< Previous24 Food & Drink Internationalwww.fdiforum.netINGREDIENTS & FORMULATION SPOTLIGHTand vegetables being a concern. Of three new products beinglaunched, perhaps the most interesting is the Hidden Vegetablesjar of sauce, which incorporates a smooth sauce with extravegetables contained within. The jar contains five portions ofvegetables, but retains the flavours people expect from thebrand.Andrew Wade, Marketing Controller at Symington’s says:“We’re incredibly proud to offer 100% natural ingredients and 1of the 5 daily recommended throughout the range – going a stepfurther on Hidden Vegetables gives us a unique selling point ina highly competitive category. Ragu Pour Over sauces, providesa fantastic option for convenient, cost effective meal solutionswith all the quality and flavour people have come to expect fromthe Ragu brand”.Where balances are met, it seems success can be attained. It’skeeping ahead of what ingredients are in vogue at the time andhow they can be added to existing products to make them moredesirable, cost effective and marketable that is where thechallenge lies. Thankfully, there are companies willing to strivefor new ways of using ingredients and marketing them in such away that some of the biggest players in the game are likely totake them up. The ways we formulate ingredients for products ischanging, thankfully for the better.BENEO’s Palatinose™extends shelf lifeand qualityTechnical experts at BENEO, a leading manufacturer offunctional ingredients, have conducted technical trials to improvethe shelf life and quality of glazed and iced, freshly and frozenpacked donuts. The results show that with the partial replacementof sucrose with BENEO’s functional carbohydrate Palatinose™ inglazings or icings, shelf life and overall product quality can besignificantly improved. Findings showed a partial replacement of sucrose withPalatinose™ in freshly packed donuts leads to an extended shelf lifestability through its ability to control water activity and moisturemigration. Furthermore, the glaze with Palatinose™ maintainstransparency, even throughout the extended shelf life. Thanks tolow hygroscopicity, the glaze doesn’t become sticky. In addition, thePalatinose™ glazed, freshly packed donuts exhibit a more pleasantsweetness in comparison to using sucrose alone.The trials also demonstrated partial replacement of sucrose withPalatinose™ in frozen packed donuts ensures a maintained glazetransparency throughout the freezing process and after defrosting.It prevents the glaze from sticking to the foil during frosting andafter defrosting. Although less sweet than sucrose, Palatinose™provides a more pleasant sweetness in frozen packed donuts, aswith pure sucrose glazing.Katja Reichenbach, BENEO Product Manager Palatinose™, says,“Sugar-based donut glazings traditionally have a lower aw value thanthe donut. This leads to increased water migration from the donut toits glaze, resulting in the donut drying out very quickly. However,BENEO trialled the partial replacement of sucrose with Palatinose™inglazings and icings and the results showed water activity was broughtunder control in the glaze, keeping the donuts moist for longer.”BENEO’s recent webinar on the trials can be found atwww.beneo.com, and for more information contactKatja.Reichenbach@beneo.com.It seems that any combination of flavourscan suit products, it’s just a case ofselecting the right one for the market.PHOTO: SHUTTERSTOCK.COM/MAREKULIASZWhey protein has successfullymade the jump from extremehealth product to somethingappearing in more public-facingfood and drink products20-25:Layout 1 20/6/14 12:16 Page 5K+S KALI GmbH · Phone +49 561 9301-2025 · healthcarefood@kali-gmbh.com · www.kali-gmbh.com A K+S Group CompanyThe Authority in Potassium and MagnesiumFor best KaliSel quality we monitor every step of the production.KaliSel, with highly purified potassium chloride of natural origin in food quality, is one of the easiest and most cost-effective ways to substitute salt. Therefore, KaliSel is already used successfully in many areas of the food industry – of course in-house produced and certified according to high-level standards.20-25:Layout 1 20/6/14 12:16 Page 632 Food & Drink Internationalwww.fdiforum.netLABELLING, CODING & MARKINGBack in the early eighties whencomputers were the size of filing cabinetswe were the first to use Toshiba TECthermal printers to print barcoded labelsto track Work In Progress in largemanufacturing sites. As AdvancedManufacturing Technology specialists wecut our teeth using plain labels on rolls toprint barcodes for the labelling andaccurate identification of pallets of goodsand for traceability.Coincidentally supermarkets started torequest food and drink manufacturers toadd barcodes onto product labels. Werecognised the power for manufacturers toprint labels in house and KTECTechnologies was born to serve the newJust-In-Time manufacturing philosophywith instant print labelling technology.We soon had requests to reprintmanufacturers’ own colour logos andcontact details to rolls of labels they coulduse directly on their product items,though the variable product dataoverprint was still limited to a singlecolour and usually black. Our customersthen had a reasonable solution for ‘ inhouse’ labelling of their actual productsas well the outer packaging. Not much haschanged since, save that the printers printfaster and we now supply 600dpi roll toroll printers to cope with the ever growingneed to cram additional details onto snackand drink labels. We majored in sandwichand bakery with overprinting pre-colouredlabels averaging around 2p per label.One good advantage of overprinting isthat printers can be operated from a smalloffice computer or from a tiny keypad likeour SOLO system, the latter enablinghighly reliable stand-alone operation 24/7ideal for forecourts or stores where the PCis turned off overnight. The user simplytypes numbers to select and print thecorrect quantity of snack labels each day.We added the PRIMERA range ofdesktop colour label printers, includingthe world’s smallest full colour labelprinter the LX400e. Initially selling at arate of 36 per month with a price tag of£500, nowadays £899 as a completestarter kit, PRIMERA gave many smallproducers and artisans the opportunity toprint their own full colour labels. For thefirst time users could print one label for asample, then hundreds when the ordercame in. We found it a big hit with snackfoods, custom wine labels, cider makersand the newly emerging microbreweries.The later LX900e model at £1790 with itsincreased print speed, printing width andlower cost ink is now our fastest sellingprinter, both machines printing at anamazing 4800dpi photo quality full colourlabels just when needed.Developments by Memjet and Canonhave bought us roll label printers with theability to print at 1600dpi full colour butat extremely low cost per print and higherprint speeds - typically 300mm persecond! With large bulk ink tanks, eachcolour ink tank is a cola can size 250ml.The icing onthe cakeFrom black barcode labels to full photo quality labels with nutritionand allergens, KTEC Group has been showing the industry how toprint labels themselves for 25 years. They’re now targeting a fullcolour snack label down to 1p each. Robert Knox, Founder andManaging Director, explains the latest advances in full colour variablenutrition and allergen labelling at a new low cost.32-33:Layout 1 23/6/14 08:35 Page 1Food & Drink International 33www.fdiforum.netLABELLING, CODING & MARKINGThese more industrial printers aresuited to any manufacturer wantingthe lowest price per full colour labelwith massive label cost savings.Having more than five thousandfull colour label printers nowinstalled creates quite a healthydemand and enables us to buy inkand self-adhesive paper in bulk.We’re able to buy and supplymaterials at less cost and aretargeting the full colour label printdown to 1p, depending on themanufacturers’ annual label usageshowing a very fast payback forinvestment.Software for nutrition andallergen bolding is a popular topicand available from us in differentguises. To satisfy the new legislationfor highlighting of allergens ourlatest BarTender PC label designand print software or stand-aloneSOLO keypad system allows for thebolding of any allergen so it standsout on the label.Our Food Management SystemColour Print systems for use withany of our high resolution mono orfull colour label printers is the verylatest development. The use of arecipe based control system and acolour label printer becomes theultimate system for now and thefuture, with the ability to label infull colour at low cost and closelyfollowing the latest legislation forfood and drink labelling. FMSCPincludes the ability to showimportant nutrition information as‘traffic light’ colour indicatingsymbols and tables, as well ashighlighting the allergens fullyautomatically.Users of our FMSCP installationssimply input their basic ingredientand nutrition information once onlyfor each ingredient and thencombine ingredients to createfinished product labels. FMSCPprints out labels ‘on demand ‘ withall the correct descriptions,composition, highlighted allergens,manufactured date, expiry date,batch numbers, price and barcode aswell as the customer’s own logo! Ifyou find you have to substitute aningredient, the FMSCP system willupdate all the information on everylabel in under a second, as well asprinting out a revised productspecification for each product.SNACKAWAY of Birminghamrecently installed FMSCP using ourSPEEDSTAR 3000 full colour rollto roll label printer printing photoquality labels at 300mm per second.This printer has the benefit of aninternal linear camera watching theedge of the label material andcontinuously aligning the colourprint to the labels at the highthroughput speeds. A popular labelsize supplied to SNACKAWAY isdie-cut to a special T shape popularfor labelling sandwich wedge shapedpackaging.The FMSCP system enablesSNACKWAY to print customers’logos onto the labels as well asdelivery round numbering to assistwith sorting and final destination tosafe delivery. Even a full colourpicture of the customers’ businesstheme can be printed in thebackground of the labels, furtherpersonalising products and winningnew contracts.For more information, visit www.ktecgroup.co.uk orwww.snackaway.co.uk.32-33:Layout 1 23/6/14 08:35 Page 234 Food & Drink Internationalwww.fdiforum.netMANUFACTURING EXCELLENCEFood and drink companies have alwaysreached for high standards, but theircustomers now often expect them to goabove and beyond their legal requirementsto ensure absolute quality before theyaward contracts. This means manufacturersneed to ensure their equipment andprocedures are absolutely exceptional.Although the investment in training andtechnology requires some short termexpenditure, the long term results can behugely impressive, with companies able tocompete at the very top level and be well-placed to land major contracts. The mostsuccessful companies in the food and drinksector are those which have benefited frominnovation and investment in a highquality infrastructure.The food and drink industry, like mostother manufacturing sectors, is constantlyin need of a steady stream of new talent,both to replace those who are lost to theindustry through retirement and to ensureemployees are well equipped with up todate knowledge of their roles and theindustry as a whole. Initiatives such as theSee Inside Manufacturing scheme in theUK, which is supported by the Food andDrink Federation, helps achieve this byraising the profile of food and drinkmanufacturing and providing an excellentopportunity to identify new recruits – aswell as developing existing employees whoget the opportunity to pass on their skills.The National Centre for FoodManufacturing, part of the University ofLincoln, is of particular importance as akey training resource for foodmanufacturing businesses. With a currentbody of 2500 full and part-time students,the Centre serves the UK’s largestconcentration of food manufacturingbusinesses by providing purpose-builtfacilities, which include a productdevelopment kitchen, food manufacturinghall, conference rooms and foodmicrobiology and chemistry analytical labs.The Centre also has partnerships with anumber of leading manufacturers and playsa key role in supporting employers whowish to cultivate talent within theirbusinesses, and develop their own foodtechnologists. The Bakkavor Group isamong those who regularly uses the NCFMto support the development of theiremployees, and Gillian Haythornthwaite,Head of Talent and Development, says,“Our aim is to attract and develop youngindividuals who have the potential to setand drive industry-leading standards in keyareas such as manufacturing and foodtechnical. This means ensuring ourapprentices have the necessary skill set andconfidence to carry out their roles, and oursuccessful partnership with the University’sNational Centre for Food Manufacturingfully supports this.”The Centre is also involved in a numberof collaborative research projects in anattempt to unlock new opportunities formanufacturers. The latest project is acollaboration with Olympus Automation inthe hope of developing a fullerunderstanding of the innovative new PDXpatented steam injection technology. PDX is an advanced cooking process thatheats, mixes and cooks liquid based foodproducts extremely quickly and efficiently,and the Technology Strategy Board arefunding the project to gain a full scientificunderstanding of the potential benefits.Across the world there are manyexamples of collaboration such as thisensuring huge benefits for all concerned.Rockwell Automation, for example, runs itsOEM Partner programme which hasrecently expanded with the addition of fiveNorth American machinery and equipmentmanufacturing companies. Members of thisprogramme are required to demonstrate acommitment to offering high quality,ExcellenceassuredThe quest for high standards has ensured manufacturers are able tocompete at the very top levelT +44 1564 793 039 www.lineview.com34-36:Layout 1 20/6/14 12:18 Page 1Food & Drink International 35www.fdiforum.netMANUFACTURING EXCELLENCEinnovative machinery and equipment that uses Rockwell Automationsolutions. The result is a network working collaboratively to help solvemanufacturing and automation challenges by simplifying the supplychain and advancing innovations in project design, to the benefit of allmembers and their customers.Identifying machinery and working out how it can be included inthe production line is a vitally important aspect of ensuringmanufacturing excellence. Many companies now offer the ability toreview the potential impact of robotics and automation to theexisting production line before a commitment is made to purchasingand installing the items, ensuring potential disruption and ill-advised purchases are kept to a minimum.Much machinery these days is available in a bespoke form to allowit to exactly meet the customers’ needs. Advanced Engineering, forexample, supply mixers as individual units or integrated with skidmounted process vessels, lifting frames and control panels. It’simportant that the correct mixer is chosen for the job in hand andAdvanced Engineering therefore offer free on site trials with purposebuilt test rigs. With off-the-shelf spares, machine repairs and on-siteservice, AE Mixers also provides dedicated support throughout theoperational life of the product to all customers, small or multinational.36 Rockwell Automation areamong those companiesemphasising the value ofa collaborative approach.At interpack, OEMsshowcased over 215 newand enhanced machinesrunning on RockwellAutomation-basedautomation, motion,process and safetysolutionsFood sector specialists from UKTI are amongthose who have recently seen the value of theNational Centre for Food Manufacturing Courtesy of Ishida EuropeFoundation Degree and BSc (Honours) in Food ManufactureFlexible, part-time courses by day release or distance learning,with options in: •Operations Managementfor Manufacturing and ProcessingManagers who require expert knowledge of food factoryprocessing, automation and manufacturing management. •Quality Assurance & Technical Managementfor thoseworking in Technical, Quality and NPD Functions. Whilst involvingin-depth study of food manufacturing and related science /technologies, this option provides additional insight into thepractices and systems which help ensure business control offood safety, quality and legality.Enhance your Career and Management PotentialThe National Centre for Food ManufacturingUniversity of Lincoln, Holbeach Campus, Park Road, Holbeach, Lincolnshire, PE12 7PTContact: 01406 493000 or email: ncfm@lincoln.ac.uk www.lincoln.ac.uk/ncfm34-36:Layout 1 20/6/14 12:18 Page 236 Food & Drink Internationalwww.fdiforum.netMANUFACTURING EXCELLENCEidentify potential improvements. As part ofthe UK government’s Trailblazer project,the food and drink industry has developeda standard for Food and Drink MechanicalMaintenance Engineer and Food andDrink Multi-skilled Maintenance Engineerroles.The new standard, due to be rolled out atthe end of 2014, will help create a morerobust pipeline of specialist engineers,enabling industry to be in the driving seat ofdesigning and delivering high qualityapprenticeships. With backing from theInstitution of Engineering and Technologyand the Institution of Mechanical Engineers,the new standard will ensure individuals areable to progress towards professionalaccreditation. Angela Coleshill, Director ofEmployment and Skills at the Food andDrink Federation, says, “An initiative likethis not only helps industry bridge its skillsgap but it also allows manufacturers todevelop the necessary skills needed for amore sustainable food and drink industry.”The introduction of new talent,alongside a collaborative approach betweendevelopers and manufacturers, shouldensure consistent high standards across theindustry – benefiting companies and theircustomers alike.Initiatives supported by the Food and Drink Federationhelp raise the profile of food and drink manufacturing.Recently, students took a closer look at foodengineering at a visit to KP Snacks in RotherhamIt’s certainly possible for manufacturersto reach the highest standards, but it’salso vitally important that they’re able tomonitor and measure the quality of thework to ensure those standards remain inplace, and to provide relevant informationwhen pitching for contracts.Many businesses now use the LineViewsystem which monitors the entireproduction process in real time, constantlyidentifying the real area of loss to enableteams to use highly accurate data to makeeffective decisions. All data is storedcentrally and is available on every PC inthe factory to enable effective decisionmaking. The system has proven sovaluable that LineView is now installed inall Coca-Cola Enterprises bottling facilitiesthroughout Europe, as well as themanufacturing facilities of many othermajor manufacturers.Manufacturers also benefit from takingpart in standards schemes to illustratetheir skills and concentrate minds tomixingis our businessCreamsandOintmentsPaintsandResinsGelsSoupsandSaucesSalsaandDressingsEcoFuelsHigh Shear Mixersand Agitators34-36:Layout 1 20/6/14 12:18 Page 3Food & Drink International 37www.fdiforum.netCLEAN AIR SOLUTIONSThe value of clean air within the foodand drink industry is incredibly important.There’s a whole smattering of reasonswhy contaminated air or environmentsfull of particulates is a bad idea. The mainreason is explosive risk. Often overlookedby companies, there’s a real risk presentanywhere in which dust particles canbuild up. A single spark can ignite abuild-up of dust, be it food or otherwise,and completely level facilities and causeuntold injuries. Several high-profile casesin recent years have proven it’s an unseenbut ultimately incredibly dangerousphenomenon.To underline this, a global fire,explosion and pressure relief solutionscompany recently introduced a product toassist the prevention of dust explosionsand eliminate risk of potentiallydevastating disasters occurring in theworkplace. Fike UK has introduced theFike Dust Detection System.The FDDS functions by signallingthe presence of unusually high airbornedust particles enabling the prevention ofexplosion devastating the workplace. Keith Avila, General Manager of FikeUK says, “A dust explosion can bepotentially catastrophic. We are veryproud to be the first in the industry tointroduce such ground breakingtechnology and be at the forefront ofproviding safety solutions like this whichprevent devastating and irreversibleeffects.”Featuring unique technology the FDDScan identify levels of dust that can causeexplosive hazards, validating theprotection of non-zoned areas. Theadvanced technology is installed in ductsand will alert a business to any earlywarning signs of potential contaminationcaused by nuisance dusts. The system works by detecting thenormal amount of dust particles passing bywith an easy ‘traffic-light’ notificationsystem indicating the levels of dustconcentration within the duct.Safety is ofcourseparamountand the issue of odours is one that meanssmells can seep into other products andtaint them, with the taste being impaired.It is often only discovered at the lastmoment when the consumer notices astrange taste. A real problem too, is lossof product. If a product relies on a heavyamount of particles then to simply letproduct escape seems irresponsible.Shooting the breezeClean air solutions are becomingcommonplace across theindustry, be it production facilitiesor within hospitality. Whattechnology is driving thesesolutions forward?LABOM’s air measurementcontrol units mean there’sno chance of dust build upor ingress, all in the design.38 37-39:Layout 1 23/6/14 12:22 Page 1Thankfully, technology developedrecently means this presents less of aproblem than it used to. For example,within foodservice and hospitality,Lincat has launched Refresh, a rangeof ductless air recirculation units.Developed in conjunction with sistercompany Britannia KitchenVentilation, these self-contained, freestanding kitchen air recirculation unitsare designed to be used where ductingto the outside is impractical.They work by extracting thecooking fumes from directly above theequipment, filtering that contaminatedair through an advanced four-stagefiltration process before recirculatingclean air back into the kitchen. Theyare ideal therefore where venting tothe atmosphere is impossible, difficultor costly. Refresh units are designedto be used with electric rather thangas equipment since these must, onevery occasion, be vented to theoutside with safety interlocks.“There are many occasions whereventing to the outside is eitherdifficult or impossible,” said Rachel Smith, Marketing Manager ofLincat. “Take concession areas within airports or train stationsfor example, or listed buildings in conservation areas. Our newRefresh units are designed to enable you to operate where youmight not have been able to before, or to expand your existingoutput, with a minimum of disruption or additional investment.”It’s also a case of being green. Dust extraction specialists,Dustcontrol have recently introduced new eco-green motors intoevery appliance within their entire mobile dust extractor range. Previously, motors were just used in Dustcontrol’s AirCube500 and AirCube 2000 models. The upgrades now mean that100% of Dustcontrol’s mobile dust extractor products include aneco motor. Each motor has 100w lower consumption thanprevious Dustcontrol motors.James Miller, Dustcontrol UK’s General Manager, explains,“We’ve had the technology for our eco motors for a long timewhere we have been using them in our AirCube range. It wasalways the plan to have all our mobile products equipped withthese new motors, and it’s fantastic to have achieved this.“The motors are a true innovation. They use less energy, butare more powerful than before. Here at Dustcontrol, we’re alwayskeen to minimise the impact of our equipment on theenvironment.”The idea of control when dust or air is concerned is also oftenan issue. For example, LABOM the German manufacturers ofmeasuring equipment now offer its pressure transmitter seriesPASCAL Ci4 and PASCAL CV with an optional ingressprotection class of IP69K, according to the DIN 40050-9standard. This means the devices not only offer the highest possibledegree of protection against the ingress of dust, but they are also38 Food & Drink Internationalwww.fdiforum.netCLEAN AIR SOLUTIONSDust Control’s James Miller with the new,more eco-friendly motors.Preparing for the future?•Waste to Energy • Recycling OSILClean Air Solutions +Delivering tailored clean air solutions + odour and air pollution control to a wide range of specialist industries:-•Food & Beverage •Energy•Water & WasteWith a team of highly skilled process and chemicalengineers, OSIL are a full independent serviceprovider offering extensive experience and expertise for all requirements.•Tailored efficient, effective and affordable solutions that are easily manageable. •Full In-house Project Delivery:- refurbishment, asset, studies, design & build, commissioning, training & maintenance.•Continued support and aftercare excellence guaranteed. Start preparing for tomorrow, today!To inquire about a site survey or to discuss our range of services, please contact us on:Tel: +44 [0] 1543 506855 Email: info@osiltd.comwww.osiltd.com37-39:Layout 1 23/6/14 12:22 Page 2Food & Drink International 39www.fdiforum.netCLEAN AIR SOLUTIONSprotected against hot water with highpressure. This qualifies the pressuretransmitters for use in all fieldsrequiring high-pressure cleaning. The pressure transmitters areequipped with an air filter for equalisingatmospheric pressure inside the housingand with an integrated water-repellent(hydrophobic) PTFE membrane.Thanks to the circumferential nature ofthe air slit it is practically impossible forthe air supply to become completelyclogged by dirt. The air filter is an M12threaded element in a rugged stainless-steel design and can be integrated intoexisting PASCAL CV pressuretransmitters without any need forspecial tools.Dust-proof and reliableIt’s not just traditional equipmentlike machinery that needs protectingfrom dust and adverse elements in theair. Computers required to be placedwithin areas of high activity andThese Referesh units from Lincatmean air circulation is possibleeven in confined spaces or whereexterior piping is unavailable orimpossible to install.therefore increased risk ofcontamination need to be robust.Thankfully, Alpha Micro has recentlybeen appointed UK reseller for Aleutiafanless, low-power computersspecifically designed for use in extremeenvironments where heat and theingress of dust present an issue. Widely used throughout the foodoutlet sector, Aleutia’s PCs are used infood chains such as Pret a Manger andYo Sushi and on solar farms.The T1 in particular is designed forchallenging environmental conditionsand is is in operation today in over fiftycountries, providing ICT access inremote and often hot and dustylocations.As well as this, the Aleutia R50provides high-end performance in anincredibly small, fanless sealed chassismachined from a single block ofaluminium, perfect for areas where dustcan be in the air in high volumes atpeak production times.37-39:Layout 1 23/6/14 12:22 Page 3Next >