< PreviousEND OF LINE PACKAGINGThere’s something circular about thechanges taking place in the packagingsector. It’s an evolution that’s not uniqueto the food and drink industry, but it isperhaps where it’s most keenly felt. Take,for example, the growing need for moresustainable practices, relating both to thematerials used but also the method inwhich they’re packed. Sustainability is oneof the key drivers in this regard, the effectof which has the packaging sector inconstant flux. Curiously, thisphenomenon is representative of morethan simply a desire to curb energy andmaterials excess and expenditure, and isencompassing of the desire for greaterefficiency. Both of these needs are beingincreasingly met with improvedautomation.Automation has become something of abuzzword, due in no small part to itsubiquity across the industry, fromprocessing, to packaging right through toEngagingefficiency Developments to automation and sensor technology are ensuringthat end of line packaging is in a state of continuous improvement. PHOTO: SHUTTERSTOCK.COM/MOLPIX20-25_Layout 1 17/12/2015 12:40 Page 1Food & Drink International 21www.fdiforum.netEND OF LINE PACKAGINGdelivery. Yet, there are constantdevelopments taking place which improveupon current wrapping machines, robotsand rotating arms to achieve a greaterefficiency, operate more sustainably andprotect bottom lines. There’s no easy means of defining endof line packaging, given the depth of itscapabilities and requirements. Instead, it’seasier to focus on individual aspects.Some of the most significantdevelopments to the packaging industryaren’t whole machines, but rather sensors.22 ÁPHOTO: SHUTTERSTOCK.COM/MOLPIXRobothandleschallengingpackagingapplications FANUC has extended itsM-10iA range of materialshandling robots with theintroduction of the highspeed, long reach M-10iA/8L. Capable of handlingpayloads up to 8kg, the M-10iA/8Loffers a reach of 2028mm. Previously userslooking for such a reach would have had tolook at a much bigger robot in the company’srange, but the M-10iA/8L is 40 per cent lighterand 20 per cent slimmer, addressing the needsof applications where space for robot accesswithin a machine is limited and angles ofaccess challenging. It will also prove more energy-efficient andoffers a number of performance benefits insituations where a high payload robot is notrequired - offering a reduction in powerconsumption of up to 30 per cent contributingto overall profit margin. In addition capital costsavings of a smaller, lighter robot wide a widemotion area.The M-10iA/8L is likely to be of particularinterest within the food industry, where manycompanies are still struggling to deal withergonomic issues, labour availability, legislationand the need to improve key performancemeasures such as overall equipmenteffectiveness. Plasfilms launches SenzoZIP - a re-closable zipper thatprovides sound and sensationLeading films distributor, Plasfilms, has recently announced the launch of a newinnovation and addition to the SANZIP range of products, known as SenzoZIP, a re-closable zipper that provides both sound and sensation when closing. The innovation combines both audible characteristics and tactile sensationtogether with an excellent inner holding force. SenzoZIP not only providesunmatched security, it also offers consumers a convenient and pleasant experiencewhen using the product. SenzoZIP is available as a double or triple type zipper andis manufactured in LDPE.Plasfilms’ Stephen Harpham said: “This is the first zipper of its kind that providesfeedback during closure. The user can actually feel and hear SenzoZIP, creatingconfidence and certainty in the mechanics of the closure operation.”Plasfilms are the sole UK distributor for the SANZIP re-closable zipper range,which are manufactured by C.I Kasei (CIK), the leading Japanese manufacturer of re-closable zipper products.For more information, visit www.plasfilms.co.uk. 20-25_Layout 1 17/12/2015 12:40 Page 222 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGGiven the increased demands from theindustry, which need to correspond tochanges in consumer taste and habits, aswell as legislative changes, sensors need tobe up to the task. Therefore, the verylatest sensors and sensor systems need tobe designed for complex, frequentlychanging tasks while also meeting evermore demanding brand protection, safetyand documentation requirements.Working in conjuncture with sensors isthe use of offline case marking.Implementing such a strategy greatlyreduces the human error which in turnbolsters efficient practices and decreasesthe risk of damaged goods and loss. The ability to mark-up secondarypackaging offline meets a growing need intoday’s grocery market, where theemerging retail channels of discount,convenience and online will account forall the growth over the next 10 years asconventional supermarkets decline. Formany food operators, this shift is driving arapid rise in the complexity of theirlogistics operations as demand grows formixed cases and little-and-often deliveriesto a wider range of locations. With this in mind, having a supply ofboxes that are pre-marked withinformation about their contents anddestination helps minimise the chance ofhuman error as products reach the end ofthe packaging line. Rotech directorRichard Pether explains: “Pre-labelledboxes tell operators what they need to do.If the box is already labelled ‘prawnsandwiches’ they know they should befilling it with prawn sandwiches, not ham.Each box can also be marked up with itsdestination or whatever code it needs toensure products end up in the right place.“Rotech’s existing RF range is alreadywell established for offline markingoperations in primary packaging. The newRF-Box Feeder is in response to a surge indemand we’ve recently received fromsecondary packers looking to adopt aflexible and cost-effective off-lineapproach.”Offline coding speeds boost overalloperations by removing the need for amarking step within the packing lineitself. This can be an important advantagein high-speed production environments,especially when handling perishableproducts with short use-by dates, such aschilled foods. Marking boxes while flat also offers theadded advantage of enabling users toapply codes and labels that will cover twosides of the box once erect. This would bemuch more complicated and expensive toachieve once the box is assembled.Although the cost saving itself varies witheach application, the system itself willalways be much simpler. Many of today’s food manufacturingSonoco offer clear alternative totraditional metal cans Sonoco has introduced its new TruVue™ Can asan alternative to the traditional metal can that hasbeen a mainstay packaging option for more than200 years. The clear, retortable plastic can has the potentialto revolutionize not just the canned food aisle insupermarkets, but an entire food category that hasnot seen significant innovation in decades and ischallenged to meet the demands of a newgeneration of shoppers.The TruVue can, made with Sonoco’s patentedFUSION Freshlock Technology™, is made of ahighly engineered, multilayer plastic substrate thatallows consumers to see the product inside. Itincorporates the easy-open metal lid and metalbottom that consumers prefer on a traditionalmetal can. Most importantly, TruVue is the firstclear plastic can to withstand the rigors ofcontinuous retort systems without overpressure,performing in high-temperature and high-pressureenvironments. In addition, the unique construction of the TruVue can provides a more uniform heatingexperience, a quicker retort cycle and greater strength performance throughout the supplychain, compared to competitive formats. The package is non-BPA (BPA-NIA) for food contact.PHOTO: ROTECH20-25_Layout 1 17/12/2015 12:40 Page 3Food & Drink International 23www.fdiforum.netEND OF LINE PACKAGINGfacilities face an ever-expanding variety of products passingthrough multiple packing lines. In these situations, pre-markingboxes enables users to install only as many marking systems asthey need to meet their capacity requirements, rather thanhaving to install a separate system at the end of each line. Forexample, one early adopter of the RF-Box Feeder uses just twosystems to mark up the boxes for 3.5 million packs ofsandwiches each week.The RF-Box Feeder takes flat boxes from the bottom of ahorizontal stack and feeds them through the user’s chosenmarking system, stacking them again neatly on the other side.Two conveyors working at slightly different belt speeds optimisethe gap between each box, so a photocell can trigger themarking system as each item approaches. This enables the RF-Box Feeder to achieve the optimum throughput in terms ofboxes per minute at the lowest possible belt speed.United Caps open newstate-of-the-art manufacturingfacility in Germany United Caps has unveiled and officially inaugurated its newmanufacturing facility in Schwerin, northern Germany. The new plantputs the company in an ideal position to fulfil its aim of becoming theindustry reference for plastic caps and closures for customers globally.The facility is currently equipped to produce closures for thebeverages sector. It will allow the manufacturer to capture business inthe German beverage industry. Expanding its customer base in thebeverages sector is a key part of its overall strategy. The new 10,000 m2Schwerin plant features two production halls,each of which can produce up to 2.5 billion closures each year. In onehall, caps of standard dimensions such as 28 mm and 38 mm for stilland carbonised waters, as well as juices, are produced. In the other,two- and three-piece closures are made in different standarddimensions. These closures are used for milk and juice cartons. Theconstruction of two further halls is planned for the future. The new plant is the result of the manufacturer’s acquisition ofSchoeller Cap Systems (SCS) in Schwerin in 2013.24 Á20-25_Layout 1 17/12/2015 12:40 Page 424 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGFLEXI LINE: NETWORKING MODULAR MACHINES - A SMARTER WAY TO GO ONLINEMerging several tasks into one process, together with man and machine interactions mean higher requirements for your safety network. The Flexi Line extension concept networks up to 32 Flexi Soft modular system safety controllers, improving the exchange of information, and HQVXULQJHIÀFLHQWFRPPXQLFDWLRQZLWKRXWDGGUHVVLQJWKHVWDWLRQV6,&.LV\RXUVLQJOHVRXUFHfor machinery safety that will maximise your productivity. We think that’s intelligent. www.sick.co.ukRotech is a handling specialist with expert knowledge of therange of third-party marking systems available in today’s market.This means that the company is not tied to using its own markingtechnology and can help users choose the optimum system foreach application, whether that’s an inkjet printer to code directlyonto the box or a label printing and dispensing system, forexample. Rotech’s handling expertise also means that the RF-BoxFeeder is optimised to provide a compact, ergonomic solution.“The handling aspect of packaging systems is too often puttogether on an ad hoc basis and performs in a way that is notoptimal. Our RF-Box Feeder is reliable, simple-to-operate andextremely cost-effective,” says Mr Pether. It might be somewhat predictable to list the benefits andimportance of automating the packaging line, and in many waysin should go without saying. However, new developments, bothfrom the industry itself to those from consumers andGovernment, mean that there are no certainties. As the need forgreater efficiency, transparency and more sustainable packingsolutions arise, the introduction of new, intuitive and reliablesolutions can be relied upon to constantly improve end of linepackaging. PHOTO: SHUTTERSTOCK.COM/BALONCICI20-25_Layout 1 17/12/2015 12:40 Page 5Food & Drink International 25www.fdiforum.netEND OF LINE PACKAGINGPiab solves aflavoursomeproblemWith an eye on increasing their client base, TasteTech, the Bristol based food flavouring specialist,needed to streamline their production lines andincrease production at short notice.Taste Techmanufactures a widevariety of flake, granularand powdered flavourings.Their existing systemwasn’t capable of providingthe necessary flexibility. Soafter extensive researchwhere both pneumatic andmechanical systems from arange of manufacturerswere looked at, Taste Techchose Piab to provide thenew system. A large piFLOW p33vacuum conveyor fittedwith a P60L pump hastaken the place of the oldconveyor. The piFLOWtransfers product fromFIBCs at a rate of around2 tonnes per hour. A second, smaller C21 range vacuum conveyorfitted with a M200 pump transfers dry mixed product into sacks forweighing and palletising for dispatch to customers. And finally, athird vacuum conveyor has been installed in a differentproduction room for transferring dried product from a cone dryerfor small batch transfers. All of the conveyors are compressed airpowered and have integral pneumatic controls to allow simple on /off control. As a direct result, Taste Tech has been able to increaseproductivity - a ten tonne order can now be completed in a singlerather than multiple shifts and as the Piab system is simple tomaintain and clean, product changes take a fraction of the timethat was previously necessary. For more information, visit www.piab.com orcall 01509 857010, alternatively you canemail UK-info@piab.com. Automated packing lines helpsScottish producer boost salesTwo speciallyconstructed Endolinehigh speed packinglines has helpedleading Scottishhaggis producerMacsween meet itsobjective inautomating theproduction of a newhaggis brand to meetretail demand, andassisted inincreasing output by 200%.While in demand all year round in Scotland, the requirement for theirvariety of haggis recipes was seasonally limited from the rest of theUK. Following market research and focus groups, Macsweendeveloped the ‘Delicious Everyday’ range to offer a variety of haggisbased products to appeal to non-Scottish customers. The company contacted Murray Packaging, Endoline’s Scottishdistributor, to install two packing lines. Both lines needed to beinstalled within the original factory and space was tight so MurrayPackaging and Endoline designed a ‘cruciform’ system with threeconveyors running in parallel. While managing the design and installation of Endoline kit, MurrayPackaging also ensured the smooth integration of other suppliersystems, including compressed air supply and labelling, into the lines.20-25_Layout 1 17/12/2015 12:40 Page 626 Food & Drink Internationalwww.fdiforum.netHEALTH, SAFETY & HYGIENEThis month we examine the latest legislation affectingcompanies in the sector and look at the progresses made in riskassessment which is helping manufacturers to identify andreview potential flashpoints, reducing the amount of accidentson their premises in the process.Today, there are a bewildering number of laws concerningbest practice in the workplace, but fulfilling basic health andsafety requirements needn’t be complicated if businesses makesure they keep abreast of important changes. In the UK, thelong-standing Health and Safety at Work Act 1974 has beensubject to a series of amendments over the past two decades,many of which concern questions of employer liability in casesof injury, or where the safety of pregnant or disabled workers iscompromised. Legislation such as the Dangerous Substancesand Explosive Atmospheres Regulations 2002 continues toshape the way food manufacturers run their plants, such is thecombustibility of food dusts such as flour and custard powder.Meanwhile, the Framework EU Health and Safety Directive(based on Article 137 of the EU Treaty) still has the power toshape national legislation in Europe and regularly passes downnew ideas.The Food Safety and Hygiene regulations of 2014 could alsobring about changes in the food manufacturing sector. The newrules are particularly stringent in regard to the pasteurisationand processing of milk (which, if not heat-treated may contain“organisms harmful to health”) and the labelling anddistribution of food products – all things of obvious concern tofood producers.So, what can businesses do to comply with the legislation?Risk assessment is one option, and we have certainly seen anupsurge in risk assessment activity in recent years. According tothe UK Health and Safety Executive, the most common causesof workplace injuries in the food and drink sector are manualhandling, slips on wet or contaminated floors, falls from height,29 ÁA recipefor safetyHealth and safety has never been a more pressing issue forbusinesses in the food industry. We live in increasinglylitigious times, and companies who fail to live up to theirresponsibilities could find themselves dealing withgargantuan fines, judicial proceedings, and, perhaps worst ofall, a sullied reputation. problems with workplace transport, being struck by somethingsharp or heavy, and accidents concerning food processing andpackaging machinery. Falls from height and accidents withmachinery are listed as the main causes of fatal injury.Therefore, implementing a carefully planned risk assessmentprogramme – ideally on a regular basis – is an absolute mustfor conscientious companies.But what should a risk assessment address? To prevent thekinds of incidents listed here, it is imperative that businessesidentify potential flashpoints before they occur. This is easilydone when a company has access to accredited expertise, and itis most likely to entail a detailed inspection and appraisal ofevery process, machine and operative used in production. It isvital that mechanical faults are identified and attended to andthat poor employee practice is eliminated. To be doubly sure that nobody gets hurt, all workflows needto be standardised on the factory floor. This will help toprevent operatives from coming across potentially hazardousmachinery or substances unexpectedly (for instance, if areashandling liquids are clearly demarcated and occupied by the26-30_Layout 1 17/12/2015 14:48 Page 1www.etiltd.comdigital thermometerSuperFast Thermapen®‘Our NEW Thermapen® 4 features a 360° self-rotating display, auto intelligent backlight, motion-sensingsleep mode & waterproof casing to IP66/67’ NEWMODELFood & Drink International 27www.fdiforum.netHEALTH, SAFETY & HYGIENEPHOTO: SHUTTERSTOCK.COM/BORIS1526-30_Layout 1 17/12/2015 14:48 Page 228 Food & Drink Internationalwww.fdiforum.net• Four actuation directions and multiple mounting configurations • Fast reaction time 150ms enables shorter safety distances • Type 4 device in accordance with EN ISO 14119 • Series connection possible without fault masking (as per ISO/TR 24119• Unique high level of coding, reducing chances of defeat of guarding• Anti-tamper screws are available • Intuitive LED messages enable rapid diagnostics and troubleshooting • Probability of failure is extremely low - high number of operations without exchanging the device during the machine’s service life• Performance Level e, Safety Intergrity Level 3 Simplify Machine Design & Economise Simplify Machine Design & Economise Simplify Machine Design & Economise Simplify Machine Design & Economise•Four actuation dir configurations •eaction time 150ms enables shorter safety Fast r distances • ype 4 devicTT• Series connection possible without fault masking (as per ISO/TR 24119• Unique high level of coding, r defeat of guar Simplify Machine Design & Economiseections and multiple mounting Four actuation dir configurations eaction time 150ms enables shorter safety dance with EN ISO 14119 ype 4 device in accorSeries connection possible without fault masking (as per ISO/TR 24119educing chances of Unique high level of coding, rding defeat of guar Simplify Machine Design & Economiseections and multiple mounting eaction time 150ms enables shorter safety dance with EN ISO 14119 Series connection possible without fault masking educing chances of defeat of guar• Anti-tamper scrHigh Machine AMaintenance•Intuitive LED messages enable rapid diagnostics oubleshooting and tr•obability of failurPr number of operations without exchanging the device during the machine’•Performance Level e, Safety Inter ding defeat of guare availableews arAnti-tamper scrvailability, Safety & SimpleHigh Machine AMaintenanceIntuitive LED messages enable rapid diagnostics oubleshooting emely low - high e is extrobability of failur number of operations without exchanging the s service life device during the machine’grity Level 3Performance Level e, Safety Inter vailability, Safety & SimpleIntuitive LED messages enable rapid diagnostics emely low - high number of operations without exchanging the grity Level 3 The coded safety switch PSENcode is used for safety gatwith EN ISO 14119 and EN ISO 13849 uptections and opermultiple actuation direchnology Corby NN1ilz AutP oring in accore monitThe coded safety switch PSENcode is used for safety gato use thanks txible te, and is fleo PLwith EN ISO 14119 and EN ISO 13849 uptating distances.ections and oper.pilz.co.ukwwJ 01536 460766 sales@pilz.co.uk w 8TT •Performance Level e, Safety Interdance oring in accoro o use thanks t.pilz.co.uk Scan the QR code eo find out mortgrity Level 3Performance Level e, Safety Inter grity Level 326-30_Layout 1 17/12/2015 14:48 Page 3Food & Drink International 29www.fdiforum.netHEALTH, SAFETY & HYGIENECleanZone TechnologyDON’T LET CONTAMINATION DAMAGE YOUR REPUTATION Cleanrooms and Healthcare environments are popular areas for the installation of Dycem due to its high efficiency; but increasingly Dycem is becoming a key product in a variety of controlled areas such as Food & Beverage Processing and Packaging Plants. With high profile cases of cross contamination and costly product recalls, can you afford to ignore the risks? All Dycem products incorporate BiomasterTM protection.This highly effective anti-microbial has been proven to inhibit the growth of organisms including Salmonella, E.coli, Listeria, Campylobacter, Pseudomonas, A.Niger (black spot mould growth), Algae and MRSA.www.dycem-cc.com/where-to-use-dycem#reducetheriskDycem Ltd EuropeAshley Trading Estate, Bristol, BS2 9BB UKt: + 44 (0) 117 9559921 f: + 44 (0) 117 9541194e: contact@dycem.comCELEBRATING 50YEARSsame staff performing the same tasks day in day out, itfollows that there is less chance that somebody will slip, ashabit breeds familiarity.) Of course, there is also a raft of health and safetylegislation concerning food safety. Here, too, risk assessmentcan play a vital role. The hazard analysis and critical controlpoint system (HACCP) promoted by the World HealthOrganization is widely used by businesses in the sector,although the UK Department for Business, Innovation andSkills has noted that the system, which often entailsemploying outside expertise to carry out the assessment, isseen by some smaller businesses as “burdensome andbureaucratic.” Indeed, there are less onerous practices companies big orsmall can adopt to ensure they comply with food hygiene andsafety legislation. Quality assurance measures and riskassessment programmes can be conducted without outsidehelp if businesses are fully aware of their responsibilities andthe finer details of their operations. As far as risk assessmentis concerned, proper planning constitutes half the battle.Simple measures such as ensuring that preparation surfacesare cleaned fastidiously, refrigerator maintenance and stafftraining in matters of health and hygiene can help food anddrinks manufacturers to avoid the ignominy of productrecalls, consumer complaints and worse. There is no doubt that health and safety legislation willbecome stricter and more complex in future. This should notbe a cause for concern for producers. Food and drinksmanufacturers that keep up to date with the latest legislativechanges may well find that best practice pays dividends in thelong-run.PHOTO: SHUTTERSTOCK.COM/BDSTUDIO26-30_Layout 1 17/12/2015 14:48 Page 4Next >