< Previous40 Food & Drink Internationalwww.fdiforum.netGEARS & DRIVESIt’s clear that automation and semi-automation can have a major impact onthe success of a production line, with bagpackaging and container filling now beingcarried out far faster than ever before andreaching very high standards while doingso. This strategic move can ofteneliminate a production bottleneck, removea hazardous manual function and, hence,make a substantial contribution to cuttingcosts.Yet automation is not without itspotential pitfalls, most obviously when itcomes to the reliability and the quality ofthe gears and drives used to power themachinery. In the food and drink sectorthere’s an additional challenge in terms ofsafety and hygiene, where the potentialfor food to get caught up in small partscan be very great. It’s therefore vitallyimportant that effective gears and drivesare carefully selected and maintained.It’s likely that many manufacturers willhave reviewed their gears and drives on aregular basis now that electric motorshave been required to meet the IE2standard of energy efficiency. Theseefficiency ratings are based on a Europeanstandard with IE2 requiring highefficiency, similar to the old Eff1 voluntarystandard which has now beendiscontinued. The latest motors availablefor the food and drink industry all reachthese standards, as well as meeting otherstandards, such as those that allow themto be used in explosive atmospheres.Don’t think this is the last change thatwill need to be made, however, as fromthe beginning of 2015, motors rated from7.5 to 375kW will be required to reachthe IE3 standard – representing premiumefficiency. That will be the case for allmotors above 0.75kW from 2017. There isan alternative, though, as companies canstill use IE2 motors with a variable speeddrive. These drives are particularlyvaluable for the food and drink industrywhich, with safety in mind, can oftenmake use of motors with oversized drives.Often these motors are running at partialloads losing a great deal from the runningefficiency, but this can be dealt with byintroducing frequency inverters that canmatch the varied demand.Indeed, businesses that have installedfrequency inverters have reportedsubstantial cost savings on the regularrunning costs. This can be improved stillfurther with the new breed of invertersthat make use of cold plate mounting.These remove the heat sink that is usuallystandard at the back of the drive, toensure the motor runs at a low enoughtemperature to stop it overheating, andinstead make use of a substantial metalmounting surface. This mounting gives areduction in the volume of panel spacerequired of about 25%. Running costs canalso be reduced by the introduction ofmore protective coverings which can copewith particularly humid atmospheres andclose contact with chemicals. Thesecoverings can now be found on servo andgeared motors.There are many high quality options forapplications where hygiene is a majorPHOTO: SHUTTERSTOCK.COM/SURKOV DIMITRIpriority. NORD DRIVESYSTEMS, forexample, supplies aluminium two-stagehelical bevel gear units in five sizes with amaximum torque of 660Nm that are easyto clean. The washdown design is basedon smooth inclined surfaces, transitionswith large radii without dead spaces, andrequires no assembly covers.Cleaning liquids can therefore wash offparticularly easily and thoroughly from thesurfaces, which also remain considerablycooler than those of conventional drivesthanks to their method of construction.The design is optimised for use in thefood industry and complies withinternational guidelines and standardssuch as EHEDG, ANSI/BISSC, andANSI/NSF. If required, the gear units canbe fitted with double shaft seals, orderedas open or closed frame versions withhollow or solid shafts.Designed according to the provenUNICASE principle, the housings are verytorsion-resistant and withstand highmechanical stress. With the optional NSDThe drivefor qualitySafety and hygiene are the major factors in the development of qualitygears and drives40-41:Layout 1 20/6/14 12:08 Page 1Food & Drink International 41www.fdiforum.netGEARS & DRIVEStupH surface treatment, they becomeextremely resistant to corrosion as well asacids and alkaline solutions. NORD aremaking use of their CleanDRiveSolutions,which is not a coating, which means nolayers can peel. Instead, the processtransforms surfaces with up to seven timesthe hardness of the base aluminiummaterial. This means the housings haveparticularly robust and durable qualitiesthat are similar to stainless steel versions,while remaining much lighter and moreeconomic.The gear units are also ideally suited forconveyor systems and hoists, especially inapplications where geared motors have tobe moved and their lightweight becomesessential.The new directives affecting motorshave help to concentrate minds andensure that the gears and drives nowavailable to the food and drink industryare more cost-effective and reliable thanever before. Automation is no longer anovelty in the food and drink industry andeven the smallest companies can see thebenefits – so it will be speed and flexibilityof the automation in the individualcompanies that will begin to offer thatvital competitive advantage.NORD DRIVESYSTEMS, suppliesaluminium two-stage helical bevel gearunits in five sizes with a maximum torqueof 660Nm that are easy to cleanAutomation is no longer anovelty in the food and drinkindustry and even the smallestcompanies can see the benefits40-41:Layout 1 20/6/14 12:08 Page 242 Food & Drink Internationalwww.fdiforum.netDAIRY FOCUSWith a whole glut of new products andwith more onus on unique and specialistproducts, dairy as a whole has been aninteresting ride for many over the pastfew years. With so many differentproducts coming to market and withpackaging and technology keeping upwith new tastes, it’s never been a bettertime for the industry. This is particularlytrue when you consider the move ofmany consumers to more healthy andconvenient products overall. The key tosuccess lies with the use of new, efficientmachinery and its associated supply chainwhich has also increased its duty ofresponsibility to condition of products,including making leaps in refrigerationtechniques and storage.Say cheese!The rise of cheese as a luxury productas well as a staple foodstuff has beenthanks largely to differentiation ofartisanal or specialist products andeveryday value items. It’s also beenhelped by innovativeproducts aimed at the foodon the go market which hasgone hand in hand withpackaging advances as well asmachinery improvements.On the production side, forexample, new cheese cultureranges for cottage cheese applicationshave recently been specifically developedto allow medium and large-scale cheeseproducers to create dairy products withgreat texture and mouthfeel, whilemaximising profits.It’s also about making the cheese-making process an easier operation andthe use of innovative robotics as well asadequate lubrication of gears and driveshas led to faster and more efficientproduction processes. The use of roboticsin particular is fascinating. Until recenttimes, it was believed robotics could onlybe used in industries that dealt withheavy payloads. This is no longer thecase, with more intricate and delicateDown atthe dairyThe dairy sector is one that has seen success in recentyears in somewhat unexpected areas. The rise of artisanalcheese makers and the perceived value and healthproperties of certain products means it remains dynamic.42-47:Layout 1 23/6/14 08:32 Page 1Food & Drink International 43www.fdiforum.netDAIRY FOCUSprocess onsite – from milking our herd ofcows to maturing the finished cheese forup to 24 months. Bills are particularlyhigh during the summer months, whenthe weather is hotter, but thankfully thisis when our solar PV system will work toits highest capacity. All of the electricityit generates will be used to help powerour refrigerators.”An average solar PV system providesaround 50% of the energy it generatesdirectly to the business that owns it,while the remaining 50% is exported tothe national grid. However, businesseslike Quickes that have constant energyThe perceived health benefits of dairy areslowly shifting to focus on whey protein.PHOTO: ARLA FOOD INGREDIENTSRobots being less bulky andmore intricate mean they arenow ideal for dairy packershandling a variety ofproducts including cheesePHOTO: FANUCproducts being handled by robots nowthat more flexible and engineered modelshave become more affordable.It’s also about energy these days, withso much power being used, it’s sometimesworth considering just how that power isproduced. Devon-based cheese makerQuickes Traditional – which useselectricity 24 hours a day, seven days aweek – has joined a growing list of foodmanufacturers that are turning torenewable energy to drive down theirenergy costs by getting a 200-panel solarPV system installed.“We use electricity continuously,” saysAdam Reeves, Farm Manager at QuickesTraditional, “as we carry out every45 The use of robotics inparticular is fascinating. Untilrecent times, it was believedrobotics could only be usedin industries that dealt withheavy payloadsPHOTO: SHUTTERSTOCK.COM/MARAZE42-47:Layout 1 23/6/14 08:32 Page 244 Food & Drink Internationalwww.fdiforum.netWe deliver throughout the UK mainland from our network of 8 frozen and chilled food depots, so you and your customers can rely on the same unrivalled levels of service – whichever depot is delivering your valuable product.Do you also trade directly with business partners in other European countries? Whether that be import or export – No problem! We are part of a group with over 100 depots in 17 countries. We can deliver growth to your business. Contact us today to start that process. Nagel Langdons Ltd.Tel 01278 411 114 sales@nagel-langdons.co.uk www.nagel-langdons.co.uk… and it’s possible.For frozen & chilled food distributionacross the UK and Europe -we’re the only ONE you need! Thenumber ONE networkTM Electronics (UK) LimitedCold Storage Temperature Kit Protects Your StockFed up with discarding valuable food stores due to refrigeration problems? For as little as £30 per cabinet, you can protect your stock by spotting problems early with a Cold Store Temperature Kit from UK thermometer manufacturer, TM Electronics.What’s in the kit?•A slim-line TFS01 food simulant sensor that sits inside the cabinet, simulating the true temperature of stock;•A robust MM2000 digital thermometer that plugs into the sensor for a fast, accurate result;•Compatible with TME’s waterproof probes – needle, immersion and in-between pallet – for quality control in-store, during transit and in the warehouse.For extra due diligence, this kit is compatible with the MM7000 Bluetooth Barcode thermometer,which records and downloads all temperature readings including the unique identity of any product, appliance or location tested – a paperless system reducing the risk of false recording.Contact TME’s friendly sales office at 01903 700651sales@tmelectronics.co.uk www.tmelectronics.co.ukAccurate, quality thermometers and sensors for food manufacturing, catering and retail.• Processing • Storage • Delivery • Due DiligenceRobust waterproof thermometers •Bluetooth Barcode thermometers •Oven-proof stainless steel probesWall mounted instruments •Printing thermometers and dataloggers •Cold store food simulants •Calibration and repair42-47:Layout 1 23/6/14 08:32 Page 3Food & Drink International 45www.fdiforum.netDAIRY FOCUSneeds will often use every bit for themselves.Renewables are playing a part across theindustry however, with many productionfacilities working off self-generated electricityand using innovative methods such asbiomass to heat and run extensiveoperations. Reusing waste water and run-off is also becoming more commonplace,offering untold savings for many whosewater use will be incredibly high at certaintimes.Milking itMilk is one area of dairy that reliespossibly most heavily on hygiene andefficient production methods. Being aneasily spoiled commodity, it’s clear thatpackaging is playing its role in keeping itfresh and cool. Filling technology also isplaying its part. The high hygiene standardsneeded by manufacturers are being met andwith ease of variation between sizes ofbottle and carton too. New machineryenquiries, particularly for aseptic productshave seen an increase and this can only beseen as a good thing, with more onus beingput on safety of product as well as onprofit margins.Efforts have been made in recent yearsto avoid wasting product too. Every year,the left over cream from milk productionis now used to create cream, yoghurt andchilled dessert products.This fact, combined with innovativepackaging that has meant milk anddairy products staying fresher forlonger and remaining attractive onshelf, has led to a steady few years.Health products in particular havebeen key in keeping milk afloat. Recentefforts by dairy companies to make sureconsumers that the proteins found in milk arenot as unhealthy as some may think have hadsome effect too. An example of this is the switch inunderstanding of the health benefits ratherthan the disadvantages. Troels Laursen, Headof Health & Performance Nutrition at ArlaFoods Ingredients, says, “We’re seeing hugenumbers of new consumers buying into thewhey protein space for the first time. Butthere remains large untapped potentialbecause many women still believe –wrongly – that consuming higher levels ofprotein could have a negative impact ontheir physiology. Manufacturers mustwork with their ingredients suppliers todevelop concepts that will shatter thesemyths by educating female consumersabout the true benefits of whey protein.”Keeping it coolIce cream has faced somewhat of adifficult time in recent years, with it beingseen as a luxury and occasional treat, thechallenge has been to make not only full fatproducts sell well, but to increase the profileof healthy alternatives. A plea was recentlymade to Chancellor George Osborne tomake ice cream more affordable.The UK ice cream industry is reelingfrom a huge increases in overheadsincluding the cost of ingredients, fuel andthe rise in VAT. This, coupled withrecent wet summers and harsh winters hasseen sales drop alarmingly for some icecream sellers and there is a fear thatmany could be forced out of business.The Ice Cream Alliance recently calledon the Chancellor to classify ice creamas a food rather than a luxury itemand reduce its VAT loading whichis currently 20%.Zelica Carr, Chief Executive Officerfor The Ice Cream Alliance says, “The icecream industry plays a major part in theeconomy of the UK with sales of around£1.3 billion a year but many businesses arefearing for the future after being hit by asuccession of swingeing price increases.46 The Ice Cream Alliancerecently called on theChancellor to classify icecream as a food ratherthan a luxury item andreduce its VAT loadingwhich is currently 20%.New products have the killercombination of excellentpackaging and health claimsbacked upPHOTO: MUSCLE MILK42-47:Layout 1 23/6/14 08:32 Page 4Traditionally, ice cream contains8-10% fat and approximately15% sugar, which, together withhigh eating appeal, put itfirmly in the firing linefor health-consciousbuyers.46 Food & Drink Internationalwww.fdiforum.netFor Sales & Technical Support:01772 323 5297+(5,*+7&211(&7,21)25<285+<*,(1,&352&(66Dixon Group Europe Limited350 Walton Summit Centre, Bamber Bridge, Preston PR5 8ASTelephone: +44 (0)1772 323529 Fax: +44 (0)1772 314664marketing@dixoneurope.co.ukwww.dixoneurope.co.ukFor Sales & Technical Support:01772 323 529U Hygienic Fittings & AdaptersU Manual & Actuated ValvesU Food & Brewery HoseAssembliesU Washdown & Steam HoseAssembliesU Bespoke Design and FabricationU Full Hygienic ProductsCatalogue Available“I have written to Mr Osborne asking him to reconsider theclassification of ice cream as a luxury product and re classify itas a food and reduce the VAT levied on it to zero.“Ice cream plays an important, if often underappreciated,role in British life. It provides an affordable feel good factorwhich in today’s economic climate is sadly lacking for manyfamilies.”In her letter Mrs Carr said a reduction in VAT on ice creamwould “be welcomed by a struggling ice cream industry andwould have a significant and positive impact upon the spiritand morale of the nation.”With this in mind, obviously slashing fat and sugar contentwould clear consumer consciences and take pressure off themarket’s revenue growth curve. However, manufacturers mustfind new ways to address health concerns – yet without alteringthe essential, great experience of eating high-quality ice cream.Traditionally, ice cream contains 8-10% fat andapproximately 15% sugar, which, together with high eatingappeal, put it firmly in the firing line for health-consciousbuyers. Of the two substances, sugar is the easiest to deal with,even if it does mean using artificial sweeteners, which carrytheir own risk of market resistance.To date, attempts to market ice cream products with lowerlevels of fat have largely failed. Consumer reactions to icecream that lacks creaminess, body and smoothness have beenless than enthusiastic, and producers have run the risk ofdamaging the entire category. Companies like Palsgaard have been working to solve theseThe challenge to make low fat icecream a success is being addressedwith audacity by the industry. 42-47:Layout 1 23/6/14 08:32 Page 5Food & Drink International 47www.fdiforum.netDAIRY FOCUSPenn PackagingHarkstead Hall Barn, Harkstead,Ipswich IP9 1DBTel: +44 (0)1473 893990Email: email@penn-packaging.co.ukwww.penn-packaging.co.ukCompany ProfilePenn Packaging supply awide range of primary andsecondary packagingequipment to many industrialmarkets. SN MaschinenbauGmbH specialise inmanufacturing high qualitypouch packing systems for 3or 4 side seal pouches, doypacks, stand-up pouches, shaped pouches and more.Product ProfileBesides precise filling and high speed production, sterility and storagelife are the major challenges when filling fresh, liquid dairy products intopouches. By integrating ULTRA-CLEAN technology into the multi-stationmachines LMS 120 LP and LMS 424 LP, SN tackles this challenge withtypical German efficiency.All standard pouch formats and contents between 70ml and 350ml canbe produced on the LMS 120 LP and LMS 424 LP machines. All machineparts, including the filling area, can be cleaned and sterilised withoutdismantling.The SN ULTRA-CLEAN technology meets all international requirementsfor clean filling and is acknowledged and certified by FDA, USDA and 3ADairy. Format changeovers are easily done by exchanging completebuilding groups and by using central adjustments.YorkshirePackaging SystemsTel: 01924 441355Email: enquiries@yps.co.ukwww.yps.co.ukYorkshire PackagingSystems, manufacturerof stainless steel shrinkwrapping machineryfor the dairy industry,has recently installedtwo lines into a dairy atthe Ashby site ofExpress Dairies.YPS hasmanufactured heavyduty shrink wrappersfor the dairy industry for many years. However, when a contract to wrapmilk for McDonald’s was won, time was of the essence. Due to the smallsize and relatively light weight of each individual bottle, a modified YPSmachine was deemed suitable and was available within the required leadtimeThe equipment supplied consisted of a stainless steel side feed sleevesealer and shrink tunnel complete with upgraded IP65 electrical controls.YPS fitted a bespoke designed standard infeed control systems to ensurepacks entered the collation area in a controlled manner. The end result isa tight transit pack consisting of 20 individual bottles of milk in a 4x5trayless format at speeds in excess of 200 bottles a minute.Following the success of this line, a full YPS manufactured heavy dutywrapper was installed for wrapping larger pints, litres and two litres.pressing issues. The result is a new offering that promises tohelp ice cream producers around the world. It’s a series ofintegrated emulsifiers and stabilisers, called PalsgaardIceTriple, with which low-fat and low-sugar ice cream has beencreated that retains the sensory properties, resistance tomelting, and storage stability of premium ice cream.The creamy mouth-feel of a great ice cream is key to itseating experience – and a powerful driver of consumer loyaltyto the brand. Defined by the distribution and size of airbubbles in the end product together with the size of icecrystals, creaminess is the result of a complex interactionbetween the composition of raw materials and the productionprocess. Prior to the arrival of Palsgaard IceTriple, no emulsifierexisted to deliver the goods where low-fat ice cream wasconcerned. Palsgaard were particularly interested in the abilityto maintain the consumer-friendly properties of low-fat icecream throughout the entire life of the product – and itstransportation. This will no doubt lead to increased uptake ofwhat should by rights already be a popular product.Overall, it seems a combination of packaging innovation anda focus on efficiency throughout the process from the field tothe retailer has meant that there is a new standard set fordairy. Once thought to be a somewhat traditional industrystuck in its ways, it is now looking like one of the mostdynamic. Reactive and embracing technology and new ideas,this could well be the start of an increasingly impressive timeto be in the industry.PHOTO: SHUTTERSTOCK.COM/ANNA-MARI WEST42-47:Layout 1 23/6/14 08:32 Page 648 Food & Drink Internationalwww.fdiforum.netDAIRY FOCUS1 + 1 = 22One sample, One preparation step, 22 testsDrug residue screening, Just add milkrandoxfood.comI+44 (0) 28 9442 2413Tenquiries@randoxfooddiagnostics.comEFor over thirty years Randox have beendeveloping and manufacturing the finestquality diagnostic assays, producing everyaspect from antibody to finished assayprotocol. This expertise and drive forquality has led Randox Food Diagnosticsto develop a range of tests for dairyproducts which allow for precision andaccurate detection of a very largeantibiotic portfolio in dairy produce.One of the many test platformsdeveloped by Randox Food Diagnostics isthe Beta-Lactam Array Plus (EV3957), amultiplex biochip test which allows for thesimultaneous detection of 15 beta-lactamcompounds from one sample and onesimple preparation.Biochip Array Technology is analysedon the Evidence range of analysers,manufactured by Randox engineers andproduces a concentration result of eachcompound below government set limits ofdetection. The results generated fromthese tests are highly favourable to that ofLC-MS/MS and provide the user with areliable semi-quantifiable concentrationresult.Randox Food Diagnostics delivers drugresidue screening – just add milk.A full test menu across all foodtypes, an explanation of thetechnology and brochures can befound at randoxfood.comAccurate detectionfrom Randox FoodDiagnosticsRandox Food Diagnostics delivers drug residue screening –just add milk.48:Layout 1 23/6/14 08:36 Page 1Food & Drink International 49www.fdiforum.netNPD SHOWCASEUnion Industries welcomes new addition tohigh speed door familyUnion Industries has expanded its range of industrial fast acting doors with the development of a lightweight internaldoor for ambient and chilled environments, the Picadoor.The introduction of the Picadoor High Speed Door comes after consultation with several customers who required alighter, smaller internal door for use by pedestrians, conveyors, pallet trucks, and trolleys. Made from high gradealuminium, the Picadoor has a maximum opening size of 2m wide x 2.5m high and has a variable fast opening speed.Unlike other doors in Union’s range, the Picadoor comes with the offer to train customers’ own engineers or theirpreferred local contractors on how to install the door. This enables future purchases to be provided on a ‘supply only’ basis,making the purchase and installation of further Picadoors more time and cost effective. Alan Hirst, Sales Director of Union Industries, says, “The Picadoor has filled a gap in the market for a lightweight rapid roll door.Its unique design and manufacture from high quality materials ensures its durability and effectiveness in the right applications.”Tel: +44 (0)113 244 8393 Email: enquiries@unionindustries.co.ukTel: 01723 584250 Email: enquiries@castlegroup.co.uk www.castleshop.co.ukLone workers are anyone who operates by themselves orwithout close supervision.Operating in uncontrolled working environments can beinevitable, but compromising your employee’s safety is nolonger an issue with a Loner SMD. Designed to raise the alarmin a variety of situations and environments ensuring that loneworkers are never truly alone.No longer should you rely on antique practices such asroutine check in phone calls to ensure your employee safety.Features of Loner SMD include:True Fall Detection Emergency Latch Motion / No Motion Monitoring Optional Check-in Monitoring GPS LocatingUltimate Sense® Technology 20 Hour Rechargeable Battery ANThill Precise Indoor Positioning LocationNeverwork aloneagain!UK first for Confection By Design ‘shines’ for Tesco FinestConfection By Design have launched a UK packaging first to fulfil a brief from Tesco for their Finest confectioneryrange. The resultant vertical quad pack is an eye catching laminate using textured brown kraft paper with aregistered window and silver hot foil applied for the Tesco Finest logo.Tesco wanted to retain the ‘Finest’ styling of a window to show the product at its best and a hot foil logo, whichare both easily available in carton format. To translate this into a flexible film is a first in the UK and CBD workedwith National Flexible to meet the brief.Innovative production methods now allow ‘shaped’ windows to be cut in register. The hot foiling held somecomplications as it is usually applied to thicker card and the texture of the paper made it difficult to retain the shinebut the result is really exceptional. A Tesco spokesman says, “We have tried to do this before without success. It ispleasing to see what can happen when an innovative packaging supplier works together with an innovative packer.”Jane Holmes, CBD’s Product Manager, says, “Flexible packaging in reel format with a registered shaped window and hot foil had not been done beforebut we asked National Flexible our film supplier for their help and the resultant pack fills all the criteria from Tesco and has produced an excellent packwhich we are delighted with.”Contact Carol Burdett, Commercial Director Tel: 01274 685566 Email: carol@nationalflexible.net www.nationalflexible.co.ukCoffee Bean Shop ‘lasers in’ on valve filmUK coffee specialists Coffee Bean Shop had successfully increased sales of their ‘artisan’ roasted coffee beans tosuch a level that to keep up with demand, they needed to move from premade bags to an automated packing line.However, there was a dilemma.To keep roasted beans and ground coffee fresh, a valve must be applied at the time of packing but the equipmentneeded to do this is very expensive and inhibits packing speed. This means roasters are faced with a problem. Do theybuy the applicator which will sit idle for much of the time, or continue to use bags which are both expensive and labourintensive?Liz Powell, Coffee Bean Shop owner, says, “Aaron Abbs, National Flexible’s Sales Manager found a solution to theimpasse. He has extensive knowledge of films and solutions to packaging problems. He worked seamlessly with ourselves and our machine company tomake sure the launch went as planned and we are very happy with the result.”National Flexible have supplied reels of printed film with lasered valves pre-applied. The valve allows the CO2 to escape and then closes to keep thecoffee fresh.Liz started her business five years ago in her kitchen and has grown by being focused on providing the finest green coffee beans from around theworld, sourced from reputable estates, and by freshly roasting beans to order in her state of the art production facility.Contact Carol Burdett, Commercial Director Tel: 01274 685566 Email: carol@nationalflexible.net www.nationalflexible.co.uk49:Layout 1 23/6/14 08:33 Page 1Next >