< Previous30 Food & Drink Internationalwww.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTMaximum food safety, maximum production output, minimal costs:Klüber Lubrication helps you achieve all these goals more easily. Our high-performance NSF H1-lubricants are 0:6 JLY[PÄLKHUKOH]LHT\S[Ptude of approvals. They are available for all branches of the food-processing industry, for all components and tricky special cases everywhere in the world in the same high quality. Our experts will provide you with support to meet your individual requirements, from consulting to optimum lubrication management, ensuring more safety of production processes and OPNOLYWYVÄ[HIPSP[`Klüber Lubrication: 80 years of experience and professional services for your success.Klüber Lubrication Great Britain Ltd.sales@uk.kluber.com / www.klueber.comCertified speciality lubricants for the best possible taste.your global specialistLUBRICANTSFood-grade lubricantscontribute toeconomic successThe most recent lubricant developments contribute to economicaland successful plant and machine operation. With safety such a keyconsideration, Kluber Lubrication ensure safety, reliability and costeffectiveness are achieved. Regarding the lubricant as an investment in economic efficiency,rather than just a commodity, pays off in many ways. If synthetichigh-performance lubricants tuned to the particular application areused, the total cost of operation decreases. There are savings indowntime costs, maintenance, energy, spare parts, storage, disposaland lubricant consumption that speciality food-grade syntheticlubricants contribute to reducing. When it comes to bearing lubrication, speciality greases ensureextended maintenance intervals. One such recent example is thewater pump bearings on a pea processing production unit. Theprocess lines wash and provide fresh garden peas to their twentycanning lines over the three-month pea processing season.In previous years, the bearings on the water pumps had beensuffering from unreliability during use and failure of two or three ofthese bearings during the processing season had not been uncommon.Each failure resulted in 1.5 hours’ downtime while the bearings werereplaced and would halt the processing of up to eight tonnes of peasor 25,000 cans, valued at over £10,000.The customer changed their currently specified white-oil basedlubricant to the PAO- based Kluberfood NH1 14-261, providingexcellent water resistance and wear reduction characteristics thatwould enable longer bearing life. No bearing related failures occurredduring the 2011 and 2012 season saving significant cost and time.High performance lubricants registered to H1 and certified to ISO-21469 contribute significantly to equipment performance and safeproduction methods. Speciality lubricants also contribute to economicand environmentally-friendly operation.For more information, visit www.klueber.com.22-33:Layout 1 22/3/13 12:23 Page 9Food & Drink International 31www.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTIn December 2012, Kasaprekocommissioned a returnable-glass line ratedat 30,000 bottles an hour, and a PET linerated at 40,000 containers an hour. Thelines are mainly used to bottle a herbalbitters product, said to have anaphrodisiacal effect. Kaspareko was founded by Dr KwabenaAdjei as a small-scale bottling operationtowards the end of the eighties, offeringhis “Kasapreko Dry Gin” on acommission basis. The ethos has alwaysbeen “Good quality doesn’t necessarilyhave to be expensive”.The PET container is concave at thefront and convex at the back, whichmeans it can be packed with particularspace-economy. Since the front and backare different in design, the bottles have tobe appropriately orientated so as to ensureonly their fronts are labelled. The high-speed PET line is suppliedwith containers by a Contiform S24 blow-moulding machine. An AirCo conveyorfeeds them to the rinser-filler monobloc,which features a gravimetric filler in theshape of a Sensometic VP-GW-PET. Therequirement was for a filler that ensuresvery accurate fill levels, and here the filllevel is additionally verified by aCheckmat F-G.Via a generously dimensioned buffertable, which ensures the requisite timebuffering, the containers are passed to theSolomatic labeller, which dresses them atthe shoulder using a cold-glue station. ALinaglide then distributes the containersamong up to six lanes. At the same time,two Variocart carton erectors unfold thecarton blanks. In a Linapac II, the cartonsand the bottles are brought together, andthe cartons are sealed by a Variocol, andpalletised by a Modulpal 2AC.The same type of palletiser is directlyadjacent, and is tasked with palletising thebottles from the glass line. The returnableglass is fed into the line by hand. For bulkglass, Kasapreko has installed a Pressantsweep-off depalletiser, which moves thebottles directly onto the conveyor locatedon the filling level about seven metreshigher.A Glideliner spaces them out upstreamof the Lavatec KES single-end bottlewasher. The washed 0.75-litre containersare monitored by a Linatronic empty-bottle inspector before they are filled in aSensometic VV-CIP, a vacuum filler witha standard deviation of +/-1.5mm. Here,too, the fill level is inspected by aCheckmat F-G. The bottles are dressed bya Starmatic labeller.End-of-the-line packaging is similar tothat in the PET line – a Variocart erectingthe cartons, a Smartpac inserting thebottles, and the packs are then sealed by aVariocol. For more information,call 0044 1942 845000 orvisit www.krones.com The fastest PET bottling line Krones has ever installed is upand running in Ghana.Alomo –an (a)rousingsuccessAlomo – an (a)rousingsuccessKasapreko commissioned two new Kroneslines in December 2012. The company firsthad a new cantilever hall built, measuring100x44m. Below: The PET container is concave at thefront and convex at the back, which meansit can be packed with particular space-economy.22-33:Layout 1 22/3/13 12:23 Page 1032 Food & Drink Internationalwww.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTTRACEABILITYVantage In-LineInspection Systemhelps United CoffeeUnited Coffee UK have invested in Stevenscheckweighers and metal detectorsWith increasing quality demands, United Coffee, the largest UKcoffee roaster, looked to improve their end of line inspectionsystems to ensure the highest quality and consistency of theirfinished, wrapped product.For this reason, Stevens installed two In-Line CheckWeigher andMetal Detection Combination Systems. The Combis, which haveintegral infeed, weighdeck and out-feed conveyors, are used tocheckweigh packs of coffee against very high weight tolerances. Theunits are capable of offering weighing speeds in excess of 200 itemsper minute with the utmost precision, and the combis are fittedwith high speed flipper reject system and reject bins.Although the main role of the Combis is to ensure United Coffeesupply the correct amount of their coffee per pack, it alsoguarantees compliance with average weight legislation. The Vantagetechnology brings unrivalled levels of data capture, reporting andanalysis to their factory floor.The units collect critical data on average and minimum weight,together with comprehensive SPC information includingthroughput by product, batch and date. Reports are sent back to acentral PC via a LAN enabled interface, thereby ensuring optimumdata security and location versatility.Attul Desai, Technical/Quality Team Leader at United Coffee, says,“We decided to replace our aging end of line units with the StevensSystems because, after a long period of assessment of what wasavailable on the market we found Stevens had the most flexible androbust system along with a first class service and support facility.”To find out how Stevens Group can help, contact them for ano obligation consultation by calling +44 (0) 1254 685200or email info@stevensgroupltd.com.PUMPS seepex pumpsproduce idealbiogas feedstock The UK has recently seen a huge increase inoperational biogas and waste to energy plants, givingfood processors the opportunity to use food wastefrom processing operations for energy production.This provides environmental benefits and potentially areduction in costs. Mostcommercialbiogas plantsprefer feedstockthat can bedelivered inliquid or slurryform, free fromcontamination bypackaging, easy tohandle andcompatible withthe inputs needed for biogas production. However most food wasteis solid or semi-solid and does not immediately lend itself to beingpumped – unless a seepex pump is used.The auger feed screw on the seepex BTM open hopper pumpshas integral knives to produce a homogenous slurry which is thentransferred through enclosed pipework to an external storage tank.In this way, food waste can be hygienically removed from processingareas without the need for tote bin movement, and because it is anenclosed process contamination by metals and plastics is prevented.seepex have systems installed handling foods as diverse aschickens and fish, ready meals, pasta, fruit and vegetables and ourcustomers enjoy many benefits. The volume of waste is reduced,particularly where vegetable and fruit trimmings are chopped, sinceair spaces are removed, tote bin movement and associated labourcosts are reduced, open waste skips are removed from externalareas, hygiene is improved and tankers can remove the waste thusreducing transport costs.Food processors in the UK are already using their seepex pumpsto produce the ideal feedstock for biogas plants and they oftenenjoy reduced gate fees as an added bonus!For more information, contact seepex UK at www.seepex.com.seepex BTM pumphandles food waste22-33:Layout 1 22/3/13 12:23 Page 11Food & Drink International 33www.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTCONVEYINGBest practice byConveyorTec fromWire BeltWire Belt have elevated their individual membership ofEHEDG to full company membership status –ensuring customers receive conveyor and beltingproducts that comply with current best practiceWire Belt constantly monitor and evaluate their product againstthe current and incoming regulations. They have worked with testsites and universities in the UK and USA to measure the hygieniccredentials of the product so they can provide the best advice tocustomers.All conveyors are of hygienic stainless steel construction, have awide range of optional features, and special variants that satisfy mostapplication requirements such as changing product direction,orientation and spacing between production processes. The Flex-Turn unit allows products to be turned using angles from 45 to 180degrees, and the Spreading conveyor can separate products into lanes.Wire Belt’s Flex-Turn 300 series of conveyors, which aremanufactured by the ConveyorTec division, are made of stainlesssteel and have an open structure. The open construction of theseconveyors maximises product exposure and allows for easy removalof debris on washing and draining operations. The Flex-Turn seriesoffers unparalleled visual access of the conveyor structure forinspection and cleaning.In the past few years there have been a number of technicaladvancements in conveyor technologies. Wire Belt focus on theclean-ability and key elements of processing such as productorientation, product placement and improved productionthroughput. The conveyors are focused on adding value to aproduct as it flows through a process rather than just moving aproduct. While that trend is becoming more prevalent in the foodprocessing business today, Wire Belt has been focused on the valueproposition of its conveyors for decades.’For more information contact Wire Belt at +44 (0) 1795 421771,email sales@wirebelt.co.uk or visit www.wirebelt.co.uk.AUTOMATIONMoody Automationprovides thesolutionMoody Automation are a modern, versatile and experiencedbusiness providing power, control, automation andinstrumentation solutions across a wide range of processindustries, utilising our project management, systemsintegration, manufacturing, installation and commissioning skills.The design and manufacture ofcontrol panels range fromwardrobe style to full form fourmotor control centres. With theinclusion of their site installationteams, Moody Automation canoffer hardware design, softwaredesign, PLC, HMI, Scada,condition monitoring, local andremote support. Moody Automation hasrecently struck up a partnershipwith global energy managementspecialist Schneider Electric toutilise the new CIP Optimisationsoftware package. The newsoftware package has beendesigned to allow monitoring of the cleaning process and identifyareas which can be improved upon.These include... * Adjust and monitor your CIP station configuration to boostplant productivity and reduce costs associated with water, cleaningproducts and energy consumption* Ensure compliance with food safety regulations and collectdocumented evidence of applied sanitary measures for your presentor future customers* Reduce your energy usage and waste to improve thesustainability of your operations and minimise your impact on theenvironmentMoody Automation, and the Moody Group as a whole, hasextensive experience in the CIP process and by teaming up withSchneider Electric can now offer this service to a wider customerbase.For more information on howMoody Automation can assistyour CIP needs or assist anyautomated solutions,contact Lee Furey on01777 712125 orlee.furey@moodyplc.comwww.moodyautomation.co.uk22-33:Layout 1 22/3/13 12:23 Page 12Automated coding &labelling verificationto meet retailers' codes ofpracticeReal timepaperless qualityto ensure RightFirst Timeevery timeRoving quality audits,H&S checks,engineer lineattendance, HACCP Automatedefficiency/OEEin real time100% inspectionthrough on-lineVisionIntegrated Production Informationanalysed, prioritised &distributed to driveperformanceimprovementGUARANTEED PERFORMANCE IMPROVEMENT througha SINGLE INTEGRATED SOLUTIONreporting on ALL your PRODUCTION KPIsAutomated Short Interval Controlon factory monitorsContact us now for your free no obligation factory auditPlease visit us at the Total Processing &Packaging Exhibion 4-6 June 2013 at Birmingham NECStand M20 34-38:Layout 1 22/3/13 11:52 Page 1Food & Drink International 35www.fdiforum.netLABELLING, CODING AND MARKINGAlthough coding and labelling are inmost conversations lumped together, theyare clearly very different things withdifferent consequences. The accuracy ofdate coding is arguably the most serious,especially with regard to use by dates,because of the health risks associated withconsuming out of date foods. The sale of products after the use bydate has expired is, quite rightly, illegal.However, the biggest danger is when theprinted use by date is not an accuratereflection of the actual product shelf life,possibly because, at the production37 packaging stage, a date coder wasmanually set up with the wrong date code,perhaps dangerously adding apparent shelflife to the proven safe period.In labelling compliance, the biggestdanger is that the wrong packaging mayhave been used for a particular batch run.This could often, however, just mean adifferent flavour or small variation ofsome kind, as potential allergens such asnuts would not normally be packaged inthe same environment as the allergen freeproduct. Nevertheless, labelling mustaccurately describe the pack contents ifconsumer confidence is to be maintained.Coding and labelling errors,largest cause of EPWsRoy Green of Harford Control says,“We understand that factory mistakes incoding and labelling have been responsiblefor more than 80% of entire productwithdrawals, a figure which has become amajor concern for retailers and the foodsupply chain as a whole.“The reason we believe that this hasbecome such a big issue, in recent years, isbecause of the increased productvariations on supermarket shelves and theincidence of shorter batch runs, leading tomore frequent product changeovers, morecomplexity and therefore more risk.All retailers are naturally concerned toensure that their product coding andlabelling is accurate and some have evenproduced codes of practice to encouragedetailed risk assessments, frequentlyleading to the installation of automatedsystems, in order to minimise the risk ofhuman error.”All food manufacturers supplyingretailers have to consistently improveThe key isCOMPLIANCEIt is only in recent years that so much emphasis has been placedupon the accuracy of coding and labelling and it can be interesting toconsider the reasons for this. What measures need to be in place tosee a healthy return on ROI? PHOTO: SHUTTERSTOCK.COM/MONKEY BUSINESS IMAGESAccurate labelling of products’ use bydates as well as origins skims legalproblems so compliance in this area isessential.34-38:Layout 1 22/3/13 11:52 Page 2© Linx Printing Technologies Ltd 2013Linx is a registered trademark of Linx Printing Technologies Ltd.No time wastedCombines an IP55 rating, auto-fl ush system and a robust sealed printhead to keep your production line moving.No constraintsOffering up to fi ve lines of coding and the ability to print graphics or barcodes, the Linx 7900 CIJ printer also comes with Linx Insight® remote monitoring as standard for complete versatility.No hidden costsWith service intervals of up to 9000 hours meaning lower maintenance costs, the Linx 7900 series offers the best value for money in its class.NOT ALL CIJ PRINTERSARE MADE THE SAMECoding onto food packaging is no hassle with a Linx 7900 CIJ printerLinx 7900Get in touch with Linx by email:7900@linxglobal.com visit: linxglobal.com/7900or call us on: 01480 30260334-38:Layout 1 22/3/13 11:52 Page 3Food & Drink International 37www.fdiforum.netLABELLING, CODING AND MARKINGperformance, achieve totalcompliance and deliver on timewithout, in most cases, having theopportunity to raise prices, even thoughthey in turn are faced with increased rawmaterial costs, increased labour costs andincreased energy costs.It’s a tough call for any foodmanufacturer to spend perhaps hundredsof thousands of pounds on automatedcoding and labelling compliance with littleor no improvement in performance and,therefore, no return on investment,especially in the current economic climate.Roy continues, “At Harford, we believethe best way to drive compliance is to linkperformance improvement into theequation, so that the same systeminstalled for effective management of risk,provides real time accurate informationabout wastage and production losses,within the same integrated structure asthe compliance system.”Increasing efficiencyWhen performance improvementinformation is simultaneously collected,from the same integrated system,automatically analysed, prioritised anddistributed, in real time, to those who canmake best use of it, performance can onlyimprove.An example this is Harford Controlinstalling integrated solutions and gainingdramatic results within relatively short38 drive down costs by installing rightfirst time methodologies in place ofcostly inspection regimes.Any company, having deployed TQM,will have already carried out their ownrisk assessments when facing complexity,not only for coding and labellingcompliance, but also for all other aspectsof quality, quantity control, materialsusage, wastage, conformance to plan, toensure Right First Time and totalcustomer satisfaction, on time, every time.In other words, ensuring that what goesout stays out, where the only thing likelyto come back is a satisfied customer.Cost of qualityCost of Quality used to receive as muchattention as TQM, this important KPIwas intended to keep account of the costof all quality failures, whether theyreached the retailer or were caught beforedespatch. The numbers were thenintended to be used as a major driver forchange and continuous improvement.But Roy Green says few companiesseriously committed to Cost of Qualityand companies using this method seemeven harder to find today.“We believe this situation stems from‘blame culture’ where costly mistakes,rework and near misses are buried in thecompany overheads instead of beingPHOTO: SHUTTERSTOCK.COM/VASILY SMIRNOVAll foodmanufacturers supplying retailershave to consistently improveperformance, achieve totalcompliance and deliveron timeIncreased automation hasmeant ROI is only possible ifmanagement of risk isfactored in too.timescales. Due to the automated natureof control systems, operational disciplineis instantly elevated, with manyproduction risks, including coding andlabelling errors, eliminated. Improvementsin materials utilisation, wastage reductionand efficiency often provides increasesgreater than 40%, with no increase inlabour costs or overheads.Supermarket demands for automatedcoding and labelling systems, whilstunderstandable given the frequency ofbatch rejections, should never have beennecessary and may have even skewed thebalance of good manufacturing practice byemphasizing just one of many areas ofrisk.The importance of TQMThough TQM, Total QualityManagement or Time QualityManagement, has been around fordecades, evidence in action of the holisticexcellence which TQM was intended todeliver is often hard to find. TQM wasnever intended to put manufacturers intoa quality only best practice straight jacket,with spiralling costs of increasedcompliance. Its primary intention was to34-38:Layout 1 22/3/13 11:52 Page 438 Food & Drink Internationalwww.fdiforum.netLABELLING, CODING AND MARKINGwww.dennybros.comIf your packaging design doesn’t adapt easily to allow for on-pack promotions or you don’t have enough space for all of your product information – maybe we can help? We are the originators of the Fix-a-Form multi-page label - which could prove to be your ideal solution.Let the possibilities un-fold! For more information visit our website www.dennybros.com, e-mail marketing@dennybros.com or call 01284 701381follow us on:Delivering your informationSpecialist Innovative Printed Products brought out into theopen. Even now, inthese enlightened andfinancially stretched times,we frequently see anoverriding fear of transparency asthe biggest bar to improvement.“Companies who have recognised that total openness is anessential prerequisite of continuous improvement, on their road tomanufacturing excellence, have seen some dramatic gains, not onlyin compliance and greater quality consistency, but also inefficiency improvement and reduction in manufacturing costs.”Sustainable gains The key to sustainable gains lies in the sharing of accurate up todate information about all key manufacturing operations so thatnon-compliance events and improvement opportunities can bedealt with.Factory floor paperwork has been largely eliminated in favour ofcomputerisation in many cases, automated where justifiable andoperational discipline has been improved as a consequence,subjectivity and gut feelings have been replaced by hard facts andanalyses followed by improvement.Companies to have embraced this new order of real timetransparency have shown a valuable ROI through the combinationof elimination of coding and labelling errors, reduced wastage,improved materials and labour utilisation, improved efficiency,reduced operating costs, delighted customers and an increasingmarket share.It seems significant expenditure to minimise risk alone is notsustainable in the long term. Similarly, an emphasis on increasedoutput in isolation, without effective risk management in place,leaves manufacturers exposed to costs, rejections, rework, finesand delisting. You need both total compliance and increasedoperational efficiency in order to keep customers satisfied.Resealable Fix-a-Forms from Denny Broshave proven hugely successful for on-packpromotionsThe key tosustainable gainslies in the sharingof accurate up to dateinformation about all key manufacturingoperations so that non-compliance events andimprovementopportunities can bedealt with34-38:Layout 1 22/3/13 11:52 Page 5LABELLING, CODING AND MARKINGThe EU 10/2011 regulation, on plasticmaterials and articles intended to comeinto contact with food, came into force on1st January. It seems most self-adhesivelabel printers know it judging by the risein requests for Declarations of Conformitywe are receiving at UPM Raflatac. It’svital that the new regulation is followed iflabel printers, brand owners and packerssupplying into the EU food industry are tobe sure of business continuing as usual.EU 10/2011 supports brand owners’ andretailers’ duty of care to their customers,as a further measure to protect the qualityand safety of food. While EC No1935/2004 applies to food packaginggenerally, the EU 10/2011 regulationspecifically concerns all components ofany primary food packaging containingplastic, with labels considered an integralpart of such packaging. Both direct food labels with a plasticlayer and all labels applied to plasticprimary packaging now require DoCsstating which controlled but authorisedsubstances are present. All authorised restricted andunrestricted substances which may beused in packaging containing plastic in itslayers are stipulated on the ‘Union List’within EU 10/2011. Restricted substancesare limited according to specific migrationlimits. As DoCs move downstream withmaterials through the manufacturingchain, these substances are documentedso that the end-user knows which tests tocarry out.Chain of documentation – rawmaterial to packerThe packer or brand owner has thefinal responsibility for checking that thepackaging as a whole conforms to EU10/2011, taking into account the nature ofthe packed food, shelf life and ambientconditions. DoCs are required from thelabel printer as a prerequisite toconducting tests for restricted substancelevels and migration behaviour in specificenvironmental conditions. Printers supplying labels into the EUfood industry need to be proactive inobtaining and supplying the rightdocumentation. Obtaining the necessaryDeclarations of Conformity from theirlabelstock suppliers shouldn’t be toodifficult. UPM Raflatac, for example,supplies DoCs featuring a high-quality ofinformation in full regulatory compliancewith EU 10/2011 – for our faces, adhesivesincluding special food grades and alsobackings where multi-layer labelconstructions are concerned. Producing DoCs to a satisfactorystandard is a level playing field for all sizesof operation. Having DoCs in good orderensures the continued viability of valuablepartnerships, and ultimately works in theinterests of consumer safety.For more information, contactJay Betton on +44 1723 583661 oremail jay.betton@upmraflatac.comAre your foodlabels legal? asks Jay Betton, Business Segment Manager, Food and Retaillabelling at UPM Raflatac EMEAJay Betton39:Layout 1 22/3/13 11:45 Page 1Next >