< Previous20 Food & Drink Internationalwww.fdiforum.netCONVEYINGwith the 2002/72/EC, 2007/42/EC and2008/39/EC directives. This has limitedthe chemical substances that are allowedto be used in their production, and also inwhat quantity these substances are used.The importance of avoidingcontamination goes hand in hand with thefact that many conveyors are now used fora huge array of products in quicksuccession – which means they nowfrequently have to be able to undergoextensive cleaning to ensure ingredientsdon’t become mixed up and productsremain unsullied.This has meant that the conventionalstainless steel conveyors are now beingjoined by food-grade conveyor systemsmade from plastic and stainless steelmaterials. These meet all the variousstandards and requirements, canwithstand extensive cleaning and won’tretain harmful bacteria from the productsthat run along them.Indeed, Dynamic Conveyor’s newDynaClean range of conveyors have beendesigned to be as easy to clean as possible,able to be disassembled and thenreassembled in just a few minutes,without any tools, so it can be thoroughlycleaned. The modular design of theconveyors also includes several removablecomponents – which as well as making iteasier to clean can also allow it to bereconfigured very quickly to deal withchanges to the system.A move towards simpler design isapparent throughout the sector, such isthe importance of avoiding any potentialflashpoints. Certainly, the more individualparts that are contained within, the morechance there is of one of them comingloose or getting product embedded withinit – and hence a drop in the number ofhealth and safety breaches that affectworkers dealing with the systems.FlexLink’s new generation X65conveyor is one example, as in thisinstance fewer drives and transfers arerequired for any given layout – not onlyensuring simplicity of operation andreconfiguration, but also lowering costs ofownership with decreased downtime and asmaller bill for replacements. The X65also has a doubled conveyor strength,ensuring a major impact on the service lifeand maintenance intervals required.Exceptional reliability and the ability totransport a far wider range of items thanever before means the options for thoselooking for conveyors have been expandedto a huge extent. Specialists in automationcan now offer conveyors that emphasisespeed and safety in equal measures.Left: As conveyors increase in speed, size and shape,DataMan 503 has expanded Cognex’s line of image-based barcode readers and is particularly well-suited forapplications that have high speeds and wide belt widthsBelow: FlexLink’s new X65 conveyor platform wasdeveloped with input from leading end users and OEMsto meet their requirementsPCE Automation LtdFor all your Bosch Rexroth Aluminium Profile & VarioFlow Conveyor needs,visit our new online shop.www.pce-online.co.uk18-21:Layout 1 24/6/13 09:26 Page 3Western Mechanical Handlingdesigns and builds innovativeproduction machinery for the food,pharmaceutical and similar industrieswhere the product is delicate andrequires careful but high speedhandling. Its automation department,WMH Automation has over theyears developed considerableexpertise with, amongst othertechnologies, Mitsubishi Electricprecision servo drives. Uncookedquiches are difficult to handle, thefilling being liquid and raw pastrybeing soft. But when manufacturedin commercial volumes they need tobe moved quickly through theproduction process, so are in dangerof collapsing and disrupting production.In the past the solution was to use analuminium foil dish to hold each quiche asit was made and cooked. The quiches couldbe handled robustly, bumping against theside of various machines and often beingbunched together against a stop bar at theend of a continuously running conveyor.The dish then became part of the finalpackaging, and often quiches had doubleprotection of a dish and outer cardboardbox/sleeve.However, as social awareness ofenvironmental issues has increased,consumers have begun to demand reducedpackaging. In the case of quiches andsimilar products there is a move to paperflan dishes, similar to but larger than thoseused for cupcakes and muffins. This hascreated a dilemma for many foodmanufacturing companies, because thecustomers still expect purchases to bepristine and undamaged on shelf.The problem WMH had to solve wascollecting randomly arriving raw quichesinto neat rows of set numbers with orderlyspacing between them so that they can betransferred oven conveyers for cooking.The solution they developed wasan in-line servo-controlledcollating conveyor and intelligentsensing system. Quiches aredelivered to this from the mainconveyor at random time intervals,the sensors identify the position ofthe next quiche on the mainconveyor, calculate the time untilits delivery and adjust the collatingconveyor to optimise spacingbetween quiches. If there is a longwait, the collating conveyor willpause.When a line of quiches iscomplete they are transferred intothe oven, emerging cooked andproceeding into a freezer to reducetemperature ready for packaging.The MR-J3 servo amplifiers offer motioncontrol performance to a high level ofprecision and are popular with manymachine builders because of their plug andplay installation and simple operation. Ofthe many MR-J3 functions WMH foundthe advanced vibration suppression systemparticularly useful considering the quichefilling is liquid, while the advanced real-time auto tuning ensures maximumprecision for aligning and positioning thequiches. Also their compact size was usefulfor the physical build.Tel: +49 (0) 2102 486 2150Fax: +49 (0) 2102 486 7170www.mitubishi-automation.cominfo@mitsubishi-automation.comSmart conveyor lines up quichesfor precision bakingIn the drive to reduce packaging and resultant waste, a specialist machinery builder has developed apressureless queuing conveyor for collating quiches prior to baking. 18-21:Layout 1 24/6/13 09:26 Page 422 Food & Drink Internationalwww.fdiforum.netPROCESSING SPOTLIGHTNew product development has gonehand in hand with innovation when itcomes to machinery, and the recent TotalProcessing and Packaging Exhibition, ofwhich Food & Drink International was asupporter, illustrated this to fantasticeffect.Many of the seminars featured at theevent explained how productivity hasbeen increased and security improved bymajor developments in processing – andcompanies of all shapes and sizes arebenefiting. It’s certainly the case thatmany small companies believe theintroduction of automation is limited tohuge multinational corporations but, asBrian Holliday of Siemens pointed out atTotal, UK companies with turnoversstarting at £100,000 have benefited fromtaking part in the recent governmentautomating manufacturing review.With payback periods typically of lessthan two years - or even from day one ifthe machinery is leased over five years –any short-term expenditure is usuallydwarfed by long-term savings andincreased custom. Yet across Europe andfurther afield, processing development hasproceeded at wildly varying rates, withGermany continuing to leap far ahead ofthe rest of Europe, and the UK regularlybringing up the rear when it comes toadopting new approaches to automation.This explains the intervention of theUK government and a number of benefitshave been made available to thosecompanies who take the plunge andrevamp their processes. The second stageof the programme is currently underdiscussion as the government may allocatefurther money for automating UKmanufacturing – an illustration of itsimportance to a vibrant manufacturingsector.Throughout the processing sector,major advancements are helping food anddrink manufacturers improve both thequality and the quantity of the productsthey supply. This has not been to thedetriment of employment, either. TheInternational Federation of Robotics areciting research carried out by MetraMartech which suggests that more thantwo million jobs will be created in thenext eight years thanks to increasedautomation. The IFR have obviousreasons for highlighting these figures andSuccess is AUTOMATICMany of the thousands of new products that reach our shelves wouldhave been unthinkable in recent years, testament to the incredibleadvancement of the processing sector22-29:Layout 1 24/6/13 09:43 Page 1Food & Drink International 23www.fdiforum.netPROCESSING SPOTLIGHT25 environments conform to health andsafety regulations, by delivering surfacesthat are classed as taint-free andCampden BRI-approved, with high levelsof slip resistance and an attractive,durable surface. The range is designed tobe hard-wearing, producing surfaces thatare easy to clean and aid thedecontamination and maintenanceprocesses.One obvious benefit of the rise ofautomation in the processing sector is theability to ensure complete accuracy. That’sabsolutely vital with increasingly stringentregulations on labelling – not to mentionthe huge expense that can be engenderedby excessive product giveaway.Maintaining and calibrating processequipment is vital to ensure accuracy andconfidence in the production process.Companies such as Applied Weighing canprovide solutions in this regard, withextensive experience in calibration.Applied Weighing’s HydraCal directforce calibration system allows for aweighing vessel or silo to be fullycalibrated much faster than the time thatwould usually be taken using flow meteror weighbridge calibration methods.ATEX approved, once positioned thecalibration operation is quick and simple,it’s true that many lower level jobs will bereduced or removed completely. Theargument, however, is that many morejobs, of increased seniority and employeeengagement, will be created thanks to theincreased sales and competitiveness thatimproved automation will bring about.Health and safety is also an aspectimproved by increased automation – andnot just in cutting down on work that canoften be dangerous to deal with. Newprocessing equipment is often extremelyeasy to clean, able to be stripped downefficiently, and with far fewer smallmoving parts. This means there’s lesspotential for them to come lose and to getproduct trapped within them which caneasily lead to machinery gettingoverloaded and overheated.Developments in pumping andlubrication can also help avoid productbuild-up. Companies such as KlüberLubrication offer food-grade lubricants,certified to ISO 21469, that can be usedthroughout the sector. Although many seelubrication as an aspect where there is noneed to invest much effort or expense, thebetter quality the lubricant, the more acompany can save in maintenance, energy,spare parts and, inevitably, lubricantconsumption.Throughout processing, health andsafety remains a top priority. Theproduction environment also needs toemphasise this and companies such asResin Surfaces manufacture a range ofresin systems suitable for food productionenvironments. The resin systems can helpState-of-the-art specialitylubricant from Klüber Lubricationreduce maintenance andoperating costsAlthough manysee lubrication as an aspectwhere there is no need to investmuch effort or expense, the betterquality the lubricant, the more acompany can save inmaintenance, energy, spare partsand, inevitably, lubricantconsumption22-29:Layout 1 24/6/13 09:43 Page 2Vessel & Tank WeighingPlatform ScalesWeight Indicators & Control Systems24 Food & Drink Internationalwww.fdiforum.netRandom sampling ... Product Inspecon ... 100% Packaging Control...scan using your smartphone or visitwww.bizerba.comProduct InspeconSystem X-RayCWF CheckweigherPerfect weighing ofpackaged goodsBVS (Bizerba Vision System)A camera supportedinspecon system to ensure product safetyCheckweigher CWEMetal detectorBizerba UK Limited, 2-4 Erica Road, Stacey Bushes, Milton Keynes, MK12 6HS01908 682740 info@bizerba.co.uk www.bizerba.comCall 0161 483 1232 to speak to our teamfood and drink innovationCampden BRIMADE IN THE UKHygienic surfaces for food & drink environmentsFoodsafeImprovedhygieneSeamlesssurfaceCampden BRIapproved22-29:Layout 1 24/6/13 09:43 Page 3Food & Drink International 25www.fdiforum.netPROCESSING SPOTLIGHTas well as being suitable for undertakingwhile product remains inside the weighingvessel – hence avoiding downtime.More accurate readings can also bemore effectively transmitted to all theimportant people in the productionprocess. It’s rare that a company’s entireprocessing machinery will be purchasedfrom a single manufacturer, more likelythat will be made up of components froma whole host of manufacturers andcontrolled from central computers. Thisdoes however create the requirement forproduction managers to oversee a range ofmachines with can often be inconvenient.This is where mobile devices such astablet PCs and smartphones can comeinto play and companies such as Bizerbaoffer new software to allow managers thefreedom to access the information fromwherever they are – and can also beshared across the supply chain. A tabletPC makes it possible to control pricelabellers, scales and inspection systems viaWLAN over a single mobile interface –regardless of how far apart they arelocated and where production managersare.As Dieter Conzelmann, Director ofIndustry Solutions at Bizerba, points out,“Their work becomes much more effectivewhen they can monitor the productionfacilities in a location-independentfashion. Production statistics includingthe current throughput figures for all thescales, price labellers and inspectionsystems appear on the display. In thisway, production managers can detectproblems early on and introduce the rightmeasures while they’re on the move. Theeffectiveness of production as a whole isenhanced as a result of this mobilemonitoring.”It’s vital that companies can haveconfidence in the accuracy of theirfinished products and so weighing,product inspection, metal detection andmuch else is all now a familiar part of theprocessing line. Companies like RiggsAutopack specialise in providingparticularly accurate depositing and fillingsolutions that can guarantee exceptionalconsistency.One example of high standards inoperation is at United Coffee, who lookedto improve their end of line inspectionsystems to ensure the highest quality andconsistency of their finished, wrapped26 Stevens Group’s VantageRecipe Formulation Systemassist the world’s mostsuccessful food productionfacilities with traceabilitycomplianceThe effectivenessof production as a whole isenhanced as a result of thismobile monitoring22-29:Layout 1 24/6/13 09:43 Page 426 Food & Drink Internationalwww.fdiforum.netPROCESSING SPOTLIGHTproduct. They made use of the experienceof Stevens Group who installed two In-Line CheckWeigher and Metal DetectionCombination Systems.The Combis, which have integralinfeed, weighdeck and out-feed conveyors,are used to checkweigh packs of coffeeagainst very high weight tolerances. Theunits are capable of offering weighingspeeds in excess of 200 items per minutewith the utmost precision, and the combisare fitted with high speed flipper rejectsystem and reject bins.Although the main role is to ensure thecorrect amount of coffee appears in eachpack, it also guarantees compliance withaverage weight legislation. The levels ofdata capture, reporting and analysis thatare made available to their factory floor isalso a major advantage. The units collectcritical data on average and minimumweight, together with comprehensive SPCinformation including throughput byproduct, batch and date. Reports are sentback to a central PC via a LAN enabledinterface, thereby ensuring optimum datasecurity and location versatility.Companies such as Franz Haas can alsooffer more intelligent design. TheAustrian company are helping bakersmonitor their production process moreeffectively than ever. When makingwaffles, the most important factors are thebaking temperature and the bakingpressure, which builds up between theclosed baking plates during baking. Thecloser in time to the process theseparameters are measured and controlled,the better the results, but previously itwas virtually impossible to measure it toany great extent because the heat wassuch no sensors could work.Franz Haas’ intelligent baking plates,however, contain a sensor using surfaceacoustic wave technology, which transmitsdata by radio signal in real time. In fact,each individual baking plate in the ovencan be reviewed. This information iseither sent to the control panel wheremanual changes can be made, or they areautomatically compared with preset valuesby the oven control system whichregulates accordingly. The differencebetween actual and target temperature isimmediately recognised, optimising energyconsumption. The huge versatility of processingequipment has allowed manymanufacturers to meet the growingdemand for natural products. The delicateingredients that many now desire wouldin the past have seem anathema to thoseinvolved in mass-producing foodstuffs,because processing equipment simplywouldn’t have been able to handle themunless at very low speeds. Many jobs stillhad to be carried out by hand because thetechnology didn’t exist to deal with themin a gentle enough fashion.That’s now all change and automationcan be introduced at virtually every point– without leaving ingredientsunrecognisable in a homogenous lump.Companies such as AE Mixers present ahuge range of quality mixers that can dealwith virtually every ingredient – at variousspeeds and sheers depending on theingredients being processed. Indeed thecompany can also offer free on site trialswith purpose built test rigs to ensure thecorrect mixers can be used as part of theprocess.Food processing has undergonesomething of a revolution in recent yearsand the huge range of products availableon retailers’ shelves is testament to thesector’s innovation.Riggs Autopack’s highquality depositors and fillingmachines provide damagefree depositing of hot or coldliquid, semi-liquid andsuspended solid products,and accurately fill mostcontainer types or sizeFood processinghas undergone something of arevolution in recent years and thehuge range of products available onretailers’ shelves is testament to thesector’s innovation22-29:Layout 1 24/6/13 09:43 Page 5Food & Drink International 27www.fdiforum.netPROCESSING SPOTLIGHTMaximum food safety, maximum production output, minimal costs:Klüber Lubrication helps you achieve all these goals more easily. Our high-performance NSF H1-lubricants are 0:6 JLY[PÄLKHUKOH]LHT\S[Ptude of approvals. They are available for all branches of the food-processing industry, for all components and tricky special cases everywhere in the world in the same high quality. Our experts will provide you with support to meet your individual requirements, from consulting to optimum lubrication management, ensuring more safety of production processes and OPNOLYWYVÄ[HIPSP[`Klüber Lubrication: 80 years of experience and professional services for your success.Klüber Lubrication Great Britain Ltd.sales@uk.kluber.com / www.klueber.comCertified speciality lubricants for the best possible taste.your global specialistLUBRICANTSState of the artfood-gradelubricants contributeto successThe most recent lubricant developments contribute to economicaland successful plant and machine operation. As Edward Janes ofKlüber Lubrication points out, “Be it the lip of a tool, rolling orplain bearings, compressors or gears, taking a close look atlubrication and the potential of speciality lubricants always pays off. “Regarding the lubricant as an investment in economic efficiencyrather than just as a commodity pays off in many ways. Of course,the price of the lubricant is a factor, but it is more important to lookat the entire cost-benefit calculation of a given application.Synthetic high-performance lubricants help save costs even thoughtheir purchase price is higher. The potential for savings can only bedetected on a second look – in standstill costs, maintenance, energy,spare parts, storage, disposal and of course lubricant consumption. “Regarding lubricants as a machine element whose qualitycontributes to performance capacity means choosing the rightproduct. If the lubricant lives up to the requirements, substantialcosts savings in lost production, personnel demands and materialscan be made. Lubricants tuned to the application at hand helpavoid such costs and are instrumental for trouble-free operation ofplants and machines. “High-performance lubricants tailored to a particular applicationfacilitate reliable low- or minimum-quantity lubrication whilemaking efficient use of energy, and therefore contribute toconserving resources. “Partner with your lubricant supplier and explain your aims.Once the solution is found, significant savings in time, parts andproduction can be made.”For more information on Klüber Lubrication, call +44 1422 205 115or visit www.klueber.com.22-29:Layout 1 24/6/13 09:43 Page 6MIXINGThe complete mixfrom AdvancedEngineeringWith in excess of forty years experience, AE Mixers areestablished as a leader in the design and manufactureof mixing equipment for fluid processing applications.Advanced Engineering manufacture mixers for the food,cosmetic, pharmaceutical, chemical, paint and eco-fuels industries.Their range of mixers include top entry batch, sealed bearing,bottom entry, single stage and three stage inline high shear rotorstator mixers and fluid mixers.Manufactured at their purpose built factory in the UK – staffedwith skilled operators trained for quality work – these mixers aredesigned to meet specific customer requirements and are availablewith a selection of precision interchangeable mixing heads toperform essential processes including homogenisation,emulsification, blending, dispersion, solids suspension, solubilisationand particle size reduction.Mixers can be supplied as individual units or integrated with skidmounted process vessels, lifting frames and control panels. It isimportant that the correct mixer is chosen for the job in hand andAdvanced Engineering therefore offer free on site trials withpurpose built test rigs. Design and manufacturing is carried out tothe highest engineering standards, ensuring total quality at all stagesof production.With off-the-shelf spares, machine repairs and on-site service, AEMixers provides dedicated support throughout the operational lifeof the product to all customers, small or multinational.For more information, call 01706 759003, email info@aemixers.com or visit www.aemixers.com.Advanced Engineering (Middleton) Ltd5D Transpennine Trading Estate,Gorrels Way, Rochdale OL11 2PX28 Food & Drink Internationalwww.fdiforum.netPROCESSING SPOTLIGHTTRACEABILITYProviding accuratetraceability withStevens GroupStevens Group’s Vantage Recipe FormulationSystem assist the world’s most successful foodproduction facilities with traceability complianceFoodservice seafoodspecialists Paramount 21are among thosecompanies to chooseStevens Group to helpensure 100% traceabilityfor their ingredients andimproved consistency fortheir finished product.They approachedStevens with a vision ofdeveloping a completefactory process controlsystem that wouldcontrol and manage thefood manufacturingprocess – from raw material received to finished product.The Paramount 21 solution required the scheduling of worksorders to each line in the factory, and then recording the use ofrecipes and raw ingredients in the creation of each product toprovide visibility of production quantities, along with traceabilityinformation to meet various quality standards.Stevens Receiving Software is installed on a PC and connected toa label printer, removing the need for a paper based booking insystem. The integration with Pegasus Opera, Paramount 21’s MRPsystem, allows cross referencing with purchase orders to ensuresupplier compliance while providing price information for later jobcosting analysis.Paramount 21 installed the Stevens Vantage RFS to control theweighing accuracy of ingredients used to make up processed mixes,and two ‘multi line’ Vantage terminals are located at the productionlines to display line specific production orders. The terminals allowcompleted batches to be combined with other ingredients usedduring the assembly process, providing complete costing for the jobsand 100% traceability.To find out how Stevens Group can help, contact them for a noobligation consultation by calling +44 (0) 1254 685200or email info@stevensgroupltd.com.22-29:Layout 1 24/6/13 09:43 Page 7Food & Drink International 29www.fdiforum.netPROCESSING SPOTLIGHTDEPOSITORSDepositing andfilling solutions fromRiggs AutopackRiggs Autopack manufacture high qualitydepositors and filling machines for the foodproduction industry. They supply foodproducers of varied typeand size with clientsranging from start-upcompanies and cottageindustries, through tomulti-national groupsand internationalfactories. Over theyears, Riggs Autopack’sequipment hasimproved a largenumber of foodmanufacturersproduction processes,and helped companiesmeet growing demandfor their goods.Riggs Autopack’s Model 1000 range of depositors and fillingmachines is the mainstay of the business. They are available as asemi-automatic stand-alone unit for small to medium scale foodproduction, or as an automatic conveyor filling system for largerbatch runs. Manufactured using high quality 316 stainless steel onproduct contact parts, these machines provide damage free andhighly accurate volumetric depositing of hot or cold liquid, semi-liquid and suspended solid products, and fill most container types orsize. With quick changeover times and easy set-up, the Model 1000machines are robust, reliable, hygienic and quick to clean, easy touse and simple to maintain, with fully adjustable depositing volumesand speeds. They are supplied with an after sales support packageand available for purchase, short or long term hire. A no-obligationon-site trial is also available upon request. If you’re seeking to invest in a high quality semi or fully automaticdepositing machine, Riggs Autopack could have the solution. For more information, call +44 (0)1282 440040,email info@autopack.co.uk or visit www.autopack.co.ukAUTOMATIONHaas-Meinckeovens enjoyincreased popularityConsumers all over the world are increasinglydemanding high quality products at low cost.Depending on the product type, the delicious bakeryproducts available internationally today require differentmethods of heat transfer and moisture addition.With Haas-Meincke’s large range of ovens, comprising convectionovens, directly fired gas ovens, radiation ovens and hybrid ovens,they can meet the requirements for the most sophisticated bakingprofiles.Haas-Meincke ovens have traditionally been known for highquality baking. Even and reliable baking of products is primarilyobtained through an extreme precise control of the moisture, theairflows and the heat distribution inside the oven. This precisecontrol also makes the ovens flexible. Haas-Meincke can combinedifferent oven types and quickly adjust them according to thecustomer’s wishes.Haas-Meincke ovens are well insulated and rank among the bestwhen it comes to efficiency. A focus on energy saving efficiency inrecent years mean they can offer customers a 15% reduction ofenergy consumption with their Heat Recovery Unit for theconvection oven.Short installation times are very important for customers and theHaas-Meincke ovens are pre-manufactured in 2 meter modules tofacilitate quick installation. This means that installation time isreduced to only a few weeks compared to a couple of months for acomplete assembly. Pre-manufacturing of the oven modules alsoensures production on nearby lines can continue during theinstallation without any interference.For more information on Haas-Meincke’s ovens, call +45 77 4292 00,email mail@haas-meincke.com or visit www.haas.com.22-29:Layout 1 24/6/13 09:43 Page 8Next >