carton packs are proven to be among the most environmentally friendly packaging solutionsfor long-life foods, and in terms of logistics and advertising effectiveness on the sales shelf,cartons clearly outperform competing packaging solutions.”Key Technologyintroduces integratedsorting system forspinachKey Technology has introduced a new sortingsystem for fresh spinach. The integrated systemincludes an Iso-Flo fines removal shaker ordewatering shaker together with an acceleration beltand Manta digital sorter to inspect fresh spinach andother leafy greens.This integrated system improves the accuracy offoreign material and defect removal to enhanceproduct quality and food safety while increasingthroughput and maximising yield. In tests, this newsorting system removed 100% of the foreign materialwhile achieving a false reject rate of only 0.5%.Marco Azzaretti, Advanced Inspection SystemsProduct Manager at Key Technology, says, “Freshspinach can be very hard to sort because the leavesare light and flat, so they fly like a sail. It tends to liftand roll, which makes it difficult to stabilize foraccurate inspection and the targeting of rejects. Withour product handling and sorting expertise, wedesigned this successful integrated system.”Loma service hits over 90% firsttime fixrateLoma Systems isattributing its unrivalled91% first time fix rate tothe powerful remotediagnostics tools nowavailable with its rangeof high performancemetal detectors,checkweighers and X-ray units, backed by adedicated service team.In line with its‘Designed to Survive’ethos, Loma’s aim is to ensure the long term reliability of its equipment.With after sales support a key component, the company measuresResponse Time and First Time Fix Rate. On average, across all service callouts in the UK, Loma is achieving more than nine out of ten problems fixed,within one working day from the time the problem is first reported.A vital part of Loma’s service delivery is the powerful remote diagnosticstool offered with its robust and reliable in-line inspection systems. This givesthe company full real-time visibility of installed equipment and can be usedto make a speedy diagnosis. Get it right quickly with enhanced Linx 7900The enhanced Linx 7900 continuous inkjet printer now comes with addedcapabilities to help food and drinkcustomers print perfectly, minimise mistakesand measure production output. Itsimproved software delivers quick, time-saving changeovers between products ormessages, while simple automated set-uphelps ensure users get it right first time.New Linx QuickSwitch Plus deliverssimple, automated code set up, reducingthe risk of costly errors and cutting the timerequired to switch products – perfect for customers with frequent changeovers.By connecting a barcode scanner, the Linx 7900 can intelligently decipher the barcode to selecta message from its memory, edit the message content, set the date and choose parameters suchas print orientation, height and width and position on the pack – all without operator intervention.The Linx 7900 already offers a wealth of features, including Linx Insight software allowing usersto monitor and control their printers through a web browser.New GSI 75 clarifyingseparator for medium-sized operationsThe new GEA Westfalia Separator GSI 75separator is suitable for medium-sizedoperations in the clarifying of beer, wine andfruit juices. This makes the principle of theintegrated GEA Westfalia Separatordirectdrive available for outputs of up to250 hectolitres per hour.In the directdrive system, the bowl isdriven directly by an integrated,frequency-controlled, three-phasemotor and is infinitely adjustable –efficiency is improved along withsignificant energy savings. Thedirectdrive also reduces space requiredfor the separator by 35%.The energy saving drive concept has proved to be exceptionallymaintenance friendly and the water-cooled motor performs much quieterthan an air-cooled equivalent. The demand for spare parts is greatlyreduced as the motor requires no bearings and therefore no lubrication.Mechanical seals are also removed, reducing the spares holding further.The robust design of the asynchronous motor provides for maximummachine reliability and allows standard frequency converters to be used.08-09_Layout 1 18/12/2014 15:03 Page 1Food & Drink International 9www.fdiforum.netIshida solution helpsdumpling businessexpandThe introduction of Ishida mulithead weighingat Monolith Fleisch und Teigwaren, has enabledthe company to substantially increase outputand embark on a major product developmentprogramme.Based in Schwabach, Germany, MonolithFleisch und Teigwaren is a leading wholesaler ofEast European specialities, including Russian-style filled dumplings known as Pelmeni. Originally thedumplings were fed into a bagmaker via a linear weigher. The accuracy was not ideal, but the mainproblem was the low speed which meant the packing process was becoming a major bottleneck.However, adding more weighers of the same type was simply not an option because of spaceconstraints.The Ishida solution was to install a modern Ishida multihead weigher as a drop-in replacement forthe linear model, leaving the rest of the line in place. This has doubled production output from eight tosixteen tonnes of Pelmeni per day.Mosca launches new crossstrapping solutionsMosca has enhanced its fullyautomated tandem machine for crossstrapping, the SoniXs TAI-6, with theintroduction of two models – Base andPro – both of which utilise thecompany’s proven ultrasonictechnology to provide reliable,quick and secure cross strappingfor high throughput industriessuch as print and logistics. The SoniXs TAI-6 Base and Procombine transverse strapping andinline strapping in a single processwithout turning the product to ensure the accurateand reliable securing of products. They offer the highest levels ofprocess safety, a vital benefit for industries with a high throughput and highmachine availability. Both machines are built on the same high-performance mechanics, andcontain CE marking from the factory. The hold-down device and the backstop have been specially designed to pose no danger and do not need anyadditional protection. Customers can therefore easily integrate the strappingsystem into their production line without any extra safety measures.PA supply high speed traysealing for meat supplierA recent installation of PA’s Revolution tray sealer at meatsupplier Central Food Services has dramatically improved theefficiencies of their foil tray sealing line. The Revolution is the fastest, most energyefficient single lane tray sealing machine on themarket and features PA’s Powerdrive fullyelectric technology. Interpolated multi axisrobotic motion ensures a continuous flow of traysthrough the machine from infeed to outfeedeliminating any need for pauses or buffering allowing thethroughput of 150 packs per minute.The seal force has been increased by 300% compared to pneumatic systems, but PA’s noveltechnology allows the tool lift mechanism to be deactivated during the seal process thereforesignificantly reducing the energy usage. This additional seal force has allowed Central Food Servicesto seal through product contamination on their foil lines and allowed them to improve the overallefficiencies of the line. Simple laser codingwith the new Linx SL1Linx Printing Technologies is making lasercoding more accessible with the launch of theLinx SL1, an entry-level solution that enables morecompanies to achieve a high quality code whichadds value to their packaging. The laser coder istailored particularly to customers who may havethought laser’s benefits were out of reach.The Linx SL1 delivers class-leading codingspeeds thanks to the use of lightweight and ultra-fast mirrors. It offers 20% more power than otherproducts in its class, but at the same time usesmuch less laser energy in the coding process.The new laser coder also offers greater codingversatility than comparable models, with the abilityto produce multiple lines of text and logos in onemessage, as well as machine readable codessuch as QR and Data Matrix codes. This versatilityenables the Linx SL1 to apply decorative codescapable of matching the look of the packagingdesign.System provides full traceabilityFood and beverage IT specialistCSB-System International has createda full traceability system for leadingGerman meat processor VionConvenience that enables all thecompany’s beef products to be trackedfrom their retail packaging back to theoriginal farm and individual ear tag.The CSB-System uses manual inputvia a CSB-Rack station or an EDIdelivery notification to collect all dataand history of every piece of meatdelivered to the company. Eachproduct is assigned a unique lotnumber and EAN-128 code which areused to monitor and confirm itsprogress through various processingstages, using relevant CSB-Systemstations.Dirk Kirchner, Vion’s Head ofProduction says, “We can demonstrate which raw material quantities werepurchased, which products were made from them, in which quantity theywere sold and how many items we still have in stock. We have createdabsolute fullest transparency within our operation. This gives us and ourcustomers maximum security.”08-09_Layout 1 18/12/2014 15:03 Page 2Next >