< Previous40www.fdiforum.netDEPOSITORSConsumers now want to be assured that their products retain theingredients’ particular texture and shape, which means thedepositing procedure has to be as gentle as possible. However, thisseems to be at odds with the requirement for the production lineto move at increasingly efficient speeds – and require as littledowntime as possible for cleaning.Yet these obligations don’t have to be mutually exclusive, asthe range of depositors and filling machines have now grownto include hardware suitable for both artisan producers whoneed accuracy and versatility within short production runs,and large corporations that depend on reliability for heavyproduction volumes.Effective depositing requires quality throughout theproduction line. For many companies, the introduction of afilling machine or depositor can often be the first step into semi-automated production, and accuracy and quality is therefore vitallyimportant to ensure customers don’t immediately notice differencesfrom the existing manual production. This is why many businessesmaking the leap opt for a machine that can work as a standalonepiece of equipment, with the option to incorporate it within theirother hardware at a later date.One example of the importance of quality is the newproduction line in place at the site of Rod and Ben’s inDevon, specialists in organic products. The challengein this instance came about at the company’sorganic code requires all recipes to be madein small, manageable batches the preserveand emphasise the ingredient’s integrity,colour, flavour and texture are preservedat all times. As demand has increased,this has meant a move towardsautomatic depositing but it wasimperative that any that was to beintroduced into production had to behighly accurate, damage-free and providesuperior weight control.The company turned to Riggs Autopackwhose Model 1000 depositors are designedto dispense a range of hot or cold foodproducts including soup with large, fragileparticulates. Following successful machinetrials, they placed an order with Riggs for a fullyautomatic conveyor filling and lid press line. Thisincluded a Model 1000 vertical transfer pumpconnected to an existing on-site steam cooker,which fed hot finished soup products direct from thecooker to the hopper of a Model 1000 low level twinhead depositor. The depositor hopper was designed witha damage free paddle agitation system to hold soupparticulates in suspension. There was also a three metre slatconveyor with container sensors, gating system and adjustable guideSmooth operationThe rise in popularity of naturalingredients in recent years has led toadditional complications for depositorsand filling machineryConsumers now demand authentictextures, hence the importance ofaccurate and gentle depositingPHOTO: TATE & LYLE CARCAO40-41:Layout 1 22/6/12 12:51 Page 1For many companies, depositors canbe the first steps into automationand artisan producers areparticularly keen to ensure accuracycan be maintained. PHOTO COURTESY RIGGS AUTOPACKDEPOSITORSwww.fdiforum.net41WWW.AUTOPACK.CO.UKManufacturers of depositors and fillings machines for the food production industryrails, height adjustable lid press unit fortamper evident lids and a rotary out-feedtable.One major requirement when it comesto filling is the hygiene factor – both interms of the amount of product left inthe depositor and the connectionbetween the depositor and the product.Clogging has regularly been a problem inthis instance, especially given the rise ofdelicate ingredients, and increasinglynozzles are being produced without usingpins to connect the air cylinders to therotors, so they are easier to strip andclean with no loose parts.Many depositors also suffer fromproduct getting into the machine’spneumatics, especially if the piston sealsare worn and product can accumulateunnoticed for quite some time. Many ofthe new breed of depositors nowintroduce a spill space at the back of theproduct cylinder, allowing for exceptionaldetection. It’s the quality of the designthat will at the end of the day often bethe key for an effective depositor – withthe fewer moving parts, the better. Valveblocks can also be internally chromed,rather than externally, which makes themmuch less likely to be damaged andrequire constant replacement.In terms of hygienic filling, newreclosable, flexible pouch formats arebecoming more common, such asSurePOUCH clean-fill machine seriesfrom Bosch which can produce fourdifferent pouch formats, with numerousfilling volumes, produced, filled andsealed with the same machine. Thisenhances flexibility for the manufacturersince it allows the expansion of theproduct portfolio without fundamentallyconverting the production line.Vertical form, fill and seal machinessuch as these are capable of filling avariety of products, achieving hygienestandards up to ultra clean-fill. The newbreed are also fitted with reclosablespouts, which are ultrasonically welded tothe exterior of the pouch and can bepositioned in various locations. Theyprovide extra hygienic value as theproduct is filled directly into the pouchand not through the spout. The closuretherefore only comes in contact with theproduct when the consumer opens thepackage.The changes of consistency betweendifferent products means that onedepositor can produce quite differentresults when a new product is runthrough it. Even a small inaccuracy in theamount deposited in a single dose can, ifit’s not addressed, quickly lead to majorproduct wastage. The new breed ofdepositors are allowing companies tosolve this by being more accurate thanever before – while working to tightdeadlines.40-41:Layout 1 22/6/12 12:51 Page 242www.fdiforum.netDAIRY INDUSTRYIf reports are to be believed, the dairy sector is growing at an enormousrate, thanks to an expanding world population and the demand placedupon the industry, it looks set only to grow. In the UK, the National Farmers Union has stated that the UK needsso-called ‘super dairies’. Common across America, these consist of dairyherds in huge numbers, making good use of land and producing theamount of milk needed by supermarkets and other retailers daily. SaudiArabia has a super dairy with around 37,000 cows and attempts have beenmade to build this kind of operation on UK soil, but so far, to no avail. Ice cream made with differentingredients, but retaining thesame taste and ‘mouth feel’ issomething many companies arestriving forINNOVATIONacross the fieldThe dairy industry is vast in its scope andambitions, but what is happening across the sectorin terms of innovation and future planning?42-46:Layout 1 22/6/12 12:53 Page 1DAIRY INDUSTRYwww.fdiforum.net43An application to build an 8000-strongsuper dairy from Nocton Dairies waswithdrawn over the environmentalconcerns raised by local residents andbusinesses over water pollution andanimal welfare. The idea behind bringingthis kind of operation to the UK is tocombat milk imports that might well becheaper, but come from animals kept inless than adequate welfare conditions. Compassion in World Farming hasopposed this idea, offering evidence thatcows are better treated if they are left toroam outside. It has also said it is hard tospot lame or injured cows in such vastnumbers and with less space. The onuson treating animals as individuals has alsobeen called into question when placed insuch high density. Establishedcomfortably worldwide, it seems only amatter of time until the UK follows suit.The full packageDelivery of dairy products is obviouslymore regular than other food and drinkproducts, which is why it is important forcompanies to make sure their packagingis tough, reliable and above all, cost-effective. Expanding operations hasmeant Acorn Dairies in Darlington havehad to rethink their particular packagingoptions. Yorkshire Packaging Systemstherefore offered up their unique side-feed shrink wrapper for bottles of milk invarying sizes. Waterproof and made in stainless steel,it is this sort of design that dairyoperations are increasingly looking into.Stainless steel means hygiene ismaintained and the waterproof elementmeans that washing and milk spillagesare dealt with before there is a problem.The SS 120 can wrap any trayless packconfiguration required by a dairy,whether in bottles or cartons at a speedof up to fourteen packs per minute andchangeover times are drastically reducedwith very few change parts required.New hope for egg replacersRecent changes in legislation havemeant a predicted ‘drought’ of fresh eggsSo-called ‘super dairies’ lookinevitable for the UK.45 WWW.AUTOPACK.CO.UKManufacturers of depositors and fillings machines for the food production industry42-46:Layout 1 22/6/12 12:53 Page 242-46:Layout 1 22/6/12 12:53 Page 3DAIRY INDUSTRYwww.fdiforum.net45and an unexpected rise in egg replaceringredients. The EU’s Welfare of LayingHens Directive came into practice at thestart of the year. This banned the use ofcramped battery cages, obliging eggproducers to use larger ‘enriched’ cagesthat allow hens more space to perch andmove.However, as many as thirteen EUcountries have admitted their eggindustries were not ready to meet thenew requirements. As a result, suppliesof legal eggs across Europe havetightened, leading to soaring prices andhitting the industry hard. In March, thecost of whole pasteurised liquid egg hadshot up by 85% to €2.40/kg since thebeginning of this year. This has meant aslump in supply from countries such asFrance and Italy, who were predicted notto be up to standards in time. This, in turn has led to an increase insales of egg replacer products. Mainlymanufactured from fractionated wheyproteins, egg replacers are not only lessexpensive than eggs, but they are alsolower in calories, saturated fat andcholesterol. They also have a longer shelflife – up to eighteen months – and theyproduce high quality end products, whichhas no doubt surprised consumers.Several of the large dairy companies inEurope have started their ownproduction runs of these products, seeingThere is a current lack of legally-produced eggs across Europe,resulting in egg replacer salesincreasing by almost double.46 42-46:Layout 1 22/6/12 12:53 Page 446www.fdiforum.netDAIRY INDUSTRYa gap in the market has obviously paid dividends for those cannyenough to see it coming.A functional future?Innovation in functional foods seems to have a real focus ondairy products, from products that recreate the taste andmouthfeel of certain products like ice cream with far fewercalories, to cheese with often a complete lack of lactose for theallergen-free market. Cheese is another area where functional foods are beingdeveloped. Recent developments include a range of functionalmilk proteins that make it possible for manufacturers to slash thesalt content in processed cheese products by up to 65%. What isinteresting about this is the emulsification properties present,which replace the salt that normally does the same job. Thisallows the properties of the processed cheese to remain the sameso it behaves the same way as regular cheese would when it issliced, melted or spread. This side-steps the problems thrown upin regard to behaviour change in consumers as well as being ahealthy option when selecting a cheese off the shelf. The challenges of reducing salt in cheese was also addressedrecently at the Cheese Ripening and Technology Symposium, heldin Madison, Wisconsin. The research on show attempted toexplain the link between salt present in salt having a direct effecton quality. There is a current study taking place between twomajor Danish dairy companies and Norwich Research Park todevelop technical solutions to reduce salt content in differingcheese types without compromising on sensory quality. The focusis on not trying to add elements to cheese, rather using thenaturally-occurring elements present in the cheese itself. Cheese is a staple food for many people worldwide, soimpacting on its currently dubious health benefits in terms ofcalorific content is something that could possibly change the waywe eat.A cake made with eggreplacement ingredientsPHOTO: ARLAHaas-Mondomix– the leadingdairy specialistAs the leading supplier of continuous aerationsystems and related process equipment, Haas-Mondomix can be found around the worldIt’s the dairy based products that require processing equipmentwhich is manufactured to the highest hygienic standards. Thesestandards include Cleaning in Place, Sterilisation in Place andoften re-infection-free construction. Naturally, all of thesestandards are well proven and catered for within the Haas-Mondomix manufacturing programme.At the heart of the continuous aeration system process is the“mixing head“, comprising a stator and a rotor each fitted withsquare pins and assembled on a mainshaft, manufactured entirelyfrom stainless steel. A liquid phase and a gas phase merge at theinlet of the mixing head and with accurate flow control arehomogenised under a controlled pressure. Infinite control of thevariables – such as mixing action, system pressure, rate of flowand ratio between the liquid and gas phases and temperature –provides for uniform texture, repeatable quality of product and,especially, versatility. Being part of the Haas Group, Haas-Mondomix provides thepower which is needed to be able to handle very large turn-keyprojects. From Holland, fifty countries around the world arecovered, whether through the company’s own offices in Germany,Great Britain, Japan, Brazil and the USA, one of the group‘ssubsidiaries or a local agent. All products are manufactured inHolland and 95 % are exported.For more information, visit www.haas.com.The aerationmachine VG-25 fromHaas-Mondomix42-46:Layout 1 25/6/12 10:13 Page 5DAIRY INDUSTRYwww.fdiforum.net47SilversonMachinesWaterside, Chesham,Buckinghamshire HP5 1PQ Tel: 01494 786331Email: sales@silverson.co.ukwww.silverson.co.ukCompany profileSilverson is the leading supplier of quality highshear mixing equipment, used throughout thefood industry for dissolving, disintegrating,blending, emulsifying, homogenising,powder/liquid mixing and hydrating gums andthickeners. No matter what size the application– from 1ml up to 100,000 litres, the Silverson range of products offersreliable, uniform results. Product profileThe Silverson Ultramix is a mixer designed for applications which arebeyond the capabilities of conventional agitators or stirrers, but don’tnecessarily require the intense high shear of a Rotor/Stator mixer.With its innovative single-piece mixing head, the Ultramix offers superiorperformance, minimised cleaning and virtually zero maintenancerequirements. It complies with 3A, USDA and cGMP requirements and isdesigned for clean-in-place (CIP) with Sterilise-in-place (SIP) as an option.Suitable for bulk powder dispersion and high viscosity mixes, the Ultramixis also ideal for mixing in IBCs. Capacities range from Laboratory scale up to2000 litre production models.Isigny Sainte-MèreUnit 88 Oakwood House,412-422 Hackney Road,London E2 7SYTel: 0207 033 9607www.isigny-ste-mere.comCompany ProfileThe fame and fortune of Isigny Sainte-Mère was built on the uniqueflavour of its butter and the rich, silky texture of its crème fraîche, with its40% fat content. These were awarded AOP status in 1986. The co-operativehas managed to apply its knowhow and commitment to quality across manyother products.Product ProfileMaster Cheesemakers ensure Isigny Sainte-Mère cheeses get the bestpossible start. Once the cheeses have been eased through the initial stagesand out of their moulds, the care and attention they receive while maturingis equally crucial – allowing a Camembert or AOP Pont l’Evêque to developthe right colour and smell. All cheeses are matured in special cellars beforebeing graded by hand, then sold with the exact degree of ripeness specifiedby the customer.Isigny Sainte-Mère has developed innovative production methods for infantformula milks, instant full fat and skimmed powder milks. All these are derivedfrom the exceptionally high quality milk collected by Isigny Sainte-Mère.YorkshirePackaging SystemsTel: 01924 441355Email: info@yps.co.ukCompany ProfileYorkshire Packaging Systems havemanufactured and suppliedshrinkwrapping machines and shrink filmssince 1977. The products range frommanual ‘L’ sealers to fully automatic, highspeed, heavy duty, stainless steel sleevewrappers for the dairy industry. YPS arethe exclusive UK distributors for Bollorehigh performance polyolefin shrink films,available on a next day delivery basis. YPSalso supply machinery spares and an aftersales backup and support service.Product ProfileYPS offer two sleeve wrappers producedfor the dairy industry – the SS-140, single-lane infeed, multiple push, and theSS-200, twin-lane infeed, single push.The machines are supplied with low voltage waterproof electrics,jaw/product safety system, high-speed low maintenance sealing jaws,powerful turbo after-pack cooling fans and film seal coolers. Furthermore, asspeed is usually of the essence in milk shrinkwrapping, YPS systems offer avariable speed infeed conveyor which has been shown to increaseproduction speeds by almost 40%.Due to YPS’s experience and expertise in manufacturing and supplying thedairy industry, they are also able to design bespoke infeeds to suit any packtype and collation requirements.Tank Cleaning TechnologiesUnits 1&2 The Barns, Emmington, Nr Chinner, Oxon OX39 4AA Tel: 01189 842001Email: enquiries@tctech.co.ukwww.tankcleaningtechnologies.co.ukCompany ProfileTank Cleaning Technologies areproud to bring to the processindustry the latest tank cleaning,mixing and instrumentationtechnology. With over twentyyears’ experience within theindustry, TCT focus on the dairy,food, beverage, brewery, distillingand pharmaceutical industries. Theydevelop specific customer solutions which generate a fast payback, madepossible by the effectiveness and efficiency of these unique technologies.Product ProfileTank Cleaning Technologies are the UK distributor for Alfa Laval’s Toftejorgtank cleaning equipment, Ensafoil energy saving agitators andinstrumentation range. Recently awarded the responsibility to provide theworld’s biggest fresh milk dairy with Toftejorg tank cleaning equipment, TCThas the experience to offer customers the right solution at the right price.Whether you are looking to reduce energy consumption by as much as80% with the Ensafoil Energy Saving Agitator or reduce water and detergentusage by up to 50%, Tank Cleaning Technologies will provide ongoing supportand advice to achieve this.47:Layout 1 22/6/12 12:54 Page 148www.fdiforum.netNANTWICH CHEESE SHOWThis year’s International CheeseAwards take place on Tuesday 24th Julyfor trade and continues into theNantwich Show day on Wednesday 25th.Last year there were record levels ofentries, with more than 3700 cheesemakers entering their produce. This yearseems set to be even bigger. Into its 115thyear, it will not only show the best intraditional favourites, but also moremodern tastes, such as lactose-freevarieties, all inside the Cheshire EastCouncil Pavilion.The awards are seen as a mark ofquality within the industry as well as byconsumers. By winning an award at theInternational Cheese Awards, the logocan be used on subsequent packaging ofthe product until the following year, sothe world’s best cheeses are on display. Last year saw an unprecedentedattendance at the Trade Lunch and thisyear’s looks set to be just as popular.There will be a presentation of theLifetime Achievement Award and theCheese Retailer of the Year award too.Tickets are still available at time of goingto press, so it would be a shame to not bepart of this champagne occasion.The public day features cookingdemonstrations from James Martin, GinoD’Acampo and Jean-Christophe Novelliin the Cookery Demonstration Theatre,the show day will also go with a bang.This year features a VIP area for around250 spectators and standing room foraround 500. There is also a cheese andwine bar, the perfect place to unwind andcombine your favourite cheese of the daywith the most suitable wine.The all-new Education Theatre is alsoon hand to show children a realfarmyard with goats, cows, live cheesemaking demonstrations and a tastingarea.For more information seewww.internationalcheeseawards.co.uk.Cheeses of distinctionThe International Cheese Awards take place every year at the Nantwich Show and it’s theperfect place to see tradition and innovation on show in equal measure.48-49:Layout 1 22/6/12 12:56 Page 1Tetra PakProcessingTetra Pak Processing is synony-mous with cheese making systemsand their equipment is favoured bymany champion cheese makers. Thisyear, their exhibit includes the TetraTebel Blockformer 6, with a visualpresentation of the benefits it canprovide.The new blockformer helps en-sure excellent, uniform cheddarquality, gives superior, provenweight accuracy, reduces energy con-sumption and minimises product losses. It uses less water and creates less effluent, helpingreduce the carbon footprint for every block formed. Design improvements include a newguillotine system for outstanding hygiene and reliability and a unique new elevator cylinder to reduce wear, while giving more accurate and reliable heightadjustment.Tetra Pak is once again the sponsor of the Single Extra Mature Cheddar class, the largest class at the event.Members of Tetra Pak’s North Europe team are on hand to discuss all cheese making requirements, from product development to system optimisationand support.www.tetrapak.comNANTWICH CHEESE SHOWwww.fdiforum.net49Isigny Sainte-MèreFrench cooperative Isigny Sainte-Mère is making a major investment in thesuccess of the Nantwich Cheese Show, this unmissable cheese industry event,by becoming a key sponsor this year.It is an occasion for Isigny Sainte-Mère to present the richness of the Nor-mandy terroir and the knowhow of the cooperative across a wide range of iconicproducts - Isigny Camembert, Pont L’évêque, Isigny AOP Butter and IsignyAOP Crème Fraîche, mature and extra mature Label Rouge Mimolettes andother, award-winning specialties.Last year, Isigny Sainte-Mère won three gold medals in the InternationalCheese Awards held during the show. They were honoured for their Strawberry Fromage Frais, for the third consecutive year, Creamy 40% Fromage Fraisfor the second year in a row and the Traditionally Churned Isigny AOP Unsalted ButterMeet them at the Show to (re)discover and sample their range!Tel: +44 (0) 207 033 0442 www.isigny-ste-mere.comStand 42Jongia Jongia supply the dairy industry with a wide range ofequipment and ingredients for every dairy product you canthink of. The company provides equipment for all types ofcheese and other dairy products from ASTA-eismann, in-cluding labour-saving devices like multi-mould turners. Wesupply cheese moulds from Laude and now also complete au-tomated soft cheese lines from Tecnal.Jongia also supplies natural rennet from Hundsbichler,goat/sheep milk powder from CBM BV and soft cheese wrap-ping. The company support education by organising trips todairies in the UK and abroad, a seminar and scholarships.The company’s products are used by many of theNantwich International Cheese Awards winners.Customers are invited to contact Jongia with any query,as there is no enquiry too small.Jongia (UK) Ltd.23 Prospect Lane, Solihull B91 1HNTel: 0121 744 4844 www.jongiauk.comTickler Extra mature cheddarTickler is a tantalis-ingly tangy and sweetcheddar which is care-fully matured for up to18 months by expertcheese makers at theTaw Valley Creameryin Devon. Tickler isideal for a cheeseboardand for cooking as itadds a unique flavour tothe dishes.Tickler will be sup-ported by a £1 millionadvertising campaign in2012 to continue todrive growth.Visit Tickler at their stand at the Nantwich International Cheese Show to have a tastethis fabulously tasty cheddar.www.ticklercheese.co.uk48-49:Layout 1 22/6/12 12:56 Page 2Next >