END OF LINE PACKAGINGUK AD & BIOGASMATERIALS HANDLINGINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netJUNE2012 £3.50 STERLINGPureperformancePureperformance01:Layout 1 18/5/12 10:52 Page 102:Layout 1 18/5/12 09:04 Page 1Display refrigeration26Upcoming changes to regulation and taxationmeans it’s all heating up for the refrigerationindustryVision, inspection and detection28Contamination and imperfections areunacceptable to both retailers and consumersalike, so what advances have been made inautomation of detection?• Lambda Photometrics• Matrox ImagingControl and automation showcase 34The food and drink sector is leading theway in environmental efficiencies but thereis still plenty of room for improvement End of line packaging35When it comes to packaging products fordistribution, there are many options available,but which will save you money in the long run?• Adpak• PlasfilmsUK AD & Biogas 41The anaerobic digestion of food waste offersmajor benefits for the industry, as theconference programme at UK AD & Biogas2012, at Birmingham NEC on 4th and 5thJuly, will illustrateAchema44The world’s biggest exhibition for chemicalengineering, biotechnology and environmentalprotection take place on 18th to 22nd June inJune 2012Cover photographscourtesy of:Main:HanoviaTop:Pacepacker FlexaPacMiddle:TGW-GroupBottom:Ondeo Industrial SolutionsNews 4• General news• On the shelf - new products and initiatives• On line - production newsUniversal Closures5 UCL have signed license agreements withmajor plastics packaging group Alpla tomanufacture their UCL Flexseal and Flexgripclosures in Mexico and EuropeImport and export14 One product that can always be counted on asa popular import and export product isalcohol, and this is especially true since theWesternisation of non-drinking countries• PD PortsEfficiency and optimisation17 Efficiency and optimisation during theproduction process is paramount and greatstrides are being taken to create a fastermoving, more effective supply chain• The Haas GroupRelocation21Many businesses in the food and drink sectorare regularly taking the opportunity to renewand refresh their property portfolioMaterials handling23Materials handling has come a long way in thelast ten years and this is due in no small part tothe creativity of those who support the industry• TGW• System LogisticsContents42844Frankfurt am MainLogistics Link Live46The logistics industry will have all eyes on theNEC in June as Logistics Link Live 2012showcases the latest innovations anddevelopments in the industryEuropean Connection48We travel to Parma to discover thegastronomic delights of the regionEvents51Your chance to keep abreast of forthcomingexhibitions and food fairs from around theworldClassified52Appointments 54Website: www.fdiforum.netEditor:Steve Fisher (s.fisher@blmgroup.co.uk) Editor’s PA:Angela Sharman Journalists: Steve Williams (s.williams@blmgroup.co.uk) Mike Shields (m.shields@blmgroup.co.uk) Elis Ballard (e.ballard@blmgroup.co.uk) Michael Fisher (m.fisher@blmgroup.co.uk) Sales Director:Teri Cooper Sales Manager:Rebecca Robertshaw Assistant Sales Manager: Sam Trott Sales: Nikki Logan, Lisa Grenney • Tel: +44 (0) 1472 310302 Accounts & Subscriptions:Dawn Cook Design & Production:Gary Jorgensen, Mark Casson, Rachel Green (studio@blmgroup.co.uk)Editorial: Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317 Email: fdi@blmgroup.co.ukWebsite: www.fdiforum.netPart of the Business Link Magazine Group: Armstrong House, Armstrong Street, Grimsby, N E Lincs DN31 2QE EnglandAll rights reserved. No part of this publication may be reproduced, transmitted, photocopied, recorded or otherwise without express permissionof the copyright holder, for which application should be addressed first to the publisher. While every reasonable care is taken, neither thepublisher nor its participating agents accept liability for loss or damage to prints, colour transparencies, negatives or other material of whatevernature submitted to this publication. The views expressed in this publication are not necessarily the views of those held by the publisher.This magazine is now fullyrecyclable. By recyclingmagazines, you can help reducewaste and add to the 5.5 milliontonnes of paper already recycledby the UK paper industry eachyear. Before you recycle yourmagazine, please ensure youremove all plastic wrapping, freegifts and samples. FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforum03:Layout 1 18/5/12 12:18 Page 1FFP Packaging Solutions take home awardsFFP Packaging Solutions have picked uptwo Gold Awards, four Silver Awards and aBronze at the European Flexographic Indus-try Association Awards.The Gold award won in the PromotionalPrint category was for Platinum Print, whichtakes advantage of developments in printingplates and research into the flexographic printprocess. In the Medium Web category, FFP achievedGold again, for an East riding Farms design,‘Bowl Size Popovers’. The Silver awards came from FFP’s print ofSwizzels Monster Bag in the Best On Shelf category, M&S Gluten Free Lochmuir Salmon for Cavaghanand Gray and Tulip International’s Wicked Pig multipack in the Line and Screen Section. Wicked Pig Hog Roast pack also picked up silver in the ProcessPrint section. FFP also notched a Bronze award in the Line and Screen category for Yeo Valley Disney Yogurt Tubes.4www.fdiforum.netService package for labellerscuts downtime and parts costsFrequent site visits, reduced cost of spares, and en-gineering support via telephone outside normal officehours are now included in a new standard servicepackage from print and apply labelling specialist Lo-gopak. Free label design is now also part of thescheme.The new service arrangements replace the previ-ous single annual inspection with up to six a year, atcomparable cost says the company, reducing down-time for maintenance and allowing wear parts to bereplaced only when necessary.Logopak’s solution has been to reduce the cost ofservice visits by streamlining the organisation of itsservice department and installing a tracker system inthe service fleet. This allows routes to groups of cus-tomers in a certain area to be planned in advance, op-timised, and non-productive travel time reduced toan absolute minimum.newsNew guide to metal detection set to becomeessential readingFortress Technology (Europe) Ltd,manufacturer of high performance‘Phantom’ metal detection systems forthe food industry has published ‘A prac-tical Guide to Metal Detection in theFood Manufacturing Industry’. Set to become essential reading in theglobal food industry, the booklet is fullof useful advice aimed at further ensur-ing food safety and reinforcing the im-portance of metal detection withintoday’s modern production facility.Sarah Ketchin, Managing Director atFortress Technology comments: “TheGuide is designed for use by food com-panies of all sizes, ranging from the fledg-ling business about to purchase its first system to the multinationalorganisation with hundreds of units across several sites.”Fortress Technology’s guide includes sections on how a metal detectorworks, different types of metal detectors, important features, optimising per-formance of detectors, testing procedures, maintenance, validation, min-imising metal detection risk and staff training.Elfab to represent UK manufacturing excellence atScience Museum Elfab has been selected to take part in anexhibition demonstrating the very best ofBritish manufacturing this summer. Elfab will feature in the Government’sMake it in Great Britain exhibition at the Sci-ence Museum, London, during the Olympicand Paralympic Games.Elfab will showcase their latest manufac-turing products and educate visitors about thevalue of manufacturing to UK business. Theexhibition is the culmination of the Make it in Great Britain campaign - an initiative launched lastyear by the Department for Business, Innovation and Skills.Elfab is Europe’s leading manufacturer of rupture discs, bursting panels and detection devices, pro-tecting people, plant and equipment.Simon Keenan, Elfab’s managing director, commented: “We are delighted that we are going tobe a part of the Make it in Great Britain exhibition, and feel very proud to be representing the man-ufacturing industry. “Malvern on-line particle sizing helpsDe’Longhi achieve 100% testing of ‘bean tocup’ coffee makerRenowned globally for the qualityof its coffee makers, manufacturerDe’Longhi has transformed QCprocesses for grinders at its manufac-turing facility in Mignagola di Car-bonera, using the Insitec on-lineparticle size analyzer from MalvernInstruments. The Malvern applica-tions team worked closely withDe’Longhi to develop an automatedsolution supporting the target ofachieving 100% testing, of each ‘beanto cup’ coffee maker. Grinder set-upis assessed on the assembly line byanalyzing particle size of freshlyground coffee beans. Commenting on the innovative solution, De’Longhi said, “Because wewanted to test every single grinder that comes off the assembly line, meas-urement speed was critically important to us. Insitec quantifies grinder per-formance in real-time. The interface we’ve developed then guides theassembly line worker as to any corrective action required.” 04:Layout 1 18/5/12 09:08 Page 1UNIVERSAL CLOSURES LTDAlpla and UCL have been workingtogether to offer the UCL beverageclosures to major end users in bothMexico and Europe – part of the processwhich has led to the closures now beingused by major bottler groups in manycountries.96 cavity production moulds arecurrently being manufactured inconjunction with Stackteck in Canadaand z-moulds in Austria, ensuring theclosures can be made for both carbonatedsoft drink and water applications. In more than 148 plants in 39 differentcountries, Alpla has approximately13,000 employees, and produces plasticpackaging solutions for renowned brandsin categories such as bottles, pre-forms,caps and tubes. As a systems supplier ofplastic bottles with caps, they design andmanufacture the entire package andhighly diverse technology enables them tocater to their clients’ exclusive needs.Alpla’s qualified project teams areconsistently and successfullyimplementing highly diverse packagingsolutions using state-of-the-arttechnologies worldwide.One of UCL’s greatest currentsuccesses is its closure project withCoca-Cola Amatil. The equipmentfor three systems (one 96cavity/400t Hycap system and two 72cavity/300t Hycap systems) weredelivered and installed at the site atEastern Creek, Sydney, during the fourthquarter of 2011 and early 2012.Two moulds (one 96 cav SSD and one72 cavity SSD) from z-moulds wereapproved for shipment after extensivefactory acceptance tests at z-moulds andHusky, Luxembourg. All lab tests andapprovals were conducted at the UCL labin Tewkesbury in the UK.Moulds were shipped, installed,commissioned and PAT tested duringFebruary and March. Process and qualitytraining was conducted on site at CCApersonnel during this period at Husky, z-moulds and UCL. CCSP (TCCC)approval testing was conducted at CCSPSydney and the TCCC China lab.Conditional approval was granted forcommercial use on 23rd March and sincethen over a hundred million closureshave been produced. Closures are now infull commercial use at CCA’s bottlinglines.For more information on UCL,visit www.universalclosures.com.Universal Closuresand Alpla worktogetherUCL have signed license agreements with majorplastics packaging group Alpla to manufacture theirUCL Flexseal and Flexgrip closures in Mexico andEuropewww.fdiforum.net505:Layout 1 18/5/12 11:44 Page 1Biocote technology certified by HACCP InternationalAntimicrobial specialist BioCote Ltd has be-come the first technology company of its kind tobe officially recognised for its benefits within thefood industry. BioCote has successfully completedthe HACCP International certification process, arecognition that no other antimicrobial solutionhas been awarded. This HACCP certification supports organisa-tions that demonstrate food safety excellence innon-food products that are designed for the foodindustry.By completing this process, companies candemonstrate that their products are fit for purpose,and if used correctly will not compromise food safety protocols.Only products certified by HACCP International can carry the mark. The mark is aimed at prod-ucts required to be ‘food safe’ compliant, or HACCP approved in order to meet food safety demands of quality conscious customers.BioCote additives can be used in food packaging and manufacturing processes to create a hygienic solution - a permanent protection against superbugsand microorganisms.6www.fdiforum.netColpac celebrates 75 years ofBritish manufacturingIn its anniversary year, Colpac, the global player inadded-value food packaging solutions, continues toinnovate with new lines such as Clasp ®, the all-in-one film to board pack, a new range of platters idealfor foods including sandwiches, crudités and bakery,extensions to the award-winning Fuzione ® rangeand the new ground-breaking ST17 sandwich pack, acartonboard pack which is laminated inside and con-structed in such a way it’s possible to seal the packwith MAP technology. Neil Goldman, Colpac’s Managing Director, says,“As the food industry commemorates 250 years ofsandwiches, we’re proud to celebrate our 75th an-niversary of manufacturing world-class packagingproducts in Britain. We ‘fly the flag’ wherever we canand promote our innovation, focus on quality, re-sponsiveness to customer needs and green credentialsto over forty countries.”Colpac takes its corporate social responsibility se-riously. Most of the range is recycled, recyclable, com-postable or biodegradable – in some cases all three.news98% read rates ensure Weights & MeasuresAct compliance Fairfield Labels, a Cognex Automa-tion Solutions Provider, have assistedEverards Brewery, which was experi-encing barcode scanner problems dur-ing their ‘kegging process’ wherereusable metal kegs are filled withbeer. The new empty kegs have IDbarcode labels applied and areweighed to establish the ‘tare weight’,which varies slightly for each keg. Thekeg is scanned and the tare weightrecorded on a database for TradingStandards auditing.The process of kegging brings sig-nificant challenges for capturing andrecording this information, as barcodes become damaged in transit and in use.Previously, Everards were using a laser scanner to read the ID barcodes,achieving only a 60-65% success rate of barcodes being read correctly. Fair-field Labels designed a system based on Procon software interfacing with theKeg Weigher combined with the DataMan 500 industrial ID reader. TheDataMan 500 now achieves 98% read rates – a huge increase on its laserpredecessor.Axium Process Filters ‘eggcellent’ states Bumble Hole FoodsBumble Hole Foods, producers of egg prod-ucts, from pasteurised egg to hard boiled eggs,recently contacted Axium Process, the filtra-tion specialists, to provide a solution to itsmesh filter media which was collapsing underpressure after pasteurisation. By selecting to use Axium Process’ stainlesssteel Pure-Screen filter range, Bumble HoleFoods was assured of a filter that can withstandcollapse pressures of two to six times the max-imum operating pressure of the filter as well asbeing ideally suited for final product filtration.Axium’s Pure-Screen Filters are manufac-tured with a range of interchangeable stainless steel wedge wire filter screens from 25 micron up to6000 micron as standard and are suitable for backflushing, clean-in-place and steam-in-place options. Axium Process filters are suitable for most liquid filtration applications as the company’s fullrange of filters includes wedge wire, sintered mesh and perforated sheet screen options where bothproduct smoothness and consistency is essential.Coop Sweden expands private label rangeswith Trace OneRetailer Coop Sweden isgoing live with a Product Life-cycle Management portal fromretail technology provider,Trace One to help increase itsprivate label product develop-ment and become more com-petitive within the market. Theonline portal also helps the re-tailer meet government re-quirements around productingredients, safety and ethicalsourcing. Thomas Säll, CIO at CoopSweden commented: “Expand-ing our own label ranges and improving brand perceptions is a key businessobjective. To match the competition, we want to increase our number ofproducts. It will give us the opportunity to innovate. To meet this require-ment and thereby increase the number of SKUs this year, we needed a so-lution that was more robust than the in-house tool we used previously. Wechose the Trace One PLM solution is it was the best and most comprehen-sive tool available for private label development.”06-07:Layout 1 18/5/12 09:11 Page 1www.fdiforum.net7newsElfab introduces new range of high-pressure rupture disc plugsElfab, one of Europe’s leading suppliers of pressurerelief systems, has launched a new range of electronbeam welded rupture disc plugs, specifically designedfor high-pressure applications up to 800barg.Elfab is fully exploiting the advanced capabili-ties of its in-house electron beam welder to createthe plugs, which are available in stainless steel asstandard with a range of half-inch thread types.The new plugs are suitablefor use with burst pressuresfrom 200barg to 800barg,and are supplied with aconventional rupturedisc, typically featuring a+/-5% tolerance. Theplugs are also featureleak-tight protection toan enviable 10-6cc/sec. Inaddition to this, the plugscan be used in tempera-tures ranging from -40°C to 400°C, meaning peace of mind for operatorsand producers working with extreme temperatures.European biscuits manufacturer sees 80%reduction in injuries after introduction ofSafeStart programmeUnited Biscuits, Eu-ropean manufacturerof biscuits and snacks,operates a national dis-tribution centre in theMidlands, supplyingretailers with thou-sands of products eachday, resulting in over100 million cases dis-tributed each year. Mike Howells, Lo-gistics OperationsController at UnitedBiscuits, explained thesituation, “There was a problem maintaining consistency in safety due tothe number of staff and the shift-style pattern of working. Although theMidlands distribution centre had a good safety record, we wanted a way ofbuilding the safety culture within the site to help focus employees and avoidunnecessary accidents”. DuPont Sustainable Solutions was asked to assist with the implementa-tion of the SafeStart programme in 2009. Mr Howells said, “We have seensome fantastic results since implementing the programme, including atpresent we have not had any lost time accidents for over 700 days.”www.fdiforum.net06-07:Layout 1 18/5/12 09:11 Page 208:Layout 1 18/5/12 09:12 Page 1Romer Labs’ new gluten detectiontechnologyRomer Labs, a leading food-safety diagnostic company,has launched two new test kits for gluten. The AgraS-trip Gluten G12 is designed for on-site factory testingand the AgraQuant Gluten G12 for quantitative labora-tory testing. Both kits will improve gluten detection andwill be discussed at two free of charge ‘Allergen Man-agement’ seminars to be hosted in Manchester on 28thJune and Birmingham on 5th July.The new test kits use Romer Labs proprietary gluten de-tection technology, which employs a next generation antibody,called G12. The method represents a quantum leap in gluten de-tection as it targets the most immunotoxic proteins for those intoler-ant to gluten – thereby establishing an important link with coeliac disease.The AgraStrip Gluten G12 kit has an adjustable cut-off level for qualitative screening at 5 ppm, 10 ppm or 20 ppm gluten while the AgraQuant GlutenG12 ELISA quantitates levels of gluten between 4 ppm and 200 ppm.Resin leading the way inhygienic flooringRSL are manufacturing and promoting the idealflooring solution for areas in need of cleanliness andhygiene.Resuthane TG69, a water based polyurethane resinscreed, is RSL’s leading product for food productionareas. It is a self-sealing product which is stable forsteam cleaning and resistant to boiling liquids up to atemperature of 100°c. Resuthane has been made withthe same formula for over twelve years and providesone of the most credible histories in the industry. Ithas also been approved as a non-taint and food safeproduct by Campden BRI.A number of other systems within the Resuthanerange can provide alternative hygienic features. Re-suthane JT40 is a cove and wall render which can beused in conjunction with TG69 to form a hygieniccove detail around the perimeter or upstands of thefloor and wall. Meanwhile, Resuflor is a self-smooth-ing resin with outstanding wearing properties andchemical resistance.newsQuality guaranteed with UPM ConveyorsUPM Conveyorshave been manufac-turing in the UK for36 years, and allo-cate circa 10% oftheir turnover forresearch and devel-opment to continu-ously improve theirproduct range. Thetrend is for UPM toact as system inte-grators offering afree consultancyservice which includes dimensioned layout drawings of the customers processhall to maximise efficiency with ideal production flow conditions based on atotal turnkey package.This is demonstrated by a recent investment of around £50,000 in 3Dmechanical solid modelling design software for creating 3D digital prototypesusing the design visualisation and simulation of products.This will benefit their customers in being able to visualise the proposed so-lution for a product handling application as the image can be rotated through360 degrees so eliminating any risk of the system not interfacing to existingequipment and being accommodated within the allocated production area.Cocktail shakercauses a stirThe combined design and engi-neering expertise of RPC ContainersMarket Rasen and Blackburn is as-sisting Tails – a premium range ofpre-mixed bar quality cocktails whichcomes in packaging designed to lookand function like an authentic cock-tail shaker.The customer brief called for acomplex pack, designed by Small Fry Design Studios, which would allow consumers to experiencethe ritual of making and serving cocktails, bar-style. In response, RPC Market Rasen developed afour-part injection moulded lid, which allows the cocktail to be dispensed as it would in a bar. Thelid is assembled and then printed with a four-colour design at the Market Rasen factory, where a re-cent investment saw the installation of a semi-automated four-colour Tampo printer. Meanwhile RPC Blackburn was approached to manufacture the ISBM PET base, which is deco-rated with a shrink sleeve. The base is induction sealed after filling to give the product tamper evi-dence and shelf life.www.fdiforum.net9Hanovia’s PureLine UV range for food, drinkand brewing applicationsHanovia’s new PureLine UV disinfec-tion range provides chemical-free disin-fection of water, syrups andbrines. The PureLine rangeincludes standard modelsfor virtually any processingapplication, including de-ozonation, as well as a vali-dated, performancequalified model for the moststringent disinfection applications.Water, brine or syrup passing through theCFD-modelled treatment chamber is exposed to UV light which deactivatesmicroorganisms such as bacteria, viruses, yeasts, moulds and algae. In ad-dition, the UV is highly effective at destroying ozone molecules present inprocess water. Installation or retrofitting is relatively straightforward, re-quiring minimum disruption and site preparation.The PQ model is approved to most international standards and materialcertificates are available for all FDA-compliant wetted parts. A revolutionaryfeature of this model is its optimised, absolute intensity UV monitor. Locatedwithin the chamber, it allows the controller to automatically correct the dosecalculation as UV transmittance varies without an external monitor.09:Layout 1 18/5/12 10:54 Page 1Next >