< Previous30 Food & Drink Internationalwww.fdiforum.netFLOW MEASUREMENT AND CONTROLmuch product is allowed through, atwhat speed and at what pressure,enables employees to make changes onthe fly without unnecessary downtime. When it comes to the valves industry,the demand for the elimination ofpreservatives from food and beveragesis set to drive demand higher than ever.Transparency Market Research hasshown that many large players in thevalves industry have taken to investingin developing regions and emergingmarkets in order to cater to the hugepotential there. The research report alsoclaims that the global hygienic andaseptic valves market is set to increasefrom $6 billion in 2015, to $9 billion in2025 – an increase of 50% in just asingle decade. Flow measurement and vales gohand in hand, so benefits in oneindustry are likely to correlate into theother, and yet there are still manymanufacturers within the UK who areeither unaware of prefer to keep theirheads in the sand as to the necessity ofregularly updating flow control systems.While it’s easy to say the goal is not towait for a disaster, but to be ahead of it– many still continue to use outdatedsystems in the hopes they will continueto work, and then face setbacks whensystems that long need replacinginevitably do fail.Good maintenance can help offsetthis, and many manufacturers andsuppliers offer such, but it is importantto make sure the maintenance isactually utilised and not just forgottenabout. Where maintenance can meandowntime and no production, it’s easyto put it off as unnecessary, butplanned downtime is better thansudden downtime.A major challenge in the pumps andfluids industry is that of ensuringtraceability is in place. Labellingregulations mean that packaging needsto explain exactly what is in the productso it is vital manufacturers can identifyingredients during the mixing process.In many cases – particularly that of arecall – a large retailer might give amanufacturer less than 24 hours toascertain where something went wrong.This is important for the retailer due tothe fast spread of negative publicitythrough the media – requiring them tomake a prompt response. However theonus is then passed down to the© Shutterstock/ASA studio29-31.qxp_Layout 1 29/05/2018 11:08 Page 2Food & Drink International 31www.fdiforum.netFLOW MEASUREMENT AND CONTROLmanufacturer, who must check theirsystems to see if it was something thatwent wrong on their end; or whether itmight have happened outside of theircontrol. In the cut-throat world ofsupermarkets it’s guilty until proveninnocent, and a poor traceability systemthat cannot meet the retailer’s demandsis sure to lead to damages – or perhapseven a loss of a major contract.Detection, scanning and visionsystems should be employed at variousstages throughout the process – withthe results of these monitored bysoftware systems or employees. Whilepumping systems can and should beable to meter and prepare the productas per the recipe specifications, there isstill a need for quality control andassurance at every stage of the process.Measurement of highviscosity glucoseBell Flow Systems wasapproached by a specialistcontractor who needed someexpertise in supplying a solution to arather challenging application. Thisproduction line specialist had beenasked to measure the flow ofglucose in a newly built processingplant for a large, UK-based softdrinks manufacturer.Bell Flow Systems offered one ofthe Macnaught oval gear typepositive displacement meters. Thisparticular range of meters areconstructed from food gradestainless steel, with high viscositystainless steel rotors capable ofmeasuring viscosities over 100,00centipoise. Hygienic tri-clampconnections, FDA approval, and locally-mounted IP67 rated batch controllers completed theselection.The oval gear meter principle ensures that there is flexibility of installation as there are nostraight lengths of pipe needed before or after the meter, they can be installed vertically orhorizontally. Additionally, these meters create an exceptionally low pressure drop - which wascritical to the application.For more information, visit www.bellflowsystems.co.uk.© Shutterstock/MOLPIX29-31.qxp_Layout 1 29/05/2018 11:08 Page 332 Food & Drink Internationalwww.fdiforum.netPROCESSINGProcess equipment canbe complicated at thebest of times, not onlyfrom the sheer amountavailable but also justhow much of a factoryit can cover.There was a time when a dedicationto the highest standards would havebeen considered a USP but retailers andconsumers alike now demand these asa matter of course. The challenge formanufacturers is to ensure standardsdon’t slip at a time when retailers arelooking for increased efficiency on thesupply chain. Costs need to be keptdown at every stage as new productsand production methods areintroduced. In many cases, this willrequire the highest degree ofoperational discipline, excellentinterdepartmental communication, fargreater awareness of issues and currentproduction status, together withautomation, wherever possible, tominimise the risk of operator error.All responsible manufacturers willhave carried out in depth riskassessments, and realised how easy it is,within such high pressure environments,to get something wrong. Errors incomponent handling, out of dateingredients, coding and labelling errors,compromised pack seals and inaccurateweights are just a few things whichnegatively impact delivery schedulesand the bottom line in foodmanufacturing environments whereshort batch runs and frequent productchangeovers have become the norm.One obvious benefit of the rise ofautomation in the processing sector isthe ability to ensure complete accuracy.That’s absolutely vital with increasinglystringent regulations on labelling – notto mention the huge expense that canbe engendered by excessive productgiveaway. This has in turn led to anincrease in the levels of traceabilitypresent within the manufacturing andsupply chain – with companies able tofind out exactly who the suppliers wereof any ingredients used in a given batchof completed products – within a fewhours. Accurate traceability enablesretailers and manufacturers to find outwhere faulty produce came from, andwhere it was delivered to. Due to thedamage such scandals can cause to thereputations of companies, such asFindus and the supermarkets whosuffered at the time, many retailers nowdemand stringent traceability methodsto be in place. An automated andperhaps more importantly – monitored– line can help in this regard.When it comes to a process line,there is more to talk about than© Shutterstock/MarxstudioGetting theprocess right34 Á32-38.qxp_Layout 1 29/05/2018 11:12 Page 1KECOLSTILL 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 E41NOW ATEX APPROVED32-38.qxp_Layout 1 29/05/2018 11:12 Page 234 Food & Drink Internationalwww.fdiforum.netPROCESSINGHOSE, VALVE & COUPLING SOLUTIONS• HOSE ASSEMBLIES • VALVES • PUMPS • COUPLINGS • UNIONS •dixoneurope.co.uk+44 (0)1772 323529automation as a wholesale term.Individual aspects of a line can be justas important and need to be consideredon their own merits and terms, seeinghow those can then incorporate into alarger system. In a sense it iscomparable to car in that one wouldnot spend all of their budget on theengine and forget to include andsuspension. Naturally this can be a daunting taskand also different depending on what acompany manufactures. Mixers can be afairly ubiquitous example within theindustry and one that sees much in theway of advancement. Integral in specificfood products and necessary in manymore, mixers can be big sources ofdowntime within a process line if theyare not up to standard. Food depositscan build up producing not only animpediment to efficiency but also a riskto hygiene within future products. Thiscan then spread to pump and fluidsystems causing further problems.Naturally this is a known issue and onethat manufacturers of mixing systemshave been working on minimising andyet a food producer would not be ableto reap the benefits of such if they donot look at what changes are availableand simply stick with an outdated pieceof equipment.It can be difficult to extrapolateresults, particularly in an automated line,from a single piece of equipment –which can be both a real issue and asimple excuse for many. In most cases itis better to ask if a trail can take placewithin a factory, often using your ownproducts as test material. This way theresults can be monitored first hand andthen estimated across the entiresystem.Methods of transition betweenindividual pieces of equipment must beconsidered as well. These are just asimportant, and perhaps even more so,than any other piece of machinery.Whether a company makes use ofpumping systems in fluid and viscousfood material or conveyors andseparators for more solid foods, thesecan be potential flashpoints for© Shutterstock/grafvision36 Á32-38.qxp_Layout 1 29/05/2018 11:12 Page 3THE UK’S LEADING PRODUCTION LINE EVENTSee the latest processing and packaging machinery in action, network with industry peers and gain valuable insight at our must attend seminars.ORGANISED BY25-27 SEPT 2018 NEC, BIRMINGHAM FREETO ATTENDREGISTER NOW!ORGANISEDBYppmashow.co.ukPROCESSING & PACKAGING MACHINERYMATERIALS I ROBOTS I INDUSTRIAL VISION32-38.qxp_Layout 1 29/05/2018 11:12 Page 436 Food & Drink Internationalwww.fdiforum.netPROCESSINGweb: www.email: dsg @ davall.co.ukTel: +44 (0) 170 728 3131AZZURI BLUE[food blue] GEARINGDavall DSG supply transmission partsin stainless steelgears sprocket motor-gearboxproblems within a process line as theymark the movement of material fromone system to another. Ensuring thatyour transition equipment is up to dateand well-maintained is integral andshould be of the highest priority. Thereis a tendency when something goeswrong to check the larger machinery,but as it is the pumps themselves whichsee the greatest amount of use, andthese should always be a focus point.High quality pumps certainly assistcompanies in dealing with delicateingredients in large quantities – but howcan they be assured that product build-up isn’t happening to too great anextent? Many manufacturers are nowturning to vision detection andinspection for the answer to this, with aview to using x-ray or other inspectiontechnologies to remotely monitor pipes. With capital expenditure budgetsremaining tight, increasing numbers ofprocessors are seeking operationalimprovements that deliver cost savings,increased production levels, enhancedproduct quality and reduced plantdowntime without the financialimplications of new equipment. As wellas the requirement to speed upprocesses, the new techniques that arenow used can also ensure completetraceability at every part of the lengthy© Shutterstock/mady7038 Á32-38.qxp_Layout 1 29/05/2018 11:13 Page 5T: +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 UKFood & Drink International 37www.fdiforum.net32-38.qxp_Layout 1 29/05/2018 11:13 Page 6supply chain, allowing inefficienciesto be pinpointed.Computerisation of procedures,together with automation wherevercost justifiable, minimises the risk ofoperator errors, either becausechanges to the production line aredone automatically, or because in thesampling procedures, operationalpersonnel have no alternative but tofollow pre-determined proceduresprescribed by management.While software may allowcompanies to identify flashpointshowever, there is still a requirementof addressing these issues to ensuremachinery runs smoother and ismore energy efficient can prove tohave the most noticeable effect onthe bottom line.Much of the food and drinkprocessing industry will be gatheringto discuss these points and more inSeptember at the PPMA Show inBirmingham, where specialists and experts from all acrossthe processing and packaging industry will gather todemonstrate the latest innovations in manufacturing andprocessing. 38 Food & Drink Internationalwww.fdiforum.netPROCESSINGIndustrial Slicer VSI THygienic fully automatic slicer with integrated target weight control for flexibility and efficiency in industrial processes.Designed for industrial production the fully automatic VSI T smoothly integrates in your production lines. It is impressive in terms of its high slicing performance at minimal power consumption due to Emotion® technology. With an integrated tendency control, the target weight is reached even when slicing naturally grown products. You avoid overfilling of same weight packages and increase your efficiency. For modern and safe operation, the VSI T is fitted with an intuitively operable touch screen.For more information on Bizerba products visit our websitewww.bizerba.comHpE Process supply completesolutions for the food industryHpE Process’Versaline range issuitable for newstart-ups or smallerbusinesses whereplant capital costsneed to be keptdown, as it offerscompetitive pricing& short deliverytimes. As lifecyclecosts are extremelyimportant to largerfood factories, theEvoguard rangeprovides the bestbenefits for them,with some clients showing annual maintenance costs to as low as1/10th of HpE’s nearest competitor. In a recent brewery installation, 1 Versa Twin replaced 3 otherpumps that had been used for product transfer, CIP return &product re-circulation. In a food factory making bouillon, the TwinScrew pump managed to move as much product in 1 day as theirprevious pump did in a week and took only 10 minutes to clean atthe end of the day, where their previous pump took up to 2 hours. For more information, visit www.hpeprocess.com. © Shutterstock/branislavpudar32-38.qxp_Layout 1 29/05/2018 11:13 Page 7Food & Drink International 39www.fdiforum.netREADY MEALSAs a consequence of changes in theglobal economy, the public arespending less on perishable foodstuffs.This has presented opportunities tomanufacturers of cheap frozen foodsand ready meals, but there arechallenges, too. Market analysissuggests that today’s consumers,particularly young people, aredemanding experimental frozen foodsthat go beyond the bog-standard pies,Advances in technology have seenmanufacturers of ready meals expandtheir product portfolios in recent years.With consumers demanding convenient,high-quality food in increasingly largequantities, manufacturers are drawingupon new technologies that allow themto vary their recipes and create betterquality produce. Extending the shelf-lifeof food products has also become amajor concern for the industry, soinnovations in refrigeration technologyare of the utmost importance.© Shutterstock/stockfourChangingdemandThe ready meals sectorhas boomedconsistently, but thesheer number ofdifferent products onoffer can put a strainon some. 40 Á39-45.qxp_Layout 1 29/05/2018 14:23 Page 1Next >