< Previous30www.fdiforum.netMACHINERY MAINTENANCEDowntime in the food and drink sector can have hugerepercussions. Not only can the supply chain grind to a halt,leading to products missing their slots in the schedule all theway along the line, but the simple job of repeatedlyswitching on and off machinery can lead to excessive use ofpower. It’s no surprise, then, that machinery maintenancehas taken on increased importance.The rising use of automation in the industry has led tomany businesses, in theory, having a greater say in theeffectiveness of their machinery. Certainly it should beeasier to pinpoint the location of a breakdown if software iskeeping a record of all operations. In reality, though, itdoesn’t always work like that, and the potential forunplanned downtime remains very great.One benefit, however, is the opportunity to schedulemaintenance operations at regular intervals – and thisdoesn’t have to be a question of time. Service contracts usedto revolve around specific periods of time with engineersagreeing to visit the plant every few months or so to inspector replace certain parts, but now it’s possible for engineersto analyse detailed service data to help predict the correctservice interval for each machine, based on its workingenvironment, the speed at which it runs and the number ofhours.Mel Davies of PFM Packaging Machinery says, “We have onecustomer with two identical machines that run for the samenumber of hours every week, but at quite different speeds. Thereplacement programme for parts that wear is thereforesubstantially different, but quite predictable.“The predictive element of the service inspection is considerablymore accurate and allows preventive maintenance to be achievedat lower cost. In some cases, the frequency of service visits can bereduced from four to three. In other more demanding application,it may of course be necessary to reduce the interval.”Preventive maintenance is certainly illustrating its value tonumerous businesses in the food and drink industry andcompanies such as Bosch are offering a range of options to theircustomers, from basic modules, which includes line check-ups, tofull preventive maintenance, possibly including full-time supporton-site by an embedded engineer. The level of maintenanceactivities performed, the product environment and seasonalchanges in production volume will more than likely decide on thetype of programme opted for.The Machinery Directive now requires that all machinery andproduction systems for use within the EU requires documentationof the product design processes to ensure adherence with a singleset of safety standards that span across the whole of Europe. Thismeans manufacturers of machinery must have planning, riskassessment and document management processes in place todemonstrate their compliance with these standards. From January,manufacturers across the world have also been obliged to meetwith EN ISO 13849-1:2008, which emphasises the reliability ofmachines and ensures that, if the safety control aspect is to fail –which it doubtless will, because parts can deteriorate over time –those operating the machine will be aware of it.As automation becomes more commonplace across the world,the potential problems caused by malfunctions increase – but theimproved standards and more efficient maintenance programmescan help address this.Movingon upAs automation becomes more necessary, so toodoes the introduction of an effectivemaintenance programmeSystems such as Rockwell’s AutomationIntegrated Architecture system helps end usersto better address key market challengesBARA’s AutomatingManufacturingProgramme is workingwith companies likeLaidler who can offeradvice to companiesregarding machinerysafety on anypotential projects30:Layout 1 22/3/12 15:15 Page 1PACKAGINGwww.fdiforum.net3133 From the initial stages of production todelivering the product to the retailer,there are aids to the packaging side offood manufacturing. There are manypitfalls to be avoided along the way whenpreparing food and drink for the shelf.Taking care at every stage is integral toyour operation, not only for yourreputation, but also for cost reasons too.Quality of equipmentIt is important when producingelements of food and drink to make sureequipment is performing in the best waypossible. Taking a casual attitude tostandards in this area can prove costlydown the line. If a machine is deliveringproduct, but not doing so in an efficientway, it could be affecting not only theappearance of the product, but alsocosting you excess product throughspillage or waste. Kecol have recently come across thisproblem with a client’s existing setup. Aspecialist with pumping equipment,particularly of viscous fluids, theyfound a cereal filler with problemsrelating to delivering jam. Methodsof emptying jam containers into aproduction system were too slowand messy, with difficulties alsorelating to the process being too slowand messy. Kecol solved this with a clean, efficientpumping system, allowing uninterruptedsupply of jam to the line. This improvedproduction rates, reduced waste andmeant less risk through health and safetyissues as drums were handled less bystaff. This of course means that existingpackaging does not need to be changed,meaning if one element is being failed byanother, sometimes there is a solution.Sometimes combining severalapplications together in the samepackaging line can work wonders. Puttingtogether weighing, inspection and theactual bagging or filling processes canmean more efficiency and massiveimprovements in both cost-saving andproduction rates. Heat and Control arepurveyors of processing, packaging andweighing systems and can often be calledupon to combine all elements in one line.Recent work with Better Made SnackProducts meant that potato snacks werePackaging with panacheWhen itcomes toimprovingperceivedvalue of yourproduct,packaging,in allaspects, is avitalelement.You have to ensure your productsare ready for transit andtransportation around warehousesand distribution centres as well ason trucks and containersPHOTO: TOYOTA MATERIALS HANDLINGPalletising and wrapping products for transit willprotect both delicate and perishable food anddrink.PHOTO: ADPACK31-37:Layout 1 22/3/12 15:24 Page 131-37:Layout 1 22/3/12 15:24 Page 2PACKAGINGwww.fdiforum.net33GLPLinerless ...Over double the amount of labels on the same rollLess down-time due to changing rolls (rolls last twice as long)Variable label length; no need to change the roll for a different label lengthFaster roll changes with no waste liner to be removed from the printerExcellent synergy with Bizerba equipment (longer life span on print heads)Reduced cost of stock (no need to hold stock of different label sizes)Minimal waste - only the core is thrown awayCost of packaging waste disposal reducedExcellent print quality - barcode readabilitySafety - no slippery liner on the floor ....Bizerba UK Limited, 2-4 Erica Road, Stacey Bushes, Milton Keynes, MK12 6HST. 01908 682740 E. info@bizerba.co.uk34 delivered into combined weighers and bagging machines,bringing together the two processes to make the line seamless.With regards to weighing, it is often forgotten by foodproducers that exact weights are important to maintain. While itmay seem over-cautious to invest in equipment that weighsproducts to within a few decimal places, the reality is that arelaxed attitude to this area can cause large waste levels and cutinto your profits. Overfill on a few products in a range ofthousands produced per day and it does not seem too bad, butthink that if every product was overfilled by even a fewgrammes, multiplied over a day, a week or a month and that isan incredible amount of your product ‘given away’. This is why there exists a range of weighers that can beintegrated into the packaging line, either just before products aresealed or just after. This will improve not only your profitmargins, but could also help avoid costly fines or your reputationin the case of incursions into legislation of weights andmeasures. The trick seems to be getting the weight down to asexact a science as you can, too much and you are increasing your‘giveaway’ rate, too little and you risk your reputation or facinglegal challenges. Bizerba have gone one step further recently. The weighingspecialists have come up with a hygienic scale that eliminates thechances of bacteria making its way into multiple foodstuffs.Made up of as few parts as possible and with a design that canwithstand high pressure washes and cleaning products, it meanscontamination is not passed from product to product by bacteriaclinging to edges, to the underside or in grooves in theOverfilling your products iseffectively giving away your profitmargins, so why do it?31-37:Layout 1 22/3/12 15:24 Page 334www.fdiforum.netPACKAGINGmachinery. This could be a great solution for those working with large andvarying quantities of fresh and perishable foods such as fish, meat or poultrywhich is often processed quickly and can carry bacteria easily.Equally, inspecting your products during the packaging process isimportant. Detection and monitoring of packaging is important as it not onlyimproves branding but also improves efficiency too. If a product arrives onthe shelf a different colour to the surrounding products, consumers willquestion the viability and perhaps avoid that product in the future. Systemssuch as Cognex’s vision systems can alert the operative to such problems,being able as it is to detect shape and colour. The detection can be set to anyparameters, so this offers excellent peace of mind. It can also detect problemswhich may jam or ruin certain products, such as bottles facing the wrong wayor elements of packaging that snag or enter in unusual positions to the line.Perceived ValueMaintaining and improving the appearance of your product is key. It’s afact that consumers will base the majority of their purchases as to howsomething looks on the shelf. This can be helped by helpful retailers takingpride in their displays, but you can do much to improve this before it everreaches this stage. Taking an unusual route to make your product stand outis always worth it, be it through using unusual materials to producesomething special or by presenting products in a way they are nottraditionally displayed. Seufert, for example, specialise in transparent packaging, allowing you todisplay products on their own merit, perhaps with printed graphics or text onDetection of defects can save products not up to your high standardsfrom reaching the shelf in the first place, equipment such as the CognexInsight 5605 can be fitted seamlessly into your linePHOTO: COGNEX31-37:Layout 1 22/3/12 15:24 Page 4END OF LINE PACKAGINGAdpak celebratessilver successAdpak have for 25 years been deliveringperfect packaging solutions to customerdistribution points and POSAdpak continueas leaders in the packaging, shrink-wrappingmachinery and materials sector. To complement the existingrange, Adpak also specialise in a range of innovative palletisationand pallet stretch-wrapping systems.Adpak succeeds by applying the latest technology andinnovations to unusual and sometimes difficult packagingproblems that arise due to the changing nature of today’sconsumer market. The range of machinery available is vast andvaries greatly in size, shape and level of automation. Thecompany offers simple standalone equipment through to turnkeysolutions with full project management from the experiencedtechnical department.Adpak Palletising market a range of innovative palletisationand pallet stretch wrapping systems, being based in a purposebuilt facility with six thousand square metres of production,warehouse, demonstration and office space. They offer bothrobotic and conventional systems, which can be customisedaccording to your specific applicationTheir palletising work goes from strength to strength, currentlysupporting over a hundred systems in the UK. Indeed, Adpakhave recently secured a substantial order with the UK’s largestwine distributor to automatically palletise cases of wine productsAdpak is a member of the influential Processing and PackagingMachinery Association and the company’s pioneeringinvolvement within the packaging industry has led to a long listof satisfied clients – large, medium and small – over 25 highlysuccessful years.PACKAGINGwww.fdiforum.net35Tel: 01282 601444 www.adpak.co.ukNo.1 FOR SHRINKWRAPPING& END OF LINE EQUIPMENTthe outside. This not only gives products a sheen, but can alsopromote brand identity. With so much competition out there forevery conceivable food and drink product, it pays to havesomething unusual in your marketing arsenal to stand out fromthe crowd. To maintain this level of sheen for all products, however, it istaking steps at the packaging stage and the following end-of-linepackaging process that makes the difference. Simply placingdelicate packaging in a box or in some sort of crate will notprotect it from the elements, rigorous journeys or distributioncentres, which can include flatbed trucks, forklifts and unknownhazards which could befall your carefully-packaged product longbefore it hits the shelf or reaches the retailer. Remember,retailers can refuse products outright if they feel they are not inan acceptable condition. This is where protective and convenientequipment comes into play. Palletising and wrapping productsnot only protects against damage, but also makes it easier for thesupply chain. Adpack and similar companies are able to providea range of automated solutions in this respect, able to be addedto any production line and with sensing technology included.This means height, width and the number of times something iswrapped can be controlled.The advice to take away is to prepare products for the marketby safeguarding anything andeverything that could gowrong on its way throughproduction, in transit andeven on the shelf itself. Theuse of R-Flute for exampleon offer from D S SmithPackaging means on-shelfpackaging is pristinecondition, protected until themoment it is displayed by acorrugated box which alsoacts as a handy on-shelf POSdispenser. Takingprecautions is not to beparanoid - it should simplybe the way food and drinkmanufacturers do business. Using R-Flute corrugatedPOS-adaptable packagingprotects your productsand can be easilydisplayed as soon as itreaches the shelfPHOTO: D S SMITHA great-looking product can mean itstands head and shoulders above thecompetitionPHOTO: SEUFERT31-37:Layout 1 22/3/12 15:24 Page 536www.fdiforum.netPACKAGINGSystems Labelling has announced a major breakthrough in thedevelopment of recycled polypropylene (PP). The widespreaduse of PP means it is the third most common polymer found inhousehold waste in the UK after high density polyethylene(HDPE) and polyethylene terephthalate (PET). Unlike milk anddrinks bottles, PP packaging is used in many different gradesand colours making it difficult to recycle. Until now there hasbeen little incentive for UK industries to consider the benefitsof reducing the dependence on virgin PP in the manufacture offood packaging and, at the same time, divert waste from landfilland boost the UK market value of recycled PP. Injection moulded pots, containers and lids for example areused to package huge volumes of food and dairy products inaddition to non-food sectors including cosmetic and householdgoods. Much of this waste is sent to land-fill given the lowdemand for “jazz” or black/grey pellets and therefore has amajor impact on our environment. The challenge has alwaysbeen to find a way to remove the printed decoration, in thiscase inmould labels, from injection moulded packaging post-use.Systems Labelling have now developed such a solution. Underthe registered trademark R-IML® this new product is a totallyremovable inmould label that does exactly what it says on thetub, lid or container. Post-use this innovative product (patentpending) can be completely removed during the recyclingprocess or indeed by the consumer. This solution can be moulded at standard dwell times andtemperatures, therefore has no impact on traditional mouldingprocesses. The commercial and more importantly theenvironmental benefits are huge if adopted across all sectors.The ability to recycle natural/clear or white polypropylene to itsoriginal state displaces the use of virgin resin in consumerproduct packaging for colour sensitive applications providing acommercial value for all stakeholders. Indeed Defra and WRAPestimate for every 1 tonne of PP recycled we would saveapproximately 1 tonne in CO2 emissions. Systems Labelling’s CEO Steve Pickford comments, “Thisinnovation will contribute directly to the sustainability objectivesset out in the Courtauld Commitment.” He adds, “Thisinnovative breakthrough is set to revolutionise the inmouldlabelling market. We have developed a solution (patent pending)that will mould at the same temperatures and dwell times whilstperforming in moist, chilled, damp or microwave conditions.” R-IML® could enable the productionof food grade polypropylene Mankind has placed men on themoon, designed mobilecommunication devices and nowdeveloped a totally removableinmould label. For more information on the largest independent labelprinter in the UK, visit www.systemslabelling.com31-37:Layout 1 22/3/12 15:24 Page 6PACKAGINGwww.fdiforum.net37Packed withinspirationPackaging is not onlyabout protecting the productfrom external influences –it’s also about giving theproduct its proper settingand presenting it in its mostfavourable light. Productswhich you want thecustomer to immediatelyrecognise “through” thepackaging are best presentedin transparent PETpackaging, nicely decoratedto encourage the customer’swish to purchase theproduct.This is where SeufertTransparente VerpackungenGmbH can help. TheGerman company, basednear Frankfurt, isrepresented by STV Packaging in the UK and specialises indeveloping innovative transparent folding boxes, transparentsleeves, lids, bases and thermoformed parts.True to the company slogan “Packed with inspiration”,creative design and innovation characterise the transparentpackaging solutions from Seufert. Each pack is customised anddeveloped according to the desires of the customer who canchoose from a wide range of materials, thickness of the film andfinishing options like litho or offset printing, embossing or hotstamping.The complete production process, including manufacture ofthe PET material, innovative design, printing and subsequentprocesses, are managed in house by Seufert. The company has setup their own recycling cycle, making sure that film scraps arereturned into the PET production and is offering PET film withup to 80% recycled material. Using low migration inksthroughout production and working under BRC/IoP accreditedconditions, Seufert supplies a large range of markets from thecosmetics to the gift, food, drinks and confectionery industries.For more information, contact Patrick Cookland on+44 (0)787 255 2285 or p.cookland@seufert.com,or visit www.seufert.com.Your partnerin automationPhoenix Handling Solutions present the Tosa125E high speed stretch wrapping machinewith corner post and top sheet applicatorThe Tosa 125E ring machine is a very versatile machine,being capable of spiral wrapping varying pallet loads at randomand, if required, placing a top sheet and corner posts. Themachine is extremely robust and reliable, using only the most upto date off the shelf components. It has two supports and is verysimple to install and commission.If two film carriages are used, the machine can handle up to170 loads per. At this speed, a patented automatic film changingsystem can be supplied, which only changes the core of the filmreel, rather than having to change the whole film carriage. Theautomatic film changing system is very simple for the operator toload a new reel whilst the machine is operating, as the shuttlewith the new reel is outside the guarded area.When corner protection is required, they can again be placedin random order providing pallet tracking is included. Thecorners can be selected from a magazine which can hold up toseven different types or sizes of corner board. No adhesive isused to hold the corners, only stretch film. There are also otherlower output models in the range which can also place cornerboards if required.Tosa are represented by Phoenix Handling Solutions, whohave more than fifty years of experience in the business of end ofline packaging systems. PHS provides sales, after sales servicesupport and spare parts.For more information, call 0845 265 7570,email info@phs-uk.com or visit www.phs-uk.com.TRANSPARENT PACKAGINGSHRINK / STRETCH WRAPPING31-37:Layout 1 22/3/12 15:24 Page 738www.fdiforum.netFLAVOURINGThe increased interest in natural flavours in recent years hasbrought about major changes in the sector. As Kenneth PManning of Sensient explains over the page, this is a trend thatfirst became prominent in Europe and, as consolidation becomesmore commonplace in the industry, has expanded to newterritories such as the USA as subsidiaries can now pass on theirknowledge to other sites.This knowledge has allowed for a much wider range of flavoursto be made available than ever before. Sensient, for example, hasexpanded its extraction capabilities with a state-of-the-art CO2extraction plant in their Indianapolis facility, in addition to thecompany’s original CO2 capabilities at their Bletchley site in theUK. The Indianapolis plant comprises two commercial scalesupercritical CO2 extractors as well as several pilot units availablefor research and development purposes. The aim is to enhance thecompany’s ability to customise and deliver ever more innovative,high-performance natural extracts.Sensient have responded to the increased interest in food anddrink with authentic tastes with an increased R&D focus on theirproprietary botanical extracts line, Sensient Natural Origins.Other technologies used in conjunction with CO2 extraction atthe plant include counter current extraction, molecular distillationand more traditional methods such as percolation distillation andcold solvent extraction.CO2 extraction is highly valuable as a way of avoidingcontamination. Flavex, for example, make use of the procedurewhen dealing with nutmeg. Nutmegs belong to the most heavilymycotoxin-contaminated foodstuffs, which means they canendanger health, even in low concentration. Legislation regulatesthe maximum residue limits of aflatoxins in ingredients, with anupper limit for the sum of aflatoxins in nutmegs as 10 μg/kg, whilethe maximum permissible value of ochratoxin A is set at 30 μg/kg– and will be halved from July.Aflatoxins and ochratoxins are only soluble to a small extent insupercritical CO2, so the nutmeg CO2 extraction meets therequirements of aflatoxins and ochratoxin A levels in foodstuffs.Due to the gentle conditions of supercritical CO2 extraction, thehydrolysis and oxidation of sensitive ingredients, which is oftenthe case during steam distillation, isn’t a problem. The finishedproduct is used for flavouring a number of items, including meat,desserts and spirits.Companies such as May Products have also emphasised thehigh quality of the flavourings they make available, and theversatility that has allowed them to be used in a number ofproducts in a range of sectors.It’s perhaps not surprising that flavours have become moreimportant in food production. Certainly the removal of salt, fatand sugar from products has left a void in terms of flavour andmouthfeel that needs to be replaced, and in many cases this hasbeen resolved with the use of herbs, spices and other strongflavours. For example, seaweed is now a familiar ingredient inmany products where the amount of salt has been reduced.Sweet sensationsNew flavour solutions are creating exciting new tastes, as well as emphasising theimportance of a natural approachThe sweet and salty combination is proving increasingly popular, andPecan Deluxe Candy has launched a new and upgraded blendingfacility so customers can combine two or three different items andcreate a balance of flavour and texture38-39:Layout 1 23/3/12 10:41 Page 1FLAVOURINGwww.fdiforum.net39Companies such as Givaudan, meanwhile, are addressing themouthfeel challenges that food manufacturers of sweet and dairyproducts face in low-calorie products. They have launched theirTasteSolutions Mouthfeel programme which includes a uniquesensory language and advanced technologies to optimise the tasteprofile of reduced-calorie sweet and dairy products and providethe premium flavour perception consumers desire.As consumers look for new taste experiences, many previouslyunheralded flavours are becoming increasingly prominent. Forexample, pomegranate, acai, goji and other berries are nowfamiliar ingredients in beverages thanks to the trend towards the“superfruits” that consumers believe offer greater health benefits.The new flavours also have major benefits for those trying tofollow specific diets. Ingredients company Brazilian Flavours, forexample, have relaunched their range of products to aim more atthe “free from” market, with particular emphasis on theiradditional value for those who hope to maintain a gluten-free diet.One great example of how consumer tastes are changingmassively is Brazilian Flavours’ gluten and wheat free Yorkshirepudding pre-mix. Chef Isobel Gordon has created the pre-mixwhich, as well as offering a South American twist on the familiarproduct, can also recreate the organoleptic properties that areusually provided by wheat which form the elasticity and texture ofthe batter. The result means it can safely be incorporated intowheat-free diets with no loss of taste or texture.A further flavouring trend that is expanding from its originallocal origins is that of floral ingredients. Although it may initiallysound bizarre, the likes of floral teas and Turkish Delight are nowwell-established products across the world, and the concept is nowcontinually breaking out from its Far Eastern origins. Jasmine,lotus, rose and chrysanthemum are, according to Innovia MarketInsights, now becoming increasingly popular additions toconfectionery and beverages, with rose, for example, being used ina number of premium chocolate brands. Chocolate is certainly agrowing market for new flavours, with the rise and rise of premiumproducts ensuring consumers have more adventurous tastes.In recent years, the flavouring market has exploded withconsumers looking for a host of new taste experiences. The factthat they can offer increased natural properties and health benefitsis a bonus for the market, and will doubtless ensure continueddevelopment in the sector.Givaudan is addressing the mouthfeelchallenges that food manufacturers of sweetand dairy products face in low-calorieproducts with its TasteSolutions MouthfeelprogrammeBrazilian Flavours’ Isabel’s NaturallyFree From brand has beenredesigned to reflect new positioningwithin the ‘free from’ sector.38-39:Layout 1 23/3/12 10:42 Page 2Next >