< Previous30www.fdiforum.netGEARS, DRIVES AND CONTROLSIntroducing automation into a foodand drink business can lead to muchsoul-searching about how this may affectemployees – as surely increasedefficiencies leads to less reliance onhuman resources. This doesn’t have to bethe case, though as many companies arefinding that increased automation canlead to more effective working and amore engaged workforce.This is certainly the message of thelatest study conducted by Metra Martechon the Positive Impact of IndustrialRobots on Employment, published by theInternational Federation of Robotics, inTokyo, reveals that three million jobshave been directly created in recent yearsby the use of robots and a further millionpositions are estimated to be createdglobally by 2016.The report found that between 2000and 2008, manufacturing employmentincreased in nearly every major nation –even as the use of industrialised roboticsincreased sharply. The most noticeableexample was in Brazil, the number ofrobots almost quadrupled during thestudy period with both production andemployment rising by over 20%.The introduction of automationsolutions, however, does vary across thenation. In Europe, for example, theGerman food and drink industry hasintroduced a huge number of robots tothe extent that it now leads the world,while in the rest of Europe, most notablyin the UK, the number of robots is verysmall. To address this, the UKgovernment is providing, through thePPMA Group, up to £600,000 offunding to promote automation in UKmanufacturing – providing anopportunity for many businesses toconsider what’s on offer.Operations such bag packaging and thefilling of containers on automated fillinglines can certainly benefits from a moreautomatic approach. Those wary of fullautomation too can perhaps benefit fromsemi-automation, implementing a robotworkcell for a specific production process.This strategic move can often eliminate aproduction bottleneck, remove ahazardous manual function and, hence,make a substantial contribution tocutting costs.Of course, the quality of theautomation depends on the gears, drivesand controls that are used in theiroperation – especially in the food anddrink industry where safety and hygieneis a top priority. Indeed there is a furtherchallenge for those looking for new drivesas, from last June, electric motors havebeen required to meet the IE2 standardof energy efficiency. These efficiencyratings are based on a new Europeanstandard with IE2 requiring highefficiency, similar to the old Eff1voluntary standard which has now beendiscontinued. The latest motors availablefor the food and drink industry do reachDrivinginnovationCompetitive advantage will come from a more advancedrange of gears, drives and controls but what effect willthis have on human resources?The Galletas Gullon biscuit factory in Palencia, Spain, hassuccessfully increased its production levels as a direct result ofinstalling Chiorino HP food quality conveyor belts in its factories –a testament to the importance of automation30-31:Layout 1 27/1/12 09:53 Page 1GEARS, DRIVES AND CONTROLSwww.fdiforum.net31AllDrives & Controls, for all your drives and control productswww.alldrivesandcontrols.co.ukTel: +44 (0) 1543 271899 these standards, as well as meeting others,such as those that allow them to be usedin explosive atmospheres.This is, however, just the first part ofthe EuP directive affecting motors, as fromthe beginning of 2015, motors rated from7.5 to 375kW will then be required toreach the IE3 standard – representingpremium efficiency – and that will be thecase for all motors above 0.75kW from2017. There is an alternative, though, ascompanies can still use IE2 motors with avariable speed drive. These drives areparticularly valuable for the food and drinkindustry which, with safety in mind, canoften make use of motors with oversizeddrives. Often these motors are running atpartial loads losing a great deal from therunning efficiency, but this can be dealtwith by introducing frequency invertersthat can match the varied demand.Indeed, businesses that have installedfrequency inverters have reportedsubstantial cost savings on the regularrunning costs. This can be improved stillfurther with the new breed of invertersthat make use of cold plate mounting.These remove the heat sink that is usuallystandard at the back of the drive, toensure the motor runs at a low enoughtemperature to stop it overheating, andinstead make use of a substantial metalmounting surface. This mounting, whichcan be seen on the latest frequencyinverters from Lenze, gives a reduction inthe volume of panel space required ofabout 25%. Running costs can also bereduced by the introduction of moreprotective coverings which can cope withparticularly humid atmospheres and closecontact with chemicals. These newcoverings can now be found on servo andgeared motors.One sector in which automation hasproven particularly successful in recentyears is that of warehousing. AllDrives &Controls, for example, are reportingstrong interest in the control systems,such as those from Unitronics that theysupply, which are based on a modular,distributed approach, using independentcontrol elements for each controlledelement. All elements are networked,commonly by a Ethernet TCP/IP networkand support a broad variety of protocols.This approach provides the benefits ofhigher system availability, as problemsand malfunctions are isolated and theMTTR – mean time to repairmalfunctions – is improved. Equallyvaluable for the warehouse staff is thereduced wiring.The new directives affecting motorshave help to concentrate minds andensure that the gears, drives and controlsnow available to the food and drinkindustry are more cost-effective andreliable than ever before. As automationbecomes ever more commonplace, it willbe speed and flexibility that will begin tooffer that vital competitive advantage.Companies such as Rockwell Automationare making used of IntegratedArchitecture systems, connecting an arrayof drives and controls on a single networkTraditional hard wiring is still thenorm inside most control panels,and the bus-based lean panelwiring system SmartWire-DT fromEaton’s Electrical Sector nowallows all of the devices within,such as motor starters, HMIpanels and even conventionalpushbuttons and indicator lights, tobe connected to the centralcontroller30-31:Layout 1 27/1/12 09:53 Page 232-37:Layout 1 27/1/12 09:17 Page 1SNACK FOODSwww.fdiforum.net33This fact was reflected in a recentreport from Global Industry Analysts,who have estimated the market to reach$334.7 billion by 2015. Improvements tothe aforementioned flavours and tastes ofsnack foods in general, combined withliberalised import policies across Asiameans more potential for mass sales. TheAsia-Pacific region is also of coursedensely populated, offering great roomfor growth. This proves that the marketis wide open at present.The rise of more intense workingweeks and busy lifestyles means peoplegraze and pick at food throughout theirweek. The rise of convenient food andfood on the go is then a logical step thatthe market is taking full advantage of.This was illustrated at September’slunch! show in Old Billingsgate inLondon, where more than four thousandpeople attended to visit around twohundred exhibitors, showcasing onlysnack and on-the-go items, which showsthe emergence of a niche market that isset to grow and grow. On the manufacturing side, machineryand techniques mean production isbecoming easier to effectively administerand companies from around the worldare taking advantage of a somewhatbuoyant market. For the conveniencefoods sector, simple bagging options willoften suffice. Branding and functionalityplay a part in making this a popularoption for manufacturers, and automatedmachinery makes it easy for costs to bemaintained at a profitable level.Machinery experts KliklokInternational’s DCL machine, forexample, a display card loader,automatically attaches bags of this natureafter being filled on other equipment, topoint-of-sale display cards. This not onlylocks in the bags to be held in duringtransit, but also allows for an attractivedisplay for retailers. Kliklok also offeroptions when it comes to filling, frombagmakers to filling systems, but theoptions for this are limitless. Mostcompanies will be able to advise oncustom packaging, but it is important toremember the essentials for the industrythese days, sustainability, safety andfreshness, as well of course as thepackaging being aesthetically pleasing. Combining several processes at once ingeneral is nothing new, but biscuit and34 Vegetable crisps are becomingmore popular, as are differentways of producing themOn the goThe global snack foods market is set to grow even further this year, thanks mainly toinnovations in taste and flavour.32-37:Layout 1 27/1/12 09:17 Page 234www.fdiforum.netSNACK FOODSwafer processing experts Franz Haas have come upwith an innovative machine that can operate insuch a way. Putting extrusion, depositing and wire-cutting together means time is cut significantly andmuch-needed floor space is also saved. Also servingthe baking side of snack food production, Haas hascome up with an intelligent sensor that is containedwithin a ‘baking plate’ which monitors thetemperature and pressure within an oven withSAW (surface acoustic wave). Before, electronicsensors will have simply been burned and destroyedwhen in contact with flames. As this kind of technology improves, we will nodoubt see more integrated solutions to problems wethought previously impossible to solve. This will ofcourse lead to more high-quality and better-tastingsnack food which gives credence to GIA’spredictions. As the technology advances, it will alsono doubt become cheaper, so even the smaller foodand drink companies will be able to take part in afuture where quality of product becomes easier toattain to high levels. Innovation is also leading the way when it comesto snack foods’ growth, crisps and potato chips havealways been an area where new flavours, styles andbranding have taken off well. In recent years,vegetable-based crisps have enjoyed much success, using beetroot,parsnip and sweet potato means less fat content and can beperceived as more healthy to the snack-buying public. Van Marcke Foods, specialists in fruit and vegetable equipmenthave developed a system in which crisps are cooked in a vacuum.This process means the crisps are of a higher quality of textureand contain much less saturated fat. Van Marcke Foods alsoproduces a cost and time-saving concept, dry snack pellets. Theseare mainly made of potato and resemble pasta shapes and areintended to be fried, meaning you can create your own flavouringand therefore a unique and innovative product. Ideas like thisalso feed innovation and could see more companies entering themarket, able to set up quickly and free of some of the initial costsof production. The crisp brand Tyrell’s have also recently expanded on theirKliklok’s DCL isjust one of theirprocessingmachinesdesigned to makeproducing snackfood easier36 Baking could become more of a scientific processthanks to monitoring technology from Franz Haas32-37:Layout 1 27/1/12 09:17 Page 3Visit us at the Foodex show - stand L32132-37:Layout 1 27/1/12 09:17 Page 436www.fdiforum.netSNACK FOODSKliklokInternationalWestern Drive,Hengrove Park EstateBristol BS14 0AYTel: 01275 836131Email: sales@kliklok-int.comwww.kliklok-int.comCompany ProfileFor over 60 years,Kliklok has held anenviable position atthe forefront ofpackaging technology,with particularemphasis on the foodindustry. Thecompany has a proud history of innovation in machinery design andmanufacture, investing its experience, skills and knowledge intoresearching and developing capabilities in packaging applications.Product ProfileKliklok’s range of durable and efficient packaging equipment offerstop load carton/tray forming and closing, horizontal end load cartoning,automatic product handling, wraparound sleeving, and end of linemachinery. With expertise and focus on core industries such as frozenand chilled foods, confectionery, cereals, snack foods and bakery –Kliklok is able to meet the growing needs of today’s demandingconsumer market. From hand-pack machines to fully automatic turnkeysystems, Kliklok’s complete range of packaging machinery providesquality, performance, reliability and efficiency. range of vegetable crisp, producing a crinkle-cut version of theirbeetroot, parsnip and carrot crisps. This may seem like a smallchange, but it is a first and adds appeal to what is already provinga popular product. It is this thinking that will continue the snackfood sector’s rise to success.Testing timesWhile all this talk of success is encouraging, it can only take theodd mistake to cost a company dear and that is where qualitycontrol and testing come in. Making claims about health is risky ifyou are not fully sure what your product contains in terms ofnutritional information. Making incorrect claims can be harmfulto your profit margin as well as reputation. This is wherecompanies such as Oxford Instruments can help. They are able tocarry out extensive tests such as oil content within snack foods,fat and oil levels in food and fat content in chocolate and cocoaproducts to incredibly accurate standards. The tests can beperformed on desktop units by unskilled workers, so testing andmaintaining quality is easier than ever. If there were a problemyou were unaware of within the processing machinery and toomuch or too little of a certain ingredient was being produced,these simple tests could provide all you need to remedy thesituation before you send out an entirely tainted batch.On a similar level, weighing is essential in this sector, thenature of snack products is that they are often small, uniformly-made shapes, sizes and weights. This, you would think, wouldprovide the perfect way to keep an eye on over or under fill rates.However, if your filling machinery is not calibrated correctly orperhaps is letting through less or more product than required youcould be in trouble. If a product is underfilled, fines could comeyour way if spot-checks find your packaging is carrying more airthan snack and equally give-away rates are an issue withoverfilling. Give just 1g away per unit for example and overseveral thousand units, you will have given away a significantportion of your profits. Companies like Stevens Group canprovide pinpoint accuracy when it comes to weighing and oftenmachinery will be able to seamlessly meld to your currentproduction lines and is able to deal with very light loads of thoseof several tonnes. Being overly cautious is no bad thing when itcomes to food production. After all, who wants to give theirproduct away? The lunch! show at London’sBillingsgate, now an annualaffair is proving ever-morepopular for the snack andfood-to-go market toshowcase innovations insnackingNatural ingredients are taking ahold in the snack food market,even with people’s preferencesfor more synthetic treats32-37:Layout 1 27/1/12 09:17 Page 5SNACK FOODSwww.fdiforum.net37Solutions for the bestcrackers from HaasAll these ovens are part of the Haas-Meincke program –for more information, visit www.haas.com.Custom-made lines areoffered out of one hand whichensures efficiency. For crackers,equipment for the wholeproduction process is offered –from mixing at the beginning tocooling and spraying at the endof the production process. In thecase of crackers, manufacturingis done on a line where anendless dough sheet is firstproduced and then rolled intothe desired thickness usinggauging rollers.Afterwards, the dough piecesare cut in a rotary cuttingmachine and the remainingnetwork of scrap dough is thentransferred back into thesheeter. The dough pieces canbe sprinkled before baking. Iflamination is required, the cutsheet laminator from Haas-Meincke is used as one out ofseveral parts of the productionprocess, as illustrated. Itproduces dough sheets with athickness from 4mm up to10mm and with up to ten doughlayers.Cream crackers as onepossible end product require adevice that spreads a fat andflour mixture between theselayers. For baking, a directlyheated oven with band pre-heating and a heavy wire meshband is usually used .Alternatively, a hybrid ovenwith direct heating in the infeedzone and indirect heating withconnected convection for theremaining baking area aresuitable.Sophisticated solutions for cracker production– that’s what the Denmark-based industrialbaking specialist Haas-Meincke stands forOxford Instrumentsimprove testing abilityFat and oil contentis an importantmeasurement ofnutritional value andproduct quality formany foodstuffs.This value is widelyused to determineenergy content andto calculate theproportion of othercomponents in foods.In addition, the fatand oil content maysignificantly affectthe texture,perceived quality andflavour of products.Accurate measurements of the fat and oil content enablemanufacturers to achieve higher standards in nutritionalcharacterisation and quality control of foodstuffs.In contrast to standard wet chemistry methods and variousalternative secondary techniques, Nuclear Magnetic Resonanceprovides a fast, direct and user-friendly method for determinationof the fat and oil content in foodstuffs. This technique is based onmeasurement of the NMR response obtained from fat (oil) in theproduct, and quantification of the fat (oil) content by calibration.In an independent test study, laboratory managers in a contracttest facility reported that the testing results using NMR exceededtheir expectations. Now, about 90-95% of the laboratory’s samplesare run on an Oxford Instruments’ MQC instrument and the labhas increased its efficiency because of the rapid measurementcapability.Furthermore, the lab developed a universal method using asample blending process, sample conditioning to ensure theoptimal temperature for reading the NMR signal, followed byanalysis using the MQC instrument. They used hundreds of datasamples from the traditional Soxhlet method and NMR-MQC toprove that the results obtained from the MQC reproducibly fellwithin acceptable tolerance. This method has been UKAS &INAB accredited to ISO 17025 since 2009.Learn how an MQC benchtop NMR system fromOxford Instruments may improve your testingability. Visit www.oxford-instruments.com/mgc formore information32-37:Layout 1 27/1/12 09:17 Page 6Invaluable advice fromindustry specialistsMeet the expert38www.fdiforum.net038-039:Layout 1 27/1/12 09:55 Page 1www.fdiforum.net39Lakeviewproviding the springboard for successful growth at Natural Balance FoodsNatural Balance Foods boasts a range of healthy cereal bars and flavour-infused raisin snacks that can be found in ‘free from’ sectionsof Tesco, Waitrose, Asda, Sainsbury’s, Boots, Holland & Barrett and other stores. The pressure increased substantially when Natural Balance Foods successfully extended its product listing with Tesco. Co-founderGreg Combs says, “This meant seven-day delivery and coping with a wide range of volume requirements, which resulted in a ten-foldincrease in the number of transactions.”Previously an order was handled seven times by individual staff. With the Lakeview system this has been cut and manualintervention is only required twice throughout the process. Greg Combs says, “This has freed up our back-office staff to undertakemuch more valuable tasks on behalf of the business and our customers.”Work is currently underway to incorporate an iPad app and web client to allow remote access to the Lakeview system.For more information visit www.lakeview.co.uk/food or call the Lakeview team on 0845 388 3329.Neogen Europe Ltd.Simple, fully quantitative tests for MycotoxinsNeogen Europe Ltd. has developed a range of tests to detect amounts of Mycotoxins in grain and feed. Reveal® Q+ testing products combine the speed and simplicity of a lateral flow test with the precision of more demanding test methods.All a tester has to do is place a test strip in an extracted sample, and then read the strip to receive results. The new products include:• Reveal Q+ for Aflatoxin delivers precise results of 2.5 to 100 parts per billion of Aflatoxin after six minutes.• Reveal Q+ for DON delivers results from 0.3 to 6 parts per million of DON after three minutes, following an extraction procedurerequiring only water. • Reveal Q+ for Zearalenone delivers precise results ranging from 50 to 1200 ppb of Zearalenone in corn, or 25-1200 ppb of theMycotoxins in wheat after six minutes.Neogen’s AccuScan® III reader provides a method of reading, storing and analysing results from lateral flow tests. AccuScan provides apermanent result that can be incorporated into a company’s food safety plan, such as HACCP.For more information, call + 44 (0) 1292 525 610, email info_uk@neogeneurope.com or visitwww.neogeneurope.comRSPHFood safety training remains a priority through austere timesThe RSPH is pleased to announce that they have significantly reduced the prices of their examination papers for the Level 1 andLevel 2 food safety qualifications. The RSPH appreciate that, financially, times are difficult for all, but they are concerned that food businesses will compromise onmethods of training and assessment that do not provide the reassurance of an accredited qualification. To help out, the organisationare pleased to offer a 25% reduction in the price of their most popular qualifications in food safety. In addition, because they are not required to charge VAT on examination papers, RSPH’s prices for Level 1 and Level 2 food safetyqualifications are 10% cheaper than their nearest competitor. They will of course maintain their usual high standards of service andduring 2012, RSPH will publish more books and tutor packs designed to help registered Centres deliver their qualifications.To register to deliver RSPH qualifications or for any enquiries, contact Angela Corpes, Centre SupportManager, at acorpes@rsph.org.uk or visit www.rsph.org.uk.038-039:Layout 1 27/1/12 09:55 Page 2Next >