< Previous30 Food & Drink Internationalwww.fdiforum.netVISION, INSPECTION AND DETECTIONThe potential for contamination in the foodand drink industry can be very great – whetherthat’s down to malice or simply human erroralong the production line. The trend for naturalproducts has led to more delicate ingredientsbeing used and, therefore, making it harder toidentify foreign bodies without extensive andintelligent vision, inspection and detectionsystems. In addition, the requirement foraccurate information on packaging means thereis also the obligation to avoid errors in thisregard and ensure the right products are in theright packaging.The options in this area are certainlybecoming more advanced, however – meaningcontamination and mistakes can be spottedalmost immediately without the requirement oflengthy downtime or the need to destroy a largenumber of products. The recent Total showillustrated the latest vision solutions, includingthose by Cognex which have particularimportance for the packaging industry.At the event, Cognex demonstrated a numberof products on a conveyor system to checkcorrect packaging using OCRMax software aswell as reading 1D and 2D barcodes. Thecompany’s entry level vision system, the In-Sight7000, integrates autofocus, illumination andEasyBuilder user interface and aims to make iteasier than ever for companies to introduce avision system. The self-contained system thatincludes autofocus optics and integrated lightingin a compact industrial housing. The In-Sight7010C version is for colour applicationsincluding colour identification, pattern findingand measurement.Also valuable for conveyor systems is theDataMan 300 fixed mount reader, which hasbeen designed to read particularly challenging1D linear barcodes and 2D Data Matrix codesfor indexed or high-speed lines. The addition ofliquid lens optics allows the reader to be easilyupgraded from fixed focus to autofocus. Forpresentation reading, tote scanning and small-package sorting applications, the liquid lens canbe configured to dynamically sweep through thefull focal range of the optics to find and readCognex’s entry level vision system,the In-Sight 7000, integratesautofocus, illumination andEasyBuilder user interface32 The visionthingInspection and detection equipment can now provide manufacturers with a clear view30-33:Layout 1 24/6/13 10:26 Page 1ifm electronic now has an extensive range of sensors to solve machine vision applications. The O3D is the first industrial 3D sensor that can detect objects in three dimensions at a glance; the O2D dualis object recognition sensor is perfect for orientation-independent contour verification and the O2V object identification sensor or ‘pixel counter‘ allows checking of presence, size, position or completeness of objects.All units are simple to set up and combine sensor, processing and lighting in one robust industrial housing.QualityA passion for QualityA passion for Visionaryifm electronic –close to you!www.ifm.com/uk/vision30-33:Layout 1 24/6/13 10:26 Page 232 Food & Drink Internationalwww.fdiforum.netVISION, INSPECTION AND DETECTIONbarcodes over a wide range of workingdistances.Both these vision systems and barcodereaders can also benefit from theintroduction of Cognex’s new industrialoperator panel. The panel’s larger 229mmdisplay allows operators to quickly identifyissues on the manufacturing line so theycan respond promptly, which has obviousadvantages in improving quality andreducing downtime.For very complicated or uniqueinspection requirements, 3D laser profilingalso comes into its own, calibrating real-world units of measurement forinspections too difficult to perform withtraditional two-dimensional machinevision. Cognex’s DS1000 is capable ofverifying the presence of low-contrastitems in boxes or packages, identifyingsurface defects and chips with low or nocontrast and calculating volumes anddimensions for food portioning.The changes in packaging in recent yearshave themselves brought about challengesin inspection. In the past, for example, thedetection of the transparent material PETrequired complicatedadjustment of thesensors to the application.Manufacturers are dealing with thisthanks to IFM’s new system consisting ofan O5G500 retro-reflective sensor withpolarisation filter and a very fine E20722prismatic reflector. The “plug and play”system can be immediately put intooperation and, particularly valuable for thesector, the very high switching frequencyof more than 1500Hz enables it to be usedin particularly fast-moving applications.Innovation in packaging has gone hand-in-hand with innovation in inspection anddetection systems that have consistentlykept up to date with challenging newmaterials and trends. One blind spot forinspection has always been the base ofglass jars, which can present a realchallenge for X-ray inspection systems, asthe thicker glass in the base absorbs morex-rays than the thinner wall – making iteasier for foreign bodies to go unnoticed.New machinery, however, features anangled single X-ray beam to inspect blindspots at the base, as well as in the body.This means the body, neck and cap are allfully imaged, ensuring not onlycomprehensive inspection of the containerbut also enabling inspection of jar filllevel as well, thus avoidingexcessive product giveaway.The packaging of products is a highpriority but equally important is ensuringthe products themselves are of the higheststandard imaginable. Photoelectric sensorsare used increasingly in wet areas, in whichaggressive cleaning agents are used, andIFM’s OG wetline series uses sensorsspecifically developed for the food industry.One particularly tough aspect to identifyis that of metal contaminant, especiallywhen it comes to free-falling powders,granulates and particulates – which can bea vital part of the production process butprone to flashpoints.Machinery such as Mettler-ToledoSafeline’s upgraded Gravity Fall metaldetector is already successful in thisregard, but the technology has since beenupgraded to introduce the Profile searchhead with ultra-high frequency technologyto boost detection sensitivity. The resulton the production line is the precisiondetection of metal fragments within theproduct stream. To facilitate detection ofmetal foreign bodies from particulates infree-fall, the system is equipped with highspeed automated diverter rejecters, whichopen to direct contaminants away fromthe main product flow. It can also becustomised with a range of rejectiondevices according to the manufacturers’specific needs.Powdered ingredients certainly bringwith them their own challenges. It’s vitalto ensure the process runs quickly andeffectively to avoid excessive build-up ofthe product, which can often have aIFM’s new system consisting of anO5G500 retro-reflective sensor withpolarisation filter and a very fineE20722 prismatic reflector isparticularly valuable for PET bottlesMettler-Toledo Safeline’s InspireX R50G x-ray inspection system can enhance foreignbody detection in glass packaging at high throughput speeds30-33:Layout 1 24/6/13 10:26 Page 3Intelligent image-based code reading has successfully replaced laser scanners in complex barcode reading applications for years. Now this premium technology is available for 1-D oriented barcode reading applications, delivering read rates above 99%.Upgrade your laser barcode scanners now. Visit us at www.cognex.com/tryit for a FREE 30 DAY TRIAL!Try it, Buy itMeet the DataMan 50. The tiny image-based barcode reader that brings big performance to 1-D barcode reading applications.Read it. Don’t Scan it.Food & Drink International 33www.fdiforum.netVISION, INSPECTION AND DETECTIONliterally explosive effect on thesmooth running of the plant –and detection systems canmonitor this efficiently. It’salso particularly easy forcontaminants to be obscured bythe product and not be spottedwithout the use of inspection andvision systems.Lock Inspection Systems’ Insight VF metal detector is designed todetect the presence of metal contamination in any product which isflowing freely under gravity. A fast-acting sealed flap rejectmechanism accurately removes ferrous, non-ferrous and high-gradestainless steel contaminants from the product flow. To ensure thehighest possible levels of detection a high frequency system isspecified and in optimum conditions this detector can identifycontaminants as small as 0.6mm ferrous, 0.7mm non-ferrous and0.8mm stainless steel.Many other products present their own unique challenges when itcomes to detecting potential contaminants. Frozen products havealways been an issue and ice cream, for example, can often provetough to inspect because the conductive signal varies according to thetemperature of the product. The requirement is therefore to combatany unexpected rises and falls in the ambient and make the necessaryfine adjustments to ensure consistent sensitivity to contaminants.In today’s production facilities, however, it’s not just importantthat this work is done – it’s also vital that the work is seen to bedone and records of their success can be easily acquired. This doesn’tjust provide peace of mind to the manufacturer that the introductionof the system has been justified in both saving downtime andavoiding flashpoints, but also helps provide the information thatclients now often demand to provide assurance they are reaching thehighest standards. Hence, the combination of a USB data port andmanagement software on the latest detection components can help tocompile detailed reports and log all tests performed.No company wants the embarrassment and expense of a productrecall, but the new inspection and detection systems provide a clearvision for a more efficient production process.The more delicate aningredient, the harder it canbe to detect contaminants.PHOTO: LOCK INSPECTION SYSTEMSNocompany wantsthe embarrassmentand expense of aproduct recall30-33:Layout 1 24/6/13 10:26 Page 434 Food & Drink Internationalwww.fdiforum.netPACKAGING MATERIALS & DESIGNIndeed, purchasing departments arebeing challenged to reduce costs,challenge suppliers and reduce packaging,as environmental factors come into play.The question posed at the Big PackagingDebate at the last easyFairs PackagingInnovations London show was “Who buysdesign and does good design ever getconsidered as an asset?” It’s certainlyworth pondering – because no matter howmuch money that’s saved by cuttingcorners in the quality of the packaging, itwill be of little benefit if the product is sounappealing that it could almost be gluedto the shelves.There are certainly many examples ofeffective packaging design proving atalking point. The recent “personalised”Coca-Cola bottles, for example, havegenerated much enthusiasm and interestamong the brand’s target audience and isa testament to how personalised printinghas now become effective on a large scale.The Packaging Design Challenge atTotal also illustrated the innovationapparent. The first prize went to Innopakfor its ComboLid concept, which waschosen as the winner by both the judgesand visitors at the show, and praised forits innovation, practicality and investmentopportunity.The ComboLid concept offers a lid witha difference – in addition to sealingtakeaway cups to avoid spillage, itcontains a recessed space which can beused to store food items. Particularlysuited for use in cinemas or at outdoorevents, the recess featured in theComboLid can be used to store amultitude of items, ranging from icecream, sweets and chocolate, through tohot food items such as chicken bites orchilli and rice. This is a fantastic exampleof how existing packaging solutions arebeing reviewed to create added value andconvenience to the consumer – and themanufacturer.Yet those who specialise in packagingdesign have some other serious questionsto ponder. The most pressing regardswhat actually needs to appear on thepackaging – thanks to the arrival of theEU Food InformationRegulation, which will beintroduced in 2014. These bringLa Fermière, the Frenchgourmet dairy, has chosenCombiRound packaging fortheir new product innovationMy Smoothie Yogurt.CombiRound is 100%peelable, whichmeans that thecardboard and plastic canbe separatedGood thingsin smallpackagesThe recent Total exhibition illustrated just how vibrant the packagingindustry is at the moment – and how it is rising to the challenge ofcontinuing to produce eye-catching and high quality designs whilealso keeping a close eye on the bottom line.34-39:Layout 1 24/6/13 09:36 Page 1Food & Drink International 35www.fdiforum.netPACKAGING MATERIALS & DESIGNtogether all the existing piecemeal requirements intoone catch-all piece of legislation, with allergens, nano-ingredients and imitation foods among the aspectsneeding to be made explicit as well as offering moreguidance regarding the presentation of nutritioninformation on-pack.Among the specific requirements that will haveobvious impact on design is the requirement to giveallergens information more prominence in theingredients list via the use of typefaces and colours.There’ll also be minimum font sizes specified for thedisplay of mandatory information.The challenge for designers will be how to incorporatethese regulations into existing packaging while stillensuring they are attractive. The specification of specificfont sizes could certainly lead to some familiar brandshaving to make various changes to ensure they workalongside existing design concepts, and indeed it couldwell be the case that the minimum font size andincreased amount of compulsory information will36 Miller Brands UK have launched a corrugatedbeer case for Miller Genuine Draft thatexpands when opened and holds ice to chillbottles before drinking. The inside of the packfrom CRP Print & Packaging has a laminatedwaterproof barrier and is externally lithoprinted with an aqueous varnish.34-39:Layout 1 24/6/13 09:36 Page 236 Food & Drink Internationalwww.fdiforum.netAs well as servingas a valuable promotional tool,these QR codes are alsoincreasingly playing a vital rolein improving traceabilityADPAKNo.1 FOR SHRINK WRAPPINGAdpak Machinery Systems Ltd established in 1987 are recognized as one of the leaders in packaging technology.Adpakmarket a range of innovative shrink wrapping, palletisation and pallet stretchwrapping systems supplying both new and second hand machinery and providing a fullafter sales service.Our reputation for these systems is well respected within theindustry. The speciality of the company however, is inapplying the latest technology and innovations tounusual and sometimes difficult packaging problems.We can provide full project management for your installation.Tel: 01282 601444 Fax: 01282 6122013 Pendleside, Lomeshaye Industrial Estate, Nelson, Lancashire BB9 6RYWWW.ADPAK.CO.UKPACKAGING MATERIALS & DESIGNrequire companies to change the pack sizesof some of their products that are availablein particularly small formats.The introduction of these regulations,however inconvenient they may be, are atleast consistent with the increased interestby consumers in the provenance andconstruction of the products they buy, andindeed many have expressed interest inreceiving more information. Whereas twoor three decades ago only professionaldieticians or those suffering from foodintolerances would usually study theingredients of the food they ate in any greatdepth, this has now become a mainstreaminterest and consumer awareness of whatthey are eating has never been morepronounced.This explains why many products are nowmaking use of QR codes on their packagingwhich allows consumers to scan them withtheir mobile phones and connect to websiteswith more information. As well as servingas a valuable promotional tool, these QRcodes are also increasingly playing a vitalrole in improving traceability – placed onpackaging, they can allow people working inevery aspect of the supply chain to scan theunique codes and access information on thebatch number, the exact contents and muchmore important information, in a user-friendly fashion.Digital packaging is being introducedthroughout the food and drink industry andis illustrating its myriad advantages. Theability to personalise packaging and developshort print runs can allow for specialadvertising campaigns (like the presentCoca-Cola campaigns) as well as making iteasy to run competitions and offers onpack. The ability to create and validate adesign in real time and receive instantapproval on final substrates, meanwhile,ensure there aren’t any nasty surpriseswhen the first print run comes back. TheDigiflex packaging from the newlyrebranded UNI UK offers a great exampleof this – its digital printing of flexiblepackaging, vacuum pouch and stand-uppouch manufacture, lamination, laserscoring, co-extrusion and logistics is provinghugely popular.Added value for customers can beprovided by a range of new packaging34-39:Layout 1 24/6/13 09:36 Page 3Food & Drink International 37www.fdiforum.netPACKAGING MATERIALS & DESIGNtechniques. Using their latest patent pending technology Editions,Rexam can now produce eight to 24 designs of the same labelsimultaneously on a single pallet. This printing innovation allowsRexam’s customers to deliver several designs to one single fillingline, creating increased marketing opportunities for brands usingbeverage cans and improving efficiency in the filling process asdesigns are already mixed on the same pallet.Thermochromic inks are now a familiar part of packaging,changing colour to illustrate when the product is at its best.Rexam are now offering thermochromic printed ends, whichmeans the indicator is highly visible to consumers whilst the canis stored in the fridge door or horizontally on the shelf, whilephotochromic ink can also add value for the customer, andgreater interaction between brand and the end consumer. Thewhite transparent ink reacts and changes colour outdoors whenexposed to natural daylight.Other packaging materials are enjoying increased popularity.Cold foiling isn’t a particularly new technology, but as API Foilspoint out, recent developments in the processes, techniques and38 The packaging for Bacardi Dewar’s, a solution designedand produced by the STI Group, fought off stiff competitionto take the Premium Beverage Packaging award in SydneyRecent developments in the processes,techniques and effects, specifically in sheetfed label applications, means that the sectoris finding cold foiling, thanks to companieslike API Foils, increasingly valuable EUROPEANSERIES1 & 2 October 2013 Business Design CentreLondonThe exclusive eventfor branded andinspirational packagingINNOVATIONSPlease refer to the website for all the show’s supportersRegister now...www.easyFairs.com/PI-London34-39:Layout 1 24/6/13 09:36 Page 438 Food & Drink Internationalwww.fdiforum.netPACKAGING MATERIALS & DESIGNBottle Safepackaging fromCaps CasesBottle Safe is the affordable way of reducing bottlebreakages without the need for flo-pac, air pocketsor polystyrene fittingsThe Bottle Safe system from CapsCases is designed for sending wineor drinks through courier networks,and offers excellent protectionagainst breakages. Extensive trialshave resulted in zero reportedbreakages, even when they havebeen sent via the most carelesscouriers.Bottles are suspended within anouter case above an innovative airspace for protection. The top fittinghas different size holes toaccommodate different bottle neckwidths, and prevents productsknocking together in transit.One of Bottle Safe’s benefits is itsflexibility. Without forcing clients tobuy lots of components It can caterfor case sizes of one, two, three,four, six or twelve bottles, from justthree base sizes, three top sizes andsix carton sizes. A six bottle fittingcan be split into 2x3 bottle classes,or two can be used in one outer caseto create twelve spaces – keepingcosts of storing component parts toa minimum. It can be stored in flatformat and assembles quickly to aidpack times. An additional benefit isthat Bottle Safe is 100% recyclable.Bottle Safe is the latest conceptfrom Caps Cases, a major supplierof all manner of transit andshelf/retail ready packaging. As aBRC/IoP low risk certified company,they are experts in secondary food and drink packaging and haveproducts to suit all requirements.Caps Cases also have relevant experience in chilled packaging, andthey can design and manufacture packaging which keeps goodschilled in transit.For more information of Bottle Safe and Caps Cases’ othersolutions, call 01638 667326 or visit www.capscases.co.uk.effects, specifically insheet fed labelapplications, means thatthe sector is finding itincreasingly valuable. Hotfoil is also finding supportthroughout the industry.The introduction of these EU-wide packaging regulations, and thelengthening supply chains, have added an additional dimension topackaging decisions and mean many companies work togetheracross the continent. Kite Packaging, for example, have expandedits European network in recent years, joining forces with A-förpackning in Sweden, MC Emballage in Denmark, Knüppel inGermany and Paardekooper in the Netherlands. The KOBRAnetwork, as it’s known, has a combined turnover approaching €250million and the marketing and purchasing synergies that areapparent from this collaborative approach are benefiting customersand suppliers alike.The requirement to cut down on excessive packaging, while stillensuring it’s safe and secure, is exercising minds in the food anddrink industry, but there are numerous new products coming ontothe market that can address this. One of the latest is Bottle Safefrom Caps Cases, which offers immense flexibility in allowing thefast and safe storage of bottles. A six bottle fitting can be split into2x3 bottle classes, or two can be used in one outer case to createtwelve spaces, keeping component parts to a minimum. It also foldsflat to minimise storage space and is 100% recyclable.The challenge of sustainability is likely to dominate thinking inthe packaging sector in the next few years. However continualinnovation when it comes to introducing new materials anddesigning more attractive and convenient products will doubtlessensure a bright future.Orangina-Schweppes France isexpanding the package portfolio forOasis with the launch of P’tit Oasisin a brand new 200ml package withan air-filled handle and strawattached from Ecolean Air AsepticDigitalpackaging is beingintroduced throughout thefood and drink industry andis illustrating its myriadadvantages34-39:Layout 1 24/6/13 09:36 Page 5Food & Drink International 39www.fdiforum.netPACKAGING MATERIALS & DESIGNSome Exciting News from Cellac, we’re Changing Our Name!UKPACKAGINGAs part of the UNI Packaging Group,Cellac UK is re-branding to UNI UK from 1st July 2013.KƵƌƌĂŶŐĞŽĨŇĞdžŝďůĞƉĂĐŬĂŐŝŶŐƐŽůƵƟŽŶƐŝŶĐůƵĚĞ͗ͻ Graǀure prinƟng - up to 10 coloursͻ &ledžo prinƟng - unlimited colour range• DIGIFLEXTM - digital prinƟng of Ňedžible packaging (only one of 4 in Europe)• Vacuum bag & stand-up pouch manufacture• Co-extrusion - up to 7 layers • Laser scoring capability• Design & artwork managementtĂŶƚƚŽŬŶŽǁŵŽƌĞ͍Call us on 01ϴ7ϱ ϲ1ϲ ϵ20 to Įnd out more about our capabiliƟes or email salesΛuniuk.co.uk and we͛ll call you.Unit 2 Satellite Park, Macmerry Business Park, TRANENT EH33 1RY, UNITED KINGDOMTel: +44 (0)1875 616 920 Fax: +44 (0)1875 614 381www.uniuk.co.ukNew brandingfor flexiblepackagingspecialistsCellac, the UK arm of the flexible food and industrialpackaging group UNI Packaging, is rebranding itsoperation as UNI UK on 1st July.With Cellac celebrating their tenth anniversary, the move isdesigned to strengthen brand identity in the UK and create a greaterawareness of its role as one of the leading flexible packagingspecialists.Operating from six production sites across France, UNI Packagingprovide a full range of flexible packaging solutions including Gravure,Flexographic and DIGIFLEX™ - digital printing of flexible packaging,vacuum pouch and stand-up pouch manufacture, lamination, laserscoring, co-extrusion and logistics. With a turnover in excess of €104million, the UNI Packaging Groupemploys over three hundred peopleacross fifteen sites and officesthroughout twelve countries.Functioning as acomplementary group ofbusinesses, supportingeach other with specificoperational strengths andproducing a complete set offlexible packaging solutions,the group’s interlocking businessmodel is unique. With its full range ofcapabilities, resources can be deployed directly to answer customers’needs. With ongoing investment in infrastructure and newtechnology, reserve capacity is always available, ensuring supplychain efficiency throughout. With this full control over the manufacturing processes, the groupcan provide bespoke solutions by reacting quickly and accurately tomeet demand.Rod Entwistle, MD of UNI UK, says, “With the resources we haveacross the group, we can operate on a different level to other flexiblepackaging companies, allowing us to give our customers aconsistently high level of service at every stage.“Our broad manufacturing base and barrier laminate range is ourstrength - there are very few other businesses that do what we dowith the speed to market.”“With theresources we haveacross the group, wecan operate on adifferent level to otherflexible packagingcompanies.”34-39:Layout 1 24/6/13 09:36 Page 6Next >