PROCESSINGNEWSINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netJUNE 2017£3.50 STERLINGSUSTAINABLEPACKAGINGSustainablebusinessSustainablebusiness01_Layout 1 26/05/2017 11:56 Page 1Anderol® Specialty lubricants offers tailored solutions to demanding industrial environments, achieving reduced maintenance, longer service life and optimum performance. Specialized in gas compression, vacuum applications and a comprehensive range of H1 food grade lubricants, we can assist in optimizing every lubrication aspect of your manufacturing process.Give your applications the lubricants they deserve!www.anderol-europe.com02_Layout 1 26/05/2017 11:57 Page 1ContentsJune 2017This magazine is now fully recyclable. By recyclingmagazines, you can help reduce waste and add tothe 5.5 million tonnes of paper already recycledby the UK paper industry each year. Before yourecycle your magazine, please ensure you removeall plastic wrapping, free gifts and samples. FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforumNews 4• General news • On line - production news• On the shelf - new products and initiatives Tsubaki 7Food and beverage processing recognisesthe link between chain technology andproductivity gainsImport and export 12Commitments to automation, recycling andlogistics ensure Germany remains one of theindustry’s most important locations and avaluable export destinationWarehousing and distribution16 While automation may not be popular withunions, a balance between human andmachine can allow a warehouse to run atoptimal efficiencyTemperature control spotlight20The cold chain is one of the food industry’stent poles – new technology is helping tolighten its carbon loadReady meals 26Ready meals are evolving from the high fat,salt and sugar meals of yesteryear to fresher,more wholesome options. But where doesthis leave manufacturers?Processing31There was a time when a dedication to thehighest standards would have beenconsidered a USP but retailers andconsumers alike now demand these as amatter of course. In today’s world, efficiencyis what truly counts• Riggs AutopackFlow measurement andcontrol39Flow doesn’t merely describe thetransportation of beverages, but a plethoraof constituent parts used in food production.Each present their own specific set ofchallenges, from a meat paste or slurryGroup Editor: Steve Fisher (s.fisher@blmgroup.co.uk) Editor:Michael Fisher (m.fisher@blmgroup.co.uk) Editor’s PA: Angela Sharman (a.sharman@blmgroup.co.uk)Journalists: Stuart Pearcey (s.pearcey@blmgroup.co.uk)Dominic Cuthbert (d.cuthbert@blmgroup.co.ukSales Director: Teri Cooper (t.cooper@blmgroup.co.uk)Sales Manager: Sam Trott (s.trott@blmgroup.co.uk)Sales: Nikki Logan (n.logan@blmgroup.co.uk)Vicky Hunt (v.hunt@blmgroup.co.uk)Tel: +44 (0) 1472 310302 Accounts & Subscriptions: John Downes (j.downes@blmgroup.co.uk)Design & Production: Gary Jorgensen, Mark Casson(studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Email:fdi@blmgroup.co.ukPart 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 bereproduced, transmitted, photocopied, recorded orotherwise without express permission of the copyrightholder, for which application should be addressed first tothe publisher. While every reasonable care is taken, neitherthe publisher nor its participating agents accept liability forloss or damage to prints, colour transparencies, negatives orother material of whatever nature submitted to thispublication. The views expressed in this publication are notnecessarily the views of those held by the publisher.MAIN: SHUTTERSTOCK/ZORYANCHIK • TOP: KRÖNER-STÄRKE • MIDDLE: SHUTTERSTOCK/MEHMET DINLER • BOTTOM: INNOVIAto soups and juices. Fortunately, theequipment and machinery is in place toensure food keeps flowingSustainable packaging41Sustainable packaging has long been therealm of companies with cash to burn, butthere are ways to produce sustainablepackaging and reduce costs.NutrEvent45Over 600 participants from more than 25countries will gather in Lille on 14th and 15thJune for the 5th edition of NutrEvent – thekey business convention for innovation infood, nutrition and healthSnackex46Taking place in Wien Messe, Vienna on 21-22June, Snackex is the international savourysnack and nut trade fairUK AD & Biogas48On 5-6 July at the NEC in Birmingham, UKAD & Biogas and World Biogas Expo 2017will bring the global biogas communitytogether at the #1 global biogas trade showEvents50Your chance to keep abreast of forthcomingexhibitions and food fairs from around theworldClassified 53Food & Drink Diary 5403_Layout 1 26/05/2017 11:58 Page 1news4 Food & Drink Internationalwww.fdiforum.netNeed Speed? It’s awrapMartyn Sumner, Technical Stretch FilmConsultant at Kite Packaging, shares his tips onhow to get the best performance out of yourpallet wrapper.Take a regular health check: Just like a car, ifyou don’t service your pallet stretch wrapperyou will not get the best out of its performance. Get in the right gear: Gears are a vital factor ingetting the best performance out of your wrapper. Weight up pay per wrap vs. rental or outright purchase: With pay per wrap, users pay thesame amount per pallet wrapped, no matter what the size. Don’t settle for second rate film performance: Just because a film doesn’t snap on themachine, doesn’t mean it’s working efficiently. Solve crushed case problems: Boxes getting crushed is a common problem that is usuallycaused by a poor combination of film and machine. Choose the right machine: There are two pallet stretch wrapping technologies - core brakeand power pre-stretch. SIG Combibloc andFIRDI establishcompetence centre inTaiwanSIG Combibloc has entered into a newpartnership in Asia that will enable customersto try out and test product ideas quickly andreliably. SIG’s cooperation with the Food IndustryResearch and Development Institute (FIRDI)in Taiwan allows Asian food and beveragemanufacturers to carry out short-run testfillings of new products. These test fillings,such as innovative drinksplus beverages withperceptible particulate content, can be thekey first step towards turning product ideasinto success stories. For this purpose, a SIG Combibloc CFA 112filling machine with drinksplus kit was installedat FIRDI in March of 2017. FIRDI was established in 1967 as a non-profit organisation with the aim of offeringconsulting services for the regional foodindustry. The organisation’s main focus is onworking with companies to produce cutting-edge strategies for the food industry, toimprove the quality of processed foods, tryout new technologies and carry out practicaltesting of new products for the Asian markets. Qualvis create packs for Border Biscuits’Sheeran promotion Border Biscuits teamed up with leadingprint and packaging business Qualvis to sendpersonalised digitally-printed packs of theirDark Chocolate Gingers to flame-haired popstar Ed Sheeran, ahead of the singer’s recentsold-out performances in Glasgow. Border wanted to celebrate the 30thanniversary of their Dark Chocolate Gingers,the number one special treat biscuit inScotland, by sending Sheeran unique packs ofthe biscuits to match his hair colour, alongwith the message: “From one Number 1 to another”.The packs were delivered personally by Border’s heroic mascot Ginger George to Sheeran’sdressing room at the SSE Hydro. The packs were developed and artworked in the new Qualvis Innovations Studio and thenprinted by their digital offering - a £2 million dual digital packaging line investment, recentlyinstalled at their Leicester site and featuring a Xerox iGen 4 sheet-fed digital printer, side-by-sidewith an iGen5 automated line. AmbaFlex safely guideAsian’s favouriteingredient downA sesame oil manufacturer in Tonoshou-chouJapan had to get their tin cans containing theprecious content from the upper floor, which was7 meters high, down to ground level. The unstable footprint of these tin cans, due totheir unorthodox width to height ratio, required acritical look regarding the way they should betransported down, keeping in mind the scarcelyavailable floor space. Compact, safe and with ahigh throughput, the AmbaFlex SpiralVeyor SVswas the only realistic solution for this particularchallenge.Thanks to the unique friction coated slats, theSpiralVeyor only needed 11 windings to lowerthese types of tin cans 7 meters at a safe angle.The coated, 32-meter long narrow ultra-flat beltensured the delicate metal cans would stay firmon their respective place on the belt and maintainscratch-free. This unique AmbaFlex solution safely transported the goods whilekeeping a minimum footprint of less than a meter.‘Metal Detection, X-ray Inspectionor Both? - Making the Right Choice’Metal detection and X-rayinspection are long establishedsolutions for protecting againstcontamination in food manufacturing.Yet as technology has developed, itisn’t immediately obvious whichprovides the best performance forproduct safety. METTLER TOLEDO’s white paper,‘Metal Detection, X-ray Inspection orBoth? - Making the Right Choice’,examines the design and capability ofboth technologies in detectingcontaminants across a range of wetand dry products and packagingtypes.The paper also discusses the importance of conducting a HACCPaudit in determining the right inspection solution, making comparisonswith differing contamination, packaging and production scenarios. By understanding how to choose the right inspection technology,manufacturers can maintain product safety and quality controlrequirements, whilst maximising brand protection and customersatisfaction. 04-11_Layout 1 26/05/2017 14:08 Page 1Two-wire temperature transmitter for food production. Bright 4-digit LED display. Fast response T05/09 = ᅑ sec. Preset measuring range can be adjusted over IO-Link. Range of probe lengths and process connections available. Stainless steel. IP69K.First loop-powered temperature transmitter with LED displayFirst loop-powered temperature transmitter with LED displayifm Telephone 020 8213 2222ifm Telephone 020 8213 2222www.ifm.com/uk/tdwww.ifm.com/uk/td04-11_Layout 1 26/05/2017 14:08 Page 26 Food & Drink Internationalwww.fdiforum.netnewsBlue Cube set to achieve 30% growth innext two yearsBlue Cube Portable Cold Stores – part of the TurnerGroup – has announced plans to achieve 30% growth inthe next two years.The company’s ambitious expansion strategy is backedby significant investment in technologically advancedtemperature controlled solutions which offer unrivalledperformance benefits and low lifetime cost of ownership. In line with its growth plans, Blue Cube is currentlysearching for larger premises and will increase headcount,with additional roles in service and sales predominantly. “In the past couple of years we have fundamentallyreshaped and built a very different Blue Cube,” said Steve Blakemore, Blue Cube’s ManagingDirector, pictured. “The changes have delivered the best results in the company’s history lastyear, and we are now ideally positioned to increase market share and achieve 30% furthergrowth by 2019.“With this in mind, we have put a number of exciting initiatives in place including relocationto larger premises and a recruitment drive.” More food processorstaking advantage ofMicron’s certifications Increasing numbers of food processors aretaking advantage of Hosokawa Micron’s FSSC22000 food safety management, Halal andKosher certified toll processing service to meetdemands for improved cleanliness, purity andquality in food production.Whether companies lack capacity, need accessto specific processing technology or are notcertified to handle certain ingredients or processes,cleaning regimes or product segregation,Hosokawa Micron can provide the solution.Kathryn Hipkins, Technical Centre Manager,Hosokawa Micron, said: “Our ability to processgoods in accordance with strict procedures isincreasingly of interest to those producing goodsfor those with food sensitivities and is becomingmore widely accepted food production practiceacross a range of goods.”With a range of equipment and foodtechnologies to hand, including mixing, milling,separation, granulation, classifying, agglomerationand pack off available, Hosokawa can meet a vastrange of food processing requirements tailoredto meet one off or regular production needs.Wireless temperature monitoring withThermaData® WiFi loggersUtilising the latest WiFi technology, the newThermaData® WiFi range of temperature loggers fromElectronic Temperature Instruments are a user-friendlysolution for remote food temperature monitoring. Two thermistor models are available, both offeringaccurate wireless WiFi temperature monitoring andlogging by securely transmitting temperature dataover the range -50 to 125°C to a WiFi router. Datacan be accessed and viewed from a PC, laptopor tablet anywhere in the world, allowing real timemonitoring and the logging of temperature sensitivefood and storage areas.Each logger has an intuitive LCD displaying temperature, WiFi connection status, max/minrecorded temperatures, alarm status and battery life. The loggers are powered by two AAbatteries with a life expectancy of over a year. The easy-to-use ThermaData Studio softwaremakes the ThermaData WiFi loggers ideal for HACCP temperature analysis.ThermaData Studio software is available to download free from the ETI website, and islicence free, with no subscription charges. Croxsons delightYarty with superiorpackaging solutionIn creating their premium glasspackaging, award-winning artisan fruitcordial brand, Yarty, said that Croxsonshave “helped fulfil the impossible”.Once described by US actor JohnnyDepp as “England in a bottle…” Yarty’scordials are handmade using the finestfruit, hand-bottled and hand-labelled tocreate a truly artisan drink. Acknowledging that their current glasspackaging didn’t adequately reflect thequality of their product, Yarty reached outto Croxsons to provide a premiumsolution in two different sizes: 250ml and750ml for retail and trade sales. In creating a unique and stylish look, Croxsons supplied a bottledesign that fully complements Yarty’s requirements - the distinctive‘Olivia’ bottle, produced exclusively by specialist manufacturersSaverglass, takes its shape from containers used in ancient times for theconservation of liquids.To finish the packaging to a high standard, Croxsons included heat-sealed capsules branded with the Yarty ‘Y’ logo on top.Direct Food Ingredients namesits ‘Employee of the Year’Direct Food Ingredients hascrowned Andy Watt as its Employeeof the Year. Mr Watt, pictured, has revolutionisedthe company’s IT structure andlaunched a bespoke intranet systemthat supports Direct Food Ingredients’comprehensive provision of a thoroughaudit trail and compliance inaccordance with stringent industrybodies. The intranet controls thesespecifications, improving in-houseefficiency and reducing long termcosts. It speeds up orders, theinputting of data and is instrumental insupporting the company’s expansion into new markets.Managing Director Steve Loake said: “Andy’s devotion to theimprovement of our IT system has been outstanding and it has helpedto make everyone’s job that bit easier. Our customers have reallybenefitted from the upgrade which ensures that we are consistentlydelivering our renowned ‘raving fans’ service.”The business is a leader in the importation, storage and distributionof functional foods, nutritional and sports ingredients as well as vitaminand mineral premixes. 04-11_Layout 1 26/05/2017 14:08 Page 3Food & Drink International 7www.fdiforum.netThe production intensity of the foodand beverage processing industries,which simultaneously needs speed,efficiency and hygiene, leaves littleroom for unplanned maintenance ofplant and machinery. Greg Sharp, Engineering Manager atTsubakimoto UK, looks at thechallenges and offers some solutionsbased on past projects and hiscompany’s regular R&D advances.Food and drink processing is usuallyhigh speed, and often done in relativelysmall production batches. Typicallythere is also pressure to meet adeadline so that delivery of the finishedproduct meets supermarkets’demanding schedules. Both retailersand consumers insist that both productand packaging are perfect in every way.Then, on top of all this, there has to bea tremendous focus on hygiene at alltimes.A lot of food processing machineryincludes chain drives, which arefavoured because they are efficient inuse, maintain precision and are suitablefor both high and low speedapplications. Further, chains arerelatively easy to fit, maintain andeventually to replace at the end of theirlife. As one of the world’s best regardedchain makers, Tsubaki has beensupplying product to the foodmanufacturing sectors for many yearsand has long been aware of its uniquerequirements. To address these it hasnot simply developed specialistchain designs, but has constantlyinvested in redevelopment; alwaysimproving on the performancecapabilities and addressing new userrequirements. Tsubaki has two specialist ranges ofchain that are particularly suitable forfood industry applications: Lambda RSand Neptune. Both are fairly newproducts and their development has, inpart, been an evolutionary process fromearlier specialist chains.Lambda chain has been developedfor use in locations where it is difficult,impossible or undesirable to applylubrication in-situ. This includes foodmachinery, but also clean and hygienicindustries such as pharmaceutical,paper and electronics. The key featureof Lambda is its sintered bushes, whichare impregnated with oil duringmanufacture so do not need lubricatingonce installed. Lambda is now suppliedin a sixth generation design.Ever since Tsubaki launched theworld’s first lube-free industrial drivechain onto the market, the benefits ofthis technology have been welldocumented. The latest generation ofLambda is lubricated with a specialfood grade lubricant as standard. Whilefood grade lubricant has been availableas an option for many years, thisdevelopment has improved Lambda’swear life by more than 30% andperfectly demonstrates how wellsuited the technology is to foodproduction and processingenvironments.Wise chain users will always maintainan open dialogue with reputable chainmakers, who will feed users commentsand requests into their on-goingdevelopment programmes and becomea trusted consulting partner to the user.For more information, visit www.tsubaki.eu,Email marketing@tsubaki.eu, or call +44 (0)1623 688700 Food and beverageprocessing recognisesthe link between chaintechnology and productivity gains 04-11_Layout 1 26/05/2017 14:08 Page 48 Food & Drink Internationalwww.fdiforum.netnewsPackaging Automation shortlisted for2017 E3 Business AwardsPackaging Automation, the Cheshire-based tray sealing and pot fillingmanufacturer, has been shortlisted as afinalist in the 2017 E3 Business Awards, heldon 13th July 2017.The company, which is the leadingmanufacturer and exporter of specialistfood packaging machinery, was selectedfrom hundreds of nominees to become oneof the finalists for the prestigious‘Manufacturing Business of the Year’;‘Employer of the year’, and ‘Business of theYear’ categories.Commercial Director Sam Ashton said: “Being selected as a finalist in three categories ofthe E3 awards is a fantastic endorsement of the hard work that is being done by the brilliant team of employees at Packaging Automation. “We have all been on an incredible journey during the past 31⁄2years that has seen growth and changes in our people as well as the business.Everyone has worked to overcome challenges set by our customers and each other to improve our business, products and overall performance.”2 Sisters invests £10m inprepared meals facilityUK food giant 2 Sisters has invested £10 millionin new technology and innovation as it ramps upthe capabilities of its prepared meals facility inSouth Wales.2 Sisters Food Group’s Rogerstone site – thebiggest prepared meals facility in Europe – now hasa dedicated Oriental foods ‘pod’, which wascompleted ahead of the Chinese New Year. This willact as the foundation for sustained growth andmomentum for the business’ Meal Solutions division.The new pod will enable the site to grow andinnovate so it can continue to push the boundariesof what is possible within prepared meals.The new automated coating line and latestcooling technology will enable Rogerstone tosupply a greater variety of meal options withimproved consistency and better eating quality byoptimising the production process at critical points.The new in-line cooling system has also reducedthe sites environmental footprint and the investmenthas given a boost to the site’s ongoing commitmentto continuous improvement of its colleagues.Wheat starches go gluten-freeGermany and the UK are bothexperiencing a rise in the sales ofgluten-free food products, and thetrend shows no signs of slowing down.Gluten-free product sales in Germany,for example, are predicted to rise to£143.4 million in 2019 from £116.8 millionin 2014, according to Euromonitor.The gluten-free market offers massivepotential for food processors that havetraditionally created alternativecarbohydrate-based foodstuffs fromother crops, such as corn. Now, thanks to leading German wheat starch innovator Kröner-Stärke, these items can be produced from native wheat starches and organic wheatstarches which have had the gluten content washed out. This news comes as a real boon for companies who wish to extend their ranges to suit awider audience and are also looking to lower production costs. Gluten-free wheat starchesare not just intended for coeliacs or those wishing to follow a ‘clean-living’ style diet, butcan be eaten by anyone who can tolerate wheat including very young children. YPS installation drives Gopakefficiencies Shrink wrappingspecialist YorkshirePackaging Systems hasrevealed the impressivebenefits delivered by itslatest installation – a 60%reduction in transitdamage for educationalfurniture firm Gopak, whomanufacture lightweight,folding educational and community furniture. The requirement for a streamlined and highly efficient shrink-wrappingsystem was born from its specific business model, which focuses on flat-packed products, put out for delivery by a carrier network. Faced with repeated damage to cartons in transit when usingcardboard, Gopak needed a less bulky and more effective method ofwrapping its products for delivery. YPS initially provided a hire machineto demonstrate the capabilities of its machinery and film offering and theresults were very positive. YPS went on to supply a bespoke machine, which has transformed theefficiency of its dispatch area and reduced the number of itemsdamaged in transit by a staggering 60% increasing both customersatisfaction and profitability. Duerr’s citrus jar wins big atWorld Food Innovation AwardsArdagh Group and Duerr’s have been awarded ‘Best PackagingDesign’ for their unique citrus jar at the World Food InnovationAwards, organised by FoodBev Media.Judges were impressed by the design innovation in the intricatedetailing of the jar’s texture, commenting: “Looks like peel, feels likepeel! All round great packaging design. No wonder shoppers can’twait to buy, use and then repurpose the jars.”They added: “This design strikes a perfect balance betweenmeeting the aesthetic expectations of the customer and thepracticalities of volume production.”Ardagh’s designers were given a specific brief by Mark Duerr, Duerr’sManaging Director, to develop a totally unique jar that looked like andfelt like citrus fruit. What on paper sounded a straightforward projectwas in fact full of technical challenges. To create a stunning and tactile‘citrus’ jar to the right size and scale, and replicate the peel effect.04-11_Layout 1 26/05/2017 14:08 Page 5Swapping beef for beanssecret to reducing greenhousegassesA researchconsortium hasfound that ifAmericanconsumersswapped beeffor beans, theUS wouldimmediatelyrealise 50 – 75%of itsgreenhouse gasreductiontargets for 2020.The researchers – from four US universities – said that beef cattleare the most greenhouse gas-intensive food to produce, and thatthe production of legumes results in one-fortieth the amount asbeef.“Given the novelty, we would expect that the study will be usefulin demonstrating just how much of an impact changes in foodproduction can make and increase the utility of such options inclimate-change policy,” said Loma Linda University researcher HelenHarwatt, PhD – who headed up the research.In a 10-page paper, Harwatt and her colleagues noted that dietaryalteration for climate change mitigation is currently a hot topicamong policymakers, academics and members of society at large.In addition to reducing greenhouse gases, Harwatt and her teamconcluded that shifting from animal-sourced to plant-sourced foodscould help avert global temperature rise.Food & Drink International 9www.fdiforum.netScottish food industry tobenefit from £1.1m innovationserviceScotland’s foodand drink industryis set to benefitfrom ‘MakeInnovationHappen’, a newservice to supportfood and drinkbusinesses toinnovate.The service isdelivered througha coalition of key public sector and industry bodies workingtogether collaboratively to drive innovation, with £1.1 million ofcritical funding coming from Scottish Enterprise and Highlands andIslands Enterprise.In March, the Scotland Food & Drink Partnership launched‘Ambition 2030’ – a vision to cement food and drink as Scotland’smost valuable industry and outlines the goal to double turnover inthe sector to £30 billion by 2030.Make Innovation Happen is being launched by the Scotland Foodand Drink Innovation Working Group as the first step towardsAmbition 2030 which prioritises innovation as critical to continuedsuccess in the sector.Innovation in farming, fishing, food and drink is vital to empowerScotland’s food and drink businesses to respond to today’sconsumer and market needs and to adapt to future challenges andopportunities.© shutterstock/barmalini© shutterstock/Antony McAulay04-11_Layout 1 26/05/2017 14:08 Page 6Next >