< Previous20 Food & Drink Internationalwww.fdiforum.netPROPERTYWe hear much these days aboutsustainability, and when it comes tocommercial property, more and morebusinesses are looking to a new approachwhich can help lower costs and emphasisetheir environmental credentials. Highquality buildings in the food and drinksector are allowing businesses to enjoy amore productive and attractive workingenvironment while also saving on theirenergy bills.As the supply chain undergoesincreased consolidation, more companiesare looking towards new premises thatoffer immense flexibility and convenience.For example, the newindustrial/distribution development atTower Thurrock offers a host ofopportunities. The site is approximatelyseventeen miles to the east of CentralLondon, and transport links are excellentwith Junction 30/31 of the M25 lyingapproximately a mile and a half to thenorth west.West Thurrock itself is an establishedindustrial location with a variety of localand national occupiers including Unilever,Proctor & Gamble and Co-operativeGroup, and the site extends to circafourteen acres with a long frontage to thebusy A126 – providing a primeopportunity for an occupier to have itsown bespoke distribution or industrialunit.Similarly, Nagel-Langdons’ Scottishoperations are now moving from rentedpremises in Shieldhall, Glasgow to a 10.22acre site on the Eurocentral BusinessPark, near Motherwell. The conversionwork is due to start shortly and the facilityshould be ready for use by late May 2014.In total, the cost of the site purchase andre-development is expected to be around£5.5 million. Malcolm Wilde, GeneralManager for Scotland, says, “This excitingnew development will give us significantadditional storage and pallet throughputcapacity and confirms the company’s on-going commitment to the food industry inScotland.”It’s not just distribution companies thatcan benefit from new premises to betteraccess a growing customer base.Denmark’s largest manufacturer ofworkwear, MASCOT, has inaugurated anewly built factory in Laos – the fourth ina series of MASCOT factories in SouthEast Asia.Choosing Laos for the establishment ofthe new factory was based on the closegeographical proximity to the company’sexisting factories in northern Vietnam,where they have been based since 2006and since then have established threemanufacturing plants. CEO MichaelGrosbøl says, “Laos has an excellentbusiness environment, and thegovernment and local authorities havebeen very helpful. Since we obtained theinvestment license, it has taken less than ayear to complete the project, and I amvery much looking forward to seeing thefirst ‘made in Laos’ MASCOT products.”Meanwhile, Derprosa, producers ofspecial coated films, are celebrating thefirst anniversary of the opening of theirfirst warehouse in Newark, New Jersey.The need for this new facility arose fromBuildings of the highest quality are allowing companies to changetheir culture and provide a better service for their customersSpeculate toaccommodate20-22:Layout 1 24/1/14 12:03 Page 1Food & Drink International 21www.fdiforum.netPROPERTYthe great demand for material that exists in the USAamong the different markets that Derprosa serves,and since the warehouse has been opened, it hasallowed the company to serve customers in the USAmarket directly. This means they can acquire smallquantities of film in the country without the need toimport material they might need from Derprosa’sheadquarters in Spain, as was previously the case.The spirit of consolidation and the requirements oftheir customers have also spurred manufacturers on toconsider new premises. Chippindale Foods, forexample, has invested in a multi-million pound55,000 sq ft purpose-built production facility tohandle the growing demand for its free range eggs.The company has doubled its space after relocatingproduction from Harrogate to its new state-of-the-artsite in Flaxby, with the new property also providingroom for further expansion as they secure newcontracts.Further to offering a larger and improvedtemperature controlled packing environment, the newpremises also house a quality assurance testing area, acustom-built demonstration kitchen, meeting andtraining rooms, office space and an improved logisticsarea all under one roof.One of the biggest property projects, though, isundoubtedly the creation of “The Pride” multi-beverage plant of New Zealand’s food and beverageconglomerate Lion. To relocate to the new facilities,two existing production facilities had to be shut down,most of the equipment installed there relocated andcombined with new machines and lines.In addition, Lion set themselves a number of targets- the plant was required to meet rising expectations inenvironmental protection, and while upgradingproduct quality, productivity levels weresimultaneously to be increased by 40% and beer lossesreduced by 30%. This illustrates how many companiesare using developments in property to create a seachange in their operations.That Lion was able to make a success of the move –where plans had to be constantly changed due to thedisruption to existing plants caused by theChristchurch earthquake – is thanks to the work ofcompanies such as Krones, who were contracted toinstall a four-kettle brewhouse comprising mash tun,lauter tun, wort copper and whirlpool, plus a vapourcondenser and an energy storage tank with aninstalled capacity of 600 hectolitres per brew.22 The creation of “The Pride” multi-beverage plant of New Zealand’sfood and beverage conglomerateLion was assisted by exceptionalfacilities from KronesCrown Holdings have openednew facilities in Da Nang,Vietnam and Sihanoukville,Cambodia to meet local demand20-22:Layout 1 24/1/14 12:03 Page 222 Food & Drink Internationalwww.fdiforum.netPROPERTYCall 0161 483 1232 to speak to our teamfood and drink innovationCampden BRIMADE IN THE UKHygienic surfaces for food & drink environmentsFoodsafeImprovedhygieneSeamlesssurfaceCampden BRIapprovedKrones has also integrated an LMS line management system toensure production can run smoothly and that managers canaccurately locate and deal with any potential flashpoints.After locating the new property, the next challenge for acompany is identifying the most effective materials to ensureeffective production. A strong durable floor is vital within a heavyduty manufacturing plant, for example due to the large amountsof pressure applied by bulky machinery and the damage which canbe caused by products such as oils being used.White resin flooring is, perhaps, a surprising choice but manycompanies have decided to introduce it when considering flooringsolutions. Indeed, as Martin Wroe, Commercial Manager at ResinSurfaces Ltd, points out, “Heavy manufacturing environmentsrequire a durable industrial flooring solution but that doesn’tmean that they don’t want something that looks good too. Awhite seamless floor can ‘lift’ the working environment andambience without sacrificing any of the other essential properties.“This type of environment is subject to heavy impacts on smallsurface areas which undoubtedly may cause floor damage at somestage. Resin floors are a versatile product whereby sections can beremoved and replaced and a seamless, good as new finishachieved. This is a critical factor for manufacturers dealing withheavy machinery. They need a long lasting flooring solution whichworks well for their demanding environment and enhances theproduction.”Many major companies are making use of new propertysolutions to change the culture in their organisations and takeadvantage of existing infrastructure to provide a better and moreefficient service for their customers. Property developers andsuppliers alike can ensure these moves run as smoothly aspossible.Denmark’s largest manufacturer of workwear,MASCOT, has inaugurated a newly builtfactory in Laos – the fourth in a series ofMASCOT factories in South East Asia20-22:Layout 1 24/1/14 12:03 Page 3Food & Drink International 23www.fdiforum.netEND OF LINE PACKAGINGEnd of line packaging is often the lastmoment a product is processed beforeleaving a facility. Therefore machinerythat seals, secures or transports theproduce at the last point possible needs tobe reliable, robust and perhaps above all,cost-effective. This of course comes with caveats -hygiene, health and safety andenvironmental concerns need to beaddressed and there’s no shortage ofinnovations taking place within the designand manufacture of machinery thataddresses all these points. One particularinstallation seen recently saved a companyaround 50% of its energy costs. This wasachieved simply by switching a line usedto pack salads for major supermarkets toan air-compressor powered setup withmore efficient motor. However not all savings can be made insuch rudimentary ways. A company whichproduces wines and beverages recentlyrealised it needed a solution whencartonising andpalletisingvariousproducts. Prior toworking towards asolution, upper surfacesof cardboard boxes were gluedand transported to a binding machinewhere the palletised beverage cartonswere tied up. Beverage cartons wouldthen be carried through the pallettransport system to the goods issue -where they could be prepared for theshuttle truck of the logistics serviceprovider. Every year, around 300,000 palletsleave the production facility. However, inthe past, due to frequent hard braking,sudden steering moves and sharp curves,during transport, cartons loosenedthemselves from the compound, fallingonto the loading space. The result wasbroken bottles and lost product. In order to reduce damage duringtransport and to meetincreased logisticsrequirements, a stretch hoodhigh-capacity packaging systemwas used. The system pulls a 40micrometres thin film hood over thepalletised beverage cartons. Optimallypackaged, the cartons are protectedagainst damage during transport andreach the customer in perfect order. Twodifferent pallet sizes can also be packagedwith this multi-format system which mustbe invaluable when it comes tointroducing new lines or irregular shapesof carton.End of line packaging that combinesother functions as well as the wrapping orpalletising of products is always welcomenews to manufacturers too. With apremium on floor space and time of theessence it’s a valuable option for many inFinishingtouchesWhen it comes to readying products for transit,there’s a whole host of solutions available, butwhat’s right for you?PHOTO: BEUMER25 Effective packaging at the last momentof the production process is becomingever more streamlinedPHOTO: BEUMEROneparticular installationseen recently saveda company around50% of itsenergy costs23-25:Layout 1 24/1/14 12:04 Page 124 Food & Drink Internationalwww.fdiforum.netmaxxGLM-I 40 Identification Systemspecially designed for box, cardboard and other bulk labellingDoes your business sector involve heavy loads and maximum performance? If so, only genuinely specialised equipment is an option: the fully automatic Bizerba GLM-I maxx 40 goods labeller. Due to its high performance capacity, it holds a special place within our labelling device family.Highlights:Weight-variable price and goods labelling for all label shapesWorks with a continuous printing process easy to serviceThree belts for isolation, weighing and labelling areasAdjustable display and user interface01908 682740 info@bizerba.co.uk www.bizerba.com23-25:Layout 1 24/1/14 12:04 Page 2Food & Drink International 25www.fdiforum.netEND OF LINE PACKAGINGthe industry. Recent innovations includemultiple-laned checkweighers that alsocombine wrapping and palletising options. Weighing and sorting products beforedispatch to logistics can be fraught, so tocombine several strands of production tomere moments can make all thedifference. These elements of the processare often controlled by easy-to-use screensutilising touch screen technology socontrol is also made simple. This ensuresa clear time and therefore cost-savingprocess, meaning it negates the need tomove often bulky and unwieldy pallets tomultiple locations too. Use of robotics is becoming much morewidespread in end of line operations too.With robots no longer stifling andunreliable they can add much to thecomplex end of the packaging process.Palletising robots in particular have comeon leaps and bounds, with new modelsbeing able to flexibly lift and manoeuvreincreasingly large items. Bulk amounts ofproduce or particularly heavy loads such asflour or sacks of grain can be easily movedwith improved servo drive and motortechnology. With improved grip andadaptable functionality most current formsof robot will be able to handle delicateloads as effectively as heavy ones.Use of display technology can also giveoperators an idea of how the robot isgoing to stack units and in what order.This can of course be modified if thehuman element spots something theautomated robot does not.Generally, manufacturers will havemethods in place that ensure theirproducts are protected and prepared fortransit, but employing just a littleinnovation or new thinking across theboard could do wonders for the process. No longer can a manufacturer takeleave of responsibility when a productleaves the factory or processing plantfloor. Even though you may betrusting others todeliver or transport your products, theonus is on you to safeguard againstdamage. All the way from large scaleitems like film-wrapped pallets to small,individual packaged items, care must betaken, not only in terms of wastage, but inreputation. A spoiled load could tarnish agreat working relationship with a retaileror leave a brands reputation in tatters.The care taken to prepare for suchproblems should they arise seemsmandatory. Not only this, but the safety aspect hasa bearing on your reputation. Pilingpallets high with no regard for safety orleaving palletising or wrapping machineryopen to dangerous situations istantamount to ignorance of the problem.Accurate and detailed plans of actionneed to be drawn up, it just makes perfectbusiness sense.Using palletising robots can meanless manpower required andsignificant cost savingsPHOTO: FANUCUse ofrobotics is becomingmuch more widespread inend of line operations too.With robots no longerstifling and unreliable theycan add much to thecomplex end of thepackaging process23-25:Layout 1 24/1/14 12:04 Page 326 Food & Drink Internationalwww.fdiforum.netENVIRONMENTAL SPOTLIGHTEnergy efficiency has, in recent years,become a top priority for food and drinkcompanies. Not only has this allowedthem to save substantial sums on theirenergy bills, but many major retailers nowdemand their suppliers reach the higheststandards before they are prepared toengage in contracts.It’s certainly the case that many majormanufacturers have made great strides intheir environmental obligations. SmurfitKappa’s forestry project in Colombia, forexample, has been honoured at the BIBOAwards – the ceremony that highlightscompanies that demonstrate the bestenvironmental practices related to water,reforestation and resource management.The project has been running since 1969,and now operates in 35 forests, creating69,300 hectares, of which 21,500 arenatural forests that are protected, studiedand preserved.Other companies are also enjoyingacclaim for environmental projects.Multinational metal packaging companyCrown have recently published theirsecond Sustainability Report, whichincludes third-party industry figures aswell as internal data showing progress onseven key metrics – material consumption,VOC emissions, energy consumption,direct and indirect greenhouse gasemissions, waste recycled, waste disposaland NOx emissions. The aim is toillustrate the work they have carried outto those interested, and provide the spurto make further developments.One of the items featured is thewinners of the first annual Chairman’sSustainability Awards programme, whichwas developed to recognise the company’smanufacturing facilities that have showninnovation across all three dimensions ofsustainability. The successes achieved atthe winning plants serve as a benchmarkfor Crown’s other facilities around theworld to emulate.Indeed, John Conway, Chief ExecutiveOfficer of Crown, says, “The findings in thereport are clear and show that even as wehave increased our unit volume productionand expanded our manufacturing activitiesto new geographies we are using fewerresources and less energy.”The issue for many companies inintroducing energy efficient measures isthat although there is obvious long-termbenefit, there is short-term expense in thepurchase which many find hard to committo. Yet there are opportunities to gainsupport at this point, as illustrated by JRPSolutions, who worked in closecollaboration with the Carbon TrustScotland and Scotland Food & Drink todeliver energy reductions and cost savingsat McVitie’s in Glasgow.An extensive pilot of JRP’s methodologyEnergy Catalyst was funded by the CarbonTrust over a number of months to assessthe current energy performance ofindividual assets and processes at theMcVitie’s Tollcross plant. It also identified,evaluated and prioritised practicalimprovement measures and projects tosignificantly reduce the energy used withinthe conversion processes. A suite ofmeasures and improvement projects wereidentified that, once implemented, couldreduce energy consumption at the site byup to 41% - which equates to approximately8% of the total operating costs for the site.Paul Wedgwood, General Manager,Scotland for the Carbon Trust, says, “Thesedetailed investigations at the McVitie’sGlasgow site highlighted how significantenergy cost and carbon emissions savingscan often be identified when expert on-siteanalysis is carried out. Some of thesesavings require an initial capitalinvestment by McVitie’s, though thepayback for many measures is veryattractive and could result in a substantialreduction in the overhead costs of the site.With energy prices likely to continue torise, businesses should grasp opportunitieslike these as soon as they can.”The aim of the Energy Catalystmethodology is to identity theopportunities that exist for businesses,with JRP Solutions’ Jes Rutter pointingout, “We recognised that while foodmanufacturers were aware that 80-90% oftheir energy is used within the conversionprocess, there was no simple tool thatwould help reduce energy consumption.”It also helps manufacturing businessesmeet the sustainability targets andSmall stepsto giant leapsManufacturers and distributors are prepared to make short terminvestment to enjoy long term gains in energy efficiency26-28:Layout 1 24/1/14 12:11 Page 1Food & Drink International 27www.fdiforum.netENVIRONMENTAL SPOTLIGHTenvironmental commitments required of them bytheir own customers, particularly retailers such asMarks & Spencer and their Plan A, which commitstheir suppliers to meeting their high standards.Other manufacturers have carried out extensivereviews of their operations to identify areas inwhich changes can be made. Seafood specialistsPrinces recently appointed Cofely GDF Suez toassess their Wisbech production site andimplement their recommendations – including theinstallation of CHP using natural gas.Edina, the group of companies which specialisesin onsite power generation, were chosen to supplyand install the MWMTCG 2020V12 in a sound-proofed container –with the intention ofgenerating 1.2MWe for the plant with excess to theNational Grid. Edina offers design, supply, hireand full turnkey solutions and constructs thecontainer and all related operational products at itsmanufacturing premises in Northern Ireland.This month’s Ecopack show, which runs alongsidethe easyFairs Packaging Innovations event at theNEC in Birmingham, will bring much of the industrytogether to deal with the challenge of eco-friendlysolutions in packaging and food waste. As AlisonChurch, Event Director for Ecopack, points out,“The sustainability agenda has moved forward andthe UK packaging industry is getting to grips with it,but the impact of packaging on the environmentremains in the limelight. Consumer consumption hasincrease, so packaging must work harder.”Recoup will be at the show providing knowledgeand guidance on the plastics chain of supply, useand disposal, and the experts in plastic wastemanagement have seen the increased interest in thissector first hand with twelve new members joiningits ranks in 2013, including Campden BRI and RPCGroup. Through support of Recoup, the membersare in turn helping to support the development ofplastic recycling research and activities.Stuart Foster, CEO of Recoup, says, “In 2014,Recoup will continue to deliver a range of strategic,research and practical activities and projects acrossthe plastics supply and recycling chain inpartnership with its members and other28 EPRO, the association of national organisations charged with organising,managing, researching and promoting recycling and recovery of plastics throughoutEurope, named Green Warehouse’s uBin its Best Recycled Product.The Confederation of Paper Industries are attempting to unify the UK’spaper-based industries with a single purpose in promoting paper’sintrinsic value as a renewable and sustainable fibre-based material“The sustainabilityagenda has moved forward andthe UK packaging industry is gettingto grips with it, but the impact ofpackaging on the environmentremains in the limelight.”Alison Church, Event Director for Ecopack26-28:Layout 1 24/1/14 12:11 Page 2Europe’s Leading Supplier of Efficient GasEngineTechnology Highest Efficiency - Proven Reliability - Dependable ServiceEdina UKUnit 13 Rugby Park, Bletchley Road, Stockport SK4 3EJT: +44 (0) 161 432 8833 F: +44 (0) 161 975 1499E: Info@edina.euZZZHGLQDHXSole Distributor in the UK & Ireland for3URYHQ7HFKQLFDO6ROXWLRQVIRU&RPELQHG+HDWDQG3RZHU'LVWULFW+HDWLQJ7ULJHQHUDWLRQ$QDHURELF'LJHVWLRQ%LR*DV/DQGILOO*DV6HZDJH*DV7KH7RWDO(QHUJ\6ROXWLRQ3URYLGHU:- )HDVLELOLW\&RQVXOWDQF\'HVLJQ &RQVWUXFWLRQ)XOO7XUQNH\&RQWUDFWV- 3URMHFW0DQDJHPHQW&RPPLVVLRQLQJ1R5LVN0DLQWHQDQFH2SHUDWLRQDODYDLODELOLW\&RQWUDFWVZLWK*XDUDQWHHV28 Food & Drink Internationalwww.fdiforum.netENVIRONMENTAL SPOTLIGHTstakeholders to improve the plasticrecycling opportunity.”Meanwhile EPRO, the association ofnational organisations charged withorganising, managing, researching andpromoting recycling and recovery ofplastics throughout Europe, now includesnineteen members, including Recoup,from sixteen countries.EPRO works closely with EUinstitutions and is increasingly involved inrobust data gathering on plastic recycling,best practice monitoring, and informingand monitoring the strategies and policiesto recycle more plastics in the future.EPRO provided input into a number ofkey discussions in 2013 including the EUGreen paper and other directives onplastic resource management.Other forms of packaging are alsoemphasising their green credentials. Thefresh produce industry is combating wastewithin its supply chain – now at less than10% according to WRAP – with measuresthat include optimising packaging andincreasing re-use and recycling. TheConfederation of Paper Industries areattempting to unify the UK’s paper-basedindustries with a single purpose inpromoting paper’s intrinsic value as arenewable and sustainable fibre-basedmaterial. Over 80% of corrugated isrecycled, while new boxes are made fromrecycled material, so there are obviousbenefits to be gained from this.The move towards energy efficiencymay result in some short term expense formanufacturers and distributors but thereare opportunities to cover this cost – andthe long term results can be particularlyimpressive.Multinational metal packaging companyCrown have recently published theirsecond Sustainability Report26-28:Layout 1 24/1/14 12:11 Page 334 Food & Drink Internationalwww.fdiforum.netSIEVES & SEPARATORSWith precise amounts weighed out, arecipe followed and a product inmanufacture, it’s sometimes easy to forgetthe amount of preparation that goes intoproducing a perfect product. These days consumers demand a highstandard of uniformity. Where someprefer the rough and ready, others preferto know exactly what they are buying andaccurate preparation of ingredients at anearly stage is now a must. Consumers willno doubt be let down should a productnot be presented properly. Addto this the fact that loss ofcustomer loyalty is a realfear in this time of greatcompetition, every effortshould bemade toensure quality. Thankfully, companies specialising inthis most niche of areas have workedthrough the years to bring us machineryand equipment that can ensure uniformityand an even consistency should yourequire dry or liquid ingredientspreparing. SWECO, for example, have a widerange of sieves and separators which canconvert mixed liquids and dry particlesinto separate flows and can producetailored sizes of particulate, meaning youcan engineer your products to whateversize you require within reason. Differentmachines suit different tasks of course,but the larger models are fantastic from ahealth and safety viewpoint.With hinged doors either end andhaving removable screens, theinspection and cleaning ofsuch devices is easierthan ever, whichmeansdowntime isPHOTO: SHUTTERSTOCK.COM/MADLENA sift inthinkingUse of increasingly large amounts of fine and granulatedingredients has led to innovations within the sieves andseparators sector of the food and drink industry. However, whatpoints should you consider when selecting equipment?34-35:Layout 1 24/1/14 11:52 Page 1Next >