< Previous20 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGdŚĞh<ΖƐůĞĂĚŝŶŐƉĂĐŬĂŐŝŶŐƐƵƉƉůŝĞƌƚŽƚŚĞĨŽŽĚĂŶĚĚƌŝŶŬŝŶĚƵƐƚƌLJ͕ŽīĞƌŝŶŐĂǁŝĚĞƌĂŶŐĞŽĨƉĂĐŬĂŐŝŶŐƉƌŽĚƵĐƚƐŝŶĐůƵĚŝŶŐ͗ŝƌ^ŚŽĐŬďŽƩůĞƉĂĐŬƐWĂůůĞƚǁƌĂƉΘƐLJƐƚĞŵƐŽdžĞƐĨŽƌďŽƩůĞƐ>ĂďĞůƐan employee-owned businessso, that is. Product display packaging and trays have helped to minimise this problem, with many forms of transport packaging actually transforming into display packs with relative ease. To use the examples of biscuits again, looking back fifteen years it’s possible to remember that many biscuits were hand stacked on shelves. Nowadays it is different, with most transit packaging including perforated lines where the top part can be torn off or pulled back, revealing the products inside a branded container. This is then placed onto the shelf itself, allowing consumers to reach in and take the product at will. This kind of innovation is commonplace now but was revolutionary at the time – not only saving the manufacturer time and money, but also the retailer. It also allowed manufacturers to have more control over their branding and advertising, as they could have free rein on designing the displays. What manufacturers are more focused on today, however, is automation. Can the packaging systems be efficiently integrated into a line in such a way as to boost the efficiency of the process? Too often does it seem that the manufacturing line and the supply chain are separated by a wrought iron fence, with many accidents happening in transit between the two. The increased automation of this process can also cause problems in its own right. Most notably, in a high-speed packaging and labelling operation at a bottling plant, un- or mislabelled © Shutterstock/mandritoiu22 Á18-23.qxp_Layout 1 26/03/2019 10:46 Page 3FOR MANUFACTURING IN FOOD, BEVERAGES, PHARMACEUTICALS, TOILETRIES, COSMETICS AND MORE…1-3 OCTOBER 2019 NEC, BIRMINGHAM THE COMPLETE PRODUCTION LINE EVENTppmatotalshow.co.ukOWNED & ORGANISED BYFREE TO ATTEND REGISTER NOW18-23.qxp_Layout 1 26/03/2019 10:46 Page 422 Food & Drink Internationalwww.fdiforum.netEND OF LINE PACKAGINGThe VP 600 – perfect for products requiring a gentle touch Do you want to process small products into small formats within a small floor space? Are your products sensitive and require particularly gentle processing? Discover Penn Packaging’s innovation in case packing – The VP600. With a small footprint, the VP 600 is perfect for products that require that gentle touch such as pet food pouches, yogurt drinks and cooking sauces in small volume flexible packaging. This next generation case packer has been created using the expert knowledge and proven technology of the previous VP Series case packers. It has the capacity to do 40-cycles per minute depending upon the application. It has advanced safety features thanks to the transparent safety guards and certified SICK sensors as well as a low maintenance design and includes self-cleaning vacuum valves. The user has complete flexibility of the packaging size with fast and easy format and size changeovers. For more information, visit www.penn-packaging.co.uk.packs have to be detected by the human eye or by additional scanners, removed, returned and relabelled. In a competitive high-volume market, where product cost is low and margins are squeezed, this handling adds to costs. This is especially the case when the line has to deal with many different products with a range of sizes and shapes – all of which remains the manufacturer’s duty. This places some burden on scanning and detection equipment, which must be more robust than ever. Of course, one company’s problem is another’s opportunity, so those who are able to adapt and manage such difficult conditions will be in a position of competitive strength over their rivals. What one company classes as an end of line packaging system will also differ greatly from another’s, creating a situation in which one size certainly does not fit all. Some companies have chosen to specialise in entry-level systems, which have lower levels of investment but tend to be somewhat more labour intensive. These can be more suitable for individual lines, however, particularly for handmade or low-quantity production lines. On the other hand, large-scale industrial packaging lines can be used to fully automate a process, albeit at a higher level of investment. The challenge comes in finding out what individual assets can be seamlessly integrated into a line without any real fuss, and thankfully this is something that many packaging machine manufacturers are focused on. © Shutterstock/Ufulum18-23.qxp_Layout 1 26/03/2019 10:46 Page 5Food & Drink International 23www.fdiforum.net Stainless steel conveyor systems Stand alone units or fully integrated Robotic and end of line equipment Bespoke engineering capabilities Turnkey and standalone solutions Integration and project management Service support and upgrades Partnered with Lita Palletising Systems for over 30 yearswww.kensal.comsales@kensal.com | tel: +44 (0) 1 582 425 777Kensal Handling Systems Ltd, Kensal House, President Way, Luton, LU2 9NREmbracing the latest technology, Kensal consistently delivers improved line efficiency for customers, whilst reducing operating costs. Handling a Better Solution !"#"## $ %&'()( *+& *&'()( *+&18-23.qxp_Layout 1 26/03/2019 10:46 Page 624 Food & Drink Internationalwww.fdiforum.netLOADING BAYS AND DOORSThere’s a lot to consider when it comes to loading doors, from hygienic design to durability. In the event of theft or adulteration, a company can be left with financial and reputational damage. Though companies are often insured in the event of either occurrence, this can lead to extended periods of downtime. The inclination here may be to invest in the latest technological safeguards, with next-generation solutions providing another layer of security for worried supply chain managers and food makers alike. But there’s much more to consider. Contamination of any kind is an omnipotent threat, with the supply chain having any number of potential entry points for adulteration to occur. These can manifest in a variety of guises, from environmental damage to foreign bodies and other pathogens coming into contact with food and beverage products. The same due care and attention must be applied to the loading and unloading of goods as during its manufacture. Think of it as an extension of the production line, meaning that trucks and pallets should be regularly cleaned. A rugged washdown should also include bay doors themselves, many of which are purposefully built with hygiene in mind. In manufacturing, hygienic design prescribes a set of principles to ensure maximum efficiency and cleanliness, without leaving processors with a convoluted and time-consuming washdown routine. Dirt, however, is far from the only environmental factor that manufacturers must be wary of, with both wind and rain presenting persistent threats. Loading bays are literal shields against the elements. The difficulty faced by manufacturers is in striking a balance between function and necessity. While lighter materials may be advantageous for the constant opening and closing required of bay doors, conventional options such as these may not hold up against high winds and violent downpours. With one © Shutterstock/VanderWolf ImagesTaking stock 24-26.qxp_Layout 1 26/03/2019 10:43 Page 1Food & Drink International 25www.fdiforum.netLOADING BAYS AND DOORSbay out of order due to environmental damage, a company’s entire logistics operation can suffer, setting productivity, profits and orders back with perhaps an even more profound knock-on effect. Investing in durable, weather-proof doors, then, is of the utmost importance. Robust security doors should factor in water and airproofing measures alongside good thermal transmittance. The trend in recent years has seen specialist door makers turning to wooden fibreboards – such as MDF – treated with polyurethane-based insulators as a waterproofing solution. The doors are then reinforced with heavy duty metal armours such as stainless steel to provide a rigorous defence. This satisfies all concerned, with a lighter, more functional structure, and protection against tough weather conditions. The above assumes that all loading bays are made equally which, of course, is far from the truth of things. In reality, specific loading bays and doors are required depending on the kind of products moving through them. So what might be sufficient for an ambient product can be detrimental to frozen goods. In the latter example, a few degrees difference in temperature can spell disaster, leaving an entire shipment wasted and the producer left to absorb the costs. Loading bays are make-or-break areas in ensuring a stable and reliable cold chain. Accomplishing this aim sees companies turning towards four sided vehicle seals whereby a vehicle will only be opened from inside a facility. Here it is then loaded, secured and deployed and all without affecting the carefully controlled temperature. The specialised and expensive equipment inside warehousing and distribution facilities are often attractive to thieves and their third parties. Although a company may never suffer theft, it’s important to safeguard its potential. There are several security measures at a company’s disposal, including electronic key cards, iris recognition and keyless entry devices. As well as helping to deter and disengage would-be thieves, they also © Shutterstock/hacohob26 Á24-26.qxp_Layout 1 26/03/2019 10:44 Page 226 Food & Drink Internationalwww.fdiforum.netLOADING BAYS AND DOORSLift truck safety inspections ‘need same clarity as HGVs’, says CFTS Although forklift trucks are not subject to an MOT as HGVs are, they do require a Thorough Examination under both LOLER and PUWER, so the importance of carrying out this examination to the highest standard is critical to the industry and all those working in it. CFTS believes this lack of clarity surrounding how often lift truck examinations are carried out and documented can leave managers confused – potentially placing employees at risk. At the recent National Fork Lift Safety Conference, the HSE revealed there are around 1,300 serious forklift accidents each year – 50% more than HGVs. CFTS has therefore advised organisations to ensure their lift trucks are inspected to a safe, rigorous standard satisfying both LOLER and PUWER requirements – and to treat the issue as seriously as inspecting vehicles on the road. Established in 2004, CFTS is the fork lift truck industry’s own voluntary standard for Thorough Examination. For more information, visit www.thoroughexamination.org. do away with lock and keys. As companies of all kinds embrace automation, the idea of a physical lock and key is becoming antiquated. Better to move with the times and embrace these next-generation solutions. If still in doubt, a company can take stock in the fact that their competitors will be investing in the latest technology available. Modular loading docks and mobile platforms are being used with increasing frequency, given the flexible and practical benefits they offer over traditional fixed raised loading docks. For safety purposes, dock levellers are also a far more common site in warehouses and distribution facilities. In short, they’re a cylinder powered platform which can be used to bridge the gap between loading bays and logistics vehicles of any height or distance. This relatively simple technology offers significant gains by prevent costly spillages and worker causalities. Loading bays are critical in a products journey through the supply chain. From farm to fork simply wouldn’t be logistically feasible without these critical junctions along the way. For that reason, companies must ensure that their doors can withstand theft and forced entry, environmental damage as well as preserving the integrity of the products that move through them. © Shutterstock/TTstudio24-26.qxp_Layout 1 26/03/2019 10:44 Page 3Food & Drink International 27www.fdiforum.netINGREDIENTS SPOTLIGHTThe problem with palm oil Palm oil is one of the most commonly found ingredients on product labels, featuring in close to fifty per cent of all packaged goods in supermarkets. This includes pizza, doughnuts, packaged bread, instant noodles and chocolate, not to mention pet food, biofuel and a myriad of other consumer goods. The reason for this ubiquity is down to the oil’s extremely versatile nature. Semi-solid at room temperature, palm oil is ideal for spreads, while it can help to extend shelf life as its resistant to oxidisation. As it’s also stable at high temperatures, it can provide fried products with a crispy and crunchy texture, while being colourless and odourless so it doesn’t affect the sensory profile of food products. Yet there’s more to palm oil’s popularity than just this versatility. The crop itself is incredibly efficient, producing more oil per land than any other equivalent vegetable oil crop. For farmers and agribusinesses, this means it’s much more advantageous than, say, canola, corn or soybean. Precisely because of this versatility and the ease at which it can be grown, palm oil is a major driver of deforestation. Combined with the conversion of carbon rich peat soils, this deforestation has led to millions of tonnes of greenhouse gasses entering the atmosphere, contributing to climate change. That’s on top of the loss of habitat and the exploitation of workers and child labour reported in the supply chain. Over the last few years, palm oil has understandably become a controversial topic, with manufacturers and retailers distancing themselves and their products, while some consumers try and boycott the oil from their shopping trollies. But anecdotal evidence and ongoing research confirms that palm oil can be produced more sustainably. At present, nineteen per cent of global palm oil is certified by the Roundtable on Sustainable Palm Oil (RSPO), a non-profit uniting stakeholders from across the seven sectors of the industry – from producers to NGOs – to develop and implement global standards for sustainable palm oil. These standards set best practice for producing and sourcing palm oil and, although there’s still much more work to be done in achieving its aims, RSPO has together with these stakeholders already achieved a lot. Here in the UK, for Sustainability in ingredients supply © Shutterstock/ dolphfynThe ingredients space has seen an increased emphasis on sustainability and traceability, best exemplified by the palm oil and cocoa supply chains. But with the environmental impact of organic farming being called into question, the solutions are far from simple. Sustainability in ingredients supply 28 Á27-30.qxp_Layout 1 26/03/2019 10:41 Page 128 Food & Drink Internationalwww.fdiforum.netINGREDIENTS SPOTLIGHTexample, seventy-eight per cent of total palm oil imported in 2016 was sustainable. But there is still a long way to go. Sustainability in the cocoa supply chain As has been witnessed in the palm oil supply chain, the cocoa industry is fraught with deforestation, loss of habitat, exploitation of workers and exacerbating climate change. But there is a shift taking place from manufacturing and processing right through to retail. Tesco, the UK’s biggest supermarket by market share, has transitioned all the cocoa sourced for its own-brand chocolate products to Rainforest Alliance Certified cocoa, a move that will likely be replicated by its rivals. It’s well timed as there’s a pressing need for these kinds of initiatives at all points along the cocoa supply chain. According to Beroe, a provider of procurement intelligence and supplier compliance solutions, the global cocoa more resilient to climate change. Now, it aims to map and monitor farms to get a better understanding for farmer’s needs in order to drive more effective and targeted change. Mondelēz is far from alone in its efforts with Nestlé taking a similar approach with its own action focused on a three-pronged approach – forest protection and restoration; sustainable cocoa production and farmer livelihoods; and community engagement and social inclusions. The food and drink major is working in support of the Cocoa & Forests Imitative, a public-private partnership bringing together the governments of Ghana and Côte d’Ivoire and the cocoa and chocolate industry. Unsurprisingly, Mars and The Hershey Company have both also launched cocoa sustainability initiatives and action plans, while swiss chocolate maker Barry Callebaut last year launched a new industry standard for © Shutterstock/ Pierre-Yves Babelonmarket is expected to reach $10 billion by 2026 driven by growing global demand for cocoa derivatives – such as cocoa butter in the beauty industry – and climate conditions threatening production in West Africa. A number of studies and research reports claim that cacao plants could disappear as soon as 2050 due to climate change, fungal diseases and cocoa swollen short virus. Now, more than ever, companies need to adopt strategies to ensure the long-term sustainability of the cocoa supply chain. Fortunately, industry is taking the initiative. US multinational Mondelēz International has committed to a sustainable cocoa supply chain, prioritising both the environment and the native farmers who grow and pick the raw beans. Its latest efforts involved plans to combat deforestation in its three largest cocoa-sourcing markets: Ghana, Côte d’Ivoire and Indonesia. This follows the company’s ten-year $400 million Cocoa Life Programme launched back in 2012 aimed at making farms 30 Á27-30.qxp_Layout 1 26/03/2019 10:41 Page 2.comFor further information: Volac International Limited, Orwell, Royston SG8 5QX, UKT +44(0) 1223 206 818 | volactiveorders@volac.com | www.volactive.comVolactive® Pro20® is an undenatured, complete whey protein isolate, specially formulated for clear protein beverages.INTRODUCING THE IDEAL INGREDIENT 27-30.qxp_Layout 1 26/03/2019 10:41 Page 3Next >