< Previous30 Food & Drink International www.fdiforum.net GEARS AND DRIVES looking to save energy, enhance use of motors and remove strain put on power supply during initial start up. The former enables motors to gently ramp up speed, saving wear and energy, reducing the inrush current, mechanical stresses, and improving control. Soft starters temporarily reduce voltage or current input by reducing torque to protect equipment and lengthen life of motors by reducing motor heating. Variable frequency drives are recognised as a step above soft starters for efficient, precise control, allowing alternating current motors to speed up and slow down, and optimum speed and torque to be achieved while maintaining accuracy. Variable frequency drives ensure excess current is not drawn, and motors are not left to simply run at full speed, so the total demand factor of a plant can be managed to keep down energy bills. Motor speed can be adjusted based on demand, addressing mechanical stress damage, improving energy efficiency, and providing a better fit for applications needing varying force, like with pumping differing liquid amounts - variable frequency drives can optimise motors through fine tuning to the application. While they are more expensive, and tend to be larger than other drives, engineering is making variable frequency drives smaller and more durable. Moreover, selecting gearboxes with bevel and hypoid gearing, though seen as more expensive when compared to say worm-gear options, enables efficiency in transforming the motor’s shaft rotation into torque, saving energy use, and reducing total cost of ownership. Units are also being developed in response to the desire for minimised size, weight, and footprint of machines whilst maintaining sturdiness, efficiency, reliability, and precision. Key to improving the effectiveness of processing equipment and the performance of production lines, gears and drives are becoming more impressive with advanced engineering, enabling a longer life, quieter operation, and fast and friction free production lines. These small items can make a big difference and must therefore be reliable, tailored to the application, meet hygiene and efficiency requirements, and be able to withstand demanding conditions such as heat, cold and moisture. © Shutterstock /Bonuseventus © Shutterstock /DedMityay 28-30.qxp_Layout 1 30/03/2021 09:41 Page 3Food & Drink International 31 www.fdiforum.net TRANSPORT AND LOGISTICS © Shutterstock /TT studio Transport remains one of the most costly and complicated parts of the supply chain for many in the food manufacturing industry and is often scene as the go-to location for cutting costs, improving efficiency – or limiting environmental waste. Over the years however the industry has been squeezed so much, not only by companies looking to cut costs – but also ever-increasing costs of fuel and tax related to it, along with external factors like COVID-19 and Brexit. These have stretched an already stretched industry, and although we may soon be coming out of lockdown, there’s no denying the long lasting impact of it will be felt for many years yet. One of the big questions faced by many manufacturers in this situation – one of needing to transport fragile and strictly-regulated goods more often to meet quotas, is whether they should seek to increase their transport fleet – and all the costs associated with it, or whether they should look to invest in more facilities closer to the destination, usually in the form of warehouse or storage space. While the latter certainly sounds like the most efficient long-term option, it is by far the more costly one – which is a direct result of the supply and demand for high quality warehouse space at this time. Simply put, there is not enough Grade A warehouse space to go around, and when companies are dealing with large quantities of food goods that need to be From point to point Transport is a go-to location for cutting costs, but how much further can the industry be stretched? 32 Á From point to point 31-33.qxp_Layout 1 30/03/2021 09:47 Page 132 Food & Drink International www.fdiforum.net TRANSPORT AND LOGISTICS kept at a regulated temperature – there really is a necessity for the warehouse space to be of the highest quality. As the available space decreases, chances are the cost of rental will increase. And this only gets worse when we consider that consumer demand for goods is not likely to slow in coming years. In fact, with it being predicted that by 2050 the population of the world will top nine billion, with over sixty-five per cent of that living in urban areas… well, the logistical nightmare is expected to get worse. The other option is to consider expanding transport fleets to accommodate for the increased demands, with more goods on the road at any given time to keep product in the retail stores and supermarkets fresh. While this will certainly avoid the issue of limited warehouse space, the long- term costs of such an arrangement may become untenable for many manufacturers. Expanding a fleet not only increases fuel and vehicle related costs – but also recruitment costs for drivers, wages and associated HR and administration costs. There is also the issue of environmental impact and carbon waste created by a fleet. Because the only issue that can match consumer’s demands for fresher food – is that food and drink manufacturers should be doing all they can to reduce the impact on the environment, not contribute more to it. Many companies are seeking to combat the issue through a combined approach, both of improving the efficiency of their existing transport fleets – while also better utilising existing warehouse space. Intermodal transport is a popular method utilised predominantly in the US – but also in Europe as well. The guiding principle is to mix multiple forms of freight transport to achieve a net reduction in costs, be it energy or capital. The typical example would be to use rail to shift huge quantities of goods to a given warehouse closer to the final destination – before then having lorries ferry the goods the last distance into urban areas. While this can obviously save many thousands of road miles there is the issue of rail availability, especially in the UK. The reason why it is so prevalent in America is thanks to their abundance of flat land that is suitable for rail. UK rail systems are often not as well developed – and while that hasn’t stopped companies utilising rail for intermodal 31-33.qxp_Layout 1 30/03/2021 09:47 Page 2Food & Drink International 33 www.fdiforum.net TRANSPORT AND LOGISTICS logistics, it does mean companies are somewhat limited in location. Being forced to settle warehouses where the rail links are strongest. Savings on warehouse space can be found in improving efficiency to increase the amount of product that can be stored in any given amount of space. Advanced racking solutions, combined with more robust supply chain systems enable companies to increase throughput while also cutting costs associated with lost time or product losses. As always, the trick is in finding out exactly how much is possible given space limitations – and adapting what can be used for a company’s products, be they palletised goods – or more individually stacked produce. Even beyond efficient storage however is the concept of efficient temperature control. With the vast majority of food products needing to be kept at specific temperatures there are obviously savings that can be made in doing so. After all it is more expensive © Shutterstock /Aleksandar Malivuk © Shutterstock /Mr . Amarin Jitnathum PALLET TO PALLET TRANSFER SOLUTIONS With 5000 machines supplied to 65 countries across the world, Premier can call on over 41 years’ manufacturing experience of Pallet Inverter manufacturing.. Gressenhall | Dereham | Norfolk | NR20 4DT | +44 (0)1362 861066 | websales@premierpal.co.uk | www.premierpalletinverter.co.uk to reduce the temperature of a storage facility, than it is to maintain it. Any losses in temperature due to breaches, poor worker attention to detail – or just old age, will result in costs that can soon spiral out of control. Little has changed in terms of the challenges the industry faces, but as it always has – the technology continues to adapt. Failure to keep in touch with these changes and take advantage of opportunities that present themselves may mean disaster for many. 31-33.qxp_Layout 1 30/03/2021 09:47 Page 334 Food & Drink International www.fdiforum.net BEVERAGES Across the beverage industry, from soft drinks and alcohol to dairy, there is a major market shift taking place, prompting a flurry of new product development and innovation and providing opportunities for producers. Driven by millennials, generation Z and, increasingly, older generations looking to moderate their alcohol intake, there is an exponentially increasing market for premium low- and alcohol-free (nolo) options both in hospitality settings and on store shelves. According to Mintel’s ‘Alcoholic Drinks Review’, twenty-seven per cent of Britons are drinking more nolo drinks compared to a few years ago. Moreover, in the 18-24 age bracket, this figure rises to forty-two per cent. Although alcohol-free beers and wines have been available on shelves for years now, it’s only recently that alcohol-spirits that can compare on taste and versatility with their counterparts have been sold in stores and pubs. Although big brands are muscling in, growth in the alcohol-free spirit market is being largely driven by smaller, artisan distillers and start-ups who use traditional techniques and sustainable methods – many of which can’t be scaled up to meet the massive demand experienced by major brands. Figures from distillers Bax Botanics reveal that sales of alcohol-free spirits were up thirty per cent year-on-year. Sales of alcohol-free spirits hit £37 million in 2019 – up 506 per cent since 2014 – with revenues growing £11 million The growing trend for healthier, more mindful beverages has radically transformed the drinks aisle. Food and Drink International explores the major trends and how manufacturers are responding. 36 Á thirst A growing 34-37.qxp_Layout 1 30/03/2021 09:49 Page 1Food & Drink International 35 www.fdiforum.net BEVERAGES © Shutterstock /Alena Haurylik 34-37.qxp_Layout 1 30/03/2021 09:49 Page 236 Food & Drink International www.fdiforum.net BEVERAGES a year and expected to hit £74 million by 2024. Moreover, the number of producers has grown from none in 2014 to an estimated 70 in 2019 and could grow to 140 by 2024. It’s often as much about the pouch, bottle or can itself as what’s kept inside, with sustainability in packaging becoming of increased importance, particularly where bottled water and take-away coffee cups are concerned. But it’s an issue prevalent right across the beverage industry with brewers doing away with the plastic six pack rings for compostable and recyclable alternatives, while smaller, even flatter wine bottles, are helping to reduce carbon emissions and costs in the supply chain. This sustainability agenda is aligned with the trends happen inside the packaging with the shift towards healthier ingredients and processes and pressure from regulators – such as the UK’s soft drinks levy introduced in 2018 – all of which is driving innovation, new product development and more diversified portfolios. It’s no surprise that the move away from sugary drinks has coincided with the rise of functional beverages. Nutraceutical drinks provide more significant health benefits than a typical balanced diet, acting in much the same way as supplements. For drinks producers, this offers a unique opportunity to provide taste, refreshment and functionality. The sector has therefore been a hive of product development and innovation over the last few years and will continue to do so as the market expands and is forecast to hit $486.36 billion by 2026. One of the biggest changes over the last decade in the beverage space is the rise of alternative milks made from plant-based sources such as oat, almond, hemp, coconut, and soy – the latter of which had largely been the industry standard even as recently as 2008. In the UK, sales of plant-based milks have grown by thirty per cent since 2015, according to Mintel figures, while Nielson data confirmed that plant-based milk now accounts for thirteen per cent of total milk sales in the United States. A market where consumption of fluid milk consumption has been steadily declining since the seventies. Over the last few years, plant-based milks have become widespread, available in supermarkets (many of which have their own-brand versions) and stores alongside their lactose counterparts, and are now expected on © Shutterstock /kai foret 34-37.qxp_Layout 1 30/03/2021 09:49 Page 3Food & Drink International 37 www.fdiforum.net BEVERAGES restaurant and pub menus. Despite gaining a foothold in the traditional dairy market, the sector is not standing still with major players and start-ups continuing to innovate. From a consumer’s point of view, it’s a simple matter to find a healthier beverage on the shelf and buy it, but it’s a lot more complicated for manufacturers. There’s new product development to consider and the reformulation of existing recipes, all which affects processing. The quandary is that consumers are demanding healthier beverages, ones which avoid chemical additives and preservatives, but which don’t compromise safety. Needless to say, this is a difficult proposition for food makers. One option is Ultra-Shear Technology. This new method will allow companies to manufacture healthier beverages by reducing thermal exposure through the combined application of elevated pressure, shear and controlled times and temperatures. It’s far from the only innovative solution in the works, with data valuing the beverage processing equipment market at $18.2 billion in 2019 and forecasting it to reach $24.3 billion by 2025. From a product development point of view, companies are increasingly exploring and utilising natural food colours and flavouring in their beverage products, whilst also embracing on trend ingredients such as nutraceuticals and, more recently, cannabidiol, demonstrating the growing thirst for functional ingredients. Of course, beverage makers must respond to the changing demands of consumers and ensure they’re compliant with the latest legislation and regulatory rulings. But often this comes with significant expense, whether that’s in reformation, new product development or purchasing appropriate processing equipment. Radnor Splash unveils new flavours and packaging for Cash & Carry Radnor Splash has unveiled a set of new flavours and environmentally friendly retail ready pack sizes for its Cash & Carry customers. The popular sugar free and low-calorie drink, which celebrates its tenth anniversary this year, is made by blending Radnor’s own fresh Welsh spring water with all-natural flavourings. The product is 100% recyclable including the shrink wrap and even the sports cap. Sales of Radnor Splash increased during the pandemic as consumers turned to a brand they know and trust. The popular brand has sold the equivalent of a bottle every second for two years running – which equates to over 37 million units. Six and twelve packs of 500ml Radnor Splash are available in Strawberry and Lemon & Lime. New 12x500ml pack flavours include Forest Fruits, Orange & Passionfruit, Apple & Raspberry and Watermelon. The RRP for the 12x500ml packs is £3.45 although none of the products are price marked for individual selling. William Watkins, Managing Director of Radnor Hills, said: “Radnor Splash is one of our most successful brands. “We wanted to give the brand an exciting redesign while ensuring that we continue to deliver great tasting and trusted flavours. We have created a new range of flavours including Watermelon and Orange & Passionfruit to excite the taste buds of our customers.” Radnor Splash is made by Radnor Hills in rural mid-Wales. The family run independent business was established in 1989 by MD William Watkins on his 100-year-old family farm, Heartsease Farm. For more information, visit www.radnorhills.co.uk. 34-37.qxp_Layout 1 30/03/2021 09:49 Page 4MIXING AND BLENDING 38 Food & Drink International www.fdiforum.net © Shutterstock /Nordroden things up things up Mixing 38-42.qxp_Layout 1 30/03/2021 09:52 Page 1MIXING AND BLENDING Food & Drink International 39 www.fdiforum.net Industrial blenders introduce different amounts of energy, and high shear and high impact blending systems – all of which can have effect a product’s particle size – influence consistency and texture. This makes it ideal for emulsification, powders and thickeners. The latter 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. However, incorporating these gums into a product mix can result in 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 agitators struggle to break down rapidly. But by using high shear equipment, manufacturers can avoid these agglomerates from forming in the first place 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 relatively 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 intended for 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 option. Tumble blending is a rotating mixing machine that 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 oversight eclipses much of what these machines perform on the production line. Agitators ensure the mixing process achieves a homogenous blend faster. Given that there’s dozens of different kinds of products that require this It’s critical for food and drink manufacturers to find the right mixing solution to suit their needs. Otherwise, they could risk inefficiency, a poor product mix, and unnecessary expenses. 40 Á 38-42.qxp_Layout 1 30/03/2021 09:53 Page 2Next >