< Previous20www.fdiforum.netINSTRUMENTATION SHOWCASENew multi-channel controller has larger display and more optionsInstrumentation specialist Impress Sensors & Systems has launched a new compact, multi-channel controller with alarge touchscreen colour TFT display and up to 72 digital inputs/outputs. The controller is therefore ideal for thesimultaneous measurement and control of a wide variety of process engineering applications.The new CMC-141 controller is the ‘big brother’ of the CMC-99, providing all the same functionality and features, butwith brand new channels, including a universal input card that can accommodate a range of sensor inputs. New counterinputs are provided too, as well as additional flow meter and rate meter inputs. Despite these extra features, the CMC-141 is still housed in a compact enclosure with the same panel insertion depth (100mm) as the CMC-99.Sam Drury, Sales & Marketing Director at Impress Sensors & Systems, says,“Another added value feature of the CMC-141 is that it comes with JAVA applets,which can be embedded into any website or HTML-based web page, allowingusers to remotely access real time data from the controller via the Ethernetinterface and a web browser.”Tel: 0118 981 7980 www.impress-sensors.co.ukFlowmetering solutions from FlowtechnikFlowtechnik, a division of Hydrotechnik, specialises in selling flow, pressure,level, temperature and analytical instruments for process industries. They offer adiverse range of flowmetering solutions, offering hygienic axial turbines, ovalgear and magnetic inductive flowmeters, including a specialised system for linearand rotary filling machines where almost any liquid food or ingredient can bemeasured.Flowtechnik’s axial turbines are used for simple measurement or totalising of low viscosity liquids like milk. Sizes vary from 3/4” to 2.1/2” with Tri-Clampconnections. The oval gear flowmeters are for more sophisticated applications where accuracy of +/-0.1% of reading and work on non-conductive and low tohigh viscosity liquids making them a cost effective alternative to coriolis flowmeters. Flowtechnik’s magnetic inductive flowmeters offer flow measurement without any moving parts, are simple to install, clean and use with hygienic versionsfrom 1/2” to 2” or specialised versions specifically designed to dose liquids with an incredibly fast response time. Dosing quantities as low as 1ml and completecycles within 0.1 second are possible with this unique product.Tel: 0115 900 3550 Email: sales@flowtechnik.co.uk www.hydrotechnik.co.uk20:Layout 1 27/1/12 09:47 Page 1REFRIGERATION www.fdiforum.net21Low temperaturesat low costThe lengthening of supply chains and the increasedinterest in energy efficiency has led to many companiesreviewing their refrigeration options and looking for morecost-effective ways to meet their needs. Yet in retail andcatering environments, there is still the requirement forconvenience and style to be considered.Energy efficiency is certainly a major factor for many inthe industry, and those who attend the ACR Show thismonth will witness a sector undergoing a host of changes.Air conditioning and refrigeration equipment for exampleaccounts for around 20% of the total energy consumptionin the UK, and at a time when businesses are beingrequired to review their energy usage, these are likely tomake the biggest contribution. Running costs can also bequite significantly cut with a reduction in the amount ofenergy being used. Heat recovery for hot tap water,intuitive control systems and operator web interfaces, anduse of EC fans and inverter driven compressors have allhelped make a difference in the new refrigeration solutions.Across Europe, The Energy Related ProductsFramework Directive has helped the sectordevelop MEPS that will improve theenvironmental performance of all refrigerationand freezing equipment in the EU. Mostcommercial refrigeration systems currently sold inEurope operate above the energy consumptionminimum standard required with the newdirectives clearly having an effect.With this in mind, CESA is currentlyconducting industry-wide research into attitudestowards energy saving and plans to unveil the firstfindings at the forthcoming Hotelympia show.Called ‘Mind the Gap’, the project focuses on thedifferences in approach to sustainability betweenmanufacturers, distributors and consultants.CESA’s Mick Shaddock says, “CESA is workingwith European legislators to develop the measuresthat will be implemented under the Energy UsingProducts Directive. The research project is a realIncreased concerns on energy efficiency has led to major changes in therefrigeration sectorPrecision are among thosecompanies providing robust,dependable, quality refrigerationfor commercial cateringenvironments22 21-23:Layout 1 26/1/12 15:51 Page 122www.fdiforum.netREFRIGERATION opportunity for the supply chain toidentify its performance and benchmarkactivity in terms of energy saving andsustainability. The research will not onlybenefit companies, it could have a directbearing on future legislation andregulations.”In the UK, the British RefrigerationAssociation and Institute of Refrigerationhave worked together to support a code ofconduct regarding carbon reduction in theretail refrigeration sector. Retailrefrigeration systems are a significantcontributor to UK carbon emissions,producing around 7.3 million tonnes ofCO2 equivalent per year – about 4% ofthe annual total. The new code of conduct has beencompiled by the industry in an attempt toreduce CO2 emissions in the sector byaround 20% over the next five years. Thiswill not only save costs, but also assist thesector in adhering to regulatoryrequirements. The code has already beenincorporated into the BREEAM buildingassessment methods for 2011 and, withretailers constantly updating theirrefrigeration plant – around 25% of sitesare planning to buy new plant at any onetime – it’s highly likely to make a majordifference very quickly.Illustrating the importance ofmaintaining the very highest standards inthe industry, the British RefrigerationAssociation have also commissioned afurther code of practice on the design andmanufacture of refrigerated cabinetsrunning on hydrocarbon refrigerants. Thecode will clarify the regulations, standardsand practices which apply to the leaksimulation testing and subsequent designof these systems, and provide the basis fora consistent approach to be adopted by allmanufacturers, end users and specifierswhen using these refrigerants.The rate of change in the industry isusually led by the compressormanufacturers, and they are increasinglymaking use of new refrigerants and newtechnologies. For example, Husky havelaunched their Intelligenzia range which,it’s said, could reduce energy consumptionby as much as 40%. Chief executive GeoffThomasson says, “At its core is anadvanced system which balances theperformance of up to six super-efficientfans with the energy needs of theevaporator and compressor.” The units can identify when doors areopened and recognise when usage is low,at which time they switch to economy‘night mode’, permitting temperatures torise slightly and shutting down fans andlights. When the doors are opened – or ata predetermined time - the system kicksback in to full operation.In addition, the system generatessignificantly less in-situ heat, and usesenvironmentally safe R290 refrigerant,improved insulation and silvered glasswhich is the equivalent of triple glazing.The units are also illuminated with LEDlighting which saves energy and lasts for100,000 hours. Meanwhile, Precision’s latest blast chilleruses microprocessor-controlled, variablespeed fans to ensure that blast chilling orfreezing is fast, efficient and consistentthroughout the cabinet. The chiller canchill or freeze up to 35kg of food, withingovernment guidelines, using only astandard 13 Amp supply – not usuallypossible with a conventional chiller.Examples such as this illustrate the majoradvances that are taking place in the sector.Ever-lengthening supply chains also bringwith them new challenges for refrigeration.Businesses must ensure absolute productintegrity at every point from the factory tothe shop shelves, and so effectivetemperature monitoring and data logging isessential. Companies such as Rotronic havea host of product lines available formeasuring humidity and temperature, aswell as advanced wireless data loggers.One of Rotronic’s major success storiesin recent years has been the HygroClip2with integrated AirChip3000, whichemphasises precision, applicability andreliability. The AirChip3000, which can beused in everything from simple measurersto sophisticated laboratory instruments anddata loggers, compensates temperature andhumidity over 30,000 reference points andhas a 2000 data point memory. By decoupling the Pt100 temperaturesensor from the probe, thermal response issignificantly improved, and the UARTinterface and user scalable analogue outputsallow the probe to be used as a standalonedevice that can also be integrated into anOEM application. The probes can beinterchanged without adjustment.The huge advantage for users is that aswell as its datalogging and calibrationhistory providing information about thecurrent state of the product, its self-diagnostics can also help make predictionson what will happen next, and it can evenprovide dew point values.As well as ensuring the machines andtesting equipment is of the higheststandards, the refrigeration sector can nowalso benefit from exceptional trainingprogrammes which means those working inthe sector can be even better informed.Indeed since last year, all personnelNorthern Irish retailer Supermacs was looking forenergy efficiencies in their refrigeration and acquiredTrue single and double door upright cabinets. Thesesystems are larger than the industry standard so theypull down and recover temperature quickly, resulting inshorter run-times 21-23:Layout 1 26/1/12 15:52 Page 2REFRIGERATION www.fdiforum.net23handling F-Gases have had to be suitablyqualified, with all businesses holding acompany certificate.In recent years elearning-training.com,the online training platform by StarLearning Solutions, the training division ofStar Refrigeration, have been offeringCO2 Refrigeration training for retailoperators Marks & Spencer and Tescousing a method involving theoryunderpinning knowledge online and oneday practical assessment or training. Thismeans that when candidates arrive to thecentre for practical training, they havealready mastered the basics.Recently introduced by the organisationis a new pressure testing training courseincluding strength test and tightness test,which is completed in the same format.The practical training involves the safe useof equipment, compliance to all methodstatements and risk assessments whilecarrying out strength and tightness testingand correct completion of all necessarypaperwork, and knowledge of leak repairprocedures on a system while carrying outa strength and tightness test.The refrigeration sector will play a majorrole as the industry looks to reduce energyconsumption – and improved equipmentand training schemes ensure it can make areal difference.Companies such as Cold Service Distribution provide refrigerationcontractors and food retailers with access to a range of high qualitydisplay cabinets, counters and equipment21-23:Layout 1 26/1/12 15:52 Page 324www.fdiforum.netPACKAGING MATERIALS AND DESIGNWhen it comes to packaging, it seemsto be the case that if the customer noticesthe packaging, it hasn’t worked. We allknow consumers are quick to noticepackaging that seems particularlyexcessive, especially at a time whensustainability is a top priority for many.And, overly complicated andinconvenient packaging is just as likely toraise the hackles as well. The most successful packaging designin recent years has been that whichenhances its products – consumers won’tnotice the work that has gone into itbecause it works and seems highly logicaland intuitive.The challenge for the packagingindustry then is to produce eye-catching,user-friendly packaging that still offersproduct integrity and is simple and cost-effective to produce. Meanwhile, the big Packaging Debateis all about sustainable packaging. Amongthe arguments is that introducingadditional sustainability to the packagingprocess can have unwelcome side-effects.For example, lightweighting rigid plasticcontainers reduces polymer consumptionbut some businesses are finding that thisalso requires increased secondarypackaging to provide adequate protectionin transit. The Debate is an interestingone, and is scheduled to be aired ateasyFairs Packaging in February. It willdiscuss the challenges meeting thepackaging sector in the context of a supplychain geared to meet the requirements ofa just in time retail culture.What is the case is that many leadingpackaging companies have been able toprovide demonstrable benefits forcustomers and consumers alike. DSSmith Speciality Packaging, Belper, forexample, has recently designed new retailready packaging for the Seven Seas rangeof Liquid Pure Cod Liver Oil.The different bottles had beenpreviously packed in a variety of B-fluteopen fronted trays with shrink-wrap, butthese have been replaced with a singlematerial. Using PackRight, DS SmithPackaging was able to specify anotherspace saving material with an ideal printsurface, Cartonflute, to optimiseperformance. ImageRight enabled anexact match of brand colours, so primaryand secondary packaging work together.Supply chain efficiency has thereforebeen improved while reducing carbon.DS Smith have now become Europe’sbiggest corrugated business afterpurchasing SCA’s packaging business –testament to their successful approach.IntelligentdesignThe latest packaging combine energy efficiency withuser-friendly designAPI Holographics has further enhancedits already impressive portfolio ofsecurity solutions with the upgrading ofits selective release label base24-26:Layout 1 27/1/12 09:50 Page 1PACKAGING MATERIALS AND DESIGNwww.fdiforum.net25The increased interest in sustainabilityhas also led metal packaging productssupplier Crown Holdings to produce areport into the area. Advances in areassuch as lightweighting have made animpact, while a major contribution hascome from Crown’s patented SuperEndbeverage ends which reduce metal use by10%. The report states that, to date, over300 billion SuperEnd beverage ends havebeen produced, saving an estimated73,500 metric tons of aluminium, 1200metric tons of coatings, and 600,000metric tons of greenhouse gases.The SuperEnd saves in raw materialswhile still being user-friendly with itsbetter pouring capabilities. The same isalso true of Crown Closures Europe’sORBIT Closure, which has made itsdebut on jars of Duerr’s range of jamsand marmalades. The ORBIT Closureconsists of two parts – a central, floatingpanel that is vacuum sealed to the jar andan outer ring that acts as the openingand re-closing device. Its designsignificantly reduces the torque requiredto remove the closure, making it twice aseasy to open as compared to standardtwist-off closures. Glass jars have oftenbeen considered hard to open so this newclosure will make an obvious difference26 The plasticpackaging specialistGIZEH can nowmanufacturemulticolour PETbottles onconventional stretchblow mouldingmachines24-26:Layout 1 27/1/12 09:51 Page 224www.fdiforum.netPACKAGING MATERIALS AND DESIGNto many consumers.Equally valuable in terms of customerconvenience and efficiency is a newpackaging idea from SeufertTransparente Verpackungen. They havedeveloped a gift pack for drinks which ismanufactured from sustainable PET-Rwith up to 80% reclaimed plastic foilfrom industrial and consumer waste. Thetranslucent packaging allows sufficientroom for high quality decoration throughprinting, hot foil stamping or embossing,and as no glue is involved in itsconstruction it makes it particularly easyfor consumers to reuse and recycle, whilethe stable handle and robust materialensures security throughout.Portola Packaging Europe have alsoconsidered consumer requirements whendesigning their latest products –emphasising safety and convenience.Their NXT 1881 cap has been designedspecifically for use on water and juicebottles, and the Optimized Thread andTE band offers high speed application,while the TE breaks before the sealreleases during opening. The opening’sperformance exceeds the current BSDAcode of practice for sports closures whichmakes specific requirements on hygieneand consumer safety.Consumer safety and security is alsobehind other innovations in packagingtechnology. The EU has recently beenharmonising its legislation on food contactmaterials, including packaging materials,to ensure food safety. At the recentInternational Fresenius Conference inCologne, delegates discussed how thelargest potential for foodstuffcontamination with mineral oils comesfrom conventional offset inks forpackaging printing. To address this,mineral oil-free or migration optimisedpackaging inks have been developed.Considerable advances have been made inthis regard – in 2009, printed carbonboardpackaging could reach up to 3800ppm MOSH, the concentration of MineralOil Saturated Hydrocarbons, but nowfood packaging made from recycledcartonboard can be produced with just150ppm MOSH.There is still the issue of cross-contamination from the outer packaging,however, hence the requirement in somecases for a barrier. At the conference inCologne, Austrian company Mayr-Melnhof showcased their Foodboard – anew recycled fibre based cartonboardwith an online barrier coating.Security has also been paramount asAPI Holographics recently upgraded itsselective release label base which allowsfood and drink brands to incorporateboth tamper evident and holographicsecurity features into self-adhesivesecurity labels in order to protectproducts from tampering. When a labelmade with the material is interfered with,a pattern is revealed, making detectioneasy and re-use impossible. This can nowbe used with a comprehensive range ofadhesives and is also suitable for overprinting and sequential numbering.Certainly products need to stand outon the shelves and the move towardssustainability and security needn’t lead toless imaginative design. Breakthroughscontinue to be made, such as that byplastic packaging specialist GIZEH whichhas succeeded in manufacturingmulticolour PET bottles on conventionalstretch blow moulding machines. Thismeans blown PET bottles can beproduced with completely new opticaland tactile effects.The new PET bottles are based onmulti-component blanks developed byInotech Kunststoff GmbH. Previouslythese special preforms could only beprocessed on stretch blow mouldingmachines with microwave heating. Now aconventional two-stage stretch blowmoulding plant has been modified withinfrared heating, ensuring GIZEH is ableto perform series manufacturing ofmulticolour PET bottles on aconventional system.Those who attend the easyFairspackaging events will see a sector that’stotally dedicated to innovation, able tobalance aesthetic desires withrequirements by customers andconsumers for a more sustainableapproach. New technology coupled withinspired design is creating a host ofeffective, efficient packaging.42 leading foodservice companies fromEurope, the Middle East and Asiaattended a summit on food packaginginnovations at Cryovac’s Packforum24-26:Layout 1 27/1/12 09:51 Page 3COLOURINGwww.fdiforum.net27There is a well-worn statistic that says alasting colour impression is made within ninetyseconds and accounts for a large proportion,almost 60% of the acceptance or rejecting of anobject. This can either kill or bless food anddrink products. Often a consumer will associatecertain colours with certain feelings and nomatter how much you subscribe to thepsychological side, you have to admit anappealing appearance is the reason manypeople will select a product and the overallcolour, shade and hue can affect thissubstantially. In food and drink circles, firstimpressions count, as the old adage goes ‘thefirst bite is with the eye’. This not only countsin the foodservice sector, but also on thesupermarket shelf. An aesthetically-displeasingproduct will push your target markets towardscompetitors who have taken the time toresearch and invest in some thought towardscolour choice. Thankfully there are companies that existwho take the science of colour and colouringsseriously and can guide you towards safe, eye-catching colours that can transform products’profiles into market leaders. Although manyconsumers are still wary years on after cancerscares to do with artificial colourings in the1970s, the majority of colourings used thesedays are made from vegetable colourants. Thatsaid, colours produced synthetically are subjectto stringent health and safety checks, sopreviously dangerous, or negatively-perceivedA splash of colourCaramel Colour is oneof the most consumedcolourings in the world28 Food colouring has longbeen an important andhighly scientific element offood production. It candetermine your marketing,reputation and success, soinvesting in your product’shue is vital.27-29:Layout 1 27/1/12 09:13 Page 128www.fdiforum.netCOLOURINGproducts are no longer used.The current trend for organic or natural ingredients meansthat using plant materials such as beets, turmeric root, annattoseeds, purple carrots and cabbage, gardenia flowers, hibiscusflowers and grape skin can all be utilised to provide a wide-Salmon is often coloured toimprove its look and to deflectfrom natural variations that couldturn consumers away from aperfectly-good productranging palette of colours. From soft, natural-looking hues tobright, captivating and brand-defining colours the choice really isup to the manufacturer. The health benefits from these elementsmay not be immediately obvious, being as they aresupplementary ingredients to colour foodstuffs or drink, butmany of these elements contain antioxidants which can helprebuild the body’s cells and help with the anti-aging process.As well as brand identity, colouring foods can make fooduniform, many consumers are actually unaware, but seeminglynatural foods such as salmon or oranges are sometimes colouredto mask the natural variations that exist. Help is at handWhen choosing a product’s colour, it could be hard to knowwhere to turn. Companies specialising in colouring can adviseand guide you through the process, meaning you are notstumbling into a complex area blind. Sensient Food Colors, forexample, a North American firm who are a recognised leader insuch matters, bring together all the strands that make up pickingthe right colour. This means looking into colour preference forthe manufacturer, researching consumer insight and initialisingproduct development. The company has several distinct rangesand is currently pushing its very own range of all-naturalcolours, dubbed Cardea, which can be formulated in any rangeof colours and made to be oil or water-soluble, meaning it canbe applied to almost any foodstuff at almost any stage ofproduction. Their fusion range is also natural and has an almostinfinite palette of colours to choose from. It can also beproduced in sugar free, inverted sugar or glycerine-basedversions, also making it easier for manufacturers to get theirperfect colour.In a similar way, D. D. Williamson, who are the world leadersin caramel colouring can work with clients to create custom andintegral elements that deliver the desired results. The caramelcolouring is primarily used to colour products such as cola, butis used across the board, from bakery products to cooked meats,fish and even pet food. Recently declared as ‘Safe andHarmless’, meaning it is ‘neither genotoxic nor carcogenic’ by27-29:Layout 1 27/1/12 09:13 Page 2COLOURINGwww.fdiforum.net29Only with naturalingredientsThe CardeaTMrange providesclean labelling and offers aunique natural positioning to ourcustomers. As a special feature,the colouring principles areformulated either as water or oilsoluble, permitting maximumflexibility in food systems. The technology behind thisproject unlocks nature’s fullpotential by utilising interactionsbetween ingredients. “After screening a wide choiceof ingredients, we were able todefine interactive naturalmodules that build onfunctionality. This technologyallows us to formulate emulsionsand other colourings composedexclusively of naturalcomponents”, says Dr. AndreasKlingenberg, Director ofResearch and Development,Sensient Food Colors Europe.CardeaTMis ideal for premiumproducts where bright yellow,orange, red or green shades areneeded. CardeaTMcontains onlyfruit and vegetable concentratesand extracts such as paprika,lemon, acerola, red beet, apple,carrot and spinach.“Nature is a genius inproviding protection of valuableingredients and we haveadopted this principle for ourcolouring portfolio“, says Dr.Klingenberg. Sensient Food Colors Germany GmbH Geesthachter Straße 10321502 Geesthacht, GermanyTel: +49 4152 8000-0 Fax: +49 4152 5479Email: Sfc-eu@sensient.comwww.sensient-fce.comSensient Food Colors has launched CardeaTManew range of colouring solutions for foodapplications. Because of the unique composition ofCardeaTM, this is the first time that the totalformulation can be claimed as natural.the European Food Safety Authority, Caramel Colour is still theworld’s most-consumed food colouring ingredient andunderlines the fact we consume these elements of food withoutoften knowing it. D. D. Williamson are also innovators, having come up with asolution to colour-fade of products. The intensity of powderedannatto extract, a derivative from Achiote trees that produces ayellow and orange hue, would often fade after being oxidised inthe drying process. This led to food products fading quickly andappearing dull and lifeless on supermarket shelves, in turndiscouraging purchase from consumers. D. D. Williamsondeveloped an annatto drying process which meant minimisationof oxidisation and dramatically reducing the risk of fade. Thishas increased their clients’ products’ stability in themarketplace.Utilising colours for new productsThe production of new products means colouring plays a partin helping functional or novel ingredients to take off in a muchmore effective way. Tate and Lyle, for example, have released acocoa-replacement product named Cacao, which allowsmanufacturers to make a saving in production and ingredientcosts. With a familiar cocoa-like flavour and colouring, Carcaocan be used as a partial cocoa replacement in dairy, bakery andice cream applications. Working to unique briefs from a range ofcompanies, a range can be produced. By adjusting temperatureduring production and roasting of carob powder, you can achievecolours from a light brown with a sweet taste, to a dark colourthat has a more bitter, unsweetened taste. The highly customnature of this product is down not only to taste, then, but theability to engineer a colour, while retaining natural elements. This shows the extent to which colouring is important, notonly do they serve a great aesthetic element to products, but alsoa practical, cost-saving element too. Researching what goes intoyour product to make it cost-effective while not affecting taste,nutritional value or safety is worth it. Tate and Lyle have provedthis, even going so far as to engage consumers in taste tests thatprove its worth.D.D Williamson have come up with a method of drying yellow/orangeannatto to prevent food colour fading on the supermarket shelf27-29:Layout 1 27/1/12 09:13 Page 3Next >