INTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netFEBRUARY 2015£3.50 STERLINGFuel forgrowtheasyFairsPro2PacFuel forgrowthCONVEYING01_Layout 1 30/01/2015 13:59 Page 1Leading Innovation in Flexible PackagingTo find out how UNI Packaging can benefit your business, see us on Stand C54 at Packaging Innovations or contact our sales team.Telephone +44 (0)1875 616 920Email sales@uniuk.co.uk www.uniuk.co.ukUNI UK Unit 2 Satellite Park Macmerry Business Park Tranent EH33 1RYGoing further, keeping you closerUKPACKAGING02_Layout 1 02/02/2015 09:20 Page 1ContentsFebruary 2015This magazine is now fully recyclable. By recyclingmagazines, you can help reduce waste and add to the5.5 million tonnes of paper already recycled by the UKpaper industry each year. Before you recycle yourmagazine, please ensure you remove all plasticwrapping, free gifts and samples. FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforumNews 4• General news • On line - production news• On the shelf - new products and initiatives • AppointmentsWorld Seafood Congress 2015 12Upskilling for a sustainable futureImport and export 13It’s not just products that are being exported –technology and knowledge are valuableinternational currency tooInstrumentation showcase 15Temperature controlledstorage and distribution16 There are challenges ahead for the cold chain,yet the industry remains one of the most powerfulin the food and drink sectorBeverages 23To meet the demand for quality beverages highstandards are required throughout the productionprocessEnvironmental spotlight 25Food waste and packaging is still being cited asa major contributor to the industry’s large carbonfootprint, so what is being done to amend this?Meet the experts28Invaluable advice from industry specialistsConveying30The conveying market has, rather appropriately,moved faster than ever in recent times• Klüber LubricationSieves and separators34The huge interest in delicate and naturalingredients has brought with it a number ofchallenges for the sectorEditor:Steve Fisher (s.fisher@blmgroup.co.uk)Editor’s PA:Angela SharmanJournalists:Steve Williams (s.williams@blmgroup.co.uk)Michael Fisher (m.fisher@blmgroup.co.uk)Sales Director:Teri CooperSales Manager:Becky DarnellAssistant Sales Manager:Sam TrottSales:Nikki LoganTel: +44 (0) 1472 310302Accounts & Subscriptions:Dawn Cook, John DownesDesign & Production:Gary Jorgensen, Mark Casson, Rachel Green(studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317Email:fdi@blmgroup.co.ukPart of the Business Link Magazine Group:Armstrong House, Armstrong Street,Grimsby, N E Lincs DN31 2QE EnglandAll rights reserved. No part of this publication may bereproduced, transmitted, photocopied, recorded orotherwise without express permission of the copyrightholder, for which application should be addressed firstto the publisher. While every reasonable care is taken,neither the publisher nor its participating agents acceptliability for loss or damage to prints, colourtransparencies, negatives or other material of whatevernature submitted to this publication. The viewsexpressed in this publication are not necessarily theviews of those held by the publisher.COVER PHOTOGRAPHSCOURTESY OFMain:shutterstock.com/OrtodoxTop: UNI Packaging UKMiddle: FFP Packaging SolutionsBottom: shutterstock.com/Paula CobleigheasyFairs36Packaging Innovations, the leading packagingevent, returns to the NEC, Birmingham on 25thand 26th FebruaryCFIA43Since 1997, the largest factory in France hasinvited sector professionals to a valuable event inBrittany, the capital of the food processingindustryPro2Pac44Pro2Pac will take place alongside IFE, andWaste-Works, the only Waste & Resource eventdedicated to the food and drink industry, atExCeL London on 22nd to 25th MarchIFE48Returning bigger, fresher and more innovativethan before, IFE 2015 provides the latest foodand beverage products to hit the marketEvents50Your chance to keep abreast of forthcomingexhibitions and food fairs from around the worldClassified 53Food & Drink Diary 5403_Layout 1 30/01/2015 14:01 Page 1J&E Hall’s new beer coolercuts energy bills by up to 40%J&E Hall’s new ambient beer cooler can cut pub andrestaurant energy bills for cellar cooling by up to 40%.The unit makes use of free cooling during winter months toallow beers to be stored at a perfect temperature. When theoutside temperature is low enough, the fan-based cooler bringscold air into a beer cellar to reduce the temperature and willswitch off the main refrigeration cellar cooler system while itdraws cold air from outside – cutting energy bills and savingmoney.J&E Hall Product Sales Manager Tony Twine says, “The newambient beer cooler makes a significant difference. The key to this is theuse of free cooling, cold air from outside, a ‘greener’ way of cooling beers. The J&E Hall ambientbeer coolers contain no refrigerants. This also helps reduce servicing costs and extends the life ofthe main cellar cooling system.”IT system helps ensure fresh fishdeliveriesFood industry specific softwarefrom CSB-System is helping Frenchfish wholesaler Jean Lebeaupin inthe efficient daily compilation anddelivery of orders to restaurants andretailers.The system is able to assessavailable stocks each day andallocate these against customerorders. It ensures efficient pickingand optimal loading of the deliverylorries and is able to calculate thefastest delivery route. Since theintroduction of this paperless system,the number of complaints has beenconsiderably reduced.On receipt of the daily delivery, thefresh fish is quality assessed, given aunique lot number and entered into the CSB system with their quantitiesand values. Once orders have been assigned, CSB’s route optimisationsoftware calculates the fastest and shortest routes for the nine trucks. Thepaperless order-picking process then uses mobile devices for pickers toload the lorries, with the system defining the sequence so they can beloaded in an optimal way.Versatile ink particularlysuited to polyethyleneLinx Printing Technologies has introduced a new inkto its range that offers excellent adhesion topolyethylene and most polypropylene applications,and which is suitable for non-contact food packaging.Linx Black PE Ink 1130 has been formulated inparticular to meet the specific challenges of effectiveprinting onto polyethylene and polypropylene, whichare widely used materials in many different packagingapplications.Ndidi Ihekwaba, Product Specialist, Inks, LinxPrinting Technologies, says, “PE and PP aretraditionally challenging substrates to adhere to, due to their low surface energies. Linx Black PEInk 1130 is able to overcome this challenge and creates excellent adhesion to these substrates,ensuring a quality code each time.”Linx Black PE Ink 1130 provides excellent print quality and is fast drying to deliver clear, readablecodes in even the harshest of production environments. The ink can be specified with all new Linx5900 and Linx 7900 printers incorporating Midi and Ultima heads.Star puts Brakes ontrack for eco-friendlyfutureBrakes has replaced the cold storage refrigerationplant at its Bishop’s Stortford facility with a newsystem from industrial cooling specialist StarRefrigeration.The existing ammonia refrigeration plant at thesite had come to the end of its operational life afterforty years. Brakes required a replacement systemthat would improve operating efficiency and reducerefrigerant charge. Focusing on these two keycriteria, Star’s solution was to install a 250kWcapacity Azanefreezer. The high performanceindustrial freezer operates on a low charge of naturalrefrigerant ammonia and has zero global warmingpotential.Star’s Azanefreezer supplies cooling to a frozenfood cold store at the Brakes distribution centre.Cooling is supplied at minus 25ºC via two ceilingevaporators. The energy efficient design will helpBrakes to reduce running costs and cut greenhousegas emissions for over a quarter of a century.4 Food & Drink Internationalwww.fdiforum.netGlassGuard warning againstlighting complacencyGlassGuard is keen to remind foodmanufacturers not to overlook lightingwhile focusing attention on the new Issue7 of BRC Global Standard for FoodSafety.While there are no changes to lightingrequirements in the new issue, saferlighting specialist GlassGuard isreiterating its message to foodmanufacturers to consider their lightingrequirements, alongside the criteriachanges.Last year the BRC reported BuildingFabric (Section 4.4) and Glass, BrittlePlastic, Ceramics and Similar MaterialsControl (Section 4.9.3) as leading failuresin a list of leading non-conformity groups,prompting GlassGuard to warn manufacturers against complacency when itcomes to lighting management.GlassGuard subsequently welcomed the Guide to Lighting Best Practicefor the BRC Global Standard for Food Safety, published by the BRC toassist food manufacturing and packaging sites to develop robust systemsand procedures which adequately meet the lighting requirements of theBRC Global Standard for Food Safety.04-05_Layout 1 30/01/2015 14:02 Page 1Food & Drink International 5www.fdiforum.netHolfeld Plastics on top of the worldHolfeld’s rPETeCO, the lightweight, low carbonmaterial, enjoyed a hugely successful 2014 withthree major awards under its belt and three HighlyCommended placings. Now the product has beennamed WorldStar winner in the Food Packagingcategory by representatives from seventeenpackaging associations, among some 69 globalcontenders.Holfeld uses 20% less plastic bottles to blendtheir rPETeCO material – only eight out of tenwaste plastic bottles used. rPETeCO is a multi-market robust tactile lightweight low carbon material using 90% recyclate each bottle weighing anaverage of 20g or approximately 50,000 bottles to the tonne.During 2013, Holfeld used 439,000 less waste plastic bottles to produce rPETeCO than theywould have done had they used rigid PET. The material has a non-plastic appearance where addedvalue is required. Holsorb in the base eliminates the need for a soak pad.Greencore slashes gas bill withSpirax Sarco heat exchanger systemUpgrading its domestic hot water system from two shell-and-tube calorifiers toa compact Spirax EasiHeat solution has enabled Greencore Food to Go toreduce its annual gas bill by £30,000.The EasiHeat steam-to-hot-water system provides crucial hot water for staff atthe company’s production facility at Manton Wood in Nottinghamshire. The siteemploys up to two thousand people, who produce 3.5 million packs ofhandmade sandwiches, baguettes and wraps each week. Staff must adhere to arigorous daily hand-washing regime, due to the risk cross-contamination posesto allergy sufferers. EasiHeat is based around a compact plate heat exchanger and providesinstantaneous hot water at constant temperatures. Because it does not storewater like a traditional shell-and-tube storage calorifier, which must store waterat 60°C or higher to aid the prevention of Legionella growth, less energy isneeded to heat the water. This enabled the Manton Wood site to reduce itsannual gas bill by £30,000.Further savings will be achieved by reduced maintenance costs. Greencore’stwo calorifiers needed to be stripped down regularly for insurance inspections, atask that typically took several days. The EasiHeat system does not needdismantling for insurance inspections, saving substantial time and maintenancecosts. WinTec Technology conquers “Industrie 4.0” wenglor’s new WinTec Transit TimeSensors are equipped with everything forintelligent, future automation. Incombination with three Industrial Ethernetvariants, innovative WinTec Technologymakes the OY2TA104P0150 a new pioneerfor “Industrie 4.0” applications.wenglor’s highly advanced product isthe only Transit Time Sensor on the marketwhich is available with Ethernet’sPROFINET protocol, as well as withEtherCAT or EtherNet/IP. The sensors can communicate actively and are known individually by thesystem, and thus fulfil “Industrie 4.0”’s highest conformity level, namely CP44. Furthermore, thelarge working range of 0.1 to 10.1m qualifies the new product for numerous complex detection andmeasuring tasks in modern automation systems.An integrated PoE interface reduces expensive wiring effort to a minimum and the compacthousing permits space-saving, easy installation. A built-in web server assures worldwide access toall sensor functions. The convenient plug&play functions, as well as the graphic OLED display, alsoensure ease of use.Buffaload double-deckersreduce road miles forCo-op Primary DistributionBuffaload Logistics has further expanded itstemperature controlled double-deck trailer fleet toprovide continued support for The Co-operative’sPrimary Distribution network. The additional highcube trailers will maintain low traffic movementthrough reduced handling and fewer road miles.With 44 pallet capacity, the double-deckersprovide up to 66% more volume than conventionaltemperature controlled trailers and enable The Co-operative to cut handling times, reduce road milesand achieve optimum efficiency throughout the fleet.John Sabey, responsible for The Co-operative’sthird party Primary contracts, says, “The Buffaloaddeckers allow us to be competitive on pricing, due totheir high capacity, and reduce the physical amountof inbound movements through our gates. Thetrailers bring flexibility to our fresh, inbound networkand the Buffaload operations team works closelywith our internal planning team to ensure best fleetutilisation and ‘vehicle fill’ are achieved. At busytimes, they also complement our secondary storefleet by supporting depot transport operations.”04-05_Layout 1 30/01/2015 14:02 Page 2Loma Systems launches newSureTune metal detectorLoma Systems has launched its IQ3+ SureTune metaldetector. This high performance unit is packed with newtechnologically advanced features, designed to make thecompany’s flagship IQ3 model fully compliant. Loma’s ST metal detector offers a series of newpatented features which have been developed to make itideal for high speed food manufacturing lines and co-packers. These include a new Access Log to supportCFR21.Part 11 user traceability, an Enhanced Tracker tocompensate for product variations and AutoBalance to compensate for changing environmentalconditions and an intelligent Product Validation System, which now memorises defined testintervals by product and the individual retailer’s code of practice. This new generation model continues to lead the way in tackling key industry challenges andstandards, notably food inspection Codes of Practice and user traceability. Its breakthroughinnovations, including a new touch screen display and software upgrades, can be retrofitted toexisting Loma IQ3 systems on request. Fresh food producers benefit fromBOGE’s complete gas and air solutionBOGE is deliveringreliable performance andhigh quality air andnitrogen to producers offresh food, while alsoenhancing energyefficiency to help reduceday to day productioncosts.Thanks to BOGE’scomplete compressed airand nitrogen solutions,ensuring the supply of absolutely oil-free compressed air and nitrogen witha purity level of 99% throughout the entire fresh food production processhas never been easier. The solution incorporates a frequency-controlledSLF40-3 BLUEKAT screw compressor, which supplies Class 0,100% oil-freecompressed air, and an N2 generator with down-stream container, whichsaves costly purchasing fees by producing nitrogen of the highest qualityin-house and on demand. Keltenhof Frischprodukte GmbH is benefiting from BOGE’s completesolution. By improving compressor efficiency and recovering heat energyfor heating administration rooms, the green salad and herb producer hassaved more than €18,000 per year since it introduced the BOGEcompressed air and nitrogen formula.More good news for Universal Flexible PackagingUniversal Flexible Packaging has moregood news to add to its recentannouncement of an £11 millioninvestment in a new factory in LewisherRoad, Leicester.The company has announced that itscurrent Lunsford Road site, which was dueto be sold as part of the new factory deal,will instead remain with the company andbecome a Peanut and Tree Nut site. Thenew plans for Lunsford Road, which require an investment of £2.3 million, have been funded by theCambridge & Counties Bank, Managing Director Tinku Durrani, and the Durrani family propertycompany MANN Properties (Leicester) Ltd.The announcement means that as of Spring 2015, the company will be operating from 170,000sq ft of production facilities, and it is currently advertising twenty new jobs.Tinku Durrani says, “It’s been an exciting twelve months for us and we can’t wait for the newplant to be up and running in 2015!”Dalco increasesthroughput thanks to AirProducts’ Freshline LIN-ISDutch food producer Dalco Foods has optimisedits product forming process, thanks to Air Products’liquid nitrogen injection solution, Freshline LIN-IS. Dalco turned to Air Products to find a way tooptimise its forming process and increasethroughput by rapidly cooling its vegetarian doughmixture. A dough that is too hot fails to stay in shapeand can stick to the forming plate, resulting inunnecessary waste. Freshline LIN-IS is a proven cooling method thatinjects liquid nitrogen through nozzles fitted in thebottom of any type of mixer, helping to controlproduct temperature, prevent microbial growth, andincrease thoughput.By fitting Freshline LIN-IS to the mixers, Dalco cannow set its mixture to the ideal temperature andtexture, quickly and easily. This accurate andrepeatable temperature control of the doughensures the forming step is successful – increasingthe rate at which products can be made andreducing waste by 2%. 6 Food & Drink Internationalwww.fdiforum.netNext generation conveyor beltlightens the loadThe innovation teamat Ammeraal Beltechhave launched the uniULB Belt, whichcombines exceptionallight weight withstrength and costsavings. Launched atIPPE 2015, thepremium-qualityplastic uni ULB Beltcombines food safety, hygiene, easy maintenance, and easy cleaningfeatures with power and energy savings, thanks to its light weight, as wellas competitive pricing. Giuseppe Allais, the company’s Food Industry Segment Manager, says,“We wanted to create an all-round economical solution for light- to medium-duty applications, especially where hygiene and ease of cleaning areimportant.“Our best-of-class pin/hinge belt structure is ideal here – it’s easy toremove and reuse, making maintenance much easier, and its light weightalso makes handling much less labour-intensive. The uni ULB Belt is alsovery well suited to non-food packaging, wherever moderate speeds andlow-impact processing are the requirement. This is really a true multi-purpose product, and it’s unique and innovative in the market.”06_Layout 1 30/01/2015 14:02 Page 107_Layout 1 30/01/2015 14:03 Page 18 Food & Drink Internationalwww.fdiforum.netWORLD SEAFOOD CONGRESS 20155-9SEPTEMBER 2015WORLD SEAFOOD CONGRESSGrimsby Institute, Nuns Corner, Grimsby, NE Lincolnshire DN34 5BQSKILLS SUSTAINABILITY INSPECTIONUPSKILLING FOR A SUSTAINABLE FUTUREHOSTED BYwww.wsc2015.comwww.seafish.org@world_seafoodVisit the World Seafood Congress 2015 website to:• Register for the World Seafood Congress• Become a sponsor – bespoke packages available• View the Call for Paperswsc2015.comASSOCIATE BODYHOSTING VENUEPLATINUM SPONSORMEDIA SPONSORGuest Speaker Sir Ranulph Fiennes confirmedThe World Seafood Congress bringstogether a global audience of seafoodprocessors and importers, academia, fishinspectors and government to discuss theissues affecting this fast-moving sector.Food & Drink International is delightedto announce it is the official mediapartner for the 2015 event, which will beheld on 5th to 9th September in Grimsby.The town, often referred to as Europe’soriginal food town, is the home of theUK’s seafood industry – and the home ofFood & Drink International. The eventcelebrates this heritage while looking tothe future.Each day of the World SeafoodCongress will see discussions in tradinginitiatives and developments in theseafood sector. Different countries’outlooks on key issues will be explored asthe industry enters an era which is foreverchanging, bringing new opportunities andchallenges in sourcing and trading seafood.Discussions in innovation will be linkedto training and skills requirements for thesector and further opportunities. Newproduct development in seafood andtechnology, as well as innovation andquality management in the industry, willalso feature throughout the event.‘Upskilling for a sustainable future’ isthe theme of this year’s event. There willbe interactive sessions on skills in theseafood sector, seafood sustainability,seafood innovation, seafood markets,seafood integrity, global export and trade.The Congress will feature high profilespeakers from the Centre for Environment,Fisheries and Aquaculture Science, theSeafish Industry Authority and manymore, as well as academic establishments,NGOs and industry leaders.There’ll be much more on the WorldSeafood Congress in Food & DrinkInternational as we lead up to the eventin September. It’s going to be an eventyou won’t want to miss. In the meantime,visit www.wsc2015.com to find out more.Upskilling for asustainable futureFood & Drink International is the official media partner of thisyear’s World Seafood Congress – the biggest global gatheringof the industryMEDIA PARTNER08_Layout 1 30/01/2015 14:04 Page 1Brewery developmentgains from LanemarkinstallationThe rejuvenation of a brewery is gaining from thecommitment to high quality production processes –including a process gas heating system supplied byLanemark International.The new facility, which brings the PhippsNorthampton Brewery Company’s production backhome, has reinvigorated a long established brewinglocation and is now set up to produce fifteen barrelsper brew run – each some sixty 9-gallon casks –three times per week.Adrian Langford, Lanemark International’s General Manager, says, “The heating process iscentred on the brewing copper which receives water from the mash tun and needs to achievespecific temperature levels. This includes the raising of the water temperature from 67°c to 99°c followed by a rolling boil over two hours during which hopsare added. Importantly, the speed of this process is enhanced by the performance of the burner which also maintains the required boiling agitation – a keyfactor in ensuring the ideal creation of the beer’s flavour.” Food & Drink International 9www.fdiforum.netPunnets sealedin “berry” quicktimeA Proseal designed solution,incorporating the company’smarket-leading GT3 tray sealer, isoperating at 180 packs per minutefor the high speed sealing of largeimported strawberry and raspberrypunnets at Berry Gardens.To ensure the longest possibleshelf life, especially for importedfruit, fast packing speeds are vital.Imported punnets tend to be widerand shallower than normal and thisbrings further challenges in achieving high speeds. Proseal has thereforedevised and installed a bespoke feed system for the GT3 in order tomaximise speed and reliability throughout the eighteen hours a day thatthe line operates.The sealing process includes a checkweigher over which filled punnetsare fed, with any under or over weight packs then diverted to be adjustedas required. Accurate weight punnets are moved to the GT3 via a specialconveyor that provides maximum flexibility in the feeding of the punnetsinto the tray sealer. New optical sorter for lettuce industryProduct sorting specialist Tomra has introduced a cost-effectivepre-sorting machine for the baby leaf lettuce and spinach industry.The new Falcon sorter offers fast and efficient detection andremoval of gross defects at the earliest stage immediately afterharvesting. The machine uses high resolution cameras and LEDlighting to detect even the slightest differences in the produce’sstructure or chlorophyll level.The Falcon features a special infeed shaker to spreadthe produce evenly on a high speed acceleration infeedbelt which then guides the leaves to the inspectionzone. The produce is inspected ‘in-flight’ whichensures a thorough and high precision analysisunaffected by a potentially dirty belt. Immediatelyafterwards, all foreign materials, including heavy items,are removed by high speed ejection fingers to the rejectionzone while the good produce continues its flow. This highlyaccurate system minimises false rejects.Tomra equipment is available in the UK and Ireland from Stein Solutions.Ishida solution meetsfixed weight fishchallengeIshida Europe has devised a bespoke weighingsolution that has enabled Deutsche SeeFischmanufaktur to weigh just two large fresh fishfillets for a fixed-weight pack while keeping the overallweight close to target.Prior to the Ishida installation, the company usedstatic weighing by hand, with the worker having tomake quick decisions as to which two fillets toallocate to a pack. This was slow and also resulted insignificant overweight. With a speed of thirty packsper minute, the new system can now deliver up tonine tonnes of packaged fish per two-shift day. Moreimportantly, the reduction in giveaway has enabled itto pay for itself within two years of installation.The Ishida solution was to design a completeintegrated packing line based around a special 14-head screwfeeder weigher with scraper hoppers thatuses rotating metal spirals to gently propel the stickybut fragile fillets into the hoppers.AutoCoding Systems “soups up”coding and packaging integrityGreencore Prepared Meals arereducing the risk of coding and packagingerrors across their factories, thanks toAutoCoding Systems.The site at Kiveton comprises a bakery,a ready meals factory and a soup andspreads factory. Each factoryimplementation brought its ownchallenges – manufacturing products for anumber of different retailers with varyingpackaging designs and different codingformats. The risk of human error is,therefore, greatly increased when productchangeovers take place.In the soup and spread factory, theAutoCoding product controls DominoA300 inkjet printers, Loma CW3 combicheckweighers/metal detectors and SICKCLV431 barcode scanners. An array of four SICK barcode scanners aremounted on the line to ensure every barcode is scanned on the spinningsoup pots as they come down the line. The AutoCoding system sets up theDomino printers with the correct date code and coding profile for theproduct. This eliminates the need for operator intervention.09_Layout 1 30/01/2015 14:04 Page 1Next >