< Previousbe brought on stream with no furtherequipment cost and no waiting time forchange part delivery.Selection of components is a keyconsideration and only easily accessiblestandard off the shelf components areused. This further reduces spare part costsand, in the event of a breakdown, the vastmajority of parts can be sourced locally bylooking to pack fragile bottles andreduce spend on materials. Itprovides not only a cheaperalternative to polystyrene, butreduced customers damage ratefrom as high as 10% down to zero.This has also been followed bythe Kite Wrap & Hold System,designed to provide a fast andefficient alternative to a variety ofvoid-filling and in-box solutions, bycreating a void out of space ratherthan material. Kite’s idea was touse stretchfilm to secure productsto patented cardboard wrap designs– these not only hold the productin place without using adhesive butthe intuitive designs also elevatethe product so it is suspended inthe box, and therefore not affectedby transit damage and impact.A further way to avoid potential damageand save money is to invest in simple androbust machines with flexible design. TFreemantle’s cartoning machines are agood example of this, as the design meansit can meet a wide range of applicationswithout the need for change parts orcomplicated resetting. New products can20 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGQualitydown thelineEnd of line packaging is a sector where companies can’tcompromiseIt’s absolutely vital product security isthe top priority and items can betransported quickly and efficiently, and thelatest cases, containers and boxes areensuring these high standards can be met.Yet it’s also doing this while meeting thegrowing requirement for energy efficiencyin the supply chain.Increasingly this has led to manypackaging companies working incollaboration to provide a range ofinnovative and bespoke solutions to meetthe new challenges. One great example isKite Packaging’s successful partnershipwith Audion Swissvac, demonstrated atthis year’s PPMA Show. This meanscustomers can now choose from a varietyof packaging machines to suit theiroperation, and their vacuum packingmachines are competitive in terms ofpricing and are available with a choice ofvacuum pouches in a variety of sizes.Kite have responded to the requirementfor energy efficiency with products such asthe Kite Air Shock, which was launched atthe beginning of 2014 as anenvironmentally-friendly, space savingsolution for fragile items, particularly forthose customers in the drinks market20-24_Layout 1 19/12/2014 09:47 Page 1end users to ensure the equipment can beput back into service cost-effectively. Dayto day running costs are reduced further asthese machines offer an extremely simplesize change, reducing downtime further.A further example of exceptionalflexibility comes from Penn Packaging,who distribute Meypack packagingmachines – a company that has expandeddispensers and, through the controlsoftware, the arms can work independentlyfrom one another and can pick up productsfrom the infeed and place them on theintermediate table. By using the PP 200’sdouble pre-grouping station, both gripperarms can easily pick up the incoming packsits machine programme to include a newhighly efficient and flexible solution. Theyproduce the PackPal PP 200 with twogripper arms and the single armed PP 100which, despite its compact design, iscapable of processing all of the commonpallet formats.It is also possible to easily integrateintermediate layer or cover sheetFood & Drink International 21www.fdiforum.netRobots from ABB havehelped systems integratorRM Group to turn aninnovative idea for a mobilepackaging system into aworking reality23 Á20-24_Layout 1 19/12/2014 09:47 Page 2We manufacture machinery to suit almost every Cartoning, Sleeving and Case Packing application. Visit our web site or call on our stand and we will be happy to discuss your requirements. The UK Market Leader www.tfreemantle.com Our market leading range of Cartoning Machines. Simple manually operated Two Flap Sealers. Cost effective and reliable. For speeds up to 60/min. Semi and Fully Automatic Cartoners available in both continuous motion and intermittent options for speeds up to 150/min. The UK’s best selling Sleeving Machinery. Simple, robust and reliable Preglued Sleevers in both Semi and Fully Automatic executions for a huge range of sleeve and tray types and designs up to 120/min. Wraparound Sleeving Machines for high volume applications to suit both single and multipacks at speeds up to 120/min. Compact and innovative Case Packing Equipment. Semi Automatic Top Load Case Packers that are designed to be compact and flexible. The machine erects, presents for loading and closes the case all within one compact footprint. Fully Automatic Side and Top loading Case Packers incorporating collation and loading systems for medium to high speed applications. The UK Market LeaderT. FREEMANTLE LIMITEDAtkinson Way, Foxhills Industrial Estate,Scunthorpe DN15 8QJ UK+44 (0)1724 276908+44 (0)1724 276909sales@tfreemantle.comTFE20-24_Layout 1 19/12/2014 09:47 Page 3Food & Drink International 23www.fdiforum.netEND OF LINE PACKAGINGSpecialist suppliers of primary and end of linepackaging machinery including…• Form, fill and seal pouch packing solutions • Pre-made fill seal pouch machines• Doypack / Stand-up / Zipper & slider pouch • Wrap-around case packers • Shrink-wrapping solutions • Palletisers/de-palletisersTel: +44(0)1473 893990 or visit www.penn-packaging.co.uk floors. New features including simplifiedfork lift pockets and more space in therobot foot help to simplify maintenance.As well as improved efficiency, thesystem also helps users to realiseoperational and environmentalimprovements. By eliminatingtransportation between product source andpacking location, the system not only helpsto cut haulage expenses, but can also helpto reduce Co2 emissions, with no need toferry products to and from off-site baggingfacilities. Llewelyn Rees, ManagingDirector of RM Group, says, “The IRB6640 robots have been a complete successfor RM Group, coping with the highdemands and withstanding thousands ofmiles of haulage and continual labour,while the IRB 460 helps to deliver fastpackaging output speeds with combinedprecision in palletising.”forward from the empty pallet magazine.It’s not surprising that many companieshave taken the opportunity to introducerobotics into their packaging solutions,thanks to the increased flexibility andspeed that can bring about. For example,robots from ABB have helped systemsintegrator RM Group to turn aninnovative idea for a mobile packagingsystem into a working reality. Housed in45ft articulated trailers, RM Group’smobile packaging plant uses ABB’s IRB6640 and IRB 460 robots as part of asystem designed to provide customers witha versatile, efficient and easilytransportable way of bagging products atsource.Specifically designed for applicationsinvolving high capacity production, theIRB 6640 has a payload of up to 235kg,enabling it to handle extremely heavymaterials, and with no tail swing, it is idealfor restricted spaces such as small factoryand process them much more quickly, soan output of up to sixty packs per minutecan be achieved. When multipacks are tobe palletised, the output can be cranked upsignificantly by processing a number ofpacks simultaneously – depending uponthe layer profile.Through both the use of Meypack’stelescopic lifting table and by holding thepre-fabricated layer on the intermediatetable, it’s possible to achieve continuousmotion of the machine, even during theautomatic pallet changes. Equipped with atelescopic device, the lifting table can moveup and down, forwards and backwards. Inthe rear position, its length can be reducedby up to one half so the loaded pallet isfreestanding. It’s therefore possible toalready pick up the next layer created bythe double pre-grouping station while,simultaneously, a full pallet is beingautomatically transported to the palletwrapper and an empty pallet is movingKite Packaging have responded to the requirement forenergy efficiency with products such as the Kite Air Shock24 Á20-24_Layout 1 19/12/2014 09:47 Page 424 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGThe recent PACK EXPOevent illustrated the extensiveinnovation that is taking placethroughout the sector. Amongthe exhibitors, Bosch Packagingpresented the North Americandebut of the Sigpack TTMCcase packer, which is designedto handle a variety of pre-packed food, including those inflow-packs, trays, cartons,pouches and bags. The machinecan be adjusted without tools tothe required format and productconfiguration with vertical start-up. Able to run at a highfeeding rate, products can besupplied flat or on edge, andmultiple case closing options areavailable, ranging from a tape orhot melt solution to the releaseof unsealed cases for third-partyclosure.As is increasingly the case,overall equipment effectivenessis a top priority and the caseerecting, robotic loading, andoptional case closing units areall integrated in the case packer.Additionally, the speed of allcomponents is balanced toeliminate bottlenecks andoptimise production flow. Thesystem’s fully flexible feedingwheel can accommodate variousfactory layouts by positioningthe case packer inline, at a 90-degree angle, or other angles.To meet the need for flexiblecase packaging, Bosch alsopresented its CCM 3100 casepacker for vertical andhorizontal bag presentation.This has been designed to meetmanufacturers’ demands forshorter production runs andmore frequent changes inproduct packaging styles, andemphasises easy integrationwith VFFS, as well as HFFSmachines. Capable of pickingand placing up to 180 productsper minute, the machine’s singleframe is attached to an infeedsystem that accepts productsfrom VFFS and HFFS primarypackaging machines. Dependingon the product characteristics,products can be handledindividually or in groups, andare picked and placed by a two-axis robot with vacuum orgripper end-effectors.These latest innovations inend of line packaging arehelping to speed up the supplychain without comprising safetyand security at any point.Bosch’s CCM 3100 casepacker for vertical andhorizontal bag presentationhas been designed to meetmanufacturers’ demands forshorter production runs andmore frequent changes inproduct packaging styles20-24_Layout 1 19/12/2014 09:47 Page 5Food & Drink International 25www.fdiforum.netSORTING AND WEIGHINGWWW.SHUTTERSTOCK.COM/BIKERIDERLONDONAs Roy Green of Harford Controlpoints out, “Many production facilitiescarry unnecessary levels of wastage withintheir production overhead which affectsthe bottom line – sometimes sodramatically that it makes the differencebetween a profit and a loss.“Bearing in mind that everymanufacturing operation is a conversionprocess, from incoming raw materials tofinished packs, it’s often not fullyappreciated there are only three variableswhich any manufacturer has theopportunity to control during this process.One is weighing, perhaps more generallyreferred to as materials utilisation, two istime, or labour utilisation and the third isenergy utilisation. In this regard, we’veassisted one drinks company to improvetheir net profit sevenfold during a sevenyear journey, on the same turnover, whilea major UK dairy operation managed toimprove its bottom line by more than £2million per year within the first four yearsof our involvement.“The food industry is especiallyvulnerable, due to the razor thin profitmargins which they so frequently operatewithin, where ‘wrong first time’ or apercentage or two of material or giveawaycan sometimes be the difference betweena profit or loss. When we visit factories,27 ÁRightfirst timeWeighing in food factoryenvironments is arguablyone of the mostimportant areas offactory floor control –but rarely it is optimised.Rightfirst time25-29_Layout 1 18/12/2014 16:13 Page 1REDUCED OVERFILL for LESS WORKwith Harford’s Optimised Weight Control SystemLegal ComplianceOptimised AverageQuantity LawAuto Control Limitsto match yourProcess VariationSPC & Process Control AnalysisPortionWeighingRecipe ContentControlBetter Control withFewer AdjustmentsIn addition to superior Content Control,Harford also provide a complete end toend production floor informationmanagement system including:• Automated Coding & Labelling• Real Time Paperless Quality • Automated Line Efficiency & OEE• On-line Vision• Roving Quality Audits• Short Interval ControlT: (+44) 01225 764461E: sales@harfordcontrol.comW: www.harfordcontrol.com25-29_Layout 1 18/12/2014 16:13 Page 2Food & Drink International 27www.fdiforum.netSORTING AND WEIGHINGwe see evidence of wastage at almostevery stage, from goods in to despatch.“Measurement of weight and volume isvery important at every stage of themanufacturing process to ensure that theyield at each stage is optimised. The onlyway that this can really be done effectivelyis by highlighting, in real time, whenwastage from any particular operation hasexceeded the targets set for it, leading to adata drill down to determine and fix rootcause. Some degree of variation, especiallyseasonal, may be inevitable, but in orderto make that judgement, greaterawareness and real time visibility ofperformance is essential. One company wevisited were losing more than £50,000 perweek of fresh cream between goods in anddespatch, with no real understanding ofwhere this was going and apparently noproject improvement plan to tackle thisloss.”Though Average Quantity Law hasbeen the European standard for most pre-packaged goods since the latter part of1979, examples where Average QuantityLaw has been fully optimised – legalcompliance coupled with minimalgiveaway –can be hard to find. Roy says, “One of the reasons for this isa lack of understanding of the law, whileanother is lack of visibility through theuse of paper recording. A third reason isthe lack of computer analysis whichwould, if it was in evidence, make thewhole operational team aware of theextent of the cost of non-compliance andof giveaway. Even where computerisationof weights is in place, the statisticalanalysis of those weights is often28 ÁPHOTO: WWW.SHUTTERSTOCK.COM/DOTSHOCK25-29_Layout 1 18/12/2014 16:13 Page 328 Food & Drink Internationalwww.fdiforum.netSORTING AND WEIGHINGinadequate to enable optimal control. The mostcommon consequence of this is over frequentadjustments and overfilling. “The biggest concern about overfill is that,although some of the overfill percentages might bequite small – in some cases a fraction of a per cent– the overfilled product at this stage of themanufacturing operation often carries maximum‘value added’. It’s no longer about giving away thecost of raw materials, but giving away materials plusall of the value added during the manufacturingoperations. Hence even small amounts in highvolume packing operations can have a verysignificant effect on the bottom line. What’s oftennot taken fully into account is the natural processvariation which effectively determines whereprocess adjustments can be safely made.“Unless the natural variation in the process isfully accounted for in the setting of control limits,machine operators will be encouraged to adjustwhen the process is already in control. Suchpremature adjustment generally forces the processPHOTO: WWW.SHUTTERSTOCK.COM/BALONCICIT: +44 (0) 118 946 1900 E: sales@appliedweighing.co.ukwww.appliedweighing.co.ukFOR GENERAL, PROCESS, PHARMACEUTICAL & FOOD WEIGHING APPLICATIONSLoad CellsSilo, Tank & Vessel SystemsWeight Indicators & Control SystemsPlatform ScalesDrum FillingSystemsDynamic CheckWeighersThe UK’s leading load cell & process weighing systemmanufacturer. When you use any product fromApplied Weighing you will have absolute accuracyand total peace of mind. ComprehensiveNational ServiceOrganisationAccurate weighing - whatever your industryMANUFACTURED IN THE UK25-29_Layout 1 18/12/2014 16:13 Page 4Checkweigher + Metal DetectorThe combichecker as a complete inspection systemBizerba’s CWD, CWE and CWF series are available in almost unlimited combination options. A built-in metal detector transforms the checkweigher into a complete inspection system, in compliance with the modern requirements from HACCP, IFS, BRC and others.Bizerba combicheckers are mainly used in the food industry to cope with medium and high loads, as well as to check nominal weights of up to 15kg.Highlights:Throughput of up to 400 products/minWeight ranges: 10 - 15000gMax. Speed 170 m/minSafety class IP IP54 / IP65Metal detector for all types of metals, multi-frequency technologyView and evaluate data online with _statistics.BRAIN (optional)01908 682740 info@bizerba.co.uk www.bizerba.co.ukFood & Drink International 29www.fdiforum.netSORTING AND WEIGHINGout of control, causing more giveaway with an increased risk oflegal non-compliance and even more adjustments in anattempt to regain control.”Roy argues that Average Quantity Law is one of the fewpieces of government legislation that actually helpsmanufacturers reduce their costs. He says, “Gradually over theyears, overfills have for many companies crept upwards, partlybecause the actual fill levels and consequences of overfillingare not sufficiently visible, but also because people no longerhave the time to carry out process capability studies.“What makes the Harford system unique, in its effectivenessfor control of products to Average Quantity Law, is its specialset of algorithms that combine statistical process control,process capability and the Three Packers’ Rules for AverageQuantity Law. This means the Harford system automaticallysets optimum control limits for every product/linecombination, so operators only adjust when absolutelynecessary to maintain legality or reduce overfill.“Operators prefer to use this system because it means thatthey can achieve far better control with fewer adjustments.Management like the system because of the minimisation ofrisk of batch quarantine and the reduction of overfill to thesmallest possible level in each case, thereby reducingmanufacturing costs.”There are other obligations on food manufacturers.Companies in the EU are now specifically required to indicateallergens on packaged and loose goods and, from December2016, consumers must also be provided with detailednutritional values. Companies such as Bizerba are dealing withthese developments by altering their existing systems ofmerchandise management. Their .CWS system, for example,identifies and structures the ingredients and allergens fordisplaying the data on labels. For marking and displayon shop scales and counter labels, the ingredients suchas nutritional values, QUID data, additives andallergens will be identified for each formulation.A further obligation for manufacturers is to meetstringent hygiene standards and the new breed ofweighing and sorting equipment can deal with this.Applied Weighing’s Cleanmount II and ClevermountII range of loading assemblies, for example, have beendesigned for vessel and tank weighing applicationsand, when combined with a fully welded load cell, thestainless steel assemblies provide extensive ingressprotection, with sealing up to IP68, and are capable ofwithstanding regular cleaning operations using highpressure water.The obligations to meet high standards and thepotential for extensive product giveaway has led tomany companies having to consider their optionswhen it comes to weighing and sorting. Yet byoptimising their equipment, the potential to make bigsavings, without compromising on quality, is readilyapparent.25-29_Layout 1 18/12/2014 16:13 Page 5Next >