< PreviousMIXING TECHNOLOGY20 Food & Drink Internationalwww.fdiforum.netmixingis our businessCreamsandOintmentsPaintsandResinsGelsSoupsandSaucesSalsaandDressingsEcoFuelsHigh Shear Mixersand Agitatorsalso means that storage silos can be re-circulated more quickly, reducing batchprocessing time, while its increasedefficiency allows the use of less powerfulmotors, of around 45kW, which can cutpower usage by up to 15%.In-line mixing is currently thepreferred technology for food and drinkplants that require the high volumemixing of low viscosity products. Thismeans that plants producing milk-basedbeverages and baby foods are makingmost use of the new technology, but it’sequally suitable for the production offruit juices where similar capital,production and power usage savings canbe achieved.A further bonus of using in-linemixers is their ability to work withmuch larger volumes than Batch mixers.It’s certainly possible to use a Batchmixer for large scale jobs but in-linePHOTO: SHUTTERSTOCK.COM/IMAGEMANNew technology is now ensuring thatproducers and consumers alike will benefitfrom higher standards.18-21_Layout 1 27/03/2015 12:07 Page 3Food & Drink International 21www.fdiforum.netMIXING TECHNOLOGYmixers concentrate all their energy onwhat is within the mixing chamber at anyone time, making it more efficient thanhaving to continually circulate the entirecontents of the vessel at the same time.This means a large batch can be processedusing only a very small in-line mixer.They also offer increased hygiene –which does not just allow producers peaceof mind in avoiding contamination, butcan also allow for the production processto run smoother with less downtimeneeded to remove blockages.As the supply chain moves faster, it’soften the case that manufacturers have tomix particularly large quantities. In thiscase there are further options available ona large scale, such as in-bin blenders,which fill the gap between blending andstorage and are often silos that have beenretrofitted with internal blending devices.The blenders used in this instance havenow become ever more efficient, processinga number of materials and requiring verylittle maintenance – but invariably, giventheir heavy duty nature, they’re notsuitable for the mixing of fragile items orthose with low melting points.Some manufacturers are now able tooffer, in many ways, the perfect solution –mixers that can be used within tanks andstorage vessels. These can clearly reducethe number of vessels required in a typicalbeverage mixing operation, by carrying outde-aeration, syrup mixing and carbonationPHOTO: SHUTTERSTOCK.COM/KARTINKIN77Mixers used within tanks and storagevessels can reduce the number of vesselsrequiredin one vessel rather than requiring adifferent vessel for each part. In addition,these mixers can then be used to clean thetank, having been developed fromtechnology originally used for industrialcleaning.No longer are consumers always happywith ice cream, yoghurt and otherproducts appearing as simply a smooth,unrecognisable paste. Mixing andblending has often led to problems forfood and drink manufacturers but newtechnology is now ensuring that producersand consumers alike will benefit fromhigher standards.18-21_Layout 1 27/03/2015 12:07 Page 4Perception isKEY22 Food & Drink Internationalwww.fdiforum.netCOLOURINGThe consumer has become a muchmore intelligent creature of late,less prone to impulse purchases andmore concerned with health benefits, E-numbers and the welfare of any animalsinvolved. It was perhaps expected then,that consumers would begin to pay lesscredence to the colours in food products.This has not happened.In fact, the colouring industry seems tobe one of the most fortunate in the foodand drink industry, and one might evensay they have dodged a bullet in thisregard. Following on-going efforts toreduce the amount of food waste withinsupermarkets, there was a campaign runto inform consumers that products thatare not the accepted shape, or are slightlypast the sell-by date, are still consumableand fully healthy. The campaign saw somesuccess, with a number of well-knownchains actually stocking dedicated “out-of-shape” produce, including wonky bananasand uneven cucumbers. Fantastic news forthe farming industry, as they are now lesslikely to have a large proportion of theirsupplies rejected.Less successful however, was thetangential campaign to promote foodproducts that were not as colourful. Nomatter the shape, or the assurancesbehind it, retailers found great difficultyin convincing consumers to purchasefinished products that were not theaccepted colour. A particular example wasfresh salmon, which continued to sellmore effectively where food colouring wasused, to create an even tone amongst thePerception isKEYDespite consumersbecoming morevaried in desires andexpectations, freshand bright coloursremain a key sellingpoint. 22-24_Layout 1 27/03/2015 11:59 Page 1Food & Drink International 23www.fdiforum.netCOLOURINGcolours from their chocolate candy brandsby the end of 2015, with none of the 250different products using artificialcolorants. This decision was madefollowing a number of studies on animals,which suggested that high doses ofartificial food dyes could lead to healthproblems in humans. And, while the testsdid not prove conclusive, it was enoughfor a company with such a well-knownbrand as Nestle, to not take the risk. The concern for many foodmanufacturers however, is whether theycan afford to make the move to morenatural ingredients, which will almostcertainly be safer for consumption – but24 Áproducts on offer.Perception therefore plays a crucial rolewhen it comes to consumers choosingtheir product, even when statisticalevidence is provided at point of sale. The food industry will likely find thenews as little surprise. The importance ofcolouring ensures the popularity of agiven product on the shelves, and as suchwith the retailers themselves. However,the beverage industry has perhaps been alittle slower to catch up. Most recently a wide range of liquorshave started using subtle colouring tomirror the products they are flavouredafter. For instance toffee vodka has beenchanged to a rich toffee-brown, ratherthan its traditional clear hue. These on-shelf variances are creating a moretempting selection on supermarketshelves, while also encouraging consumersto investigate. It’s not all sunshine and rainbows forthe colouring industry however, as moremedia pressure is being focused onresearch into harmful effects of artificialcolours on the health of consumers.While this remains a divisive andinconsistent field, there are still signs ofmany manufacturers and suppliersremoving certain colouring agents fromtheir portfolios. For instance, the Dunkin’Donuts brand in the US are removing thecolouring agent titanium dioxide, which istypically used to increase whites inproducts. Similarly, Nestle have announced thatthey will remove all artificial flavours andPHOTO: SHUTTERSTOCK.COMMARAZEPHOTO: SHUTTERSTOCK.COM/K IMAGES22-24_Layout 1 27/03/2015 11:59 Page 224 Food & Drink Internationalwww.fdiforum.netCOLOURINGmight come with notonly higher prices, butalso less stable colours.This is not a weaknessin the natural colouringindustry, but with thestrength of the artificialcolours themselves.Premium products thatcome with higher price-tags, or products basedon being healthy willlikely have littleproblems, as they areable to off-set any highercosts against the potential increase in customers bypromoting the fact that they are removing artificialflavourings. But industries such as the candy industry, which thriveson being not only brightly coloured, but also sporting avariety of different colours, might find their situation moreproblematic. When it comes to attracting the interest ofchildren, it becomes clear that health benefits, reduction inE-numbers and other such techniques are of interest to theirparents but not the target market. These industries insteadmight simply have to shoulder the burden of increased costs,or perhaps seek to offset these costs elsewhere. What is clear however is that while the colouring industryremains a necessity in the marketing of food and drinkproducts, small changes are taking place in the industry,with the move towards natural food ingredients being thebiggest. PHOTO: SHUTTERSTOCK.COM/MEHMET CETINWhen it comes toattracting the interestof children, it becomesclear that healthbenefits, reduction inE-numbers and othersuch techniques are ofinterest to their parentsbut not the targetmarket22-24_Layout 1 27/03/2015 11:59 Page 3Food & Drink International 25www.fdiforum.netHANDLING & STORAGE SPOTLIGHTOften a change in one part of thefood and drink industry can havea major effect on another part.For example, customers are increasinglyturned off by what appears to be excessivepackaging, but attempts to reduce that canhave an impact on the security and safetyof the product at various parts of thesupply chain.In addition, too, attempts to improvethe energy efficiency of the supply chainat one end can have an impact at thestore as heavily stocked as possible,reducing the amount of energy required tokeep the store at very low temperatures.The downside of this is reduced handlingcapacity so it’s important to strike theright balance between storage density andselectivity and deciding on the handlingequipment contained within.Cold store operations have always been27 ÁMaintaining acompetitiveadvantageSmall but significant changes across the supply chain can make a huge difference to sustainability and securityThe FlexiEdge range of fast-action industrial doors fromStertil Door Products offersexceptional safety plusresistance to wind, weatherand impact damageother end. The challenge affecting thehandling and storage sector, therefore, isto ensure products are treated with thegreatest care at every stage of the supplychain, and that new requirements fromconsumers and retailers alike areaddressed without major upheaval.Energy efficiency is a high priority forall businesses these days, but that bringswith it challenges for handling and storage– especially in the case of cold stores. It’scertainly easier and cheaper to keep a cold25-29_Layout 1 27/03/2015 12:12 Page 1What benefits can a KLIMATEdoor bring to you?Affordable to purchase, operate and maintainReliable and robust for everyday operationsDurable to withstand timeEfficient for conserving energyNationwide technical support serviceTrouble free diagnostic control panelT: 0870 607 5050sales@klimate.co.uk www.klimate.co.ukKlimate High Speed Doors part of BID Group Ltd25-29_Layout 1 27/03/2015 12:12 Page 2Food & Drink International 27www.fdiforum.netHANDLING & STORAGE SPOTLIGHTone of the toughest material handlingchallenges. Not only do the sub-zerotemperatures affect the trucks’ batterycapacity, electronics, lubrication, bodyworkand drivers’ ability to operate the truck, butthe need for this high storage density canreduce selectivity and throughput.Conventional Adjustable Pallet Rackingrarely provides the lowest storage cost incold stores, since the floor utilisation is low,so it’s worth considering alternative rackingtechnologies such as double-deep racking,mobile racking, drive-in racking, flow-through racking and satellite storage.Companies such as UniCarriers are dealingwith this thanks to the Logistics Analyser, apowerful simulation tool that allows thecompany to design and calculate a coldstore in order to achieve an importantbalance between density and selectivity.Very cold temperatures reduce a truck’sbattery capacity by about 1% per degreebelow 20°c. It might also disturb the truckelectronics, make the oil thicker and moreviscous, and make the metal, especially thewelding joints, more brittle. In chill storeoperations, the best trucks need nomodifications at all, but in cold storeoperations with temperatures downto –35°c, some adaptations are necessary toachieve efficiency and reliability.Companies such as UniCarriers are bearingthat in mind when they choose the steelquality and welding technique to make surethat it works at these very lowtemperatures.Condensation is perhaps the biggesttechnical issue for cold store operations,however. At temperatures below the dewpoint of 6°c, the truck will be affected. Thistime can be shortened by blowing hot airover the truck with big ventilators, orchanging the schedules so the trucks spendmost of their time either inside or outside,ensuring a smaller variation in temperature.The doors of the warehouse themselvescan often be an issue, though newinnovations such as the FlexiEdge range offast-action industrial doors from Stertil28 ÁMcBride’s Manchestermanufacturing and distributionwarehouse has installed an ArdentXP High Speed Door at Klimate –the site’s fourth high speed doorand the third from KlimateWith the rapid opening and closing speed of doors, staff donot need to feel the cold rushing in from the outside andproduction can continue at a steady speed.25-29_Layout 1 27/03/2015 12:12 Page 328 Food & Drink Internationalwww.fdiforum.netGO DIRECT……to the UK’s No.1 supplier of plastic pallets and boxesThe UK’s largest range Available from stock Free expert adviceInstant, competitive quotes Immediate nationwide delivery01323 744057 sales@goplasticpallets.comwww.goplasticpallets.comHANDLING & STORAGE SPOTLIGHTDoor Products offers exceptionalsafety plus resistance to wind,weather and impact damage.The door curtains, which havebeen developed to offer flexibility anddurability, incorporate no rigidelements. A hi-tech manufacturingprocess involves the insertion ofreinforced polyester within a PVCsandwich to produce a high strengthyet lightweight door curtain. Thecurtains are available in awide range of standardRAL colours andvarious style optionsthat include vision panelsand windows, translucentcurtains, insulatedversions for chiller andfreezer applications and flyscreen curtains.McBride’s Manchestermanufacturing and distributionwarehouse, meanwhile, has installed anArdent XP High Speed Door at Klimate– the site’s fourth high speed door andthe third from Klimate. This latestinstallation is the last of a three doorproject that saw their existing high speeddoors from Klimate replaced with newmodels.The decision to install the doorunderlines McBride’s commitment tothe welfare of its staff and commitmentto the environment. With high speedopening and closing – it has adjustableopening speeds of up to 2m/s – theArdent range of doors offers the higheststandards of hygiene reducingcontamination by preventing the entryof airborne pollution, pests and vermin.Robert Lishman, Facilities & Servicesmanager for McBride’s says, “We havethe high speed doors located on hightraffic flow areas throughout the facilitywhere standard doors just would not besufficient. With the rapid opening andclosing speed of the Klimate doors, ourstaff do not feel the cold rushing in fromthe outside and production can continueGoplasticpallets.com hasintroduced to its range anew, improved version ofits Hygienic pallet25-29_Layout 1 27/03/2015 12:12 Page 4Food & Drink International 29www.fdiforum.netHANDLING & STORAGE SPOTLIGHTKite Packaginglaunches newgummed paper tapemachinesKite Packaging, the UK’s leading packagingdistributor, has launched a new range of highlycompetitive gummed paper tape dispensers fortheir online customers. The new range ofmachines hasbeen bought tomarket by thebusiness afterthey noticed asignificantincrease ingummed papertape’s popularity, andidentified a need for moreeconomical choices ofdispensing.The key advantage of using gummed tape over polypropylene isthat it is suitable for both ambient and cold temperatureenvironments, and provides a super secure seal that does not easilypeel away. The natural starch adhesive, which is activated by water,is a hygienic way of packaging food items, and the natural papercarrier also means it is fully biodegradable and environmentallyfriendly. Kite has launched two new systems on their website to use withgummed paper tape, which work by applying water to the tape as itis passed through the machine. The first of the new machines, amanual model, is a compact system at a competitive price of just£249. It has an extra-large water chamber to reduce down time andcan dispense lengths of up to 42 inches. The dispenser has beenpositioned as an entry level model that can be used continuously, itis simply activated by using an adjustable slider to set the length anda lever to release the tape required. Kite’s electronic model is even more advanced, with a warmingplate to heat the water and create an even stronger tack. Its user-friendly control panel allows you to choose from thirty differentlengths, and dispenses at an impressive rate for high volume use.Tel: 024 76 420065 • Email: enquiries@kitepackaging.co.ukwww.kitepackaging.co.ukat a steady speed.”The Ardent range of doorsalso provides valuable energysavings by minimising heat lossand benefit from lowmaintenance costs. Due to thesimplistic nature of the door, anyminimal maintenance work canbe quickly and easily undertakenin-house, reducing ongoing costs.Energy efficiency has also hada major impact on all aspects ofthe supply chain. Conveying isan obvious aspect where energycan be saved and companies suchas Rumeca are providing drummotors which are able to use lessenergy for the same performance,helping to reduce powerconsumption, benefiting theenvironment and reducing energy costs. Traditional motortransmission systems are normally able to transferapproximately 75% of the power used to the belt, but thesedrum motors are able to transfer up to 97%.With fewer parts to consider, conveyor design and assemblyis easier and quicker, but for the food industry perhaps the toppriority is the hermetically sealed design, where thanks to theirflat smooth surfaces and stainless steel finish, Rumeca drummotors are easy to clean reducing the contamination risk.More effective management in the warehouse is also of hugebenefit. Kite Packaging, for example, are moving to a newoperating centre based in Portsmouth – a 22,000 sq ft facilitywhich will be the second new property for the company thisyear. The new facility will include brand new, narrower aisleracking, to create more stock-holding facilities for customers,and state-of-the-art Aisle Master Forklift trucks. An integratedWarehouse Management System will also be implemented tofurther enhance the new operation.Equally effective in terms of making savings for companies isreviewing their pallet options. Goplasticpallets.com hasintroduced to its range a new, improved version of its Hygienicpallet, which has been optimised for superior performance inautomated conveyor systems.Manufactured from food grade virgin HDPE, the newHygienic pallet has totally smooth, sealed surfaces and is fullycompliant with EU safety legislation. Free from joints, slotsand other cavities, the Hygienic pallet has been speciallydesigned to prevent the accumulation of dirt and dust,ensuring optimum hygiene conditions are maintainedthroughout the entire handling process. The design meansthat the new Hygienic pallet is quick and easy to clean and,like all medium and heavy duty plastic pallets, it is strong androbust offering a reliable, consistent performance throughoutits long working life.There are numerous aspects across the supply chain wheresmall changes to the quality of materials used can, combined,have a huge impact on a company’s bottom line.There arenumerousaspects acrossthe supply chainwhere smallchanges to thequality ofmaterials usedcan, whencombined, have ahuge impact on acompany’sbottom line25-29_Layout 1 27/03/2015 12:12 Page 5Next >