< Previous20 Food & Drink Internationalwww.fdiforum.netWAREHOUSING & DISTRIBUTIONWe deliver throughout the UK mainland from our network of 8 frozen and chilled food depots, so you and your customers can rely on the same unrivalled levels of service – whichever depot is delivering your valuable product.Do you also trade directly with business partners in other European countries? Whether that be import or export – No problem! We are part of a group with over 100 depots in 17 countries. We can deliver growth to your business. Contact us today to start that process. Nagel Langdons Ltd.Tel 01278 411 114 sales@nagel-langdons.co.uk www.nagel-langdons.co.uk… and it’s possible.For frozen & chilled food distributionacross the UK and Europe -we’re the only ONE you need! Thenumber ONE networkefficiency. Also crucial was the availabilityof a fully automatic transmission.Iceland’s Head of Home Alex McKinlaysays, “Not only does the auto box make adifficult job that bit easier for our drivers,it will also improve safety and help toreduce wear and tear on the driveline.”Energy efficiency and sustainability arealso major drivers for those in charge ofdistribution on a larger scale, with manycompanies now making use of shared-userservices such as those provided by Nagel-Langdons, who can offer multi-temperature options via strategicallylocated depots and therefore can transferchilled, frozen and ambient foods on thesame vehicle.It’s not just the drivers and thoseinvolved with transport that need to be wellaware of the needs and requirements of thesector. There are similar challenges in thewarehouse, where the potential flashpointsare many and varied. One obvious issuecomes around the doors, where the flow oftraffic can prove dangerous and there is alsothe potential for contamination of theproducts thanks to the ability of foreignbodies to enter the site.Many manufacturing and storagelocations are addressing this with theintroduction of new doors, such as theKlimate high speed doors from BIDGroup. These open and close far fasterthan other doors, and have recently beenintroduced at McBride’s Manchestermanufacturing and distributionwarehouse. Robert Lishman, Facilities &Services Manager for McBride’s, says,“We have the high speed doors located onhigh traffic flow areas throughout thefacility where standard doors just wouldnot be sufficient. With the rapid openingand closing speed of the Klimate doors,our staff do not feel the cold rushing infrom the outside and production cancontinue at a steady speed.”There are also issues underfoot andcompanies such as Cadbury’s, Coca-ColaSchweppes and Nestle, are making use ofResuthane TG69, a water-basedpolyurethane resin screed from RSL, toprioritise safety and hygiene. It is a self-sealing product suitable for steam cleaningand is resistant to boiling liquids up to atemperature of 100°C. It also has excellentresistance to thermal shock, abrasion andchemical attack, as well as good slipresistant properties provided by its matttextured surface – making it a valuableflooring option for food production anddistribution developments.The warehousing and distributionsection is prioritising efficiency and cost-cutting at every step – but theintroduction of new ideas, new talent andnew technology means this goes hand inhand with a rise in quality.The warehousing and distribution section is prioritising efficiencyand cost-cutting at every step – but the introduction of new ideas,new talent and new technology means this goes hand in handwith a rise in quality.17-21:Layout 1 22/5/14 09:42 Page 4Food & Drink International 21www.fdiforum.netWAREHOUSING & DISTRIBUTIONAs a leading innovator in the resin flooring industry, RSL has a tailormade solution for food and drink clients in need of a robust flooringsolution that is seamless and provides high levels of hygiene. Resuthane ishardwearing and can withstand the rigorous cleaning that is required inareas of food production and storage.The meat plant in Kostroma worked with the RSL team to chooseResuthane TG69 – a non-taint food product certified by Campden BRI.The product’s anti-slip properties made it the ideal choice because of theintensive cleaning regime at the site, which meant the floor is constantlycovered in water. The floor substrate also had drainage channels, which thefloor finish had to incorporate, so Resuthane TG69 was laid to falls toenable the water and process liquids to drain into the channels and keepthe surface as free from water as possible.The project also incorporated two colours to highlight the differentprocesses in different areas – making it clear for staff to identify designatedareas for meat processing and low risk areas. The end result was a highlyfunctional, hygienic and safe floor surface that was perfect its environment.RSL “meats”demand in RussiaWhen a busy Russian meat plant was in need of a new flooringsolution in its food production areas, it chose to use a resin systemand called upon leading UK manufacturer Resin Surfaces Limited.For more information aboutRSL’s Resuthane range,visit www.resinsurfaces.co.uk.17-21:Layout 1 22/5/14 09:42 Page 522 Food & Drink Internationalwww.fdiforum.netHEALTH, SAFETY & HYGIENEWith recent difficulties and slip-ups inthe food and drink supply chain, healthand safety has come into focus as one ofthe most important aspects ofmanufacturing. Far from resting on itslaurels, health and safety is a sector of ourindustry that takes itself seriously and isconstantly revising and changing up itsbest practice to achieve the best possibleresults.Training for the futureOne way many ways companies areensuring success is correctly training theirstaff, or at least pointing them in the rightdirection. For example, the Food Storage& Distribution Federation recentlyintroduced the IOSH Managing Safelycourse to its training repertoire.The course reinforces the FSDF’sHealth and Safety Leadership Programmelaunched in early January and is designedto educate line managers, supervisors andteam managers on all major health, safetyand environmental issues and provide theknowledge and practical experienceneeded to confidently manage key issueswithin their teams.Chris Sturman, CEO at FSDF, says,“As an industry, health and safety is anarea that can always benefit from furtherimprovements, including better awarenessand communication, reflection, reviewand sharing of best practice, and greateraccountability within all levels of anorganisation.“One of the three targets of the HSELogistics strategy is Competence &Worker Involvement, highlighting thatIndividuals at all levels need to accepttheir roles and responsibilities for healthand safety. The IOSH course reinforcesthis message and helps give managers thetools to implement high standards ofhealth and safety throughout theirworking day.”PHOTO: SHUTTERSTOCK.COM/MARCIN BALCERZAKBelt andbracesThe best way to be sure of a safe environment for food and drinkproduction is to be absolutely sure of your practices and to adhere tostandards rigorously. But what is being done to help this area of theindustry excel? 22-26:Layout 1 22/5/14 09:59 Page 1Food & Drink International 23www.fdiforum.netHEALTH, SAFETY & HYGIENEwww.etiltd.comNEW TempTest® 1 Thermometerwith unique 360° rotating display‘The manufacturers of the Thermapen® bring you another totally innovative product that can be read from any angle, in either hand - making temperature readings that much easier!’ and safety research is nigh-on essential. Choosing the right equipment is alsoessential. For example, hands arevulnerable to a number of dangers such ashands exposed to prolonged or frequentcontact with water, particularly with soapsand detergents, are prone to getting workrelated dermatitis. Other high risks arewhere hands suffer cuts and abrasionsfrom sharp objects, or hand arm vibrationsyndrome that occurs in fingers, handsand arms as a result of using vibratingtools.Initiatives such as Hand ProtectionAssessment Surveys will identify whatneeds companies might have in PPE orsimilar areas, something worth lookinginto.New technologies, new problemsWith new markets, come newchallenges in health and safety within theproduction side of the industry. The rapidgrowth of the beverage industry in areaslike Bangladesh has prompted UVdisinfection specialists Hanovia to hostone of its annual UV workshops in thecapital, Dhaka. The free all-day event, entitled ‘Latesttrends in water purification anddisinfection with UV technology for thepharmaceutical and beverage industries’includes a range of talks and productdemonstrations for anyone involved inSafer food, less waste, more efficientfood production and better use of naturalresources are also areas in which aresearch group at the University ofLincoln has recently started to look into. The Agri-Food Technology ResearchGroup is aiming to develop newtechnological solutions for all stages offood production including cultivation,harvest, processing and packaging. Agri-food is the largest industry inLincolnshire and food security is also oneof the major challenges identified by theUK Research Councils. Demand for foodis also predicted to grow by 40% by 2030and 70% by 2050, so training and healthUse of the correct equipment is notonly important in terms of employeesafety, but food safety tooPHOTO: POLYCO24 22-26:Layout 1 22/5/14 09:59 Page 23M™ Clean-Trace™ Surface Protein Testss 2APIDs #ONVENIENTs 3IMPLEs %ASY TO 5SE3M™ Clean-Trace™ ATP Systemss $ETECTS CONTAMINATION ON SURFACE AND IN WATERs 3UPERIOR REPEATABILITY*s 0OWERFUL DATA TRENDING SOFTWAREs %ASY TO USEQuality, Reliability,Simplicity*References: 1. The repeatability of hygiene test systems in measurement of low levels of ATP. W.J. Simpson, C.J. Giles, H.A. Flockhart. Cara Technology Limited, Leatherhead Enterprise Centre, UK Report 30606, 27 July 2006. 2. Protocol for assessing the sensitivity of hygiene test systems for live microorganisims and food residue. W.J. Simpson, J.L Archibald, C.J. Giles. Cara Technology Limited, Leatherhead Enterprise Centre, UK Report 120906, 27 July 2006.**Terms and conditions – 3M reserves the right to set the trial length and swab usage. Offer open to new customers dealing directly with 3M. 3M and Clean-Trace are trademarks of the 3M Company © 3M 2013.To arrange a free trial** call 01509 613859(YGIENE -ONITORING 3OLUTIONS FROM - TO RAPIDLY ASSESS ORGANIC CONTAMINATION FROM MICROBIAL OR PRODUCT RESIDUESO24 Food & Drink Internationalwww.fdiforum.netHEALTH, SAFETY & HYGIENEpurchasing, designing or managingoperations in these industries. Halim Mirza, Hanovia’s Middle Eastand North Africa sales manager, says,“The rapid growth of beveragemanufacturing in Bangladesh brings withit the need for effective process waterdisinfection.” “Our state-of-the-art PureLineperformance qualified UV disinfectionsystem was specifically developed for thesetwo industries. The event acts as theofficial launch of both product lines in thecountry.” Monitoring progressIt’s not just within production thathealth and safety is paramount of course.Within foodservice, reputation iseverything and if customers on any levelget any form of illness then thatreputation can be stymied and evenruined, no matter of your record before.Adequate measures must be put inplace and outside of sourcing credibleingredients, the way in which they areprepared must be considered.Temperature monitoring is such animportant element of food preparation,but is often one that catches manyproviders out. Companies like ETI havemade it as easy as possible to maintainaccurate readings and in the case ofcooked meats for example, this isessential. This is also associated with effectivetraining, but the dangers that are presentif safety preparations are not made areobvious. An outbreak of the deadly e-colivirus in Germany just a few years ago leftseveral people seriously ill, so drivinghome the idea that clean, safe and heavilymonitored fresh food preparation isessential.Safety on the floorIt’s of course important to avoidobvious physical accidents within foodand drink preparation, but it’s sometimesa case of taking obvious precautions tocombat preventable accidents. Tocelebrate the UK’s 85% reduction in fatalaccidents since the introduction of theHealth and Safety at Work Act in 1974,the country’s leading health and safetybodies are uniting to launch Health &PHOTO: ISTOCKPHOTO.COM/PGIAM22-26:Layout 1 22/5/14 09:59 Page 3Food & Drink International 25www.fdiforum.netHEALTH, SAFETY & HYGIENEChemDAQ Steri-Trac“The only fixed gas detector to monitor Peracetic Acid at ppm levels for the NEW ACGIH Exposure Limits”GAS DETECTION SPECIALISTSProject Design y Installation y Servicewww.a1-cbiss.comLive Demo - Stand L2055 Do You Work in a Sterile Environment?& Suffer From:t#SFBUIJOH%JóDVMUJFTt&ZF*SSJUBUJPOt4LJO$PSSPTJPOVisual / Audio AlarmsSafe Entry SystemReduced Operating CostsRegulatory ComplianceUser FriendlyInterfaces You Could be Exposed to Peracetic Acid;))ChemDAQ Steri-Trac“The only fixed gas detector to monitor Peracetic Acid at ppm levels for the NEW ACGIH Exposure Limits”www.a1-cbiss.comLive Demo - Stand L2055Visual / Audio AlarmsSafe Entry SystemReduced Operating CostsRegulatory ComplianceUser FriendlyInterfaces;)) hemDheriacT-ri o.ccbiss.a1ed edutingOperostsoegulaRiendlyser Feface -udisual / AVmlate Enaftysompliancy C) ioySafety Week 2014, which runsfrom 16th to 20th June, atSafety & Health Expo andreinstate a positive image forthis exceptionally worthwhileprofession.Heather Beach, Director ofexhibition organisers UBMLive, explains “It’s about timethe UK celebrates its health andsafety record. We lead the worldwith this record and should be proudof what we have achieved and shout aboutour successes because as a result of all the hardwork, peoples’ lives are being saved every day. “We intend to put a positive light on the importance and valueof recognising and engaging with health and safety so that we canbegin to focus on the next challenge – the reduction of deathsfrom work related illnesses.” It seems that now, more than ever, health and safety is takingprecedence over other concerns and that is a real positive stepforward. The fact that increased health and safety awareness andpreparation means less of an impact on costs and a possibleincrease in profits is fantastic news for those taking it seriously.An outbreakof the deadly e-colivirus in Germany just afew years ago left severalpeople seriously ill, so drivinghome the idea that clean, safeand heavily monitored freshfood preparation isessential22-26:Layout 1 22/5/14 09:59 Page 426 Food & Drink Internationalwww.fdiforum.netHEALTH, SAFETY & HYGIENEConveyor LubricationA large percentage of accidents in the production area are aconsequence of slips, trips and falls; 50% of a leading beer brand’slost-time accidents (LTA’s) occurred in this area. A catalyst forthese accidents are slippery floors created by wet lubrication systems.Dry Lube’s technology eradicates the requirement for water inconveyor lubrication. Specially formulated, proprietary lubricant isapplied directly onto the conveyor belt using their unique brushapplication system. No lubricant ends up on the floor which reducesthe probability of a slip in the production hall.By removing water from the conveyors the conditions for biologicalgrowth are minimised reducing Total Viable Count (TVC). There isno requirement for drip trays, reducing standing water and furtherimproving levels of hygiene. Controlling coefficient of friction along the conveyor improvespackage stability, reducing the amount of fallen, broken packages andassociated LTA’s.Dry Lube’s lubricants are water, PTFE and silicone free, NSF H1approved and safe for incidental food contact. Their technologydelivers significant health and safety benefits in can, PET, one-wayglass and reusable glass bottle packaging operations.Dry Lube’s technology also delivers:Operational Benefits: Evidence of 100% extended belt-lifeEnvironmental Benefits: Substantial reductions in waterconsumption and carbon emissions plus reduced energy usage andwaste-water treatment.Financial Benefits: Investing in a Dry Lube system delivers paybackwithin 18 months for most customers.www.drylube.co.uk • Email: sdavenport@drylube.co.ukTel: +44 (0)131 240 1292FSDF – be apart of itThe Food Storage and Distribution Federation is the sole tradebody which represents and supports the interests of the entire foodand drink logistics industry, including the whole range oftemperature regimes from frozen to ambient. Recently, the FSDF hasworked closely with regulators and introduced a range of initiativesto help its members gain competence in all areas of health and safety.The Federation has teamed up with Slough Borough Council,through a Primary Authority Partnership scheme, to provide robustadvice to members that must be respected by all regulators whencarrying out inspections or addressing non-compliance – in areasincluding environmental health, trading standards legislation or foodsafety. The advice provided by the PAP team ensures any localregulation implemented is consistent at a national level, while alsoproviding the direct contact with the council to ensure a sensibledegree of flexibility is applied to address local circumstances.The FSDF also introduced its Health and Safety LeadershipProgramme in early 2014, which provides members with a highlyvisible declaration of the FSDF’s leadership in this area.Incorporating everyone from business leaders to the individualson the shop floor, the programme mirrors the aims of the widerHSE strategy in encouraging continuous improvement,accountability and recognition of the wider perspective regardingHealth and Safety and the need to actively support and share bestpractice to improve the performance of this industry sector.The FSDF also introduced its own Health and Safety Awardswhich recognise excellence on an individual and company-widelevel, selected by a panel of experts.For more information on the Food Storage & DistributionFederation, call 0118 988 4468 or visit www.fsdf.org.uk.22-26:Layout 1 22/5/14 09:59 Page 5Food & Drink International 27www.fdiforum.netREFRIGERATION & COLD STORAGEThe US refrigeration industry, inparticular, is beginning to see the effectsof the Environmental Protection Agency’sR-22 phase-out programme. The EPA’sphase-out timetable for the refrigerant willgradually decrease its production until acomplete ban comes into force in 2020.After that, refrigerant that has beenrecovered and recycled will still be allowedto service existing systems, but chemicalmanufacturers will no longer be able toproduce R-22 to service existingrefrigerators and air pumps. The cost ofR-22 will continue to rise and it’s highlylikely that existing R-22 refrigerationsystems will become uneconomical longbefore the substance is banned completely– so changes will be required soonerrather than later.Many international companies are wellplaced to assist American manufacturers,not least because Europe has alreadycompleted the same process. StarRefrigeration Group, for example, havelaunched a new subsidiary company,known as Azane, to manufacture andsupply their refrigeration technologyacross the USA. Derek Hamilton, US BusinessDevelopment Manager, says, “We arecurrently trying to raise awareness of theimpending R-22 phase-out among thefood industry and the wider refrigerationindustry. The EPA’s phase-out of R-22,which is still widely used in the US, is anissue that is going to effect a large numberof businesses. The good news is that thereare plenty of options available to allow asmooth transition away from R-22.”Azane uses its “low-charge ammonia”technology as an alternative, but there are28 The coldhard factsEnvironmental factors have been a major driver for change in many sectorsof the food and drink industry, but never more so than in the field ofrefrigeration - where the importance of energy efficiency has led to manyreviewing the technology they use and the way in which they work.PHOTO: SHUTTERSTOCK.COM/MONKEY BUSINESS IMAGES27-30:Layout 1 22/5/14 10:02 Page 128 Food & Drink Internationalwww.fdiforum.netREFRIGERATION & COLD STORAGESaving Energy . . . and Saving You MoneyWorld-leading temperature controlwww.seymour-mi.com - 01952 730630indeed other options as the industry looksfor refrigerants that are greener thantraditional HFC refrigerants but also saferthan hydrocarbons. In the UK, Precisionhas been working with Honeywell on anew HFO-based refrigerant that is saferthan hydrocarbon, and has a lower GlobalWarming Potential. Known as Solstice ze,R1234ze, it has an GWP of less than one– compared to R134a, which has a GWPof 1430, and Hydrocarbon R290, whichhas a GWP of three. Its atmospheric lifeis only eighteen days, which issubstantially lower than the thirteen yearsfor R134a. The aim is to offer this inrefrigerated storage options, while theyare also trialling another low GWP HFOblend refrigerant designed for freezerstorage.Carrier, meanwhile, has unveiled newversions of its MiniCO2OL range ofrefrigeration racks to support the value-driven move toward natural refrigerantsfor convenience stores. Based on the high-performing CO2OLtec design, thecompact and integrated refrigerationsystems use the natural refrigerant CO2to help reduce a store’s carbon footprintand improve energy efficiency.There are other benefits from usingnew forms of refrigeration. When itcomes to transport, using a more effectiverefrigeration system with a much quieteroperation can assist distributors in makingmore deliveries without worrying aboutexcessive noise. Linde’s FROSTCRUSEsystem, which uses liquid nitrogen toindirectly chill the truck compartment,and the low noise whisper units thatThermo King have supplied to Asda, aretwo examples of this principle inoperation.With a significant consumer movetoward convenience stores, energyefficiency is a key consideration fornational, signature and independentretailers. The additional benefit is thatparticularly effective refrigerationsolutions can save substantial amounts ofmoney in terms of lower energy bills –especially if the equipment qualifies forEnhanced Capital Allowance tax relief. Agrowing range of products are able tomeet this requirement, and indeedHubbard Products has added seventeennew Twin Scroll Compressor models to itsrange of ETL-approved Zenith and ZenithDigital Condensing Units.As the first digital condensing unittechnology to feature on the CarbonTrust’s Energy Technology List,Hubbard’s refrigeration and chillingsolutions have proven particularlyinnovative. By claiming ECA tax relief onboth capital expenditure and theassociated installation costs of ETL-approved refrigeration and cabinets, usersbenefit from improved cash flow, lowerenergy costs and identifiably improvedsustainability credentials. The ZenithTwin Scroll Compressor CondensingUnits also offer a range of additionalEvents such asTCS&D illustratethe huge range ofrefrigeration optionsnow availableFor all the cash and environmental savings, the most obviousrequirement for refrigeration is to ensure the product itself remains ofa high standard throughout the entire production process27-30:Layout 1 22/5/14 10:02 Page 2Food & Drink International 29www.fdiforum.netREFRIGERATION & COLD STORAGETelephone: 01473 892289 E.mail: commercial@hubbard.co.ukFrom Multi Compressor Packs through to Monoblock Units -Hubbard Products design the bestcooling solutions offering you the most energy efficient solutionavailable for your food and drink products.Many of our units qualify for Enhanced Capital Allowance,providing an immediate tax benefitfor the end user and all have a proven track record reducing energy consumption and the carbon footprint of therefrigeration system.www.hubbard.co.ukCooling Systems to suit every Food andDrink SituationMulti CompressorPacksPropaneEasy OperationR404ARefrigerantHM MonoblockZF24 MonoblockZF33 MonoblockHigh EfficiencyCoolingSelf ContainedLow Noisegreen options, including the ability forheat reclaim to water. This wassuccessfully introduced by a number ofHubbard’s retail and hospitality sectorclients and is now available to all users.One obvious challenge for thoseoperating refrigerated facilities is the needto ensure a consistent temperature. Manycold stores can suffer from leakageproblems both from the cold store tonearby areas, and vice versa. Companiessuch as Seymour ManufacturingInternational have been able to addressthis with their thermal insulation materialsuch as their Cold Stop curtains.One recent installation came at OscarMayer’s Ferndale Foods facility, and SMIChairman Brian Seymour says, “FerndaleFoods contacted us because they wereconcerned at how much temperature wasleaking from their cold store into the30 Palmer and Harvey hasspecified fridge-bodiedMercedes-Benz 18-tonnerswith automated transmissionsthat have already contributedto a valuable fuel cost savingon its dry freight fleet27-30:Layout 1 22/5/14 10:02 Page 3Next >