< Previousincludes overhauling the layouts of aisles andgrouping products, such as all of thecomponents for stir fries, pasta dishes, or cakemaking, together. Busy lifestyles meansconsumers today don’t want to graze aroundthe store as much. If they have a list of recipeingredients, they want everything to be locatedlogically near to each other, so they can be inand out of the shop quickly. To cater to thistrend and help ensure even the smaller storeshave what people need, retailers areincreasingly asking suppliers to prepare mixedtrays and cases.”Reacting to this evolution, Pacepackercreated its award-winning Mixed Tray Loader -the first known invention of its kind toautomate product swapping. It enablescompanies to pack an array of products into atray or delivery box. When handlingingredients such as meat, fish and dairy, sameday turnaround is vital to maintain freshness.Companies like ‘HelloFresh’ - which has over250,000 regular monthly subscribers - are alsoenjoying considerable success, delivering weeklyboxes direct to customers filled with a varietyof meat trays and stock pots, fresh fruit and vegand spice sachets, according to the recipesselected by subscribers.“For food producers supplying this booming market,30 Food & Drink Internationalwww.fdiforum.netCONTROL AND AUTOMATIONPHOTO: SHUTTERSTOCK.COM/VLADIMIR NENEZICNDC offers analyser for degree ofbake in snack foods NDC Technologies, aleading global provider ofprecision measurementand control solutions,offers the InfraLab e-Seriesat-line analyzer for theaccurate and reliablemeasurement of Degree ofBake (DOB) or Brownnessin biscuits, crackers,cookies and snack foods.Taste, texture andappearance are all keyquality attributes thatdetermine the success ofa food product in themarket. Testing during themanufacturing process formoisture and colour isimportant to ensure final product consistency and ‘freshness,’ buttesting typically requires the use of multiple analytical technologieswhich are often located in a laboratory remote from the production line.NDC Technologies has integrated its proven DOB or Brownnessmeasurements into the InfraLab At-Line Analyzer to providesimultaneous measurements of Moisture, Oil and DOB in five seconds.With no special skill required to operate, the InfraLab delivers processvision far beyond that of conventional testing. For more information, visit www.ndc.com.24-31_Layout 1 27/05/2016 12:57 Page 7Food & Drink International 31www.fdiforum.netCONTROL AND AUTOMATIONproduct quality and freshness are theunderpinning factors. Even for a smalloperation, products need to be shipped fastand automation is a key tool for picking,packing and delivering orders within tighttimeframes,” says Paul.There are many more success storiesaround automation within the food and drinkindustry, with few companies who invest intoit having much to complain about. On theother hand, with rising wage costs due to UKlegislation, along with a stagnating labourmarket, there is much doom and gloom withinfood manufacturers who have not consideredor invested in this area. One has to wonderhow much longer this can continue, asEuropean competitors continue to order threeto five times as many robotics for food anddrink than the UK. China has eclipsed theUK robotics intake by a factor of thirty-three,despite the amount of manufacturing inChina being only ten times that of the UK.For many in the industry it appears to be acase of sink or swim – despite there being alife raft floating just beside them. T: +44 (0) 118 946 1900 E: sales@appliedweighing.co.ukwww.appliedweighing.co.ukFOR GENERAL, PROCESS, PHARMACEUTICAL & FOOD WEIGHING APPLICATIONSLoad CellsSilo, Tank & Vessel SystemsWeight Indicators & Control SystemsPlatform ScalesDrum FillingSystemsDynamic CheckWeighersThe UK’s leading load cell & process weighing systemmanufacturer. When you use any product fromApplied Weighing you will have absolute accuracyand total peace of mind. ComprehensiveNational ServiceOrganisationAccurate weighing - whatever your industryMANUFACTURED IN THE UK24-31_Layout 1 27/05/2016 12:57 Page 832 Food & Drink Internationalwww.fdiforum.netCAPS AND CLOSURESCaps and closures offer functionalityand differentiation among similarproducts as well as providing a variety ofoptions and interactions for the end user.They also form an imperative part of aproduct’s overall safety, as Kevin Heap,Packaging Account Manager fromSumitomo (SHI) Demag, explains. The global plastic caps and closuresmarket continues to report strong growth,especially in the FMCG arena. Beveragecaps remains the most dominant market,accounting for approximately 60% of allunits, while the toiletries and cosmeticsector and homecare markets remain thelargest user of polymer caps and closures.Throughout the last few decades,bottled water has shaped the beverageclosure market using mainstream plasticscrew caps. However, there is a definitetrend emerging towards moresophisticated tamper evident closures. Inthe pharmaceutical sector, this trend ismirrored with child-resistant and senior-friendly dispensing closures, with productsecurity set to be the front runners interms of new technology features. Projected to be worth more thanUS$51.5 billion by 2021 - an increase ofUS$15.3 billion in just seven years - thecompound annual growth rate (CAGR)for caps and closures manufacturing isexpected to continue expanding at aconsistent rate of 5.2% per annumbetween now and 2021. Given this pace ofgrowth, design innovation and newclosure solutions will be fundamental tocapturing future business opportunities. Caps and closures is very much amarket driven by costs, and this filtersdown the supply chain. For injectionmoulders, we are witnessing heightenedefforts to derive more value, with a focuson lean manufacturing and optimisingproduction processes. When you’recontracted to produce caps and closuresby the millions, it makes good economicKeeping alidonit As well as forming a specific function, caps and closures are alsointegral to a product’s overall safety.PHOTO: SUMITOMO (SHI) DEMAG 32-34_Layout 1 27/05/2016 09:07 Page 1Food & Drink International 33www.fdiforum.netsense to build a complete mouldingsystem to take care of all the anticipatedapplications, rather than trying to adaptexisting equipment. Many of today’s manufacturers seek fullturnkey solutions, with robotic capabilitiesintegrated. Speed, yield, repeatability,reliability, multi-tasking and long-termcost saving are all reasons why end usersmight opt for a robotic solution.Customers, particularly in the caps andclosures market, are increasingly askingfor complete injection moulding packages,which once set up requires littlemodifications or engineering intervention.In recent years, cycle times have gotshorter, performance has increased, andhigher cavity numbers are demandedwhich in turn requires larger clamptonnage.The correlation between modernlifestyles and the functionality of caps andclosures cannot be underplayed. In fact,the use of closures is what connectsconsumers to a brand or product. It’swhat people interact most closely with.Virtually all closure manufacturersSumitomo (SHI) Demag works withproduce lightweight ranges, and in termsof volume, these, along with plastic screwand hinge caps, are expected to hold ontothe largest market share. However,lightweight closures are now the industrynorm. New technologies that improve capperformance, functionality and shelfimpact is where the market is moving withcompanies enhancing market penetrationby creating novelty solutions. One example is the self-mixingdispensing cap developed and patented byHong Kong-based Incap last year. Thecap, which stores and dispenses dry andliquid ingredients into a PET bottlecontaining still or carbonated water,features a locked, unlocked and activatedthread, which when twisted releases theadditive and triggers the mixing process.Featuring wall-thickness levels of less thanone millimetre and an extremely complexgeometry, precision and repeatability trialswere conducted on one of our all-electricIntElect injection moulding machines.Premium beverage and spirit capsfeaturing non-refillable valves and tamperPudding pots provide a sweet solutionM&H Plastic’s MarketRasen plant providespudding pots to well-knownfood manufacturers, ownbrand and independentretailers. Available in a rangeof standard colours andsizes (including 1 pint XmasPuddings), the pots aresuitable for hot fill, blastfreezing and offer an optimalsurface for foil or filmsealing. Market Rasen also has thefacility for in-mould labellingto decorate your pots priorto filling. M&H Plastics ispart of the RPC Group ofcompanies.M&H Plastics specialises in the production and decoration of high-quality plastic bottles, jars,flexible tubes and closures. In a consumer-driven environment distinctive packaging is vital, andM&H offers unrivalled expertise in developing packaging solutions for markets where quality andstyle are critical to a product’s success.For more information, visit www.mhplastics.com.PHOTO: SHUTTERSTOCK.COM/MAXIM KALMYKOV34 Á32-34_Layout 1 27/05/2016 09:07 Page 234 Food & Drink Internationalwww.fdiforum.netCAPS AND CLOSURESevidence rings, child resistant closures forhousehold cleaning products, such asbleach, and toiletry dispensingmechanisms, are just some of the manynew innovations hitting the market. Given that the average Europeandiscards 159kg of packaging material eachyear, sustainability is an ongoing concernwith a strong commercial incentive to domore with less. The challenge formanufacturers of caps and closures is theyare balancing a wide range of variables,including cost and functionalrequirements, as well as responding todemographic and lifestyle changes andenvironmental impact. With material still being the largest costelement of a closure, thin walling andweight reduction remains a focus area. Ifyou can shave off 2 grams in polymerweight per cap, for a manufacturerproducing millions of units, this adds upto thousands of tonnes saved in rawmaterial.From a machinery performanceperspective view, thinner wall sectionsbring changes in processing requirements;among them, higher pressures and speeds,faster cooling times, and modifications topart-ejection and gating arrangements.These process changes need to be factoredinto the mould, machinery, and partdesign. Polypropylene continues to be theleading caps and closure resin but thereare expectations that the material may bereplaced with HDPE which has economicand sustainability advantages. The use ofbioplastics is also poised to play a greaterrole in packaging going forward.Technically speaking, a moulderdoesn’t need to invest in newprocessing equipment to runbioplastics through it, althoughthey do need to carefullyconsider how the materialwill perform as an endproduct and factor in themelt stability.Increased worldpopulation and thespread of risinglivingstandardsin emerging economies, is resulting inhigher demand for bottled drinks andsmaller packaging sizes as well as moresophisticated dispensing systems. At thesame time, brand owners are keen to useenhanced cap technologies and graphics toreinforce brand identify and differentiatethemselves in the global market. All thesefactors will continue to be importantstimuli for growth, presenting injectionmoulders operating in the caps andclosures sector with the chance topenetrate new markets. To cap it allLooking for a caps and closures manufacturer with ranges to inspire youand to make your product stand out and give shelf appeal? Then look nofurther, Measom Freer manufacture and stock 16 different closure ranges in allvarieties and sizes to suit your chosen bottle, in neck sizes from 15mmthrough to 31mm. Choose from general screw, disc and flip caps to moreprecise application from nozzle, dropper, plugseal and luer caps or moredirectional application from spray, trigger, gel and lotion pumps, all available ina range of colours to order. Need a bottle? Well they sell those too from small 2.5ml through to largerlitre sizes in a wide variety of shapes and materials. Measom Freer arecontinually adding to their ranges, often in response to customer requests,resulting in a constantly evolving portfolio of products from jars and spatulas toboxes and fasteners. For more information, visit www.measomfreer.co.uk.PHOTO: SUMITOMO (SHI) DEMAG PHOTO: SHUTTERSTOCK.COM/MONTICELLO32-34_Layout 1 27/05/2016 09:07 Page 3Food & Drink International 35www.fdiforum.netBEVERAGESThe beverage sector is alivewith innovation, withdevelopments to formulation,packaging and processingresponding to market trends aswell as setting new ones. Soft drinks seem to be the latest targetin the ongoing crusade by governmentand certain consumer groups, demonisingthe proliferation of sugar. It has usheredin a paradigm shift in the beverage sectorwhich, for many, means adapt or die. Formajor producers, responding to thisseismic change in consumer taste meansoverhauling its production methods,marketing and formulations, although, fornascent start-ups, it could proveadvantageous. As the biggest demographic, millennialsare a significant driver of change and inthe move away from sugary fizzy drinks,functional beverages have becomeattractive and profitable. Enter theubiquitous coconut water. The success of coconut water as ahealthy alternative to traditional pop hassparked a slew of likeminded products allpurporting to similar, if not greater,health properties. It’s a similar occurrencein the milk sector, in which free-from andvegan diets have, for all intents andpurposes, gone mainstream. Where oncesoy-milk held a monopoly on thealternative milk market, there are now avariety of successful competitors from amedley of nut milks to rice, oat and seedvarieties to that latest darling of the retailindustry – pea. The latter is thought to beso disruptive a force that it could topplethe dairy industry. It might just beindustry hyperbole, but it proves that thebeverage sector is one that is keeping upwith the breakneck pace of consumers,and to legislative developmentsconcerning sugar levels and nutritionallabelling. The rise of drinkable meal supplements,craft beer/gin/coffee et al, and probioticdrinks reveal the beverage sector to beone of the most animated and innovativeof the food industry. Looking behind thisflurry demonstrates the revolution takingplace across all aspects of the productionline, from packaging to processing. Some of the biggest changes takingplace in the beverage sector are moreconcerned with packaging than what itends up containing. The biggestdiscussion in this regard isn’t so muchwhat the package looks like so much asthe materials involved in making it.Plastic is proving to be an attractivematerial among high-end food and drinkcompanies and even for alcohol brands,who highlight its lighter weight over glass,as well as the savings it passes on to theconsumer – in that it’s a premium butaffordable product. The lighter weight ofpolyethylene terephthalate (PET) meansproducts are easier, safer and moreenvironmentally friendly to move anddistribute. For those reasons, morebeverage companies are expected to moveaway from glass and turn to PET bottles.Plastic, however, does carry with it plentyof negative connotations, which can prove36 ÁPHOTO: SHUTTERSTOCK.COM/ANNA_PUSTYNNIKOVA35-39_Layout 1 27/05/2016 12:48 Page 136 Food & Drink Internationalwww.fdiforum.netBEVERAGESproblematic given attempts to ‘green-up’the supply chain. Health conscious and sustainable trendshave spurned on evolution in packagingthat goes beyond product differentiation.Big brands are continuing to makesustainability a core part of theirprocesses, but for smaller companies,particularly start-ups, it’s a fundamentalpart of their identity, somethingconsumers are keen to connect with.These two facets, coupled with the globalneed to move away from carbon intensivematerials and production methods, ishaving a remarkably positive effect onpackaging. To accomplish this, theindustry is utilising a number of zero-waste initiatives, but also drivinginnovation. Of the more pioneeringadvances in this arena, is the propagationof bio- and, by extension, biodegradablepackaging. The latter helps to solve manyof the drawbacks involved with usingplastic packaging. Carlsberg’s partnershipwith EcoXpak, for example, is exploring ameans of creating a completelybiodegradable beverage bottle made fromPHOTO: SHUTTERSTOCK.COM/06PHOTONewcastle drinks brand launchUK’s first 100% naturallyflavoured milkshake rangeNewcastle-based drinks brand, Canny Drinks, has launched theUK’s first 100% naturally-flavoured range of milkshakes meeting thegrowing demand for products that are free from artificial additives. The plant-based range is ideally suited for conscious consumersand comes in four flavours: chocolate, banana, vanilla and strawberry.Each is made from British milk that has been mixed with natural fruitflavourings, vegetable dyes and plant-derived thickening agents. Liam Watson, herbalist and creator of Canny Drinks, said: “I neverthought when I started mixing ingredients at the kitchen table 18months ago that we would be launching four fantastic flavours. It’s theshortest ingredients list, we’re completely transparent on what goesinto our drinks.He added: “There was a gap in the market for something that wastotally clean and tastes the best. Nobody else is doing what we’redoing and it’s all about how it’s produced.“The most commonly used processes are not natural and it’s longbeen accepted that there’s nothing else available, but I’ve spent a lot oftime looking for alternatives. It took ages to get it right.”35-39_Layout 1 27/05/2016 12:48 Page 2Food & Drink International 37www.fdiforum.netBEVERAGESwww.labeller.co.uk • T: +44 (0) 1444 239970 • E: sales@atwell-labellers.co.uk18 Bolney Grange Business Park • Hickstead • West Sussex • RH17 5PBYou brew it We’ll label itWraparound cylindrical labelling done by the Atwell Linear Wrapround Labellergreen fibre. Coca-Cola, meanwhile, ismaking headway with its eco-friendlypackaging, a move which is spurring otherbeverage brands to follow suit. Anotherdevelopment aims to solve two problemswith one solution, by creating a packagingapplication from waste water or, morespecifically, the material derived fromjuice processing wastewater. European scientists have developedPHBOTTLE, a prototype which is madefrom a biodegradable bioplastic that usesa concentration of fermentable sugarsfound in juice processing wastewater forthe feedstock. Once the productionprocess has been optimised, researchersbelieve that the innovation could becomparable to traditional plastic bottles,meaning beverage manufactures have agreater means of cutting down onwastewater and add an economic boostfor the company, alongside asustainability boon. agave and coconut sugar, many of whichpurport various nutritional benefits,certainly when compared to sugar. Withthe influx of these alternatives, marketanalysts and industry commentators aretouting a closing of the sweetness gap insoft drinks, but predicting that occurrenceahead of the UK sugar tax (set for 2018)can be ambiguous at best. In a processing context, manufacturesare seeking to fortify their beverages,adding another nutritional dimension toappeal to consumers as well as move awayfrom sugar. In doing so, the rise offunctional beverages is taking place at astartling rate, with enhanced water drinksand sports and nutraceutical varietiesnow commonplace on supermarketshelves and moving away from nichecategories. North America is the largest market forfunctional beverages as it containsinnovative varieties of drinks that arecustomized for all age groups and strata.Asia-Pacific and Europe come in secondand third places respectively. Futuregrowth will be witnessed in the emergingThe sustainable development ofpackaging materials and their processes isoccurring in tandem with the evolution ofbeverages as altogether healthier asmanufactures seek to capitalise on thechanging wants and lifestyles of itsconsumers. The forthcoming sugar tax inthe UK, and the changes to labelling inthe US (in which labels will have tospecify exactly how much sugar has beenadded by the producer) is leading manycompanies to reformulate their productsand move away from sugar altogether.The alternative, of course, lies in naturalsweeteners – which has sparked averitable revolution. The interest in sugarreduction also coincides with the cleanlabel formulations, which itself has beenantagonistic to existing non-caloricsweeteners which are perceived to be“artificial”. Interest in natural sweeteners, such asthose derived from the stevia plant, hasskyrocketed, as has the regulatoryapproval surrounding it. With the marketmore an avenue for health-consciousproducts, natural sweeteners arecommonplace in many products andinclude honey, maple syrup, molasses,38 ÁManitowoc Beverage Systems, the one-stopsupplier for leadingbeverage equipment Manitowoc Beverage Systems provides itscustomers with systems and solutions thatare innovative, reliable, and energy efficient.Our beverage solutions are ideal to use forhigh quality serving of beer in bars, pubsand restaurants as well as canteens andmulti-unit restaurants.Multiplex® consists of a broad range ofbeverage cooling and dispensing equipmentwhich satisfies your customer’s thirst withthe highest quality product, botheconomically and efficiently. Multiplex® advanced range of VISION beer coolers have been designed to reduce the total cost ofownership. The option of an R290 refrigeration system will offer further reliability improvements, as wellas energy consumption reduction, putting some money back in the retailer’s pocket.The ICECORE® range of energy saving, natural refrigerant coolers are achieving circa 40-50% energysaving when compared to conventional HFC R134a systems by simply using hydrocarbon, energyefficient refrigerants and smart controls, which only run when there is, dispense demand on the cooler.For more information, visit www.manitowocbeveragesystems.com/uk. 35-39_Layout 1 27/05/2016 12:48 Page 338 Food & Drink Internationalwww.fdiforum.netBEVERAGESeconomies of Asia-Pacific and MiddleEast. Growing health concerns andchanging lifestyles in various regions ofthe world are some of the major drivers ofan inflated demand for functionalbeverages. Innovation is the key to success in thebeverage industry. Utilizing ingredientssuch as natural food/beverage colours,low-calorie natural sweeteners and kosheringredients are in vogue. Manufacturersare constantly embracing open innovationto gain cost-leadership and fixed suppliersin early development stage. One of themajor advantages of a functional beverageis that consumers are ready to pay apremium price for its various functionaladvantages. Manufacturers and retailersmarket these drinks in several ways toattract different strata of consumers. Forinstance, ready-to-drink tea andfruit/vegetable juices are targeted towardsobese people who are looking to loseweight. Retailers, as well as wellnesscentres, play an important role inpromoting these products.From start-ups to industry giants, thebeverage sector is one of the mostinnovative, and most responsive tochange. Its evolution in recent years isspurred on by the move away from sugaras the primary means of sweetening foodand drinks and consumers more focussedon health and nutrition. Reacting to thesechanges ensures that beverages not onlymeet demands, but also stay competitiveand attractive in the marketplace.Innovation continues to play an importantrole in this regard, with the formulationsof the beverage themselves evolving, butalso the marketing, packaging andprocessing too. PHOTO: SHUTTERSTOCK.COM/MARIAN WEYORadnor Hills launch new ambient fruitjuice rangeFruella, the new soft drinks range from Radnor Hills Mineral Water Company, isgloriously colourful and reflects the company’s ‘We Love Great Flavours’ ethos. The 100%Apple and 100% Orange pure juice variants boast no preservatives, no additives, noadded sugar, no colourings - just pure juice and one of your recommended 5 a dayportions.Also in the range are some inspired thirst quenching dual flavour blends including Cranberry and Raspberry, Orange and Carrot, Apple and Blueberryand Tropical which contain a blended mixture of the finest pineapple, passion fruit, mango fruit and banana.The new Fruella range is full of juicy goodness and is a great way to feel refreshed. Each flavour has been carefully crafted to create a delightful tasteexperience and comes in a 400ml PET bottle and has a 6 month ambient shelf life.For more information, visit www.radnorhills.co.uk.35-39_Layout 1 27/05/2016 12:48 Page 4Food & Drink International 39www.fdiforum.netBEVERAGESCAN SUSTAINABILITY BE PROFITABLE?Find out at BEVEXPO 2016 Manchester Central, 15-16 JuneVISIT US AT STAND 103-104 OPERATIONALEFFICIENCYSustainability, whilst once a buzzwordoften used to help improve brand image, isnow firmly ingrained in the food andbeverage industries, with leadingproducers committing to significant targetsto improve the carbon footprint ofoperations and to reduce waste to landfill.Meeting these targets, however, isbecoming more challenging.A significant proportion of the industryhave 20:20 goals and research has shownthat the gap between these goals andmanufacturing goals is narrowing with theimpact of efficiency projects within theproduction process now making moresignificant contributions to the overalltarget. Profitable sustainability?If we look at the bottling hall of abrewery, there are many areas forefficiency improvement; the fillers,conveyor system, clean in place systemand bottle washers if using returnablecontainers, would arguably be the highestconsumers of resources, and offer thegreatest opportunity for optimisation.An end to end approach systematicallytraces utility usage throughout theproduction process in order to define aclear map of where resources arepotentially being wasted, where efficiencycan be improved and where attentionshould be focused for the greatest return.The cleaning in place system, forexample, requires water, chemical andheat (steam) to operate, studies haveshown that while OEM installed CIPsystems function to specification, overtime there is a deterioration in efficiency.In over 75% of cases CIP systems havenot been optimised or re-calibrated sinceoriginal installation, and in that time theproduct being manufactured may haveeven changed. Conveyors play a critical role in thepackaging hall, transferring productbetween the fillers to packaging. They alsohave the potential to hinder youroperational efficiency and decrease theoverall productivity of your plant if theyaren’t managed and maintained.Lubrication is essential to thespeed as well as to the throughput ofthe filling lines and the reduction ofwear, and with downtime reportedto cost €20-30k per hour onaverage, constant running is critical.Wet lubrication systems can be optimisedto reduce water and lubricant volumeswhile improving performance. In manycases a move to a semi-dry or dry systemcan offer significant benefits both inefficiency and contribution tosustainability targets. For more information, visitwww.sealedair.com.Can end to endefficiency drivesustainability?Featured solutions includeDiversey® CIPCheck®,LubeCheck® and DryFormance®35-39_Layout 1 27/05/2016 12:48 Page 5Next >