< Previous30 Food & Drink Internationalwww.fdiforum.netINGREDIENTS SPOTLIGHTcocoa sourcing. It all points towards a more positive future for the supply chain, one which consumers can assist in by ensuring they buy trusted and certified chocolate products. Is organic all its cracked up to be? With the increasing emphasis and visibility on environmental protection in the food and beverage industry, it would be easy to assume that going organic would be the best option for consumers and agribusinesses, but research has cast doubt on this approach and raised some difficult questions over its benefits. A study published in Environmental Research Letters back in 2017 found that organic systems require twenty-five to 110 per cent more land use than conventional systems per unit of food. More startling still was its finding that organic and conventional systems did not significantly differ in their greenhouse gas emissions or acidification potential. Another study, published towards the end of 2018, showed how researchers at the Chalmers University of Technology in Sweden developed a new method to assess the climate impact from land-use. Researchers used this new method not used. Putting it simply, to produce the same amount of organic food, a bigger share of land is needed. However, researchers did stress that this did not apply to all food, with organic beans or chicken still better for the climate than conventionally produced beef. Organic farming also remains better for farm and animal welfare but, in general, it is worse for the environment than its conventional counterpart. With the global population forecast to hit nine billion by 2050, and food scarcity already an issue around the world, can organic farming possibly be used to feed everyone? © Shutterstock/ Kaiskynet Studioalongside others to compare organic and conventional food production. Their results show that organic can result in much greater emissions. For example, it found that organic peas farmed in Sweden have a fifty per cent bigger climate impact that conventionally farmed peas. The difference between the two farming approaches was greater still when looking at other crops, with a seventy per cent difference discovered in organic Swedish wheat. The reason why, they claim, is because yields per hectare are much lower, primarily because fertilisers are Volactive® Pro2O® offers natural solution for manufacturers As demand for clean labels continues to grow, the drinks category has continued to be revitalised by reformulations that contain natural ingredients with a growing number of health benefits. Volactive® Pro2O® offers a natural solution for manufacturers looking to develop crystal clear beverages that are high in protein, sugar and fat free. Proven for its ease of use in the manufacturing process, Volactive® Pro2O® is an undenatured, complete whey protein isolate, containing only trace levels of fat and ash whilst delivering the highest protein content. It has a neutral pH, offering a clean flavour with no astringency. For further information please visit www.volactive.com 27-30.qxp_Layout 1 26/03/2019 10:42 Page 4Food & Drink International 31www.fdiforum.netGEARS, DRIVES AND CONTROLSWith a number of difficult trading conditions across the world, along with threats of tariffs and trade wars, it has become clear to food and drink manufacturers is that they need to improve efficiency to stay competitive. The industry is one with low margins as it is, and many fear it will be unable to keep up or compete with European rivals, not to mention those even further away. Automation is set to be the solution to this, and is something the UK has already fallen drastically behind on. Not a crippling blow just yet, many manufacturers have begun to see the writing on the wall and are investing. Automation as a whole is set to benefit, but there is also an integral industry attached to this, which is sure to shine. These are the gears, valves and drives industries – which, without these important additions, automation equipment would not function. Despite innovations in technology, automation is not without its potential pitfalls, most obviously when it comes to the reliability and the quality of the gears and drives used to power the machinery. In the food and drink sector there’s an additional challenge in terms of safety and hygiene, where the potential for food to get caught up in small parts can be very great. It’s therefore vitally important that effective gears and drives are selected and maintained. It’s likely that many manufacturers will have reviewed their gears and drives on a regular basis now that electric motors have been required to meet the IE2 standard of energy efficiency. These efficiency ratings are based on a European standard with IE2 requiring high efficiency, similar to the old Eff1 voluntary standard which has now been discontinued. The latest motors available for the food and drink industry all reach these standards, as well as © Shutterstock/Yakov OskanovGearing up With the need for automation becoming clearer than ever, it’s not just machinery manufacturers who are set to benefit. The gears, drives and valves industries will be at the forefront of the revolution. 32 Á31-33.qxp_Layout 1 26/03/2019 12:50 Page 1GEARS, DRIVES AND CONTROLS32 Food & Drink Internationalwww.fdiforum.netsales@aptpowerdrive.co.ukwww.aptpowerdrive.co.uk01442 212 671 SOUTH 01543 687 810 MIDLANDS 0141 885 4084 SCOTLAND đƫBonfiglioli Motors, Gearboxes and inverters from stockđƫIdentification and supply of equivalents to competitors’ drivesđƫCall us now for adviceOffi cial UK Build Centre forFlotronic introduces ‘ONE NUT’ drum / barrel unloading Flotronic has introduced a new drum / barrel unloading system, combining the unique ‘ONE NUT’ pump with its barrel unloading skid. The new system enables you to pump highly viscous materials out of your barrel at significantly increased flow rates. This system is built around the company’s ‘ONE-NUT’ sanitary style pump which is based on its 3A and EHEDG design. This style of pump has already proven itself in the hygienic/sanitary industries and is a match for any environment or process where avoidance of product contamination is paramount. The system can be Cleaned in Place using the pump itself or an external CIP rig or, because of the ‘ONE NUT’ design of the pump, it can be easily stripped down for cleaning. The drum / barrel unloading skid can be fully mobile or fixed in place, with the system designed to suit your needs, including roller systems if required. For more information, visit www.flotronicpumps.co.uk. meeting other standards, such as those that allow them to be used in explosive atmospheres. High quality gears and drives can help to not only reduce inefficiency, but also reduce the need for maintenance and repair. In an industry where even the smallest amount of unexpected downtime can influence the ability to meet orders, this is not only a preferred outcome – but an absolute necessity. As always, the allure of low-cost alternatives or sub-standard gears and drives is one of the factors holding back many in the food and drink industry, particularly given the UK’s culture of being frugal with investment. In this regard we might look to our European neighbours, who prefer quality and long-term benefit over initial expenditure, and have much more competitive food and drink brands as a result. When it comes to the components which run and operate the machinery that keeps our factories running, the old maxim `buy cheap, buy twice` should certainly be considered. When it comes to the valves industry, the demand for the elimination of preservatives from food and beverages is set to drive demand higher than ever. Transparency Market Research has shown that many large players in the valves industry have taken to investing in developing regions and emerging markets in order to cater to the huge potential there. The research report also claims that the global hygienic and aseptic valves market is set to increase from $6 billion in 2015, to $9 billion in 2025 – an increase of 50% in just a single decade. Of the various types of valves available, hygienic single seat valves are expected to do the best, outperforming all other segments and acquiring a figure close to 26% of the global market. This is due to the ability of these valves to meet the strict and varied requirements pertaining to aseptic and hygienic process in the food and drink industry. Much of this comes in comparison to the rest of the food and drink industry, who often show some reluctance to face new laws and regulations on the issue of hygiene. This 31-33.qxp_Layout 1 26/03/2019 12:50 Page 2PCE Automation and Cobot Technology – the perfect partnership PCE Automation have recently supplied a number of Collaborative Robot (Cobot) solutions, embracing the synergy that can be achieved between human and machine. Cobot Tech Technology can be deployed across a number of different industries, to overcome the manual strain of repetitive tasks, whilst maintaining higher levels of overall throughput and productivity. The highly skilled team over at PCE Automation ensure that cobot technology seamlessly integrates with customer and process requirements, whilst ensuring operator safety at all times. Julian Tarratt commented: “Cobots are incredibly versatile and readily deployable to overcome musculoskeletal injuries caused by repetitive strain. Our cobot experts are able to ensure the highest levels of throughput and accuracy, whilst making sure that the cobot responds instantly to human input, enhancing operator safety.” For more information please visit https://www.pce-automation.co.uk/products/robotics/GEARS, DRIVES AND CONTROLSFood & Drink International 33www.fdiforum.netAZZURI BLUE [food blue] GEARINGDavall DSG supply transmission partsin stainless steelgears sprocket motor-gearboxis perhaps understandable given the upsetting nature new regulation has on a well-run process, but the valves industry flourishes in such difficult times due to its focus and ability on controlling and improving hygiene. What goes hand in hand with these industries is the maintenance and monitoring of machinery, especially in identifying when these components might need to be replaced. Electrical, X-ray and good old regular inspections are always touted as the most reliable forms of monitoring, with the least desirable being to wait until something goes wrong. A new player into the market, however, is vibration monitoring. The process is relatively simple, although more advanced technology and investment will allow for closer monitoring. Essentially, it operates on the principle of identifying how much vibration a machine, belt or process normally experiences when running at peak efficiency, and then monitors this to alert line managers when the vibrations enter what might be considered an unusual territory. Some vibration from the operation of gears and drives is expected, of course, but by looking for discrepancies or sudden leaps, it’s possible to isolate components that have begun to wear down, long before they start to cause problems. In machines that work without vibration, this method is even © Shutterstock/Zoltan Majormore applicable, as any vibration at all might indicate the need for maintenance or replacement. Getting on top of these problems early helps to ensure the process continues to run smoothly – and in getting the best results from these components, a little vetting on suppliers is always advised. The first offer one receives might not always be the best, even if the price seems right. Like many esteemed and well-known manufacturers, it’s not unusual to find companies who have specialised in gears, drives and valves for many decades, showing their extreme prowess and experience in the industry. 31-33.qxp_Layout 1 26/03/2019 12:50 Page 334 Food & Drink Internationalwww.fdiforum.netMIXING AND BLENDINGTaste, texture, colour and even appearance are all factors that are directly influenced by the mixing and blending process. Product consistently is paramount; what goes into one can or pouch package must be exactly the same as the rest of that batch and all the ones before and after it. With so many options available on the market, it’s vital to process optimisation that food and beverage makers find the right solution for their needs. Getting the advice of expert suppliers such as Admix, which provides in-tank batch mixing, low shear agitation; inline mixing and milling, and powder induction, helps to ensure a manufacturer is set up with the right mixing and blending equipment to meet their needs. But those needs are understandably varied, with a staggering amount of food and beverage products available on shelves having come into contact with a mixer or blender at some point in their lifecycle. Mixing dry goods together requires different speeds and machinery from what’s required when mixing wet or viscous ingredients. Understanding the difference and installing the right equipment accordingly is vital to process Getting the mix right Mixing and blending are some of the most universal processes of food production, from niche artisan producers right through to major multinational players. Whether it’s for small batch mixing by hand or large scale production, mixing and blending are both important to achieving and maintaining product consistency in order to satisfy consumer expectation and regulatory demands. © Shutterstock/Surasak_Photo34-37.qxp_Layout 1 26/03/2019 10:37 Page 1Food & Drink International 35www.fdiforum.netMIXING AND BLENDINGoptimisation. Industrial blenders introduce different amounts of energy and high shear and high impact blending systems, all of which can have an effect on a product’s particle size, influencing consistency and texture. This is ideal for emulsification, powders and thickeners. That last example is especially advantageous as stabilising and thickening agents are crucial to the end texture and quality of many products – such as salad dressings, gummy confectionery, syrups and ice creams. But a number of issues can arise during the manufacturing process when incorporating these gums into a product mix. But incorporating these gums into a product can cause some problems during the manufacturing process, and they can be difficult to disperse and hydrate correctly and efficiently. When added to water, most gums form agglomerates which conventional © Shutterstock/Surasak_Photoagitators struggle to rapidly break down. But by using high shear equipment, manufacturers are able to avoid these agglomerates from forming and achieve the desired texture, consistency and mouth feel of their products. Industrial blenders aren’t suited to every application and, in some cases, can be of detriment to a product rather than beneficial. Other options include ribbon blenders which boast dual action ribbon-shaped agitators which creates an intimate blend in a short cycle time. Thanks to the nature of this mixer, it’s ideally suited for powder blending applications where thoroughly incorporating products together is paramount. For blends requiring a gentler mixing action, there’s paddle, tumble and vertical blenders. The latter is ideal for 36 ÁAdvanced Engineering MIDDLETON LTDmixing is our businessl Inline High Shear Mixer l 3 Stage High Shear Mixer l Dispersion Mixer l Fluid Mixers l AdPro l Top Entry High Shear Immersion Mixer l Bottom Entry High Shear Mixer l Sealed Bearing Mixermixer design and technologyUnit 5D Transpennine Trading Estate, Gorrells Way, Rochdale, Lancashire OL11 2PX tel: 01706 759003 fax: 01706 759004 email: info@aemixers.com web: www.aemixers.com34-37.qxp_Layout 1 26/03/2019 10:37 Page 236 Food & Drink Internationalwww.fdiforum.netMIXING AND BLENDINGSilverson achieve agglomerate-free dispersion in minutes Dispersing gums and thickeners is one of the most difficult mixing operations; many formulations contain unnecessarily high percentages of functional ingredients to compensate for poor yield. Silverson recently ran trials for a client that was making up a 6.5% pectin solution in order to obtain the 5% they needed in the end product. The high level of waste of an expensive ingredient was due to having to filter out agglomerates that couldn’t be dispersed by their conventional mixer. With a Silverson Flashmix they achieved an agglomerate-free dispersion in a matter of minutes, allowing them to reformulate their product with less pectin. As such the mixer is expected to pay for itself in a short space of time. Silverson has produced a series of ‘How to’ videos on the dispersion of functional ingredients which can be watched at www.silverson.co.uk. maximise quality and minimise cost, no doubt these bespoke options will become more popular still. Whatever the processing capabilities of a mixing and blending equipment, one issue still remains – hygiene. Without a thorough washdown and sanitation routine in place between batches, mixers and blenders become a major health risk. When high viscosity food ingredients are mixed together, ingredients closest the vessel walls tend to move slower which affects the overall efficiency of the mixing process. Scrapers are purposefully designed to come into contact with the vessel walls a product that is shear sensitive, or where process parameters are critical. The blending action is gentler than the agitators seen in the ribbon blender, so for loose mixers and those of a more delicate nature, this is a better fit. Tumble blending is a rotating mixing machine that, as one can deduce, mixes through a tumbling rotating action. These machines come in a variety of styles depending on the requirements, from intermediate bulk container blender, the V-shaped blender and the double-cone configuration. Agitation is often conflated to mean all types of mixing processes, but this is an oversight, eclipsing the purpose of agitation in food processing. Agitators ensure the mixing process achieves a homogenous mix faster. Given that there’s dozens of different kinds of products that require this specific kind of mixing, it’s no surprise that there are different kinds of agitators. From low shear to high shear, agitators can be used to mix, disperse and emulsify making them common on production lines. As we’ve already explored, ensuring the correct mixer or blender is in place can result in huge efficiency and process optimisation gains. This can be taken further still. With continuous mixing and blending, a manufacturer can meet the demand for ever more efficient processes and increase batch throughput. This can be accomplished by using several mixing receptables arranged in such a way that a batch is always being worked on at any given time. However, opting for multiple off-the-shelf options might have the opposite effect and compromise efficiency rather than enabling it. For that reason, manufacturers might be better off opting for a bespoke approach. Advanced Engineering design and manufacture a variety of mixing equipment for fluid processing applications. This equipment is built to exacting customer standards and optimise specific individual processes, meaning they’re purpose-built to a manufacturer’s unique needs. With the growing number of food and drink manufacturers moving towards more specialised optimised processes to © Shutterstock/mavo34-37.qxp_Layout 1 26/03/2019 10:37 Page 3MIXING AND BLENDINGFood & Drink International 37www.fdiforum.netto scrape away sticky ingredients and incorporate them back into the mix. But some particles can become embedded in the scraper itself, creating abrasion on the vessel walls which leads to wear. Ingredients can also collect on the scraper arm, where they can contaminate the next batch. This is just one example, highlighting the wider need for mixing and blenders to be regularly and thoroughly cleaned between batches. This does result in periods of downtime, which can be avoided if a company embraced continuous mixing operations, as outlined previously. Innovation never sleeps for food processing, and updates in mixing and blending technologies offer food manufacturers the chance to regularly evaluate and update their processes which, in turn, helps boost efficiency, process optimisation and improve product consistency.34-37.qxp_Layout 1 26/03/2019 10:37 Page 438 Food & Drink Internationalwww.fdiforum.netMEAT, POULTRY AND SEAFOODBackward compatible food metal detectors Exceptional sensitivity and ROI … guaranteedTel: +44 (0) 1295 256266 www.fortresstechnology.co.uk Email: sales-uk@fortresstechnology.comIn terms of demand, a growing middle class in China, not to mention better supply chains within Europe, have led to an increase in the demand for products such as beef and pork. Imports and exports remain strong, but unpredictable fluctuations in currency have led to complications for some. The industry faces other problems, however, particularly in the UK with 25% of UK abattoirs failing `dirty meat` checks. The knock-on reputational costs of this will be felt by both manufacturers and retailers and highlights the importance of independently vetting supplies for quality, rather than going with the cheapest solution. Nowhere has this been more highlighted than last year with Russel Hume, a supplier of beef that collapsed into administration following a scandal with beef supplied to several outlets Meeting the challenge The meat, poultry and seafood sector has frequently undergone huge changes thanks to consistent fluctuations in consumer demands, and while some have fallen by the wayside, others have excelled under the pressure.38-42.qxp_Layout 1 26/03/2019 10:33 Page 1Whitby Seafoods wave goodbye to poor codes and missed packs Increased reliability, throughput and reduced downtime are just some of the benefits that Whitby Seafoods, the UK’s largest scampi buyer and processor, gained when switching to Clearmark Solutions fully networked ICE coders and print and apply labellers. Whitby Seafoods were searching for highly automated low maintenance coders and labellers to help them to grow their business and keep up with increasingly varied high volume production demands. The solution was found by switching two factory lines with legacy equipment to fully networked Zodiac primary packaging Thermal Transfer Overprinters and Vulcan secondary packaging Print and Apply labellers. Whitby quickly discovered that the small footprint of the machines allowed for greater integration and synchronicity with larger industrial packaging machines, helping to increase print precision, reducing line disruption and waste. Whitby now benefit from coders that are flexible enough to print dates in any format or size, and in an unlimited range of Windows true type fonts. For more information, visit www.interactivecoding.co.uk.Food & Drink International 39www.fdiforum.netMEAT, POULTRY AND SEAFOODcan be devastating, but that is not to say it’s an unbeatable challenge. Recalls like this happen often and few are the companies who go into administration because of it. KFC, in fact, is an example of the same problem but one handled in a better manner – with an apology in national newspapers and a clear transparency ensuring that while customers were left frustrated to face a lack of chicken, they were not so disgusted as to abandon the brand © Shutterstock/TMON40 Ásuch as Wetherspoons and the Jamie Oliver range of restaurants. Russel Hume blamed the overeager FSA for this, though the media outcry certainly didn’t help, and this perhaps goes to show how important traceability and accountability really is. Had a crisis reaction plan been in place earlier, then comment might have been available from Russel Hume before it turned into a disaster that cost the company its life and possibly three hundred employees their jobs. The industry – and especially the impact social media can have on it – © Shutterstock/pilipphoto38-42.qxp_Layout 1 26/03/2019 10:33 Page 2Next >