< Previous30 Food & Drink Internationalwww.fdiforum.netENERGY AND THE ENVIRONMENTIt used to be that energy efficiency wassomething a company would considerdesirable but not essential. That’sdefinitely no longer the case with everyorganisation examining how theintroduction of efficiency measures canmake a measurable difference to thebottom line and assist them in winningmajor contracts.In the food and drink sector there arenow increasing obligations to ensurecompanies are operating in anenvironmentally sound manner, ensuringtheir waste products are disposed of orreused effectively. This doesn’t have to bea burden, and many businesses haveenjoyed great benefits from such aspectsas anaerobic digestion.There are many AD facilities treatingmunicipal food waste, farm waste andsewage waste, but there is also a growingtrend for on-site AD plants at food anddrink manufacturing facilities. Companiessuch as Nestlé, Diageo, Barfoots, QVFoods and Wyke Farms have alldeveloped on-site AD plants with widereaching benefits – energy and heatgeneration, better waste management andrevenue from the sale of energy to theNational Grid and from governmentincentives such as the Feed-in Tariff andRenewable Heat Incentive.Indeed WRAP’s comprehensive studyof the anaerobic digestion sector for thecalendar year 2013, the most recentfigures available, shows that AD hasgrown significantly in the UK. Thenumber of operational sites increased by34% to 117, operating capacity is up by55% from 2.07mt to 3.20mt and 51%more organic material is being processed,from 1.69mt to 2.55mt.In addition, there has been an increasein all the types of feedstocks processed –separated solid food, liquids, manures andcrops. However, food and drink wastecontinues to be the largest proportion ofthe material processed, with separatedsolid food accounting for 38% of thefeedstocks reported in the survey andliquids 30%. Over a million tonnes ofdigestate, the product of AD, was appliedto agricultural land in 2013 – 98% of totaldigestate use – demonstrating the benefitsof readily available nutrients as well aspotentially reducing the reliance oninorganic fertilisers.Ian Wardle, Head of Organics andEnergy at WRAP, says, “The industry isturning a wide variety of wastes intovaluable renewable energy and digestatethat can be used by farmers as a fertiliser.Each year we are seeing the sector growand this year’s data shows the ADindustry is starting to make a markedcontribution to the UK economy.”The forthcoming UK AD & Biogasevent, which takes place in Birminghamin July, will illustrate the huge potential ofAD for the food and drink industry. Oneof the most popular features at last year’sevent which shall return this year is theR&D Hub, which will highlight the valueof R&D to AD businesses and talk aboutthe prospects for higher value productsthat could compliment the AD process.The R&D Hub will act as a focal point forvisitors interested in exploring ADresearch and development covering topicsincluding biochemical research, such asinnovative materials which can beproduced through the AD process.One illustration of its effects in practicecomes from ingredients companyMuntons who have invested £5.4 millionon an on-site anaerobic digestion plant.Integral to the success of the 499 kWfacility is a 3 Tank Batch SludgePasteuriser System with Energy Recoveryfrom HRS Heat Exchangers, which willhelp turn eighty thousand tonnes ofMuntons’ liquid malt waste into valuablebiogas and a high quality organic fertiliser.This biofertiliser will be then be appliedto local farmland, helping the company’sPHOTO: JUAN SILVANo timeto wasteCompanies making use of effective energy efficiency and wastemanagement principles are reaping the rewardsExxonMobil and Energy Consulting Allgäuhave agreed to jointly offer advice andexpertise to companies throughout the foodprocessing and production industries inachieving environmental standards“The industry is turning a wide variety of wastes into valuable renewableenergy and digestate that can be used by farmers as a fertiliser. Each yearwe are seeing the sector grow and this year’s data shows the AD industryis starting to make a marked contribution to the UK economy.”Ian Wardle, Head of Organics and Energy at WRAP30-32_Layout 1 24/04/2015 11:56 Page 1Food & Drink International 31www.fdiforum.netENERGY AND THE ENVIRONMENTMaking the difference in Water Treatment Sera ProDos UK Ltd01733 396040www.sera-web.comnetwork of growers to produce the barleyneeded to make Muntons’ malt – a perfectclosed loop solution.New technology could certainly make agreat difference to AD. For example, newresearch published by AeroThermalGroup shows pre-treating food waste witha combination of steam and pressure, in amachine known as an autoclave, coulddouble the throughput of an anaerobicdigester and significantly reduce theamount of ammonia concentrations bydenaturing proteins.The experiments have shown thatautoclaving has the effect of producing afeedstock for AD which allows stabledigestion at very high loading rates,without the addition of trace elementswhich could be harmful to theenvironment. Christian Toll,AeroThermal’s CEO, says, “This couldhave a huge impact on every organisationrunning a digester, as fitting an autoclaveinto the process, a relativelystraightforward process, couldrevolutionise the world of anaerobicdigestion.”Companies such as Sera ProDos havealso introduced new technology that hasmade all the difference for manycompanies. High quality and reliablesystem engineering and dosing technologyhas become hugely important to allowcompanies to treat their wastewater in aneffective fashion. sera pumps are used todose sodium hydroxide in order to adjustthe pH-value, a metallic salt solution as aprimary precipitation agent and a polymersolution as a flocculation aid. Thewastewater treatment by means ofdecolourisation, neutralisation and heavymetal precipitation is linked with reliablesera technology as well as the watertreatment.One way in which companies canillustrate their commitment to energyefficiency is by working towardscertifications such as the ISO 50001standard, which specifies requirements inrelation to companies’ energy efficiencypolicies, target setting, data use fordecision making and measurement ofresults. It also offers guidelines on how toreview and continually improve energymanagement. Experts from more thansixty countries developed the standard asa way to save energy, reduce costs andmeet environmental requirements.ExxonMobil and Energy ConsultingAllgäu have agreed to jointly offer adviceand expertise to companies throughoutthe food processing and productionindustries in achieving the standard. Thetwo companies aim to jointly formstrategies and advice to support foodindustry company energy efficiency goals,32 ÁWWW.BILDUPPDRAGET.SETetra Pak aim to developsustainable products, reduce theenvironmental footprint of thevalue chain and increaserecycling at a consistent level30-32_Layout 1 24/04/2015 11:56 Page 232 Food & Drink Internationalwww.fdiforum.netENERGY AND THE ENVIRONMENTincluding a convention for ExxonMobildistributors in the central European andBenelux region.Many companies have introduced theirown long term environmental goals tolaunch a process of continualimprovement throughout the business.Tetra Pak, for example, aim to developsustainable products, reduce theenvironmental footprint of the valuechain and increase recycling at aconsistent level. The aim is to cap climateimpact across the value chain at 2010levels, while growing the business. Datavalidated midway through 2014 showedCO2 emissions across all parts of theTetra Pak value chain down 8% from a2010 baseline, despite a 7% increase inproduction over the same time-frame.The company has also introduced anumber of new food processing andpackaging solutions to help customersreduce their own environmental impact,while also improving their operationalefficiency. These include the Tetra ThermAseptic Flex, a continuous asepticprocessing unit that offers dairy producersthe highest levels of UHT performance atthe lowest environmental impact and totalcost of ownership, as well as anEnvironmental Benchmarking Service tohelp food and drink companies assess theenvironmental performance of theirproduction operations, and to identifyopportunities for improvement.Schemes such as this illustrate thatmajor companies now realise theintroduction of energy efficiencythroughout the production anddistribution process and the benefits tothe bottom line cannot be overestimated.A 3 Tank Batch SludgePasteuriser System withEnergy Recovery fromHRS Heat Exchangers willhelp turn eighty thousandtonnes of Muntons’ liquidmalt waste into valuablebiogas and a high qualityorganic fertiliserShowcasing the latest AD technology and services, and attracting 3,000 visitors from key sectors including farming, food and drink, local authorities, waste management, transport, utilities and more, this is the event for anyone involved in AD.Register for free now at adbioresources.orgTHE UK’S ONLY DEDICATED ANAEROBIC DIGESTION, BIOGAS AND BIORESOURCES TRADE SHOWWHAT’S ON OFFER?s Two day high-level conference s 22 seminar sessions s Our Second R&D Hub s One-to-one advice clinics s Biomethane vehicle area featuring working examples of vehicles using biomethane technologys UK AD & Biogas Industry Awards 2015 s Site visit (30 June) to Severn Trent Green Power Coleshill providing attendees with an informative insight into a brand new and innovative working AD plant. Book your place now.EXHIBITION SPACEThere is now just 15% of stand space remaining, so make sure to book now to avoid disappointment. WHY EXHIBIT?s Promote your business, technology and servicess Reach the most targeted audience directly interested in AD and biogass Enjoy two full days of networkings Share information and best practice and debate key industry issuess Get a free listing on ADBA’s website and in the event guideIf you are interested in exhibiting at UK AD & Biogas 2015 or would like more information, please contact Jamil (E jamil.ahad@adbioresources.org / T 020 3176 4414) or Rachel (E rachel.fenton@adbioresources.org / T 020 3176 5418).Sponsored by:Organised by30-32_Layout 1 24/04/2015 11:56 Page 3Food & Drink International 33www.fdiforum.netMICROBIOLOGYThere can be few worse things tohappen to a food and drinkcompany than to have to recalltheir products. The embarrassment of aproduct failing to come up to scratch canhave a huge effect on the company’sreputation, let alone the expense ofwasting a large batch and having noreturn on the investment in productionand distribution.In some cases the recall may not bebecause the product is contaminated orfound to be unsuitable, but because thelabelling is inaccurate. Regulationsdemand labelling is totally accurate andprovides customers with a guarantee thatwhat’s stated on the label is what’s foundin the product. From December, the EUFood Information for ConsumersRegulation has meant that all foodbusinesses need to provide informationabout the allergenic ingredients used infood sold or provided by them.A more informed and interestedconsumer base is now well aware of thepresence of allergens in what they eat andthere are no excuses for a product toreach the shelves without potentialproblems clearly highlighted. As TonyLupo, Neogen’s Director of TechnicalServices, points out, “Both food allergic35 ÁPHOTO: SHUTTERSTOCK.COM/FOTOFERMERA guarantee ofQUALITYIt’s essentialmanufacturers andconsumers alike canhave confidence inwhat’s in their productsA guarantee ofQUALITY33-36_Layout 1 24/04/2015 11:57 Page 1This unique lateral flow test is the first of its kind and can screen for the presence of six tree nuts at low levels of detection with results in only ten minutes.Designed to detect almond, hazelnut, pecan, walnut, cashew and pistachio, either singly or in combination on environmental swabs, rinses and validated food matrices.Tel: 01292 525 625 • Web: www.neogeneurope.com Email: allergens_uk@neogeneurope.com Reveal® for Multi-TreenutRapid multiple allergen detection33-36_Layout 1 24/04/2015 11:57 Page 2accredited certification, testing andcalibration and inspection has additionalbenefits in the food and drink sector as itreduces the need for suppliers to beassessed by each of their customers –allowing them to apply for and wincontracts more effectively.While microbiology plays a vital role inconsumer safety and the smooth runningof production operations, there has beenreports in recent years that there issomething of a skills gap in the industrywith a disappointingly slow stream oftalent entering the sector. The level ofpractical experience of both newlyqualified and even some establishedmicrobiologists, technologists andmanagers isn’t always consideredsufficient to meet the changing and evermore demanding needs of the sector.This explains why many leadingindustry representatives from companiesincluding Tesco, Sainsbury’s, Marks andSpencer, Tulip, Greencore and TwoSisters Food Group worked alongsideCampden BRI last year to create a report,aiming to inform the development ofindustry training provision and relatedcontinuing professional development. Thereport is also used to promote the sector’straining needs to other training providersFood & Drink International 35www.fdiforum.netMICROBIOLOGYconsumers and food producers rely on theaccurate labelling of food products toprotect themselves from the consequencesof the accidental ingestion of foodallergens. Tests can protect businesses inthe food value chain — and theirconsumers.”This explains the increased interest inmicrobiology and testing systemsthroughout the production process. Thegood news is that these tests now achieveimpressive accuracy at faster speeds thanever before. For example, Neogen hasdeveloped a rapid test that cansimultaneously detect the presence of sixtree nuts in a single test in ten minutesafter extraction.Neogen’s new Reveal for Multi-Treenutdetects 5-10ppm of almond, hazelnut,pecan, walnut, cashew and pistachioresidues on environmental surfaces and inrinse waters. The new test is simple to useand provides quick, accurate results,aiding food manufacturers in cleaningvalidations or verification of existingprocedures to prevent cross-contamination of tree nuts within theirmanufacturing facilities.Reveal for Multi-Treenut is in an easylateral flow format – dip the test’s devicein an extracted sample and wait tenminutes. If two lines develop, the test ispositive for one or more of the six treenuts. If only one line develops, the test isnegative.Steve Chambers, Neogen Europe’s salesand marketing director, says, “Our newReveal test for multiple tree nuts is aresult of requests from our customers todevelop a single test to detect several treenuts at once. Our customers have told usthat it’s common in productionenvironments for a commingling ofdifferent tree nuts to occur, and theywould prefer not to test for eachseparately. The new single test representsan opportunity for many to simplify theirtesting, while receiving faster test results.”It’s now easier than ever for companiesto host their own on-site testing, but forthose who prefer not to do their own on-site testing, Neogen also offers a rapidlaboratory testing service at its locationsin both the US and the UK.Companies such as Southern GroupLaboratory also offer specialist productsfor the food industry that come with adeep understanding of the unique needsof laboratories concerned with food safetyand quality assurance. They can providePrepared Culture Media to suit anyapplication, in flexible formats andstandard or custom formulations, and allactivities are certified to ISO 9001:2008with quality control accredited to EN ISO17025:2011.Many microbiology specialists, such asSGL, emphasise the importance ofreceiving accreditation for UKAS, as itprovides an assurance of the competence,impartiality and integrity of conformityassessment bodies. Applying for UKAS36 ÁThe recent Gulfood Awardscommended ViessmannRefrigeration Systems fortheir new antimicrobialpowder coating SmartProtec,which sets new standards incold room hygieneNeogen’s newReveal for Multi-Treenut detects 5-10ppm of almond,hazelnut, pecan,walnut, cashew andpistachio residues onenvironmentalsurfaces and in rinsewaters33-36_Layout 1 24/04/2015 11:57 Page 336 Food & Drink Internationalwww.fdiforum.netMICROBIOLOGYand relevant organisations which supportmicrobiological training and continuingprofessional development.The report recognises thatmicrobiological training needs differdepending on job roles, for example, thetraining requirements of laboratory staffwill be quite different from that of foodtechnologists. Acknowledging thesedifferences and tailoring microbiologicaltraining to sector specific needs is muchmore effective than a ‘one size fits all’and this is now reflected in themicrobiological training provision that’snow on offer.Academic and technical support is nowincreasingly available through venturessuch as the North West Food ResearchDevelopment Centre, a research anddevelopment facility located at theUniversity of Chester, made possible byEuropean Regional Development Fundand University funding and valued at £5.1million. NoWFOOD provides a centre ofexcellence for food science and technologyfor producers across the region. As well asencouraging and nurturing small andmedium sized food businesses,NoWFOOD also helps support theeconomic growth of the region. MaudDuthie, the Project Manager forNoWFOOD, says, “Currently there is noone venue in the North West that offers acomplete end-to-end product developmentand testing service to food producers inthe region.”Microbiology isn’t just confined toidentifying and dealing with potentialcontaminants in finished products,however. It can also be used to improvehygiene throughout the productionprocess, and the recent Gulfood Awardscommended Viessmann RefrigerationSystems for their new antimicrobialpowder coating SmartProtec, which setsnew standards in cold room hygiene.The SmartProtec powder coatingprevents the formation of biofilms byaltering the properties of the internal andexternal surfaces of the wall, floor andceiling elements of the cold rooms.Bacteria and fungi habitats are destroyedand therefore cannot survive.SmartProtec performed outstandingly inthe product tests and combated 20% moremicrobial strains, including black mould,than its predecessor SilverProtec, whichalready had excellent antibacterialproperties. The prize at Gulfood followsViessmann’s recommendation from theGerman Federal Association of FoodInspectors for SmartProtec.As companies require closer scrutiny oftheir products than ever before,microbiology specialists are ensuringpotential flashpoints are addressedeffectively. In addition to this, a numberof initiatives can also help bridge anypotential skills gap and provide peace ofmind for manufacturers and consumersalike that products are perfect.PHOTO: SHUTTERSTOCK.COM/ALEX01197333-36_Layout 1 24/04/2015 11:57 Page 4Food & Drink International 37www.fdiforum.netLABORATORY AND TESTING SHOWCASENeogen ticks all the boxesIf you are looking for a food safety testing partner, Neogen’s contract laboratory service ticks all the boxes.Offering a varied range of accredited testing options with flexible turnaround times, they can assist you with theright testing plan to suit your needs.A continual investment in new technologies ensures Neogen’s range of UKAS accredited testing addresses existingand emerging requirements. Whether you are looking to improve on the service from your current external laboratory,or if you have a new testing requirement that requires external expertise, they are on hand to help.Ordering your tests and getting samples to Neogen is a quick and easy process, with flexible turnaround times to suityour needs. All results are confidential and services are subject to extensive quality control and regular quality assurance.For customers who require on-site testing, Neogen Europe provides an extensive range of rapid food safetydiagnostic test kits to meet the growing need for higher safety and quality within the food industry. Their solutions forfood safety testing include diagnostic test kits for Allergens, Histamine, Hygiene Monitoring, Mycotoxins, Speciationand Food Microbiology.Tel: 01292 525 625 Email: labservice@neogeneurope.com www.neogeneurope.comSGL is the safe choice for testing needsThere is very little room for error in food safety and quality and that’s why SGL, a prepared mediamanufacturer with over twenty years’ experience in all sectors conducting microbiology, is a safe choice foryour microbiological testing needs.SGL offer specialist products for the food industry that come with a deepunderstanding of the unique needs of laboratories concerned with food safetyand quality assurance. They can provide Prepared Culture Media to suit anyapplication, in flexible formats and standard or custom formulations.SGL has the expertise to provide the solutions you need. All activities arecertified to ISO 9001:2008 with quality control accredited to EN ISO 17025:2011. Quality is their passion.Tel: 01536 403815 www.sglab.co.ukCompanies certainly need to keep ontop of the latest issues affecting foodquality – and much research is takingplace. One new research project aims toinvestigate the survival and persistenceof viruses on foods and in theenvironment, as well as assess theefficacy of food processes againstviruses. This complements CampdenBRI’s new validated assay for thedetection of hepatitis A and norovirusin soft fruits, salads and environmentalswabs.An update report on viruses in the foodchain has just been published by theAdvisory Committee for theMicrobiological Safety of Food, as virus-related foodborne illness is becoming amajor issue, highlighted by the recentoutbreaks of hepatitis A in Italy and theUSA. Indeed, a 25% rise in the incidenceof foods contaminated with viruses inEurope in 2014 was reported throughRASFF.Recent reviews of issues such as thehorsemeat scandal have strongly statedthat those involved with audit, inspectionand enforcement must have access toresilient, sustainable laboratory servicesthat use standardised, validatedmethodologies. The high qualitylaboratories and testing services availablefor the food and drink industry, some ofwhich we highlight on this page, are wellplaced to ensure that’s possible foreveryone.PHOTO: SHUTTERSTOCK.COM/MICHAL KOWALSKIPut yourREPUTATIONto the testFood safety issues are never far from the headlines, increasingdemand for food testing – and throughout the sector a host oflaboratories and testing services are providing peace of mindfor consumers, retailers and manufacturers alike.37_Layout 1 24/04/2015 11:29 Page 138 Food & Drink Internationalwww.fdiforum.netLook back ten years and the sandwichesand snacks industry was very different.The focus was on convenience andcost, with sandwiches being the meal for thosewho just didn’t have the time. Packaging wasfunctional, there were only a few differentvarieties on the shelves, and ultimately costwas king. This could not be further from thetruth now. High society snacking is now the name ofthe game, with premium sandwiches onshelves alongside small sushi boxes or pastapots. Never has there been such a wideselection of cuisine on offer, and with thelives of customers becoming more busy andfrantic, the convenience foods industry hasseen a huge resurgence. Focus is now less on convenience and cost,and has moved towards quality, health andflavour. Even in the most mainstream ofsupermarkets there are now Japanese, Chineseand Italian offerings alongside sandwiches andpackets of crisps. What’s more sandwiches areHighsocietysnackingSandwiches and snack foods have moved away from being amere convenience, and are now even touted as a luxury. PHOTO: SHUTTERSTOCK.COM/PHOTOSIBER38-40_Layout 1 24/04/2015 11:58 Page 1SANDWICHES AND SNACKSbranching out into new and excitingflavour options, and are able to marketthemselves as premium or artisan goods,increasing their perceived value throughquality ingredients or localsuppliers. Consumers have alsocontinued to becomemore demanding forhealthy optionsas well. Lowcalorie or diet snacks have become morepopular, to the point where many existingbrand names are taking steps to createtheir own light or diet versions. Beyondthat, there is also an increasing demandfor gluten-free snacks on shelves, withmany major retailers capitulating to thedemand. Sandwich manufacturers haveused this to their advantage in order toincrease their flavour portfolio, by offeringhealthy choices in fillings. Some firms areeven looking towards healthier recipes forbread, which has faced a lot of stigma inthe health and diet world. Packaging has also worked hand-in-hand towards the goal of increasing theperceived value of sandwiches and snacks,with exciting new designs appearing onshelves. Some manufacturers have gonefor a more minimalist approach, usingclear PET containers or pots, so that theycan show off the quality of the foodcontained. While sandwiches have foundsuccess with more vintage-lookingpackaging, from corrugated-effect card, topackaging designed to look like wood.This diversity in consumer tastes hascreated a knock-on effect for thepackaging and design industry, who havebenefitted greatly from the snackindustry’s sudden demand for moreexciting on-display packaging. All of these factors are working tocreate grand opportunities within theindustry, both for manufacturers ofsandwiches and snack foods, and thosefurther down the supply chain. Foodmanufacturers are seeking to takeadvantage of the growing market byexpanding their processes, and movingtowards full automation where possible.Removing the human element whereverpossible works not only to increaseefficiency and productivity, but can alsoreduce the risk of hygiene incidents andproduct recalls. In efforts to improve their own hygiene,well-known snack manufacturer KPSnacks recently opened a new productionsite in South Yorkshire, and chosesuppliers Kemtile and Resin SurfacesLimited to provide a hygienic flooringsolution. The two companies wererequired to meet an exacting hygiene andsafety standards brief to supply and install40 ÁPHOTO: SHUTTERSTOCK.COM/DUC DAO38-40_Layout 1 24/04/2015 11:58 Page 2Next >