INTERNATIONAL CHEESEAWARDS NANTWICHCONVEYINGINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netJULY2013 £3.50 STERLINGProcess toproduceProcess toproducePACKAGING MATERIALSAND DESIGN01:Layout 1 24/6/13 08:45 Page 102:Layout 1 24/6/13 08:45 Page 1ContentsJuly 2013This magazine is now fully recyclable. By recyclingmagazines, you can help reduce waste and add to the5.5 million tonnes of paper already recycled by the UKpaper industry each year. Before you recycle yourmagazine, please ensure you remove all plasticwrapping, free gifts and samples. FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforumNews 4• General news • On line - production news• On the shelf - new products and initiativesImport and export 16Portuguese table wine and Port have seen aresurgence in recent times. We take a visit to seefind out moreConveying18 Lean manufacturing, energy efficiency and shorterdeadlines have all contributed to advances in theconveying sector in recent timesProcessing spotlight22Many of the thousands of new products thatreach our shelves would have been unthinkable inrecent years, testament to the incredibleadvancement of the processing sectorVision, inspection and detection30Inspection and detection equipment can nowprovide manufacturers with a clear viewPackaging, materials and design 34The packaging industry is vibrant and they arerising to the challenge of continuing to producehigh quality designs while keeping an eye on thebottom line.Meet the experts40Invaluable advice from industry specialistsMicrobiology 42The importance of robust testing lays at the heartof hygienic and safe food and drink production.With spiralling costs, how do companies aim tobalance this safety with outlay?Editor:Steve Fisher (s.fisher@blmgroup.co.uk)Editor’s PA:Angela SharmanJournalists:Steve Williams (s.williams@blmgroup.co.uk)Mike Shields (m.shields@blmgroup.co.uk)Michael Fisher (m.fisher@blmgroup.co.uk)Sales Director:Teri CooperSales Manager:Becky RobertshawAssistant Sales Manager:Sam TrottSales:Nikki Logan, Ashley SpinkTel: +44 (0) 1472 310302Accounts & Subscriptions:Dawn Cook, John DownesDesign & Production:Gary Jorgensen, Mark Casson, Rachel Green(studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317Email:fdi@blmgroup.co.ukPart of the Business Link Magazine Group:Armstrong House, Armstrong Street,Grimsby, N E Lincs DN31 2QEEnglandAll 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 firstto the publisher. While every reasonable care is taken,neither the publisher nor its participating agents acceptliability for loss or damage to prints, colourtransparencies, negatives or other material of whatevernature submitted to this publication. The viewsexpressed in this publication are not necessarily theviews of those held by the publisher.COVER PHOTOGRAPHSCOURTESY OFMain:shutterstock.com/Christian JungTop: International Cheese Awards Nantwich Middle: FlexLinkBottom: Miller Brands UK / CRP Print & PackagingLaboratory / testingshowcase 46Dairy focus48The dairy industry is one of the most fast-movingand varied sectors of food and drink production.What new products have appeared and whatdoes the immediate future hold?International Cheese AwardsNantwich50Touted as the biggest and best cheese show inthe world, Nantwich is also the meeting place forthis blooming industryTotal Processing and Packaging52This year’s Total Processing and PackagingExhibition was one of the best yet and we werethere to see the latest innovations close upEvents55Your chance to keep abreast of forthcomingexhibitions and food fairs from around the worldClassified 56Food & Drink Diary 5803:Layout 1 24/6/13 08:49 Page 14 Food & Drink Internationalwww.fdiforum.netAJ&RG Barber chooseAxium’s pure-screenfiltersWorld Cheese Award winners AJ&RG Barber arenow using Axium Process’ Pure-Screen wedge wirefilters exclusively throughout its operation forapplications associated with softened water, wheyprotein concentrate, raw milk and curd fines. The company, which traditionally used mesh filters,changed to Axium’s 316L stainless steel wedge wirefilter range as this versatile range of filters is easy tomaintain and clean and is available withinterchangeable screens providing filtration levels of25 micron up to 6000 micron. As well as providing both product smoothness and consistency, the Pure-Screen filter range offers high security for critical applications where filter failure or collapse is not an option. The filters, which require no tools for access, are designed with a 316L stainless steel safety clamp closure, metal to metal seal, and are suitable forbackflushing, clean-in-place and steam-in-place operations. Demanding Dragon“Loves Da Pop”National Flexible has helped create packagingfor Love Da Pop popcorn, as seen on Dragon’sDen.Love Da Pop popcorn is made with vegetable oilas this overcomes the cardboard taste of standardbulk manufactured popcorn blown by hot air. OnTV the Dragons gave the popcorn credit for itstaste but were not so sure about the packaging.However, Peter Jones decided an investment inLove Da Pop could pay dividends. In order to overcome the problems associatedwith the existing packaging, the entrepreneursturned to National Flexible. Their solution was alaminate with increased thickness of the outerpaper layer and a metallised inner layer. The newpack increases the popcorn’s shelf life andsignificantly enhances the pack’s rigidity giving it ahigh quality feel. Amendments to the originalgraphic design were also made to reduce thenumber of plates and reduce the overall cost ofprinting the full range of six designs.Kraft Foods saves time by upgradingto image-based barcode readersTo avoid costly labelling mix-upsKraft Foods Canada scans each labelafter it has been affixed on thepackaging line to ensure that itmatches the package contents. Thelaser scanners used on its barbequesauce product line were struggling toread 30 different stock keeping unitsat a rate of up to 265 bottles perminute and each time lines changed,scanners had to be repositioned.Kraft replaced one laser scannerwith a Cognex DataMan 300 reader,immediately virtually eliminating readfailures, providing 99.9%+ read rates.Kraft replaced three other ID readersand has also replaced scanners onthree additional lines. No adjustment isrequired, so the technical staff have been freed from managing changeovers.Dave Fortin, Technician for Kraft Foods Canada says, “DataMan 300 IDreaders have significantly improved the efficiency of our packaging lines.They are also economical and easy to install and maintain.”Thanks a latte DC!Costa have shaken things upby revamping theirsummer drinks menu. Thesedrinks have been called ‘CostaIce’ and feature iced coffees andlemonades. Costa Coffee Franchise PartnerHoosein Dadabhoy has beenusing DC warewashers acrossmany of his Costa sites so when itcame to needing a new icemachine he was more than happywith the guidance and knowledgefrom Iain Addison owner of IdealCatering Solutions to invest in DCagain.Iain says, ‘’I am really pleasedwith how the DCT140-40A Pebble Ice machinehas been received not only from Hoosein but his staff as well’. ‘‘I have always found DC’s catering equipment to be reliable and thismachine was ideal for their new iced drinks range’’.Iain has successfully installed the new DC Ice machine into two ofHoosein’s Costa coffee sites, the first one in Corby and now the secondone in Wigston. Allen CodingSystems revealsnew corporateimage Allen Coding Systems unveiled itsnew corporate image at the TotalProcessing & Packaging Show, tomark the company’s next phase ofgrowth and development and topromote consistency and synergy across the ITW European Coding & Marking Business Unit.The new corporate image includes revamped logo and website and was created to reflect thecompany’s professional standard and unrivalled reputation as a leading European operation withhighly respected products and expertise, as well as its enterprising business strategy and vision.A corporate identity guide sets standards for the mission, vision, core values, logo, colours,typography, images and many marketing materials.The Allen Coding logo was re-designed as part of the corporate image launch to give it a moremodern and dynamic look, while a new Allen Coding website - www.allencoding.com - acts as agateway to each of the business unit member’s websites.04-05:Layout 1 24/6/13 09:15 Page 1Lidl uses the Schaefer Case Picking Systemfor order pickingSSI Schaefer has expanded the logisticscentre of food retailer Lidl in Kirchheim/Teck,Germany with an automated pickingwarehouse. In addition to a Schaefer Case PickingSystem, the scope of equipment andservices supplied includes a high bayracking system with five aisles and around15,000 pallet storage spaces, plus aSchaefer Tray System with 16,000 storagepositions on five storage levels. The greatestchallenges in implementing this were the very high requirements on pallet composition and thehandling of packages.The system now guarantees optimally packed pallets for transporting and then unloading goods at the store. The project was completed successfully lastyear. In addition to the implementation of this modular, scalable total solution that can be extended virtually without limit.Lidl particularly valued the partnership and solution-oriented collaboration with SSI Schaefer.New Flexolam systemdelivers better choicesfor buyersCorrugated packaging specialist Charapak haslaunched in conjunction with Forum Packaging acost-effective and more flexible alternative to pre-printed corrugated.The completely new process is called Flexolam andcombines award winning Flexo print, particularlysuited to the requirements of shelf ready packaging. Flexolam uses the most advanced Flexographicpre-print technology printing up to 175 lines per inchcreating top quality, high impact images for maximumon-shelf appeal, coupled with the ability to choose awide range of corrugated base substrates tocomplement it. This means the customer has a much wider choiceof flute and print quality combinations not provided bythe typical pre-print corrugated route.Another important benefit of the system is its abilityto run in smaller batch quantities, offering greaterflexibility and more efficient stock control.NatureFlex Packagingadopted by CaturraCoffeeInnovia Films’ cellulose NatureFlexcompostable films are reinforcing CaturraCoffee’s commitment to high quality standardsand sustainability philosophy.The coffee pack structure is made usingthree-layers, which comprises a printable,transparent barrier layer NatureFlex NK 20µmfilm on the outer layer, a metallised high barrierlayer NatureFlex NKME 20µm in middle layerand a 50µm Bio-Polymer sealant layer whichprovides high seal strength and integrity. Mike Palos, Operations Manager of CaturraCoffee, says, “We are proud that Caturra isalways first when it comes to being innovativeas a leader in the coffee industry in SouthAfrica. Our commitment is together with sustainable business practices tosupply our coffee in environmentally friendly packaging.”Peter Van Belle, Area Sales Manager, Innovia Films, adds, “NatureFlexFilms are well suited for the coffee market because they fit well withconcerns about sustainability and renewability.”Automated Vision Inspection – areyou doing enough toprevent productrecalls?METTLER TOLEDO explores theimportant issue of label mix-up preventionin its free online webinar – Implementing aLabel Mix-up Prevention Programme.Advances in technology meanmanufacturing processes can reducecostly product recalls by ensuring theconsistent integrity of your productlabelling. A product recall due to wrongand missing labels has far reachingramifications to a brands reputation andprofitability. Automated vision inspectiontechnologies are a great tool for not onlydetecting labelling issues but eliminatingthem from manufacturing in the first place. During this free webinar, experts from CI-Vision will discuss visiontechnology and how it can be effectively applied to your packaging line toprevent product mislabelling. To register for this informative webinar, visit www.mt.com/uk-label-webinar.Cook safely outside with ThermapenThe British designed and built SuperFastThermapen thermometer by ETI Ltd has fastbecome an essential piece of equipment forchefs.Its speed, accuracy and user-friendly designmake it ideal for busy kitchens; for dishes thatneed careful temperature control or simply forknowing nearly instantly that meat or fish isperfectly cooked.Outdoor catering, such as BBQs and hogroasts, present a slightly different set ofchallenges with equipment that may not cookquite as evenly or as predictably as the kitchen.Here the SuperFast Thermapen and the newBacklit Thermapen are your ideal cookingcompanions. Thermapen’s fine, stainless steel,foldaway probe won’t damage the look of yourfood, whilst allowing you to check it thoroughly and ensure that everything’s safely cookedthrough.Food & Drink International 5www.fdiforum.net04-05:Layout 1 24/6/13 09:15 Page 2Mercedes-Benz Used 1Approved Used Vans & ServicesSometimes second handcan be first choice.www.mercedes-benz.co.uk/vansThoroughly checked,both inside and outside.06:Layout 1 24/6/13 08:50 Page 1Amorim and O-I launch wine packaging innovationAmorim and O-I have launched HELIX,an innovative cork-glass wine packagingsolution for the popular premium, fastturnaround still wine segment.The result of a four-year partnership, thedevelopment of HELIX drew on bothcompanies’ innovation capabilities andexpertise in serving global wine markets,gained from a heritage that stretches backover a century.The new ‘twist to open’ conceptcombines an ergonomically-designedstopper made from cork and a glass bottle with an internal thread finish in the neck, creating ahigh performing and sophisticated wine packaging solution. HELIX combines all the benefits ofcork and glass – quality, sustainability and premium image with user-friendly, re-sealableconvenience. It can be quickly and easily implemented by wineries with only a minor adjustment to existing filling lines.Erik Bouts, President of O-I Europe, says, “HELIX meets consumers’ growing desire for sustainability and quality, while delivering the brand building andpremium image packaging wineries rely upon.”Star treatment is naturalfor AsdaThe green credentials of Asda’s new chilled andfrozen distribution centre have been bolstered by anenvironmentally conscious cooling system from StarRefrigeration.Asda’s new central distribution centre occupies a44-acre site at the Kingsway Business Park inRochdale. The 493,000 sq ft multi-temperaturestorage facility incorporates many carbon reductionand energy saving features.Star engineered and installed a two-stage pumpedcirculation cooling system for Asda, operating onnatural ammonia refrigerant. The plant provides 1MWof cooling for Asda’s new frozen food cold store,1.7MW for the chill chamber and 0.5MW of cooling forthe produce chamber.James Ward, Star Refrigeration’s Director of Sales –Food Market, says, “This was a new style of buildingfor Asda in the UK, as a single skin constructiondemanded a specific type of cooling system. Our teamworked closely with the principal contractor to engineera bespoke refrigeration plant that would deliver vitalenergy saving and environmental benefits.”Safeguarding product quality and brandintegrity with Vision Inspection SolutionsEnsuring all products are properlylabelled guarantees consumer safety andmaintains product quality. CI-VisionInspection solutions from METTLERTOLEDO offer a reliable, accurate and highspeed method of inspection for defectiveand non-conforming products. Request your free copy of the WhitePaper ‘Vision Inspection Supports FoodSafety - Risks of Misinforming ProductContent’ at www.mt.com/uk-foodsafety-whitepaper and learn how vision inspectioncan enhance productivity and regulatorycompliance.The paper also features two casestudies where manufacturers who haveadopted vision inspection have boosted productivity and customersatisfaction. Advances in technology mean vision inspection solutions can offer foodmanufacturers a more effective method of product inspection. This ensuresthey are properly labelled and coded as part of a proactive food safetyprogramme.J&J Pont Packaging launches newProfile foodjarsLeading container packagingspecialist J&J Pont Packaginghas extended its food jarsrange with the introduction of alarge family of Profile glass jars.The new range is available inround profiles with distinctiveshoulder detail and standardtwist-off cap neck and in adozen different sizes between70ml and 1500ml.This outstanding range offood jars is suitable forpackaging most jams andpreserves as well as sauces,chutneys and pickles. Itstrengthens J&J Pont Packaging’s extensive food jars offer which includeseverything from standard shapes through to striking modern designs formaximum shelf impact and safe and attractive food packaging andpresentation.Reliable colour detection withminimal distance changeSeveral colours can be simultaneously and reliablyevaluated with wenglor’s new OFP401P0189 ColourSensor, despite minimal distance changes. The sensorworks with white light and is distinguished by intuitivemenu prompting and an integrated wizard for teaching incolours within just sixty seconds.The innovative Colour Sensor from wenglor can beused wherever colours or contrasts need to be detectedand distinguished. Not even the slightest colour nuancesare a problem for the OFP401P0189. Colours can betaught in to the sensor within just sixty seconds thanks tothe teach-in wizard. In addition to the integrated teach-infunction, external teach in is also possible. However, thedecisive attribute of the new colour specialist is its ability to recognise variously coloured objects,which can be reliably detected despite varying distances.The sensor’s scope of functions is extended by its configurable emitted light which can beswitched off entirely for the detection of self-luminous objects.Food & Drink International 7www.fdiforum.net07:Layout 1 24/6/13 09:02 Page 1FINISHINGPRESSURE SENSITIVEDIGITAL TECHNOLOGYECO DEVELOPMENTSENGINEERED FILMSSECURITY & BRAND PROTECTIONWORKFLOW SOLUTIONSPACKAGE PRINTING:::/$%(/(;32(823(&20&20(6(()25<2856(/)$735(3$5(72%(/,(9(72(&/,36($1<7+,1*(9(5$77(037(',17+,625$1<27+(5$*(35,17<285)8785(3$&.$*,1*,1129$7,216+,1.-(7+3$&.$*(35,17,1* WI71E66WO1'O86)EA78EAEA6E17E5A1''I6&O9E5O9E50O'E510I5A&/E6A1'A67O81'E'%<7+E&5EA7I9EA57I675<A1'0A*I&A/I11O9A7IO1 7+ALL6O)WO1'E BEA0AZE'ELIE9E <O856ETHE SPECTACULAR24-27 SEPTEMBER + BRUSSELS EXPONNNNNIIIIISSSSSHHHHHIIIIINNNNNNGGGGGGGGGGGPPPPPPRRRRREEEEEEEESSSSSSSSSSSSSUUUUURRRRRREEEEEEESSSSEEEEEENNNNNNNNNNNNNNNNSSSSSSSSSSSSSIIIIIIIIITTTTTTTTTIIIIVVVVVVVVVVEEEEEEEEE2222444----2222277777SSSSSEEPPPTTTEEEMMMMBBBBBEEEEERRRRR++++++BBRRRRUUUUUSSSSSSSSEEEEELLLLSSSSSEEEEEXXXXPPPPOOOOOeeeeeateateatateeateestststttssxxxxxxlablablablalabababbel elel l l eeshoshossshhooohoowwwwwzzzzzonononononoonyyyy eaeeaaeaartrtrrtrtrtrrthttthth!!!TTTTHHHHHHHEEEEESSSPPPEEEEECCCCCTTTTAAAACCCCCUUUUULLLLLLAAAAAARRRRRTheTheThTheeeTwwwwwwgrgregregreeeggg08:Layout 1 24/6/13 11:39 Page 1Maintaining sustainable quality with weighingIn food production, not only can weighinggreatly impact the overall quality and integrity ofthe product, but it can also enhance a business’sproductivity and competitiveness. When a foodmanufacturer’s weighing equipment is not verified,it risks inaccurate weighing and inadequateprocess quality, safety and compliance. METTLER TOLEDO’s new white paper, GWP –The Global Weighing Standard for the FoodIndustry, outlines how to ensure consistent productquality. It also details how companies can achieveregulatory compliance, to pass audits successfullyand save money by avoiding overfilling. The free white paper describes the principles ofGWP, the global standard for risk-based lifecyclemanagement of weighing equipment, and explains how businesses can benefit from its use.To learn more about how GWP verification can enhance product quality and profit, download the whitepaper at www.mt.com/uk-GWPFood.Dairy Plus replaceschlorine disinfection withHanovia UVDairy Plus in Thailand has replaced its chlorine-based disinfection system with medium pressure UVtechnology from Hanovia. The company decided toreduce high levels of chlorine dosage throughout theprocess because it was proving ineffective at removingall microorganisms, particularly in the rainy season. Ying Xu, Hanovia’s Asia-Pacific Sales Manager, says,“UV, which is a non-chemical disinfection process, wasbrought to the attention of Dairy Plus by our localdistributor. When Dairy Plus saw the advantages of ourmedium pressure UV systems, which effectivelyremove microorganisms without any problems of after-taste or re-infection, the company decided to switchfrom chlorine to UV as its main disinfection method.”Five Hanovia UV systems are installed at the plant –four duty and one standby. Two units disinfect clean-in-place (CIP) water and two are used for treatingdairy mixing water. Each UV system treats up to130m3/hour of water.Fortress Technology on target fortop salesFortress Technology, the globalspecialist in food industry metaldetector systems, is on target to haveits best ever year since theorganisation’s inception in 1996,according to half year sales figuresjust released. Compared to the same period lastyear, orders are up by 57% for metaldetector heads and by 25% for theVector combined conveyor / metaldetector system, which is provinghighly popular with retailers. The robust, all-in-one Vectordetection solution features an alarm toindicate when metal is rejected inorder to identify the origin of theproblem early. In-line conveyors are specially developed to achieve themost accurate detection results by optimising the performance of theFortress stealth detector. Available with a wide choice of reject options andfixed or variable speed, the Vector can be custom-designed to meetcustomers’ specific application needs.Flexlink’s new conveyor platformtriples user valueReduced Total Cost of Ownership,sustainability and innovation havebeen the focus in thedevelopment of FlexLink’s newgeneration X65 conveyor. Theresult is significantly highervalue to users compared topresent solutions in productionand packaging lines.The new X65 conveyorplatform was developed withinput from leading end users andOEMs to meet the requirements oftomorrow, while offering added value tothe needs of today.The X65 offers twice the strengthcompared to the standards of today. Göran Abbestam, Product Manager atFlexLink, says, “The doubled conveyor strength has a dramatic effect on theservice life and maintenance intervals of systems installed. In addition, thelayouts can be made simpler as fewer drives and transfers are required forany given layout. This has a substantial, positive impact with less complexityand a lower cost of ownership.”Everyone is shouting about the new Whisper-Booth from Hosokawa Micron Hosokawa Micron Ltd has developed the new design, lownoise Whisper-Booth. This compact Downflow Booth achievesnoise levels of approximately 60dba, which is less than a normalconversation. Capable of delivering OELs of <1µg/m3 this new DownflowBooth is ideal for applications where it needs to be positioned within‘quiet zones’ or within multi-processing areas where acousticinterference is a problem and when ‘silent running’ is preferable.Always at the forefront of containment technology design,Hosokawa Micron engineers have worked closely with customersin the development of the Hosokawa Whisper-Booth to ensure itmeets containment level requirements and low noise levels.Carl Emsley, Hosokawa Micron Ltd says, “In using acombination of high efficiency, low vibration and quieter runningmotors, low noise fans and high density sound attenuatinginsulation we have been able to create a unique Downflow Booththat operates at whisper sound levels.”Food & Drink International 9www.fdiforum.net09:Layout 1 24/6/13 09:03 Page 1Next >