< Previous20 Food & Drink Internationalwww.fdiforum.netCONVEYINGeffector, which places the food itemwithin the bag or box, it is both thegripper and the conveyor that will makethe most contact with raw produce, givingrise to potential cross-contamination.Designs of conveyor systems have long-focused on minimising crevices and otherareas where the ingress of contaminationcan occur, while facilitating easy cleaningbetween production runs. Accordingly, there have been significantadvances in the materials used within thedesign and build of conveyor systems toensure they are flexible enough to copewith changing environments, in additionto meeting harsh wash down procedureswhich enable them to be IP69Kcompliant. As an automation and roboticsintegrator, Pacepacker favours the UPMConveyors’ High Molecular WeightPolyethene (HMWPE) design for many ofits food production clients. The sides of the conveyor are made ofHMWPE with stainless steel supportframes. This makes it fully compliant withFDA regulations and being IP69K rated,the conveyor can withstand high pressureand close proximity washdowns. Thesimplistic side channel ‘groove’ is likewisemade from HMWPE, and because thereare no pinch or trap points between theside frame and belt, it can be deployed inhygienic food processing areas, reducingthe risk of cross-contamination. Ideal fortransporting unpackaged primaryproducts, this HMWPE conveyor caters toevery type of product handlingrequirement, from raw fish, meat andpoultry to sliced vegetables, biscuits andconfectionery as well as fresh and frozenproduce.In traditional conveyors, the belt isstretched over two rollers and thisrequires regular tracking and tensioning.With the HMWPE design, the belt runsin the side channels - top and bottom. Asa result, friction is significantly cut,making for an overall more efficientconveyer system. Inevitably, production layouts change,especially if a conveyor has a 25 year lifespan. Built using joining rods, themodular conveyor designs also make iteasier to reconfigure. As they are notwelded together, the conveyor can bebroken down at any point. For example, afood production line featuring a horizontalconveyor may want to introduce a verticalelement and the insertion of modules canachieve this and increase the life of aconveyor indefinitely. Thedurability of many conveyorstoday also enables them tobe installed withinchangeable andextremeenvironments. The belt on the HMWPEdesign is so robust it can be installed inenvironments where temperatures reachor drop to +/- 200 °C. Food manufacturers want quality,reliable, high-spec systems that will lastand can be modified to boost the ROI. Inthis arena, the technology moves fast.However, as with any automationinstallation, production flow efficiency willalways take centre stage, and the choice ofconveyors is a vital link in the wholeturnkey chain. PHOTO: UPMDesigns ofconveyor systemshave long-focusedon minimising crevices andother areas where the ingressof contamination can occur,while facilitating easycleaning betweenproduction runs.18-21_Layout 1 01/02/2016 11:18 Page 3Designed for maximum available production time and operating convenience, the new modular belt conveyor in stainless steel is robust, safe and easy to clean.The standardised design and modularity make changes of the production line easy. It’s the smart, long-term investment in your bottom line and your operators!Contact us at info.uk@flexlink.com for more information or give us a call on 01908 327200.flexlink.comClean, safe conveyingFood & Drink International 21www.fdiforum.netCONVEYINGEK Automation joins forces with Jolodato offer a one-stop End-2-End solution Automated the end of your production line but still looking to reduceoverheads further? Want to expand production but haven’t got the space?Looking to drive down remote Distribution Centre operating costs? Want aone stop answer to all of these questions? Well, here it is!EK Automation, the leading provider of Automated Guided Vehiclesolutions, has recently teamed up with Joloda, the worldwide leader in loadingsystems to offer the one-stop solution that answers all these questions. TheAGVs transfer your finished goods to the despatch docks where the Jolodaequipment automatically loads a waiting trailer. The trailer becomes themarshalling area, freeing up your space. At the DC the trailer unloadsautomatically - the trailer, the tractor and driver are all utilised efficiently. Theend result is reduced manual handling, improved space utilisation, reduceddamage, improved stock traceability and reduced overheads.For more information, visit www.ek-automation.com. Alternatively, youcan email info.uk@ek-automation.com.PHOTO: SHUTTERSTOCK.COM/ASA STUDIODMITRY18-21_Layout 1 01/02/2016 11:18 Page 4PROCESSING SPOTLIGHTPOWER DISTRIBUTIONENCLOSURESCLIMATE CONTROLClimate controlfrom the smallest to the largest.See us on stand D23DRIVES & CONTR12th-14th April at the NEC2TEThere was a time when a dedication tothe highest standards would have beenconsidered a USP but retailers andconsumers alike now demand these as amatter of course.The challenge for manufacturers is toensure standards don’t slip at a time whenretailers are looking for increasedefficiency on the supply chain, costs needto be kept down at every stage as newproducts and production methods areintroduced. In many cases, this willrequire the highest degree of operationaldiscipline, excellent interdepartmentalcommunication, far greater awareness ofissues and current production status,together with automation, whereverpossible, to minimise the risk of operatorerror.All responsible manufacturers will havecarried out in depth risk assessments, andrealised how easy it is, within such highpressure environments, to get somethingwrong. Errors in component handling, outof date ingredients, coding and labellingerrors, compromised pack seals andinaccurate weights are just a few thingswhich negatively impact delivery schedulesand the bottom line in foodmanufacturing environments where shortbatch runs and frequent productchangeovers have become the norm.One obvious benefit of the rise ofautomation in the processing sector is theability to ensure complete accuracy. That’sabsolutely vital with increasingly stringentregulations on labelling – not to mentionthe huge expense that can be engenderedPart ofthe processDuring the last half century the industry has seen many changes,mainly in the complexity, demands and power of the supply chain,but has the manufacturing side been able to keep up? 22-26_Layout 1 01/02/2016 11:20 Page 1PROCESSING SPOTLIGHT2TEIT INFRASTRUCTURESOFTWARE & SERVICESwww.rittal.co.uk230 & D964TROLS 2016EC Birminghamby excessive product giveaway. This has inturn led to an increase in the levels oftraceability present within themanufacturing and supply chain – withcompanies able to find out exactly whothe suppliers were of any ingredients usedin a given batch of completed products –within a few hours.This is particularly important in thelight of recent product recalls in themarket – of which there always seems tobe one going on. Sainsbury’s was a recentstory, with loaves of bread being recalled,but one doesn’t have to think back too farto recall the horsemeat scandal. Accuratetraceability enables retailers andmanufacturers to find out where faultyproduce came from, and where it wasdelivered to. Due to the damage suchscandals can cause to the reputations ofcompanies, such as Findus and thesupermarkets who suffered at the time,many retailers now demand stringenttraceability methods to be in place. Anautomated, and perhaps more importantly– monitored – line, can help in thisregard.24 ÁPHOTO: SHUTTERSTOCK.COM/VLADIMIR NENEZIC22-26_Layout 1 01/02/2016 11:20 Page 224 Food & Drink Internationalwww.fdiforum.netPROCESSING SPOTLIGHTTake the heat off next summer – get expertadvice on cooling solutions now“Prepare your panels now and be readyfor next summer.” That’s the messagefrom leading international panelmanufacturer and climate solutionsspecialists, Rittal.“Don’t be lulled into a false sense ofsecurity because the temperatures aredropping,” advises Christian WestwoodRittal’s Product Manager for Climate offersadvice on designing effective climatecontrol systems. “Instead why not usethis time to consider your best options?“Rittal’s expert team can provide youwith free advice as to which coolingproduct is suited to your particularapplication, or arrange a survey, so wecan propose the best solution.“We always consider options with users from the perspective of functionality, energy efficiency,ease of installation, service and maintenance, based on real life data measured on site.“I cannot underline how important it is to choose the right product. Climate control is not a onesize fits all solution, and its success depends greatly on the local environment,” adds Christian.www.rittal.co.uk This improved accuracy, and thereduction in human error that comes withit, has proven itself very valuable for thepackaging industry as well. Particularlywhen dealing with the stringent legalrequirements of the labelling, coding andmarking aspects of the packaging process.The quantity of goods that passes througha single production line continues to growas technology improves, with up to 25,000units passing through a packaging line ina short frame of time. Correct andaccurate label application needs to keepup with the increased demand, and withmany manufacturers now exporting toother countries as well, the process hasonly become more difficult. During the last half century theindustry has seen many changes, mainly inthe complexity, demands and power of thesupply chain. There is a very real fear thatthe internal changes in food and drinkmanufacturing haven’t kept pace with thechanges in the supply chain. That iswhere much of the risk comes in forproblems, and in many cases can be aresult of outdated systems not beingreplaced – simply because nothing hasgone wrong yet. An automated processingsystem is more however, than just apreventative tool to problems. It is also atool to increase efficiency in themanufacturing process.With capital expenditure budgetsremaining tight, increasing numbers of26 ÁPHOTO: SHUTTERSTOCK.COM/GRAFVISION22-26_Layout 1 01/02/2016 11:21 Page 322-26_Layout 1 01/02/2016 11:21 Page 426 Food & Drink Internationalwww.fdiforum.netPROCESSING SPOTLIGHTDEPOSITORSRiggs Autopack Ltd -Manufacturer ofdepositors for the foodproduction industryRiggs Autopack Ltd is a British manufacturer of high qualityvolumetric depositors and filling machines. They are a UKmarket leader with an excellent reputation and supply theirequipment to the food production industry.The company’s origin dates back to the early 1930’s. They’re aproud member of The Fort Vale Group, a Rolls Royce plc approvedsupplier, member of the PPMA, and an ISO 9001:2008 registeredfirm with BestCERT quality ‘Gold’ customer satisfactionaccreditation.The main stay of the company is their range of depositors, fillingmachines, transfer pumps and conveyor filling lines, and take pridein supplying their equipment to a huge variety of foodmanufacturers throughout the UK and overseas. Clients range from cottage industries through to multi-nationalfood groups such as Bakkavor, Kerry, Greencore and SamworthBrothers. They also supply their depositing equipment to operate inconjunction with third party machinery such as in-line tray sealing,rotary pot sealing, thermo-form and VFFS applications.Their depositors and filling machines are built in-house at their50,000 sq ft Nelson factory; they are one of the most precise andhygienic on the market with exceptional performance,reliability and build quality. They effectively dispense hot or coldliquid, semi-liquid and suspended solid products on a damage freebasis, and accurately fill most container types or size. If you’re a small, medium or large scale food manufacturer seekinga high quality system to accurately fill jars, bottles, pots, tubs, readymeal trays, cake tins, buckets, jerry cans, pouches or bags, thenRiggs Autopack could have the solution. Tel: 44 (0)1282 440040 • Email: info@riggsautopack.co.uk Web: www.riggsautopack.co.ukprocessors are seeking operational improvements that delivercost savings, increased production levels, enhanced productquality and reduced plant downtime without the financialimplications of new equipment. As well as the requirementto speed up processes, the new techniques that are now usedcan also ensure complete traceability at every part of thelengthy supply chain, allowing inefficiencies to bepinpointed.Computerisation of procedures, together with automationwherever cost justifiable, minimises the risk of operatorerrors, either because changes to the production line aredone automatically, or because in the sampling procedures,operational personnel have no alternative but to follow pre-determined procedures prescribed by management.While software may allow companies to identifyflashpoints however, there is still a requirement ofaddressing these issues to ensure machinery runs smootherand is more energy efficient can prove to have the mostnoticeable effect on the bottom line.And that is what it will often come down to in the end,careful analysis of the ROI will always be important. Toachieve this, it’s often best to contact manufacturers ofprocess machinery directly. Many are willing to offer quotes,and might also be willing to give testimonies, figures or casestudies as to what has been achieved in other, similarfacilities.Further investment by PrincesPrinces has invested again in its Bradford (Yorkshire, UK) soft drinksfactory this year as part of an ongoing programme of investment in itsmanufacturing operations.The move, which has seen Princes install a new Ready To Drinkbottling line, follows significant investment over the past two yearsincluding the launch of a new on-site warehouse and state-of-the-artingredients processing centre.The new line produces 250ml and 500ml bottles – increasingcapacity at the site and giving scope for further growth anddevelopment of new products.The site, which employs more than 350 people, is Princes’ largestsoft drinks manufacturing site – producing in excess of 400 millionbottles of soft drinks each year. As well as supplying customer ownbrand soft drinks, the site also produces Jucee , the fourth largest UKsquash brand by volume and the only squash brand that has noadded sugar in any of its products.22-26_Layout 1 01/02/2016 11:21 Page 5Food & Drink International 27www.fdiforum.netINSTRUMENTATION SHOWCASERotronic Handheld Water Activity AnalyserWater Activity measurement is used throughout the food industry to determine the quality of a product as partof Quality Control procedures. The ‘free’ moisture can affect product shelf life, taste, contaminant growth,agglomeration and product stability. Moisture measurement techniques only provide the total moisture within aproduct which is of limited value in terms of quality.Rotronic Water Activity analysers ensure accurate and repeatable results due to long term sensor stability.Aw-Quick is an accelerated measurement mode that provides the user with results in typically five minutes; it isavailable in our laboratory grade benchtop and portable instruments. The analysers are used in qualityassurance, goods inwards, production processes and product development. The portable HygroPalm HP23-AW-Set with two interchangeable probe inputs provides off-line water activitymeasurement to confirm product stability and indicate shelf life. The Set includes a lightweight ABS carry caseand everything needed to obtain accurate measurements and to check sensor performance periodically.Please contact us for further information and a datasheet; a demonstration can be arranged.Tel: 01293 571000 Email: instruments@rotronic.co.uk www.rotronic.co.ukBox clever with DavallDavall Stock Gears introduce smooth, full stainless steel housing gearboxes, designed for the harshest of environmentalapplications. The gearboxes are ideally suited for food or drink preparation sites.The ranges are constructed with stainless steel housings (316 bevelT unit, 304 for the helical and worm units)These gearboxes are available in three gear geometries, spiral bevel, in-line helical reduction (co-axial) or worm andwormwheel reduction (right angle).The gearboxes are designed to ensure a minimum maintenance regime. The worm unit has two bearings on theworm line and two bearings on the wheel (output) line, to ensure maximum power transmission capacity.The three styles of gearboxes have a choice of reduction ratios available, worm gearing from 7:1 up to 100:1,bevel 1:1 or 2:1 and helical gearing from 3:1 up to 60:1, and power ratings from 0.18Kw, up to 4Kw.The high efficient in-line coaxial helical unit is fitted with a stainless steel output shaft, the bevelT has 316 shaftsand the worm unit is available with a stainless steel output female sleeve, with an option of a plug-in male shaft.Tel: 01707 28 31 31 Fax: 01707 28 31 32 Email: dsgpower@davall.co.uk www.davall.co.ukMecmesin announces new friction, peel and tear testerLeading testing instruments manufacturer Mecmesin has introduced its latest model, the FPT-H1 horizontalfriction peel and tear tester, designed for ease of use and supplied pre-programmed for all the main industrystandard friction-testing methods. With fixtures also for peel and tear testing, it is ideally suited to thepackaging industry, and for manufacturers, converters and users of sheet materials.In the dynamic environment of sheet and web-fed machinery, quick and accurate measurement of thecoefficients of friction is vital. Machine speeds can only be only optimised for productivity if tearing, jammingand misfeeds are prevented, so the FPT-H1 is designed for reliable and rapid testing. With an integral touchscreen to access test routines, and guidance through each run, testing requires minimal training withmaximum repeatability.For quality testing of seals, closures and perforations, and the tear strength of sheet materials, the FPT-H1presents convenience and high throughput. Affordable for the smaller user, it is also robust and reliable forthe more demanding environment. With Mecmesin’s Emperor™ software for control, data acquisition and analysis, the FPT-H1 is also ideally suited todetailed laboratory testing and extension into other tensile testing.For more information, visit www.mecmesin.com or email info@mecmesin.com. Alternatively you can call +44 (0) 1403 887503. Innovation in instrumentationIt’s never been more important for manufacturers, distributors and retailers to be totally aware of the contents andthe quality of their products. Lengthy supply chains mean there are numerous potential flashpoints so theimportance of accurate temperature measurement and instant identification of contaminants cannot beoverestimated.27_Layout 1 01/02/2016 11:00 Page 128 Food & Drink Internationalwww.fdiforum.netCLEAN AIR SOLUTIONSClean air is of paramount concern forthe food and drink industry, not only dueto the stringent requirements involved inthe manufacture of food produce, but alsoto avoid the reputational crisis of anyincidents occurring. With a variety ofharmful microbes and particles able totravel via air, there is great potential forharmful microbes to interact with theprocess at a crucial stage, possibly leadingto contaminated products. Competition in the food and drinkindustry is intense enough as it is, withoutconsidering the fallout of failing to assurethe hygiene of products. And withtraceability becoming an ever-increasingrequirement of manufacturers, it won’t bedifficult for retailers to trace problemsbackwards and identify where a mistakewas made. With recent shifts in the foodand drink industry leading to more pre-cooked meals, which can often byreheated via microwave, this becomes aneven bigger challenge. Pre-cooked mealsneed to have extremely limited contactwith the atmosphere, and if any of the airin a factory is less than clean, there will begreat chance for spore growth.That’s where clean air solutions comesto the fore. It’s worth noting that clean airsolutions as an industry is more than asingle machine which can purify air. It isalso the way a processing line is laid out,how a factory is arranged, how workersoperate – all the way through toenvironmental controls to limit exposure.While this means there might not be onecatch-all solution, it also means that thereis a range of solutions which might beflexible to varying budgets andcircumstances.In many cases the establishment of acleanroom is common, which despite thename can be as large as a manufacturingfacility or process line, or as small as asingle storage room. These can bedesigned to protect both products andpersonnel. Cleanrooms can help topreserve freshness in products as well asprevent contamination. When it comes to operating acleanroom, it’s important to rememberthat staff themselves are one of the largestfactors of contamination. This not onlyincludes particles they might bring intothe facility themselves, but also how theyoperate machinery and interact withsurfaces. Workers should use cleanroomgarments, and should be well trained andmotivated. In some cases, facilities mightalso use cleaning booths to ensure staffare decontaminated before they actuallyenter the facility. Cleanrooms, and in fact investing inclean air solutions in general, can have apositive impact on more than just hygienehowever. As dust and particles are keptaway from the process line, the health ofemployees is also improved – leading toless absenteeism, and higher levels of jobsatisfaction. This is particularly importantin the food and drink industry, due to thecareful nature of quality control, and thestringent demands placed upon staff tomeet them. As always, however, what matters themost is the bottom line of the company –and in that regard a cleanroom certainlyClean air might be necessary to meethygiene requirements, but are thereoperational benefits to the investment?Keepingthe airclean Keepingthe airclean 28-29_Layout 1 01/02/2016 11:15 Page 1Food & Drink International 29www.fdiforum.netCLEAN AIR SOLUTIONSPersonnel-Cleaning Booth ensures safeand effective powder removalWith ingredients and fine powders used within food production processes, the potential problems thatcan be caused by excessive dust and other impurities are numerous. ACI’s Personnel Cleaning Booth provides a safe and highly effective means of removing and collectingthese powders from people and clothing. It is ideal for cleaning employees’ contaminated work clothes toavoid exposing themselves, co-workers, or their work environment to elevated dust levels.The main advantage of the Personnel Cleaning Booth is that workers, without taking off clothing/PPEequipment, can remove most visible traces of any dust/fibre from themselves and clothing withinapproximately 20 seconds.The Booth itself is a self-contained, free-standing unit incorporating the company’s blower-powered,internationally-proven JetBlack personnel de-dusting system. The JetBlack delivers a high volume offiltered air at low pressure, sufficient to remove powders and dust effectively and safely, even whendirected at exposed skin.For more information, visit www.aircontrolindustries.com. Alternatively, you can emailsales@aircontrolindustries.com.delivers. Higher levels of cleanliness promote fresher produce withlower chances of defects, leading to higher customer satisfaction,and the meeting of standard requirements from large retailers. In atime where supermarkets are facing increased levels of productrecalls, namely due to the industry’s struggles to keep up with thesupply chain demand, any actions that can be taken to reduceproduct recalls will make a manufacturer popular with the bigsupermarkets. UK university becomes‘centre of expertise’ forfood authenticity testingImportant work to combat food fraud has seen Nottingham TrentUniversity recognised by the government as a ‘Centre of Expertise’ forfood authenticity testing.The announcement by the Department for Environment, Food andRural Affairs (Defra) means that the university will become part of thegovernment’s ‘Food Authenticity Network’. The network aims to bringtogether – and raise awareness of – expertise in the area of foodauthenticity. It also ensures that the UK has access to a network oflaboratories capable of testing food on behalf of retailers and suppliersand giving consumers confidence in the food they buy.Nottingham Trent University has been at the forefront of helping thegovernment to reduce food fraud for a number of years, specificallythrough the detection of undeclared offal and added blood in meatproducts.Led by Professor Ellen Billett, the university has pioneered thedevelopment of novel tests capable of identifying adulterated meatproducts through the presence of specific proteins. In addition totesting food samples, Professor Billett’s team will provide technicaladvice and guidance to industry on how to identify proteins ofrelevance to food authenticity.PHOTO: SHUTTERSTOCK.COM/MOMENTE28-29_Layout 1 01/02/2016 11:15 Page 2Next >