< Previous20 Food & Drink Internationalwww.fdiforum.netSOFTWARE SPOTLIGHTvalue add requirements, it’s very difficultto fully automate efficiently. Instead itmay be preferable to introduce a level ofautomation, which is designed specificallyfor each requirement. As a provider of warehousemanagement software (WMS) solutions,Indigo Software is seeing significantdemand from its food and drink customersto integrate their existing WMS with othertools and device as an alternative to fullautomation. This originates from a desireto improve process efficiency and movetowards greater automation. In addition toincreasing efficiency and productivity,manufacturers also regard partialautomation as a good opportunity to addquality into the supply chain processrather than having to implement qualitychecks as a final stage.For example, Indigo’s food and drinkFood-tracking wearable could help fightbowel disorders and obesity University of Buffalo computer scientist Wenyao Xu is creating a library that catalogues the uniquesounds that foods make as we bite, grind and swallow different foods. It is part of a software package thatsupports AutoDietary, a high-tech, food-tracking necklace being developed by Xu and researchers atNortheastern University in China.AutoDietary is like Fitbit and other wearable devices, but instead of tracking burned calories, it monitorscaloric intake – in other words, what we eat – at the neck. A tiny high-fidelity microphone records thesounds made during mastication and as the food is swallowed. That data is sent to a smartphone viaBluetooth, where food types are recognized.The initial study describes how 12 test subjects, male and female, ages 13 to 49, were given water andsix types of food: apples, carrots, potato chips, cookies, peanuts and walnuts. AutoDietary was able toaccurately identify the correct food and drink 85 percent of the time.Xu says the device could someday help people suffering from diabetes, obesity, bowel disorders andother ailments by enabling them to better monitor their food intake.PHOTO: UNIVERSITY AT BUFFALOcustomers are asking it to help themintegrate equipment like automatedweighing scales, conveyors, cardex systemsand third party services such as parcelcarrier services. Their main objective is tojoin together the picking, packing anddispatch processes into a single, seamlesstransaction. The end goal is to minimisethe necessity to build quality checks intothe process at each stage, thereby savingtime and resource costs. Instead, with anintegrated and automated process, a singleindividual can be responsible – andaccountable - for picking, packing anddispatching, which is driven by the WMS.Examples of partial integration ofautomation in the warehouse includeintegration of a conveyer system andautomating the release of sales orders.Integration of a conveyor system doesn’tneed to be expensive and it is worthPHOTO: SHUTTERSTOCK.COM/WELLPHOTOconsidering the installation of a conveyorin a key area, maybe goods inwards, orbetween picking zones, or for operatorworkstations to help improve efficiency.Automating the release of sales ordersinto different picking streams can saveorder management time. This works byassigning set attributes so orders areautomatically batched and directed todifferent streams, which automaticallydetermine the picking and dispatch style,thus eliminating the need for humanintervention.Integrating warehouse equipment cangive rise to rich data, which is used byfood manufacturers for demandforecasting. With improved data, themanufacturer is able to significantlyimprove forecasting accuracy and scaletheir manufacturing capabilitiesaccordingly. However when doing this,18-21_Layout 1 23/03/2016 13:42 Page 3Food & Drink International 21www.fdiforum.netSOFTWARE SPOTLIGHTPHOTO: SHUTTERSTOCK.COM/BALONCICIproblems can arise because although they get the demandprojections right and increase production levels to make enoughproduct, problems occur because the warehouse cannot cope withthe extra flows. The business lacks the right level of visibility toforecast resourcing requirements, or experiences other constraintsdue to an inadequate supply of vehicles or containers, forinstance. And the knock on effect of encountering this problemcan be a penalty for non-delivery imposed by the retailer. A new breed of WMS can use rich data to mirror theforecasting capabilities of manufacturing solutions and allowproducers to very accurately forecast the impact of increasedproduction levels on their warehouse operations. Greater accuracycan be achieved by overlaying forecast data with other third partydata and internal models. This enables contingency plans to beput in place to ensure the necessary extra warehouse ortransportation capacity is available.Technology like this is essential for manufacturers who need tomanage demand seasonality because here, the seasonal demandpeaks are often very short term and can be created by unforeseenopportunities e.g. hot weather. Being able to capitalise on flexibleseasonality opportunities is where a good WMS can have a hugeimpact, by enabling accurate logistics scenario planning to supporta very flexible manufacturing operation. Most large food manufacturers accept that forecast accuracy levelshave reached a ceiling and are unlikely to get any better. Ratherthan emphasising better forecasting, they have instead invested inimproved manufacturing flexibility and reduced manufacturingresponse times, increasing batch capabilities so that last minuteorders can be fulfilled with very short notice and resource planningto ensure the warehouse can cope with additional throughput.18-21_Layout 1 23/03/2016 13:42 Page 422 Food & Drink Internationalwww.fdiforum.netCONTAINERS AND PALLETSWhen it comes to pallets andcontainers, the industry has a few difficulttargets to meet. Strength and security areabsolutely key with the need to keepproducts in good condition and those whodeal with them safe top priorities.However convenience and efficiency isalso a major driver of innovation.Increasingly the pallets themselves areoften on display in stores so have to allowconsumers the ability to access theproducts, while lightweight constructionalso ensures they are easier to transportand use less energy.The quality of containers and pallets isincreasingly important to an organisation.Indeed, with the rise and rise of no-frillsretailers in the past few years, in manycases the pallets are now no longer usedPHOTO: SHUTTERSTOCK.COM/GUALTIERO BOFFIRisingto thechallenge New technology and automation is placing increased demands onpallets and containers – while a changing retail market alsodemands more. 22-25_Layout 1 23/03/2016 13:45 Page 1Food & Drink International 23www.fdiforum.netCONTAINERS AND PALLETSfor transportation along the supply chainbut also to display the products at the endof it.This brings with it increasedresponsibility. In fact, under the Provisionand Use of Work Equipment Regulationsa pallet is classed as work equipment andtherefore an employer is under “strictliability” to keep it in good working orderand repair. This means that if an accidentinvolving a faulty pallet occurs, theemployer is liable for what could bethousands of pounds paid out in personalinjury claims brought by employees ormembers of the public.For some it’s easy to takepallet quality for granted whenthey’re an everyday piece ofequipment used in warehouseor factory operations. But pallets aredesigned and made specifically for movingmassive weights, which mean accidentscan and do happen if a company cutscorners by using inferior pallets.In many ways, the containers andpallets market is battling with twodifferent and seemingly contradictoryrequirements. It’s certainly the case that,as the supply chain moves faster, palletsneed to benefit from simple constructionthat can allow them to be stacked andpicked up in a fairlysimple fashion, and from a decent capacitythat ensures as few are required aspossible. Yet at the same time security isparamount and the load has to be securedincredibly firmly, with the introduction ofanti-slip intermediate layers, wrapping inplastic or by strapping which, you wouldexpect, provide additional complexity.Generally plastic pallets – with theiradvantages of precision dimensions andincreased hygiene – are becoming moreand more popular throughout the supply24 ÁClugston Distribution invests£1.2m in new fleetClugston Distribution, a UK-based independent bulk tanker specialist, has investeda further £1.2 million to develop its tanker fleet capability. Building on its long-term relationship with Renault, the company has ordered threenew T460 6x2 low cab mini mid lift tractors for use in the petroleum sector and fivereplacement Renault T460 6x2 tractors for its food and cement fleet. Five are beingdelivered with standard height cabs, again using the mini mid lift solution to reduceweight. All the new trucks will be fitted with Lytx forward facing camera systems.Further investment has been committed for three additional 42,000 litre fueltankers from Cisternas Cobo. Two are going on fleet in March to support Clugston’sexpanding fuel operations, with the third to be exhibited by Cobo at this year’s FPSExpo in Liverpool. By June, Clugston Distribution will have 18 fuel tanker/tractorcombinations operational across the UK.Three replacement bulk flour tipping silo tankers have also been ordered from Feldbinder. The 60m3 capacity vehicles have been purchased toreplace three existing tankers on Clugston Distribution’s expanded shared user flour and bulk dried food operations.PHOTO: SHUTTERSTOCK.COM/BALONCICI22-25_Layout 1 23/03/2016 13:45 Page 224 Food & Drink Internationalwww.fdiforum.netCONTAINERS AND PALLETSchain, making huge inroads into sectors whichpreviously relied entirely on wooden pallets. Theirdurability has also been illustrated withcompanies looking to returnable transit packagingas opposed to single trip packaging. The benefitsof this kind of packaging include reduced productdamage, security and easier handling, while thereare also obvious environmental benefits fromusing packaging on several occasions – after ahygienic wash down. Another benefit of plasticcontainers and pallets is also their recyclability.An ever-increasing concern given the stringentrequirements and expectations placed on food anddrink companies – and those who work alongsidethem. With the requirements regardingenvironmental efficiency and health and safety inmind, it’s becoming increasingly the case thatcompanies are making use of pallet networks,meaning they can be assured that the pallets areof the highest quality, and providing exceptionalflexibility without extensive capital expenditure.One example of the former is the DSV DailyPallet, which offers a daily pick-up and departuresystem with on-time delivery of palletisedshipments of up to 3500kg to any destination inEurope. Every country in the network has a dailylink with every other country in the network viathe hub near Stuttgart, and by utilising the DSVEuropean road network as the backbone of thenew service, there are extensive traceabilitybenefits, as goods stay within its control andcustomers can track the progress of theirshipment. The initiative was launched thanks tocontinual demand for customers to be able todeliver smaller shipments on a more frequentbasis.Consolidation in the sector now means thatmaking use of larger networks such as these willlikely offer greater flexibility. The obvious counterargument is that a company which oversees all itsown deliveries in-house should be better preparedfor this, but it’s highly likely that adding a newdrop or route into a network comprising just tenjourneys might represent significant potential fordisruption.With traceability and energy efficiency nowdominating thinking across the supply chain,making use of higher quality containers and pallets– whether purchased outright or rented from oneof the many high quality suppliers – is bound toensure an exceptional return on investment.It’s not all about the content and material usedin the manufacturing process however. Asmanufacturers and warehouses make stridestowards higher levels of automation,there is a necessity for containers andpallet companies to offer flexibilityin design – in order to meet theneeds of the automatingmachinery. It may seem asimple task at first; addingsome specific grooves or ridgesthat a robotised system can grip onto.But the bespoke nature of the additionscould mean vast delays or alterations beingLogistics Institute partnerswith Morocco freight operatorSNTLExperts from the University of Hull are embarking on a new partnership with theleading logistics service provider in Morocco. Staff from the University’s Logistics Institute are set to begin work on two supplychain and logistics related projects, as part of a long-term collaboration with state-owned but privately managed transport company SNTL.Initially, the company and the Logistics Institute will be jointly developing a newlogistics hub index. The index will be used to measure the potential of countries,particularly in Africa, to become logistics hubs and taps into the Logistics Institute’sextensive expertise and research in this field.The joint venture to develop the index was agreed after Professor Amar Ramudhin, Director of the Logistics Institute, visited Morocco to give a talk onemerging trends in the logistics sector.Professor Ramudhin, pictured, said: “For the Logistics Institute, it brings added credibility to be able to showcase our expertise in emerging countriessuch as Morocco. It builds on the work I have done before with Georgia Tech Panama to position that country as the logistics hub of the Americas.”22-25_Layout 1 23/03/2016 13:45 Page 3Food & Drink International 25www.fdiforum.netCONTAINERS AND PALLETSOur complete truck range atyour serviceYou can call us for further information on 01844 215501or email marketing-uk@unicarrierseurope.comwww.unicarrierseurope.commade to a manufacturer’s line. This was the issue faced by Schoeller Allibert whenthey partnered with Hatteland, inventor of the AutoStorecubical automated warehouse system. Unlike traditional“from the side” warehouse order picking systems,AutoStore’s unique “from the top” robotised technique,combined with the stack’s constantreorganisation (to access bins at the bottom,the robot must first remove thoseabove it), means that the top of thebin is subjected to far greater levels ofmanipulation and weight stress.Schoeller Allibert therefore had todevelop a more robust bin structure thatwill easily withstand this new workingenvironment. This was achieved withoutdelay, and the containers were made to be100% recyclable – but it still highlightschallenges which might soon be faced by manymanufacturers of containers or pallets as theindustry continues to evolve. As always, thoseat the forefront of innovation are more likelyto thrive in the challenging times ahead. PHOTO: SHUTTERSTOCK.COM/3DMIIceland and XPO logistics agree 5 yearsupply chain deal As Iceland looks to continue to grow its storenetwork across the UK, the frozen-food retailerhas agreed a five-year warehousing anddistribution deal with XPO Logistics. XPO will manage Iceland’s distribution centresin Warrington, Enfield, Livingston and Swindonwith its responsibilities including warehousingactivities which range from product receipt tonationwide store distribution. It will also include anumber of primary collections. The retailer’s temperature controlled fleet of 320tractor units and 450 trailers will likewise beoverseen by CPO in a move that is expected tocreate further operational efficiencies for Iceland by implementing an integrated inbound supply chain platform. Richard Crawston, managing director, supply chain, UK & Ireland for XPO Logistics, said: “We’re delighted to beworking with Iceland and believe that our significant experience working with major food retailers will be invaluable insupport our customer’s expansion.”Iceland currently has 850 UK-based stores and a growing network of out of town food warehouse outlets.PHOTO: MICHAELPUCHE / SHUTTERSTOCK.COM22-25_Layout 1 23/03/2016 13:45 Page 426 Food & Drink Internationalwww.fdiforum.netSUSTAINABLE PACKAGINGPlastics maintain a precariousrelationship with sustainability. On onehand, they are one of the most commonand widely recycled materials, but on theother, they represent a significanthindrance, contributing to the evergrowing issue of wastage. The ultimateproblem with plastics is that there are somany varying types. Some are perfectlyreusable, and can be recycled in everythingfrom clothing to building materials orreturned to the supply chain as foodpackaging, and others, like shopping bags,have a disastrous effect on animal life andecosystems. In one particularly frighteningstatistic, it has been forecast that therewill be more plastic than fish in the sea by2050. As is often the case, fromopposition and necessity comes invention. Plastic is one of the touchstones of thedeveloped world, and one of the biggestpropagators of plastic, beyond computers,smart phones and tablets of course, ispackaging. As more and more consumersturn to online shopping (or e-commerce)for goods and foodstuffs, so the amount ofpackaging in the supply chain increases.As a relatively new phenomenon, e-commerce waste is unprecedented. Beyondthe cardboard boxes and sleeves typicallyassociated with online shopping, there isalso the protective packaging needed to fillup the air space, from air bags topolystyrene chips. With Amazon now amajor player in the online ordering anddistribution of fresh groceries andfoodstuffs, e-commerce has seen manyconsumers switching from traditionalshopping to the comfort, convenience andease of use of their own homes instead.Supermarkets, of course, have long beenoffering home delivery via online shoppingfor years, but this too results in excess andunwarranted baggage and packaging. With sustainability becoming more ofan obligation rather than simply ticking abox in a company’s corporate socialresponsibility, innovative and eco-friendlysolutions have entered the fray to disruptPerfectpackagingFood packaging is increasingly turning towards more eco-friendlymaterials, but packaging can also be utilised to help curb foodwastage. Research grant for invisible markers toboost plastics recycling quality A high-level consortium has wonrecognition funding from governmentinnovations agency Innovate UK for itsproject to identify new luminescent materialswhich can be applied, invisibly, to labels onplastic packaging, offering a low-cost sortingtechnology for the performance-boostingsub-categorisation and purity of recyclables. The project, Plastic Packaging Recyclingusing Intelligent Separation technologies forMaterials (PRISM), has secured £772,000 offunding over two years. It will develop newfluorescent materials from novel metal oxidesas well as converting reprocessed powders from recycled fluorescent lamps into suitablefluorescent materials.The fluorescent marking technology is one of the most important developments in sorting indecades, according to recycling consultancy and lead partner in the project Nextek.The UV light adds an additional, high-value layer of sorting. PRISM technology captures theunique code created by the normally invisible application-specific luminescent compounds in thelabel. This will allow, for instance, food-grade polymers to be distinguished from non-food-grade, blackplastics to be identified and full-length shrink-sleeves to be tagged according to the underlyingplastic. Brand-owners could even establish closed-loop collection of specific packaging formats. 26-29_Layout 1 23/03/2016 13:48 Page 1Food & Drink International 27www.fdiforum.netSUSTAINABLE PACKAGINGtraditional packaging solutions. Take, forexample, the rise in fibre-based packagingchallenging the food production and retailsector to move into more environmentallyfriendly directions. The innovativemushroom packaging, developed by NewYork-based company Evocative (amongother companies and start-ups), hasnumerous benefits which range fromeconomical to its natural and home-compostable properties. It can also berecycled many times over, and works inharmony with most contemporaryrecycling systems. Sustainability, however, is one of manyaspects consumers and industry now wantsfrom food packaging. Of increasedimportance is the need for transparencyacross the supply chain, with theconsumer now more than everchampioning clean labels and the originsof their food products. Opting for moresustainable materials, either partially orwholly, in food and beverage packagingcan act as a reliable vehicle fortransparency. Consumers have longdecried confusing recycling regulations andiconography, and attributed it to their ownlack of recycling in the home or workplace.And for many companies, products suchas disposable cups, contain a polyethylenelining, meaning they can’t be recycled.Such is the case with high street coffeeretailer Starbucks, who, as of writing, isembroiled in controversy over its recyclingclaims. By its very nature, sustainablepackaging is more readily recycling, andPHOTO: ALESSIA PIERDOMENICO / SHUTTERSTOCK.COM28 ÁHeat, grease and oil resistant PLA film for paper bagsTaghleef Industries and Nicoletti SpA, an Italian manufacturer of paper bags for freshfoods, have developed a bag for roasted chickens made entirely of renewable resources.The paper bag is fully laminated with recently introduced NATIVIA® D808 20 µm film andhas a transparent window which allows see-through of the packaged products. Uniqueperformance and thermal properties of D808 20 µm film ensure heat resistance of the bag atstorage temperatures up to 80°C. Improved heat resistance was the primary requirement ofthe film, since roasted chickens that are cooked every morning in the deli corner need to bekept at a temperature above 65°C (in bulk) in order to avoid proliferation of microorganisms.Like all NATIVIA® films, D808 20 µm provides very good barrier to grease and fatty juicesfrom the foodstuff, protecting the paper packaging against grease penetration. For further information please contact Emanuela Bardi atemanuela.bardi@ti-films.com or visit www.nativia.com. 26-29_Layout 1 23/03/2016 13:48 Page 228 Food & Drink Internationalwww.fdiforum.netSUSTAINABLE PACKAGINGmaterials. Some of the solutions includeusing breathable packaging, which allowsmoisture and gas to be released from thepackaging to help prevent fresh goodsfrom spoiling and thereby extending theirshelf life. Other solutions are boostingfunctionality, such as developing thearchetypal resealable packaging. Whileothers are developing the polymers used inpackaging to ensure that they are moreeasily recyclable for the consumer.Packaging is a necessary part of theconsumer experience, and a fundamentalpart of the supply chain. For years,however, it’s been dogged with plasticsthat have a detrimental environmentalimpact during production, difficulties withrecycling for the consumer and they don’tdecompose in landfill sites, affecting theecosystem and animal life. In order toachieve carbon targets and usher in a trulysustainable age, making the move to moreeco-friendly packaging is imperative.There are already a slew of ground-braking alternatives to traditionalpackaging, and those grown from fungi areset to be a disruptive force for the better.But developments in the packaging sectoris also ensuring that food waste be kept toa minimum and usher in a sustainable ageacross the supply chain. PHOTO: SHUTTERSTOCK.COM/TIMURTAS ONANhelps cut down on wastage on its journeythrough the supply chain and, morecrucially, offers ease of disposal for theend user. The call for transparency is, in part, aresult of food scares and recalls andsustainable packaging has a surprisingfuture in boosting food security. Foodwaste has been making a big stink in themedia, since the extent of food wasted byconsumers and supermarkets has beenhighlighted. Since then, supermarkets, inparticular, have committed to curbingtheir in-store wastage, donating theirsurplus stock to charities and foodbanksand have begun selling ‘wonky’ vegetables,where before they would simply turn themdown on aesthetic grounds. Food waste,and the energy and resources involved inproducing and transporting it, areresponsible for far more carbon emissionsthat can be attributed to packaging.Therefore, it is vital that packaging worksin harmony with food to reduce wastagewhich, in turn, curbs emissions. In thisregard, packaging is fulfilling a sustainableneed but, combined with more eco-friendly materials, packaging can be apivotal cog in the machine ensuring analtogether more environmentally friendlyfood industry. Although there’s no shortage of start-ups bringing innovative packagingmaterials to market, such as theaforementioned mushroom packaging,there’s a whole other arena where thefunctionality and design of packaging isbeing outright challenged, performing asmuch of a service as the revaluation of26-29_Layout 1 23/03/2016 13:48 Page 3Food & Drink International 29www.fdiforum.netDISCOVERtheARTofoffsustainablefPACKAGINGVisit: www.connectpackaging.comCORRUGATEDPHOTO: SHUTTERSTOCK.COM/PHOTKANEW - Home compostablepackaging to reduce food waste& increase shelf-life sustainablyUK-based SPPare delighted toannounce theimminent launchof their new,market-leadingrange of certifiedcompostablepackaging –2humusTM. 2humusTMis setto be the UK’smost versatile, high performance, non-laminated flexible packaging forfood use that is certified as home compostable and industriallycompostable. It can be produced as a very extensive range of plain orprinted bags and film. Sourced from nature, 2humusTMis the sustainable way to extendingshelf-life and reducing food waste – ensuring a sustainability cycle in itsreturn to nature.* Certified as home compostable.* Minimises food waste, litter and landfill.* Increases fresh produce shelf-life, compared to traditionalalternatives like LDPE.Email info@2humus.com or visit www.2humus.com to findout more, and keep up-to-date with important industryupdates and directives by subscribing to our PackagingSustainability newsletter.Wine Bole Boxes Our Wine Bole packs have integrated internal dividers for added strength and stability Key Features: All in one simple soluon Made from heavy duty cardboard Integrated internal dividers Space saving Compevely priced www.kitepackaging.co.uk Call today to speak to one of our friendly and experienced team on 02476 420065 It’s not just us that say so, visit our website to see what our customerssay about us on Trustpilot. Unique design We have the UK’s leading B2B ecommerce website, offering 2,500 stock products. Lowest prices. High quality products. Next day delivery available. One-to-one account Credit facilies. Service levels that are second to none. Our commitment to our customers: 26-29_Layout 1 23/03/2016 13:48 Page 4Next >