< Previous30 Food & Drink Internationalwww.fdiforum.netREFRIGERATIONThe refrigeration sector has undergonesubstantial changes in recent years – withthe importance of energy efficiency andsustainability being the most obviousdriver for change. Companies are lookingfor new solutions that are just as effectiveas before, but which possess a far smallercarbon footprint.Conventional refrigerators and chillersoften waste a substantial amount of coldair. This is especially the case for retailersas many open chillers use an air curtainrefrigeration system, whereby a wall ofcold air cascades down the front of theunit. This protects the food and drink byThe coolCOLLECTIONEnergy efficiency is revolutionising the refrigeration sectorNew developments in refrigeratedtransport include the fully insulatedGray & Adams Eco-Aer body whichincorporates fuel-saving savingfeatures such as a roof-mountedvortex generator to smooth theairflow over the back of the vehicle.Companies such as Wellocks arenow using this technologymaintaining temperature, and it is ofobvious benefit for the retailer as it offerscustomers easy access and provides a moreattractive display. The problem with thesetraditional designs, however, is that manyare particularly voracious users of energy,since much of the cold air curtain is lostinto the environment.Happily, there are a number ofsolutions that are emphasising a moresustainable approach. The R&D team atWilliams Refrigeration, for example, havedeveloped a new air curtain system as partof the company’s Greenlogic initiative.Careful angling of the curtain ensuresthat, once it has done its job, nearly allthe cold air is recycled, either into thecabinet, helping maintain temperature, orby being drawn through vents and grills tocool the refrigeration system itself andthus reduce energy consumption.There are other benefits to be had fromconsidering the design of refrigeratorsused in retail environments. For example,a repositioning of the night blind –integrating it into the frame of therefrigerator – can leave the whole topshelf clear for display items, as opposed tothe old designs where space had to be leftto allow the shutters to be pulled down.With most designs, there also needs to bea gap between the products on display andthe cabinet’s back wall, to ensure airflowpasses through, but the introduction of airwalls can allow retailers to use the wholedepth of the cabinet. This also avoids therisk of customers inadvertently movingstock and blocking the airflow.Food safety remains perhaps the mostimportant aspect of refrigeration, butenergy efficiency can play a major rolehere too – high performance insulation30-31:Layout 1 25/1/13 11:21 Page 1Food & Drink International 31www.fdiforum.netREFRIGERATIONmeans that temperature pull down timescan be made particularly short and thetemperature of the refrigerated cabinetwill consistently remain within setparameters.Of course, products need to be keep atthe correct temperature at every stage ofthe supply chain, and refrigeratedtransport also requires the sameconcentration on energy efficiency andsustainability. More and more companiesare making use of eutectics in this regard,which can maintain temperatures as lowas -30°c and allow multi-drop for up totwelve hours without reliance on thespecific vehicle.The bottom line for operators is thatthere are lower fuel costs compared to ablown air system as the refrigerationcharges overnight, not while the vehicle ison the road. There is also substantiallyless temperature loss when the doors areopen as compartments to the vehicles giveaccess to the specific area required, notthe entire body. Vehicles from pick-uptrucks to 26-tonne lorries can now befitted with the eutectics system and agrowing number are now on the road.One other concept for refrigeratedtransport currently being considered isknown as Frostcruise, which has recentlybeen trailed with a number of customersby the Linde Group company BOC. Thetechnology uses the cryogenic effect ofliquid nitrogen at a temperature of -196°cto produce rapid and evenly-distributedtemperature drops. The benefit fordistributors in the food sector is that ithas the ability to maintain accurateproduct temperature throughout thevehicle even during multiple deliverystops, ensuring the product remains at ahigh standard throughout – particularlyimportant as the supply chain islengthened.This cryogenic concept also, happily,brings about increased environmentalbenefits. The system doesn’t rely on thevehicle engine to perform the coolingprocess and therefore doesn’t require theengine to keep running to maintain thetemperature. Additional advantages fromthis are that it reduces quite substantiallythe amount of noise generated, and cancontinue running independently of thevehicle – a huge advantage if the vehiclebreaks down.Energy efficiency is certainly taking onincreased importance, and with that inmind, last year’s annual general meetingof EPEE, the European association ofmanufacturers of refrigeration, air-conditioning and heat pump equipment,emphasised the importance formanufacturers to look at new solutions –especially as governments now have theirown strict rules on energy consumption.The current EU target is to reach a 20%reduction of energy consumption by the2020, and the refrigeration sectorwill be expected to play its part.Andrea Voigt, EPEE’s Director-General, said at the event, “Energyefficiency is not just a buzzword forour sector. We can provide thesolutions to get to a low carboneconomy. EPEE supports the principle ofmandatory targets on energy efficiency asproposed in the draft Energy EfficiencyDirective. Member states need tounderstand that even if the initialinvestment may be higher, the reducedoperating cost will ensure that the overalllifecycle cost will turn out to be muchlower. That’s particularly true for energyefficient technologies such as heatpumps.”The industry is certainly taking theissue of energy efficiency seriously – andwith companies across the supply chainbeing able to benefit from lower runningcosts and a more robust and consistentsystems, it’s a win-win situation for allinvolved.The R&D team at Williams Refrigeration have developed anew air curtain system as part of the company’s Greenlogicinitiative, as seen on their Gem Sandwich ChillerThe current EUtarget is to reach a20% reduction of energyconsumption by 2020,and the refrigerationsector will be expected toplay its part.30-31:Layout 1 25/1/13 11:22 Page 2PHOTO COURTESY FAIRFIELDS FARM CRISPSNot only does effective sieving ensure that theproduct is free of foreign bodies, but it alsoaerates the product to ensure greater volumeand quality later in the process.The challenge for manufacturers is ensuringaccuracy without sacrificing speed. A split decisionA split decision32 Food & Drink Internationalwww.fdiforum.netSIEVES & SEPARATORSSievmasterManufacturers of all types of sieving & screening equipment worldwide since 1976+44 (0) 1252 322 233 www.farleygreene.cominfo@farleygreene.comDelicate and natural ingredients are now afamiliar sight on production lines, but theybring with them particular challenges forthose looking for a fast and effectiveproduction line. Much of this is down to theincreasingly stringent labelling regulationsthat require exact information about theproduct to be detailed – which can prove tobe a tough job with fine powders.The latest sieves andseparators ensureabsolute product integrityand a fast-movingproduction linePHOTO: SHUTTERSTOCK.COM/VALERIE POTAPOVA32-33:Layout 1 25/1/13 11:20 Page 1Food & Drink International 33www.fdiforum.netSIEVES & SEPARATORSNot only does effective sieving ensurethat the product is free of foreign bodies,but it also aerates the product to ensuregreater volume and quality later in theprocess. Dealing with delicate ingredientsbrings about numerous potentialflashpoints as they can very easily get stuckin the production line. To this end, sievesare now usually incorporated alongside amagnetic separator which can identify andremove ferrous items that would lead to aproduct recall. Incorporating the sievesand separators into the production lineensure this happens without slowing downthe production process.That said, although high poweredmagnetic separators may seem the obviouschoice for the production line, they are notsuitable for all products. Products thatcontain flour can often cause separators tobecome confused as the harmless ferrousoxide in flour is slightly magnetic. In thisinstance, it’s now possible to separatematerials up to five fractions, which wouldmean the ferrous properties in this casecould be ignored.Whatever form of separation isintroduced, however, the aim remains thesame – increased accuracy on theproduction line. Check screening of baggedpowders and ingredients are now of primeimportance. In addition to the accuracy,working with fine ingredients also has anobvious safety obligation, with theexcessive dust that can sometimes begenerated creating obvious health risks forthose working on the production line andcausing numerous potential flashpoints ifit interferes with machinery, somethingthat is frowned upon thanks to the EU’sATEX regulations.To deal with these requirements,Farleygreene have launched a new additionto their range of ingredient check sievingstations. The Sievmaster 553 – STSmachine claims to deliver powerful,fast check sieving with the benefit ofa dust extraction cover to protect theoperator from harmful airborne dust.These new machines areconfigured to comply with auditrequirements. This means that allgaskets are metal detectable blue siliconeand the unit complies with food contactfor any tools, ensuring downtime isreduced to a minimum.The importance of avoiding excessivedust and ensuring complete accuracy hasled to changes in the way sieving andseparating takes place during theproduction process. In recent years,vacuum sieving has become more andmore popular. In this method, sacktipunits are fitted with a single vacuumhopper loader to provide the interface toeach mixer, allowing the correct quantitiesof ingredients to be dispensed into thesieving system and, via the hopper loader,to the mix. The vacuum sieving methodensures that there is no leakage, while theconnection can be made quickly andsimply without the need for tools.In fact, despite the increase in theirquality, the latest sieves andseparators are also becoming simplerin their construction. This ensuresthey are easier than ever before toclean, using the smallest number ofcomponents necessary to avoidproduct build-up. The result isabsolute product integrity and a fast-moving production line.Farleygreene have launched the Sievmaster 553 – STS machine which claims to deliver powerful, fast checksieving with the benefit of a dust extraction cover to protect the operator from harmful airborne dust.applications under EC directive2002/72/EC and amendments up to andincluding 2005/79/EC. These regulationslimit the materials that are permissible tocome into contact with food during theproduction process.As part of the new hardware, there areoptions for underscreen magneticseparators and it can also be coupled tomechanical or pneumatic conveyorsystems. Generally, the unit is primarilydesigned to fill into a 120 or 200 litre totebins but it can be tailored to suit anycontainer. The machine also completelystrips down for cleaning without the needWhateverform of separation isintroduced, theaim remains the same – increased accuracy on theproduction line.32-33:Layout 1 25/1/13 11:20 Page 2excellenceininnovativeperformanceCeruleanRockinghamDrive,LinfordWoodEast,MiltonKeynes,MK146LY,England,UKTelephone:+441908233833Fax:+441908235333E-mail:info@cerulean.comwww.cerulean.com3smallstepsforCartonQualityControl,1giantleapforProductionLines.Withyearsofexperienceinproducingpackagingandtestingmachinery,weunderstandtheneedforreliability,simplicityandflexibility.Ourequipmenthelpsyoumaintainqualityinyourpackaginganddetectproblemsforyourproductionline,beforetheyhappen.OurNewtonLaboratoryCartonTester(LCT)isdesignedtohandlethreeessentialqualitycontroltests–makingyourqualitymanagementquick,easy,accurateandeffective.Firstly,theLCTmeasurescreasestrengthandbox-formingforce–providinganinstantaneouscurveshowingthetorquerequiredtobendacreaseorformabox,foreverydegreeofdeflection.Secondly,theNewtonCartonTestermeasuresspring-backforce-andfinally,hasanoptionalfrictiontesterwhichenablesittomeasurethecoefficientoffriction(μ)atwhichslippageoccurs.Integratedcomputeranalysisandreportingmeansyougetquickandmeaningfuldata,toallowcomparisonagainsthistoricaldatastoredonaconnectedPC.TheLCT’sGraphicalUserInterfacemakesitanintuitivemachinetouse.•3testinginstrumentsin1•Integrateddataanalysistool•GraphicalUserInterface•Measurescreasesupto590mmwide•Suitableforcartonsupto5mmthick•SuitableforbothcorrugatedandpaperboardLearnmoreat:Packtech2013,NECBirminghamStandC1527-28February34:Layout 1 25/1/13 11:10 Page 1Food & Drink International 35www.fdiforum.netCARTONING & SLEEVINGBecause cartons and sleeves are soenvironmentally friendly, it addresses theever-present cultural stigma attached towasting packaging. Those who use far toomuch in the way of cardboard, plasticsand films will find themselves appearingdated, uncaring toward the environmentand ultimately, could see a shiftdownward in sales.Use of sleeving means you can beeffective in so far as presenting nutritionalinformation and design, but it also meansyou are saving a significant portion ofpackaging. This, coupled with the costsaving, means it is a green, cost-effectiveand aesthetically-pleasing option forpackaging food and drink. Similarly, cartons mean less use ofplastic, the ability to use recycledcardboard and the room to include asmuch design or supplementaryinformation as you wish and with asepticpackaging in particular, increased safety,protecting sensitive products like milkfrom bacteria and infection.Customised cartoningWith cartoning becoming a moreadaptable and customisable option formanufacturers, sometimes over traditionalboxing itself, more unusual and uniquepackaging is being produced. Seasonaldesigns are always popular and cartoningoffers more options to modify shape andother design considerations that might tiein with the event. A recent Cadbury’sdesign for a Halloween chocolatepumpkin included chocolate being housedin an outer carton made from a heavy-duty board, used to give strength. Thecarton also features three pumpkin-shapedbiodegradable plastic windows, and a carryhandle for transportation of the delicatecontents.37 Cartoning andsleeving isbecoming a muchmore common wayof presenting foodand drink, but whatare companiesdoing to runpackagingoperations safelyand maintainappeal?PHOTO: ROBERT KNESCHKE / SHUTTERSTOCK.COMSafety selectedFinding new ways of reducing materialused for cartons while maintainingintegrity and safety is a challenge theindustry is meeting head-on. Stephen Shortland, managing directorat New Vision Packaging, says,“Christmas and Easter are inevitably thekey times of the year when it comes toworking on confectionery products, so it’sgood to see brands exploring opportunitiesto coincide with other annual events too.”A greener optionSleeves and cartons, by their verynature are greener. Not only do they useless material to effectively package foodand drink safely over options like boxeswhich need more in the way of unseenand wasteful tabs and integral elements,but they are also easily recycled.Remaining safe in terms of barriers andeffective in terms of printing on cartonsare challenges that manufacturers areaware of, which is why new materials in35-37:Layout 1 25/1/13 12:41 Page 1Automated coding &labelling verificationto meet retailers' codes ofpracticeReal timepaperless qualityto ensure RightFirst Timeevery timeRoving quality audits,H&S checks,engineer lineattendance, HACCP Automatedefficiency/OEEin real time100% inspectionthrough on-lineVisionIntegrated Production Informationanalysed, prioritised &distributed to driveperformanceimprovementAutomated Short Interval Controlon factory monitorsContact us now for your free no obligation factory auditGUARANTEED PERFORMANCE IMPROVEMENT througha SINGLE INTEGRATED SOLUTIONreporting on ALL your PRODUCTION KPIs35-37:Layout 1 25/1/13 12:41 Page 2individuals, issues identifiedfor corrective actions are notalways acted upon withappropriate urgency, mainlybecause the paperwork is notinstantly available to theengineering team tasked withfixing the issues. “To remedy theseweaknesses we at Harford have expandedour integrated system to include popularhand held computer tablets for carryingout health and safety checks, rovingquality audits, engineer tracking andthe like. Within these compactdevices, we remind users when andwhere different checks should bemade, whether they are hourly, daily,weekly, monthly, and thenautomatically record the time anddate of every test, together withcorrective actions. “These have the added option ofphotographs for broken machineguards and similar compromisedelements, which are then instantlytransmitted to the desktops or mobilephones of those responsible forcorrective actions. Such info withphotographs, where appropriate, is alsodistributed across existing computernetworks to inform the wholemanagement and operational teams ofoutstanding actions required.”Food & Drink International 37www.fdiforum.netCARTONING & SLEEVINGExperts in automac packaging systems for the food industry - Cartoning Sleeving Product handlingwww.kliklok-int.comthis regard are fascinating. Mineralised resins areincreasingly being used toaddress this, increasing yieldsfrom material while remaining safe.The balance between being scant onpackaging material but still safe andregulated for contact with food is one thatmany have attempted but failed to capitaliseon, but developments are forthcoming. In thefuture, we will probably see even morelightweight and clearly recyclable elements ofcartons and sleeves, but for the most part,the green responsibility remains with theconsumer.Safety on the floorWith so many moving parts, cartoning andsleeving machinery is highly effective butmust be maintained properly in order toprovide the best throughput available.Elements that could be of concern includedetection of defective packaging andmechanical jams, but as Roy Green ofHarford Control suggests it is perhaps timefor safety to be taken even more seriously.He says, “Production line and packingmachine safety is paramount. Systematicregular checking of production machines toensure they are as safe as possible is a seriouscommitment which the majority ofmanufacturers do not take lightly. “However, in many factories such routinechecks are recorded on paper and filed away.The weakness of manual systems is that theyrarely enforce operational discipline in that itis impossible to be certain, as with all paperbased systems, that health and safety checkswere actually carried out where and when thepaper records suggest they were. “Even where paper records are diligentlyrecorded by well-motivated safety consciousEasily recyclable, sleeves offera reduced carbon footprint Novelty or seasonal cartonsare possible these days inever-increasing varietiesPHOTO: CADBURY’S“Christmasand Easter are the keytimes of the year when it comesto working on confectioneryproducts, so it’s good to seebrands exploring opportunities tocoincide with otherannual events.”35-37:Layout 1 25/1/13 12:41 Page 338 Food & Drink Internationalwww.fdiforum.netSTV Packaging UK Ltd | Patrick Cookland | +44 (0)787 255 2285 | p.cookland@seufert.comTRANSPARENT PACKAGINGwww.seufert.comPACKED WITHINSPIRATIONPackaging Innovations 27 – 28 February 2013NEC, Birminghamstand F58For more information visit www.easyFairs.com/PIUKDelivering tomorrow’s packaging innovations for today’s buyerVISITORS AT 201298% found the exhibition to be worthwhile or very worthwhile79% identified new suppliers Registration is open for the UK’s leading event for primary and secondary packaging. Visit www.easyFairs.com/PIUK8 YEARS OF CONSECUTIVE EXHIBITOR AND VISITOR GROWTHOfficial Media PartnerSupported by38-44:Layout 1 30/1/13 11:06 Page 1hugely popular twitter forum #PACKCHATat 1pm on Wednesday 27th February in theSocial Media Lounge. Here show attendees will debate with the‘twittersphere’ regarding a critical packagingissue.The 3D Print feature returns by populardemand, while Pro Carton, the EuropeanAssociation of Carton and Cartonboardmanufacturers, will be showcasing all theoutstanding carton packaging from theECMA Carton awards. Expert professionals, from The PackagingSociety, will provide one-to-one advice onany area of your product’s lifecycle at thePackaging Consultancy Clinic. There willalso be a return of the Lions’ Lair, where anumber of the show’s exhibitors pitch theirlatest innovations to a panel of experts, in abid for their development to be crowned bestof show.Packaging Innovations is co-located withfive other shows - Ecopack, Contract Pack,Packtech, Print Innovations and new for2013, Labelling Innovations. Food & Drink International 39www.fdiforum.neteasyFairs PACKAGING EVENTVisitors to the show, which takes place on27th and 28th February at the NEC inBirmingham, will be able to see new ranges ofbottles, ‘tamper evident’ jars, innovativeprinting technologies, aluminium tubes andscrew top canisters as well as countless otherinnovations.The exhibition will also feature fifty free-to-attend learnShops, spanning every aspectof packaging and delivered by industryexperts. There will also be a high-levelConference where packaging industryprofessionals including James Averdieck,founder of Gü Chocolate Puds will discussinnovation, the future direction of theindustry, opportunities and trends in themarket. Show favourite, The BIG PackagingDebate, inspired by BBC Question Time, willtake place on the first day of the show. Thepanel of packaging professionals will bedebating the topic: ‘Consumers don’t buySustainable Packaging’. Also included, and new for this year, theexhibition will host a live edition of theFor furtherinformation onvisiting and to registerfor the event visitwww.easyFairs.comPackaging event setto be packed outWith 63% of exhibitors launching new products and services at theshow, easyFairs Packaging Innovations is set to play host to the mostimportant new developments in packaging design, materials andtechnology, with many making their global or UK debut.38-44:Layout 1 30/1/13 11:06 Page 2Next >