< Previous30 Food & Drink Internationalwww.fdiforum.netREADY MEALSwhich have the double effect of minimisingpackaging and allowing consumers a glimpse ofthe product – certainly an act of confidence on afood maker’s part. One of the biggest climbers in the ready mealmarket is soups. And it’s not just hot soups either,with the cold soup market enjoying a dizzyinggrowth and representing a real threat to the juice– which is increasingly coming under fire for itssugar content. Cartoning is an ideal means ofpackaging these products, which had once beenlimited to metal cans and, later, plastic tubs. As technology continues to blur the linesbetween work and rest, the need for conveniencefoods will likely only grow. The image of an officeworking eating lunch at their desk might conjureimages of soggy sandwiches or salt laden readymeals, but no longer. With a nudge fromconsumers, and more than a little persuasionfrom Governments looking to counteract theobesity epidemic, ready meal makers areproducing healthier and fresher options. As themillennial demographic, with its fondness forfresh and nutritional foods, continues to overtakeboomers, the ready meal market space will lookincreasingly more wholesome. KCClaunch 100% biodegradablepackaging solution for ready mealsRiji® is a new plant-based packaging solutionfor ready meals, whichenables retailers tocomply with the CO2reduction demands of theEU/UK governments, andshows meaningfulCorporate SocialResponsibility to eco-aware customers. A unique biodegradablebarrier coating gives thepackaging the shelf-life needed for producer and retailer alike.The tray stays rigid in both microwave and conventional ovens, which means it’smuch easier for the consumer to handle than plastics, which soften when heated. Ithas considerably better heat-retention, so it’s easier to handle when hot, and keepsthe ready meal hotter for longer. Riji® can withstand much higher temperatures than plastics and cooks foodfaster, which means that a meal such as lasagne can crisp and caramelise in aconventional oven when it’s cooked in a riji® tray. Riji® is believed to be the first serious replacement for carbon-hungry CPet andaluminium trays. For more information, visit www.k-c-c.co.uk.26-30_Layout 1 26/05/2017 12:05 Page 5© shutterstock/mehmet dinlerFood & Drink International 31www.fdiforum.netPROCESSINGThe challenge for manufacturers is toensure standards don’t slip at a timewhen retailers are looking for increasedefficiency on the supply chain; costsneed to be kept down at every stage asnew products and production methodsare introduced. This requires thehighest degrees of operationaldiscipline, excellent interdepartmentalcommunication, far greater awarenessof issues and current production status,together with automation, whereverpossible, to minimise the risk ofoperator error.All responsible manufacturers willhave carried out in depth riskassessments, and realised how easy itis, within such high pressureenvironments, to get something wrong.Errors in component handling, out ofdate ingredients, coding and labellingerrors, compromised pack seals andinaccurate weights are just a few thingswhich negatively impact deliveryschedules and the bottom line in foodmanufacturing environments whereshort batch runs and frequent productchangeovers have become the norm.The evidence suggests thatcompanies who have the mostMaintainingstandardsThere was a time when a dedication to the higheststandards would have been considered a USP but retailersand consumers alike now demand these as a matter ofcourse. In today’s world, efficiency is what truly counts.32 Á31-37_Layout 1 26/05/2017 12:06 Page 132 Food & Drink Internationalwww.fdiforum.netPROCESSINGproblems are those who have tried todeal with this increasing complexity byhanging on to their old methodologies,largely paper-based, which were put inplace decades ago and, at the time,probably adequate to deal with thepace of business and the lower levels ofcomplexity that existed. While easy toput in place, these systems are difficultto manage and a nightmare to analyse.During the last half century, theindustry has seen many changes,mainly in the complexity, demands andpower of the supply chain. The internalchanges in food and drinkmanufacturing haven’t kept pace withthe changes in the supply chain. Whenit comes to problems, however, researchsuggests these can be broadlynarrowed down into three categories.The first is that momentary lapse ofattention or loss of focus which enablesproblems to occur. The second comesfrom taking short cuts – in other words,breaking the rules. Employees believethey are finding a quicker, easier way toachieve the desired outcome whenunfortunately this route sometimesleads to disaster. The third is errors ofjudgement – guessing or taking achance they might be right instead ofasking or consulting standard operatingprocedures.For designers and manufacturers offactory floor processing systems, thechallenge comes from the need todevelop systems which address thosecauses of mistakes, but to do so in sucha way that the systems are easy toinstall, implement, modify and most ofall, to use, such that operationalpersonnel find it much easier to usethem than to try to find ways aroundthem.Computerisation of procedures,together with automation wherevercost justifiable, minimises the risk ofoperator errors, either because changesto the production line are doneautomatically, or because in thesampling procedures, operationalpersonnel have no alternative but tofollow pre-determined proceduresprescribed by management. This canstill lead to problems from lack ofunderstanding, however, which is whyall staff need to be trained and madeaware of any changes to equipment,processing or even managementsystems on the floor. It would be unfair to give theimpression that no companies havedone anything about addressing theseissues. Clearly, many companies havedone much in terms of training,retraining and the installation of somedegree of computerisation, such asperhaps an OEE system or acomputerised average quantity system,but in most places, it hasn’t been done35 Á© shutterstock/Jaromir Chalabala31-37_Layout 1 26/05/2017 12:06 Page 2Food & Drink International 33www.fdiforum.net forallyourPowerTransmissionSolutions !" # $% ShadyLane,GreatBarr,Birmingham,WestMidlands.B449EUTel+441213600155Fax+441213251079 31-37_Layout 1 26/05/2017 12:07 Page 3Tel: +44 (0)1772 323529Email: sales@dixoneurope.co.ukwww.dixoneurope.co.ukYour Right ConnectionFor Hygienic Process SystemsValvesFittingsHoseEngineered ProductsFabrication34 Food & Drink Internationalwww.fdiforum.net31-37_Layout 1 26/05/2017 12:07 Page 4Vision System ThermoSecureFull packaging inspection by vision for easy end-of-line integrationThermoSecure inspects seal seams, labels and information on top and bottom of packs. Before case packing, the stand-alone inspection machine detects defective packs and is able to reject them. In the event of a drift in production, an alarm alerts the operators so that the problem can be corrected immediately. ThermoSecure prevents rework operations on defective packaging, complaints or product recalls due to package integrity problems.01908 682740 info@bizerba.co.uk www.bizerba.comFood & Drink International 35www.fdiforum.netPROCESSINGas a planned holistic approach, but more often largelythrough pressure from supermarkets or from the resultsof outside audits.This is understandable, as profit and continuedsuccess will always be strong motivators for change.However, manufacturers in places like Japan, long hailedfor their efficiency and productivity, take a much morelong-viewed approach. To them it is not about fulfillingsome customer criteria they don’t really believe in, norabout grudgingly adhering to new ways of thinking.They take a more natural approach, in which suchthinking is not only embraced, but allowed to flourish –with each and every person wanting to make it work.This holistic, almost cultural, approach ensures that suchchanges are bound for success, and don’t get held up byresentment or backwards thinking. In this department,being held back by nostalgia seems to be somethingonly the UK suffers from.The UK food and drink industry is falling far behindother countries when it comes to automation and theadoption of robotics into the food industry. These werethe findings of a recent study into robotics within thefood and drink industry, which found that even withinEurope, the UK is ranked 15th in terms of robotics usage.To give an idea of what that means, the UK is behindcountries such as Germany, Sweden and France – butalso now falls behind Slovakia, Slovenia and the CzechRepublic. The bigger problem still is that the changes inrobotic investment within the UK are some of the lowestin the bloc.37 Á© shutterstock/Aleksandr Kurganov31-37_Layout 1 26/05/2017 12:07 Page 5THE UK’S UNMISSABLE TRADE EVENT FOR PROCESSING AND PACKAGING MACHINERY26–28 September 2017NEC, Birmingham“A day at the show gives you a year of vision”PPMA Show 2016 Visitorppmashow.co.ukOrganised byIncluding materials, robots and industrial visionSee the latest machinery in actionNetwork with industry peersGain valuable insights at seminarsFREE TO ATTENDREGISTER NOW!31-37_Layout 1 26/05/2017 12:07 Page 6Food & Drink International 37www.fdiforum.netPROCESSINGHesper Farminvest in yoghurtpot filling &sealing solutionSet off thebeaten track inthe YorkshireDales, HesperFarm is a proudproducer oftraditionalIcelandic styleSkyr Yoghurts.Made by theirpedigreeHolsteinFriesians, theAireburn Herd,they are part of a proud dairy tradition that goes backgenerations.Hesper Farm first purchased their first Riggs Autopackdepositor in 2015 to operate in conjunction with a manual sealerfrom Seal-it-Systems. The Riggs Autopack Model 1000 Series 3 depositor was asemi-automatic unit and proved invaluable with the flexibility tofill 150gm, 450gm, and larger containers with all styles ofyoghurt ranging from smooth vanilla to strawberry, blueberryand black cherry flavours, complete with fruit additions.However, due to increased demand and rapid growth, they soonrealised that a higher level of automation was required.As part of their investment program, Hesper Farmapproached Riggs Autopack and Seal-it-Systems to find a fullyautomated solution. Working together, engineers from RiggsAutopack and Seal-it-Systems modified the existing semi-automatic depositor to a fully automatic depositor to work witha new, bespoke Rotary Sealer.The Rotary Sealer de-nests one pot at a time from a stack,then using a rotating platen passes each pot through variousstages from product depositing with full control integration tothe depositor, through foil lid placement, sealing, coding, andfinally delivery via a belt conveyor to the packing station.Previously, 2 operators were required; one mixing and fillingthe product, and one then sealing and coding. This has allchanged with the new integrated automatic solution that is notonly working faster but reducing labour, enabling greatlyimproved production efficiency. For more information, visit www.riggsautopack.co.uk,email info@riggsautopack.co.uk,or call +44(0) 1282 440040.What this shows is that there is a weakness withinmany UK manufacturers in that they are slower to adaptto new technology such as robotics, not only comparedto European and global rivals – but also domestic ones.The efficiency and cost-saving benefits of robotics arewell documented, to the point that certain industries, suchas the motor trade, make almost exclusive use of them.This has enabled the motor industry to remaincompetitive with China, Japan, the US and many othercountries, something which the food industry is strugglingto keep up with. The reasons why might sometimes be just as importantas the how, and in this case specialists in the roboticsindustry believe it is a lack of understanding which holdsmanufacturers back. As one supplier states, “As there arestill many countries, even within the European Union, whohave much lower labour rates than the UK, the onlyoption for UK food and drink manufacturers, therefore, isto continue maintaining their high quality standards,whilst improving efficiency. This can only be effectivelydone with a vision of the end result required and acommitment to automation and performanceimprovement.” It’s this vision of the end goal that is most important, aspiecemeal automation, without the overall vision, tends toimprove some areas, but can create ‘bottlenecks’ inothers, so the overall door to door efficiency is often notimproved but, due to the significant cost of automation,the unit costs go up rather than down – the exactopposite of the intention.With Brexit looming and the National Living Wage inplace, now ought to be a time for the UK manufacturingindustry to make the changes they need and invest inmore efficient processing systems. Certainly it cannot beignored for much longer.The market won’t allow it. © shutterstock/FreeProd3331-37_Layout 1 26/05/2017 12:07 Page 7KECOLSTILL NO.1 FOR VISCOUS PUMPING SOLUTIONSWith over 25 years experience in pumping viscous materials, Kecol is the number one choice of many of the World’s leading pharmaceutical, cosmetic and food manufacturers.Kecol equipment is used to transfer flowable & non-flowable materials from drums,IBC’s, mixing vessels and process vessels of various shapes, sizes and designs,without heating the material.Kecol’s extensive range of equipment is designed to transfer products from tripleconcentrate Tomato Paste through to Petroleum Jelly and Mascara, quickly, cleanlyand efficiently from standard 200 litre drums, tapered or conical drums fitted with anaseptic bag, tote bins and IBC’s.Our vast experience has shown there are nevertwo applications the same and that’s why wealso offer bespoke systems designed and manufactured to suit your specific vessels and production requirements. &&)'(+$(%&$)('+%)"%.(&$!)"!!-.#')" -&$,.'&.#$!#.% !$''.Ve(&#&-&"'.-#("#('.&#,.&).(# !'.!'*'.$$(%'(.,.)#$($#'.!)"#)" -&$,. #&"'.*#&". !-&#. $#-. ((&.)((&.-$##'.#)()((er .&)($##(&(.&&#.".$"($)&.$%%$"($.!!#'.-&)%'.')(&"'.&"!&$)ts .&)('('.$$ #('.$##('.+(#(. '$'(- &'.'(.$$!!&.!$#.#(.I# .$!-"&'.%$,-'('.!#('. !).'#www.kecol.co.ukTel: 01746 764311Fax: 01746 763375 Email: sales@kecol.co.ukNOW ATEX APPROVEDSystem for IBC’sSystem for 4 x palletmounted drumsTrolleyMounted Vertical orHorizontalpumpsVISIT US ON STAND E41STAND H3038-40_Layout 1 26/05/2017 12:09 Page 1Food & Drink International 39www.fdiforum.netFLOW MEASUREMENT AND CONTROLAs one of the five senses, touch is thegreat unforgotten experience when itcomes to food and drinks. Studies haveshown that the way people eatdepends greatly on food textures, withsome preferring crunchier profiles, withothers tending towards soft. Although anumber of products have played tothese particular sensory experiences,it’s only in the last few years that foodmakers have made a concerted effortto target a specific demographic basedon their texture preferences. The mostobvious example is older consumers,who statistically prefer softer foods, asthey’re easier to chew and digest. Texture doesn’t just refer to thecrunchiness or softness of a product,but also its fluidity. The processing andtransportation of fluids throw up anumber of hurdles for manufacturers.There are numerous food and drinkproducts with varying levels ofviscosity, from slurry to fats and evensolids, and each will require its owncorresponding equipment with its owncalibrations and sensitivities. With thetrend for more wholesome, healthierfood, many products are now relying onreal fruit and vegetables rather thanheavily processed or artificial flavours.Ergo, processing equipment is nowhandling a similar product as it hadbeen before, but one decidedly morefibrous and with potentially much morepulp. This can lead to equipmentbecoming jammed or compromised,meaning downtime spent cleaning orcostly repairs to be carried out. The above example is representativeof the shifts taking place in the foodproduction and retail sectors, but it alsoserves to highlight the issue of fluidhandling problems that can plague afood manufacturer. Often, theseproblems stem from using pumps forpurposes for which they weren’tdesigned or intended, so it’s littlewonder they don’t perform as desired.A pump used in the disposal of waste© shutterstock/Salov EvgeniyFlow doesn’t merely describe the transportation of beverages, but aplethora of constituent parts used in food production. Each present theirown specific set of challenges, from a meat paste or slurry to soups andjuices. Fortunately, the equipment and machinery is in place to ensurefood keeps flowing. 40 ÁGo with the flow38-40_Layout 1 26/05/2017 12:09 Page 2Next >