< Previous20 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS - AISLE MASTER Q&A Aisle Master recently delivered a forklift solution to Higgidy, a producer of pies, quiches and savoury snacks. Can you tell us a bit more about the process and the solution? Since it was established in 2003, Higgidy has seen significant growth and is now a household name. The company’s three warehouses at its premises in Shoreham-by-Sea are packed full of ingredients such as flours, oils, herbs, butter, cheeses, eggs and frozen vegetables. These are transformed in nearby kitchens into its ever-growing range of baked products that are stocked by major supermarkets across the country. To ensure efficient materials handling and space saving storage on site, Higgidy is using two Aisle Master articulated forklifts from the Irish manufacturer Combilift, which work in the ambient, chilled and cold store areas as well as in the packaging stores. What are the benefits of these Aisle Master models over traditional forklift solutions? The Aisle Master models have replaced a stand-on stacker truck and a counterbalance forklift and a main reason for the choice of these was their ability to “do everything”. Both previous trucks were very limited in where they could operate, which also had implications if they ever broke down. The stacker truck could only work in the cold store for example, and the Q&A Aisle Master Food and Drink International recently spoke with Aisle Master, suppliers of the versatile articulated forklift that does it all, about a recent solution they delivered for a food maker and the advantages and versatility of its forklift. 16-21.qxp_Layout 1 28/01/2020 11:50 Page 5Food & Drink International 21 www.fdiforum.net LOADING BAYS AND DOORS - AISLE MASTER Q&A counterbalance truck didn’t cope well with some of the surfaces when it was outside. The beauty of the Aisle Masters is that they can go everywhere, offload outside and bring goods directly to their designated storage bays so we have a much higher degree of versatility. Making the most of available space was a further issue that was solved thanks to the Aisle Master’s design and its ability to work in narrow aisles and confined areas. John Kelley of materials handling consultants Mexmast recommended the trucks and worked with Logistics Manager Dean Parsons and the team on the configuration and installation of a double deep storage system in the packaging warehouse, which has doubled its previous capacity. How do your models hold up in chilled storage environments? The constant transition between -22° C in the cold store, +3° C in the chilled section through to ambient can be challenging for any equipment and Higgidy needed to make sure that any new trucks could cope with these temperature fluctuations with no adverse effect on performance. The cold store spec Aisle Masters are fitted with anti-mist glass on the top, front and rear windscreens and the powerful 930 Ah batteries counteract any possibility of battery draining which can be a problem in extreme cold. Tell us a bit more about the specs and features. The trucks have other features that were designed around Higgidy’s specific requirements, namely triple telescopic forks. The 1,200mm closed length of these enables the Aisle Masters to manoeuvre around tight angles and corners, particularly those in the cold store and the extended length of 2,350mm means they have no problem accessing pallets, even in the double deep racking. This isn’t a typical feature on Aisle Master models, but was suggested by the engineers in Ireland as the best solution. The 2t 20WE models have a rear width of 1420mm which offers excellent stability when lifting 800kg pallets of, for example, frozen spinach to the top bay of 3.6m. It’s quite a spread-out site in Shoreham and the road worthiness of the Aisle Masters is an improvement on previous trucks, enabling them to move quickly between the various units and offering a smooth ride on a bumpy road for the drivers. To find out more, visit www.aisle-master.com, or www.combilift.com, or www.mexmast.co.uk. What lasting impacts have the Aisle Master models had? In the few months since the trucks have been on site they have proved to do just what they promised and when the current contract hire of the two older electric counterbalance forklifts runs out with Mexmast in the next year or so they will be replaced with Aisle Masters. There are a lot of benefits from using just one type of truck, assuming it is one that has the capacity to do so much and work long hours on just one battery charge. Now Higgidy will only need the one type of licence for its drivers and maintenance is simplified too. 16-21.qxp_Layout 1 28/01/2020 11:50 Page 622 Food & Drink International www.fdiforum.net CONTAINERS AND PALLETS While wood dominates the pallet market, a new wave of pallets, from recycled plastic pallets to those specialised for tracking and made from creative materials like coconut husks, are poised to take over. A new While wood dominates the pallet market, a new wave of pallets, from recycled plastic pallets to those specialised for tracking and made from creative materials like coconut husks, are poised to take over. 22-24.qxp_Layout 1 28/01/2020 11:52 Page 1Food & Drink International 23 www.fdiforum.net CONTAINERS AND PALLETS Pallets and containers are vital within the food and drink supply chain, a factor that is no different to most other manufacturing industries. After a twist revelation last February, during one of 2019’s many periods of Brexit anxiety, that the UK could experience a shortage of the type of pallets needed to continue exporting products to the EU, the remainder of the year’s pallet news thankfully refocused on the growth of the sector and exciting new developments. Companies are ready to innovate within the flourishing pallet market, which is set to be worth $95 billion by 2029, and change is firmly on the mind of pallet producers, providers and users, focusing on creating pallets that reflect topical issues including environmental friendliness and waste reduction, improving pallet traceability and the automation boom in our industry. While wood remains a top seller, a new generation of pallets is certainly on the way. When one attempts to conjure up an image of a pallet in the mind, often the first picture seen is that of a wooden pallet. Accounting for more than ninety per cent of pallets, they are cheap, easy to repair, sustainable and can be recycled. However, wood doesn’t last as long as other pallet materials, meaning new pallets are called for more frequently than if one were to utilise, say, plastic pallets. Wooden pallets are also heavier than plastic, meaning higher transport and fuel costs. The maintenance and health and safety issues that come along with wood pallets are a major disadvantage too - wood decays, splinters, could leave nails behind and is susceptible to fungus, mould and insect infestation. This is problematic for food companies which face high hygiene requirements and sees a significant number of pallets go to landfill, rather than reused. Wood pallets are also subject to ISPM15, the international phytosanitary measure that means timber must be heat treated if it is over 6mm in thickness to make sure it is clean of invasive species when shipping products to different countries. Wood pallets are commonly employed for one-way journeys, such as single-use wood stringer pallets. Though they have a short lifespan, and many are damaged during transportation, they are cheap. It can therefore be more economical to buy new pallets than spend more to upgrade to those that one will want to retrieve and repair. Using these short- lived pallets engenders a variety of concerns, including the fact that they use large amounts of lumber and their frequent disposal produces significant waste. In a more environmentally conscious society, pallet customers are gradually shifting their attention to longer- term reusable options that can be utilised in circular pallet plans. Companies are looking to pallet pooling, where pallets are leased and shared between multiple operations. As pooled pallets need to be able to take many trips, they are built to be more robust, which is better for avoiding product damage, giving companies access to higher quality pallets. With pallet pooling businesses can also flexibly increase the number of pallets they need during busy periods instead of having to buy more, and the smooth flow pallet pooling creates means that less storage is required for pallets. The other main pallet of choice, quickly rising in adoption, is the plastic pallet. Comparatively lightweight, lowering transportation costs as well as potential back injuries, plastic pallets last longer than wood, approximately 250 trips, thus create less waste, and are ISPM15 exempt. They are particularly popular in the food industry because they are not porous or susceptible to fungus, mould or insects, are impervious to water and can be easily cleaned and sterilised, meeting the industry’s strict hygiene regulations. Plastic pallets are key for food and beverage companies where contamination can see product recalls, lost sales and revenue. The food industry therefore frequently looks to hygienic plastic pallets with a smooth surface to avoid contamination. With an attached container, it can be ensured that food is safely stored. New moulding processes are also producing stronger plastic pallets, decreasing breakage risk. Further, as plastic pallets are created with a mould, coming out identical every time, they have become the more desirable choice for the growing number of firms investing in automated systems for materials handling, palletising and storage, where the most reliable and, importantly, compatible pallets are needed - those designed to be used with new automated equipment that won’t jam systems. © Shutterstock /Fahroni 24 Á 22-24.qxp_Layout 1 28/01/2020 11:52 Page 224 Food & Drink International www.fdiforum.net CONTAINERS AND PALLETS However, manufacturing plastic pallets consumes more energy and is more expensive, they can cost three times as much as wood pallets and therefore are not desirable for one-way shipping, and in instances where it is unlikely the pallets will return. There is also the worry that using plastic pallets will increase use of fossil fuel materials and carbon emissions. In addition, though they can be recycled, potentially straight into another pallet, this process is generally more difficult, especially if a company using the pallets is based in an area with poor plastic recycling infrastructure. In response to concerns over the environmentally friendliness of plastic pallets, the number of pallets made of recycled plastics, including old pallets and household waste, is surging. This, paired with the added benefit that plastic pallets last much longer than wood pallets, sees these pallets become a more sustainable choice. Plastic packaging taxes are also pushing customers to consider recycled plastic pallets, such as the UK Government’s plan for a tax on plastic packaging with under thirty per cent recycled content. Further, plastic pallets are particularly useful in pooling where reuse is central to operations. The pallet sector is not limited to wood and plastic of course. Indeed there are many innovative new materials that are hitting the market. Paper-based pallets, made from paper board or moulded paper pulp, are one now well- established option. Often using recycled materials, these pallets weigh less than wood and advances in design and engineering technology are improving the loads they can carry. As a lightweight option they are suited for air freight and shipping, and without nails and splinters they are simple to handle. Additionally, paper pallets are exempt from ISPM15 regulations, enabling worldwide shipping, and are praised for being cost effective, recyclable, easy to dispose of and useful for one-way transport. Primarily the paper pallet market consists of corrugated paper pallets and honeycomb paper pallets. Another, rather creative, material is eco-friendly biodegradable coconut husks, which when used is said to create pallets that are cheaper and lighter than wood but remain strong - the CocoPallet can withstand a static load weighing 3,000kg. While the fibre of the husk can be used, so can the lignin as a glue. Employing coconut husks also makes good use of coconut waste. Though 7.4 billion coconuts are harvested annually worldwide, approximately eighty-five per cent of the husk is wasted. Moreover, when these pallets are no longer functional, they can be made into mulch. Planks for pallets are also being made from hemp, able to biodegrade to compost. An Australian entrepreneurial company has patented a product using industrial hemp fibre that is recyclable, nonporous, fire and water resistant, does not require heat treatment and is food industry compliant. Further influencing development in the pallet industry is the desire for increased visibility of pallets as they travel through the supply chain. Pallets, primarily plastic, have been designed to feature space for RFID tags and IOT beacons to allow tracking. Some are utilising this technology to trace lost pallets, for general effective pallet management and real time location tracing, while others are embracing the wide breadth of information sensors on pallets can record for condition monitoring, to oversee the safety and quality of goods. © Shutterstock /Fahroni 22-24.qxp_Layout 1 28/01/2020 11:52 Page 3Food & Drink International 25 www.fdiforum.net READY MEALS P erhaps it is a result of consumer tastes opening up, or maybe it’s a sign of the busy lifestyle many are experiencing, but the ready and convenience meals market has boomed in recent years. Where once people dined on sandwiches and crisps at the office table, it’s now possible to see Indian, Chinese or Japanese meals – all cooked within the microwave. This trend has exploded across the UK and Europe, even reaching as far as China and the US. Advances in technology have seen manufacturers of frozen and ready meals expand their product portfolios in recent years. With consumers demanding convenient, high-quality food in increasingly large quantities, manufacturers are drawing upon new technologies that allow them to vary their recipes and create better quality produce. As a consequence of changes in the global economy, the public are spending less on perishable foodstuffs. This has presented opportunities to manufacturers of ready meals, but there are challenges, too. Market analysis suggests that today’s consumers, particularly young people, are demanding experimental frozen foods that go beyond the bog-standard pies, chips and peas orthodoxy of yesteryear. As people travel more, they are being exposed to new flavours, and this is one factor that is driving product diversification within the industry. Another is healthy living. This has led to a boom in the alternative ready meals market, particularly for oriental and continental food, which now occupies dedicated shelf space in many supermarkets. It is also not unusual to see low calorie and healthy living options available in ready meal format. These range from diet versions of traditional ready meals, to dedicated healthy options themselves, 26 Á Ready to cook The ready meals industry has experienced significant growth in recent years, and this trend doesn’t look to be slowing down. © Shutterstock /Sergey Mironov 25-27.qxp_Layout 1 28/01/2020 11:54 Page 1READY MEALS 26 Food & Drink International www.fdiforum.net and represent consumer shifts towards higher transparency in foodstuff ingredients. This range of demands from consumers creates difficulties within the manufacturing line, particularly in mixing and blending equipment. Portions need to be measured carefully, and because the products are often cooked within their packaging, extra care must be taken in quality control and monitoring stages. High profile recalls in recent years have done little to stymie the popularity of ready meals, but they can leave a brand effectively barred from a supermarket entirely. It’s more common for ready meal manufacture to either be outsourced entirely, perhaps to a contract manufacturer who specialises in such things – or for multiple lines to be used. In the latter case, the multiple lines can be set up for vary recipes and ready meals, allowing continuous production without changes that might compromise the ingredients. Contract manufacturing remains a popular option, however, and there are a number of such companies that specialise in ready meals. Traditionally own-brand ready meals sold by retailers will have been produced at a contract manufacturer, and it’s not unusual to see that rival supermarkets have used the same company. One of the biggest factors of ready meals, however, is its packaging. Ready meal packaging usually comes in two parts. A plastic material frame with a film lid, and then a sleeve over the top of that. The ready meal is often cooked within the frame and film, so it is often to removable sleeve that contains the branding, information and labelling for © Shutterstock /Elena Veselova 25-27.qxp_Layout 1 28/01/2020 11:54 Page 2READY MEALS Food & Drink International 27 www.fdiforum.net © Shutterstock /alterfalter the product. Cartoning and sleeving technology has been around for a long time, but the ready meals sector has been a big cause of its resurgence in recent years. Labelling on the sleeves does cause some problems, mostly due to the relative lack of space compared to fully packaged products – and the additional information that needs to be included (such as how to microwave or oven cook the meal, from chilled or frozen). This means that there is less space for branding, particularly as a photo shot of the finished meal is often also a prerequisite. Ready meals create something of a conundrum for packaging design, least of all due to the vast amount of information – but also because it is more often than not the ingredients and materials used that determine a sale, rather than the aesthetics. Just about any consumer who purchases such a meal is doing so due to convenience, and therefore does realise that the finished product will likely not be as high-quality as one made by hand. It is a sacrifice they are willing to make, but it does mean that idealistic or misleading packaging is more likely to generate scorn than interest. In fact, this is a trend recognised by many in the industry, and it’s not difficult to see that many mainstream ready meals feature very plain and realistic packaging – with accurate pictures of what the food will look like. This is something that has been learned through experience, as many things about ready meals have. In terms of age, the market is actually quite a new one (at least compared to longstanding industries that have existed for hundreds of years), and there are still opportunities to be had and things to be found out. But don’t let the relative youth of the industry fool. Ready meals and convenience foods are here to stay. 25-27.qxp_Layout 1 28/01/2020 11:54 Page 328 Food & Drink International www.fdiforum.net PACKAGING SPOTLIGHT We live in an era of demands. From the demands of the health conscious to those who want greater transparency of ingredients and labelling, through to some arguing on the predatory nature of packaging, its environmental impact, its waste content and even whether animal matter is used in the production of its manufacturing. The sheer number of complaints that can be thrown at a company is growing out of control, and it often feels like packaging takes the brunt of it. With people clamouring for more information, manufacturers clamouring for lesser costs and Governments keen to punish for any waste, it’s a trying time to be a part of the industry, and yet to ignore those issues invites disaster. The goal, as wild as it seems, is to exceed in all aspects no matter the perceived difficulty. Design Packaging has long been the determining factor in the success of many brands, and this has changed little in recent years, but A sector always on the move Made local. Limited waste. Environment conscious. No contaminants. Freshest food. The standards to which packaging is held is at times more rigorous than the food it protects. With so many demands coming from so many directions, how does the industry cope? 28-33.qxp_Layout 1 28/01/2020 12:32 Page 1Food & Drink International 29 www.fdiforum.net PACKAGING SPOTLIGHT © Shutterstock /Gts with companies beginning to perfect this art, businesses need to compete on different terms. What works and what does not is becoming increasingly known, which means businesses need to seek USPs in other ways. Digital technology has certainly provided more flexibility for packaging design, especially as legal requirements have required much more information is on packaging that was previously the Signed. Sealed. Delivered. With the increased customer focus on postable items such as health foods, drinks and gifts, UK plastic bottle manufacturers Measom Freer have developed its very own recyclable Post Bottle (Ref 6143). With a flat rectangular shape, the bottle can easily be boxed and posted through standard letterboxes, fitting the UK large letter dimensions. Made from clear PVC, which is fully recyclable, it has a capacity of 100ml with an 18mm R4 neck size. It also be made in other plastics such as recycled PE and PETG, with colours available to order. A wide range of caps and closures to suit are also available from Measom Freer, samples and orders can be placed on its brand-new website. For more information visit, www.measomfreer.co.uk. case. Many companies have introduced QR codes on their products to allow customers to receive promotional material and much else, while it also has value when it comes to traceability. Combined with this, though, the challenge for products more than ever before is to stand out on the shelves – so the importance of a distinctive, high quality package is emphasised. Design should also be in the spotlight lately due to evidence from the British Brands Group, who cited a report by Which? that identified some 150 food products which marketed themselves by imitating the packaging of better known brands. In the study, the key factor which led to the customer’s mistake was seen to be colour, so brands that rely on a distinctive colour 30 Á 28-33.qxp_Layout 1 28/01/2020 12:32 Page 2Next >