< Previous20 Food & Drink Internationalwww.fdiforum.netENGINEERING AND COMPONENTSThis is something that has become ofgreater concern to food and drinkmanufacturers over the last fewdecades, with the intensification ofdemand and a rising population. Asdemand increases, companies areforced to scale up their operations toremain relevant in an increasinglycompetitive market. And so anincreased emphasis is placed onengineering as companies look for waysto strengthen and increase efficiency onthe production line. The waste issue The most efficient production line isn’tsimply the one which runs the fastest,but rather one which has the leastdowntime and produces the leastwasted yield. Consumers, campaignersand governments alike have22 Á© Shutterstock/zlikovecInnovateAutomateAccelerateEfficiency in the supply chain often gets conflated tomean productivity, though these terms exist asseparate entities, rather than being synonymous of oneanother. It might be better to say that achievingproductivity is achieved through the implementation ofmore efficient processes along the production line. 20-25.qxp_Layout 1 25/06/2018 12:38 Page 1ORGANISED BY25-27 SEPT 2018NEC, BIRMINGHAMORGANISED BYPROCESSING & PACKAGING MACHINERYMATERIALS I ROBOTS I INDUSTRIAL VISIONppmashow.co.ukTHE UK’S LEADING PRODUCTION LINE EVENTSee the latest processing and packaging machinery in actionFREETO ATTENDREGISTER NOW!NEW FOR 2018)NHMƏ@MƏHMɓTDMSH@KƏKHMDTOƏNEƏJDXƏMNSDƏROD@JDQRƏ@SƏNTQƏLTRSƏ@SSDMCƏRDLHM@QR-DSVNQJƏVHSGƏHMCTRSQXƏODDQR20-25.qxp_Layout 1 25/06/2018 12:38 Page 2ENGINEERING AND COMPONENTSUNIQUE SYMMETRY. INFINITE POSSIBILITIES.POWER DISTRIBUTIONENCLOSURESCLIMATE CONTROLCountdownbegins tothe PPMAShowCelebrating its 30th anniversarythis year, the PPMA Show willreturn to the NEC Birmingham 25-27 September to showcase thelatest innovations in smartmanufacturing, processingtechnology and packagingmachinery.New to the show this year willbe the Enterprise Zone, whichwill offer visitors a focal pointfor learning, networking,discovery and live debate.Presenting the biggest andmost comprehensive line-up ofproduction technologies and solutions for the food and beverage, pharmaceutical, toiletriesand FMCG sectors, visitors to the show will see 350 exhibitors representing 1,500 brands, allunder one roof.The Enterprise Zone will include a series of educational features including live workshops,presentations, interactive discussions, question and answer sessions and panel debatecovering key topical issues and industry trends.The keynote address will be delivered by Lord Mark Price, Minister of State for Trade andInvestment who will bring his years of experience as Managing Director of Waitrose andDeputy Chairman of The John Lewis Partnership to the podium.Celebrating industry excellence and recognising innovation and smart manufacturing, theprestigious PPMA Group Industry Awards ceremony and three-course gala dinner will moveto the Hilton Birmingham Metropole Hotel at the NEC.This year, the event, which will take place on the evening of the 25 September, the firstday of the PPMA Show 2018, will be hosted by TV presenter and comedian Brian Conleyand include two new award categories; ‘Customer Service’ and ‘PPMA Best’.Dr Andrew Mint, CEO of PPMA Group of Associations, said: “Against this future optimism,the PPMA Show 2018 looks set to be one of the biggest and best to date, where visitors canbenefit from an unsurpassed skill set of experience, expertise and industry knowledge andwitness the latest processing and packaging technologies in real-time demonstrations.”For more information and to register, visit www.ppmashow.co.uk.championed behind rallying cries ofreducing food waste in the supply chain.While much of the attention has beenfocussed on supermarkets and domesticsettings, food manufacturers have a keyrole to play going forward. Food wastebegins with raw ingredients, be that onthe farm from which they were pickedand grown, or in transit. Wasted yield isan inevitable part of processing and anyaspect will, in all probability, accruesome kind of damaged goods or wastedproduct along the way.According to the Waste andResources Action Programme (WRAP),© Shutterstock/Vereshchagin Dmitry20-25.qxp_Layout 1 25/06/2018 12:38 Page 3ENGINEERING AND COMPONENTSVX25. SYSTEM PERFECTION.More options, more efficiency, less effort: This is thanks in particular to a frame profile with a 25 mm pitch pattern that is symmetrical across all levels. The VX25 is also infinitely extendable and accessible from all sides – even from the outside.IT INFRASTRUCTURESOFTWARE & SERVICESwww.rittal.co.uktwo of the biggest causes of food wasteare down to production. Firstly, thereare problems with machineryperformance, such as product blockagesand mechanical mishandling. Productdamage is estimated to be between 2.5per cent and 9 per cent. Secondly,there’s poor quality production, such asover or under baking, or products beingover or under weight. WRAP claims thatreject rates average 3.5 per cent. Overtime this adds up and can put a dent inprofits.In order to minimise this excess waste,companies are investing heavily in newtechnologies and equipment. Part of thesolution is with savvy design and overalltechnical improvements. Whilediagnostic tools and software performan invaluable role, nothing can quitecompare to “walking the line” as it were.By examining and inspecting productionprocesses first-hand, problems can beidentified between various parts of theproduction line. For example, anoperations manager might noticewhether there are any cases ofmachinery performance problems suchas product jams and mechanicalmishandling. Companies can also minimise wastemy ensuring Standing OperationProcedures are appropriate. Here WRAPasks whether customer or internalspecifications can be challenged to24 ÁRittal’s essential tips for enclosuretemperature management Protection of critical equipmentMaintaining an internal temperature withinrequired parameters is of fundamentalimportance. This often requires an activecooling solution because heat is trappedinside enclosures designed to protect againstthe ingress of solid objects and water to alevel appropriate for many manufacturingfacilities. Care needs to be taken when selectingclimate control equipment to ensure it’ssuitably robust to handle the rigours of theenvironment in which it’s situated.Cleaning/maintenance regimeEstablishing a regular inspection andcleaning routine for cooling equipment isvery good practice. Cooling systems must also be kept clean to maintain the highest levelsof hygiene. Increasing energy efficiency = reduced costsIt’s important, from both an environmental and a cost-saving standpoint, for foods andbeverage producers to adopt energy efficient technologies. With a spotlight on carbonfootprints and energy prices rising globally, it’s vital that the energy consumed bymanufacturing processes is reduced where possible.For more information, visit www.rittal.co.uk.20-25.qxp_Layout 1 25/06/2018 12:38 Page 4SCHOTT breaks through the 100k unitsmark with transparent doorsSince the market launchin 2015, SCHOTT hassuccessfully deliveredmore than 100,000transparent glass doorsystems to customers. Fora long time, food retailerslike Lidl, Dia and Auchanhave been benefiting froman unobstructed view oftheir product range –without cumbersomedoorframes and verticalprofiles. “The transparent,frameless glass doorsystems from SCHOTTproved to be really useful here. They allow a clear view of the products and therebysimplify the orientation and decision at the POS for the customer,” said Christian Köhler,Vice President Food Display at SCHOTT. “This new transparency in the chiller section isa key aspect when retailers are choosing how to close open chiller sections.”As swing or sliding doors, the Termofrost chiller door models require no visible frameon the long sides. Due to transparent spacers in the isolating glass, the frame structureis hardly noticeable enabling an unobstructed view of the goods on the shelf.For more information, visit www.schott.com.HYGIENIC PROCESS VALVES• HOSE ASSEMBLIES • VALVES • PUMPS • COUPLINGS • UNIONS • CLAMPS • ADAPTERS •Hygienic & Aseptic RangeCall Dixon on: +44 (0)1772 323529 or visit dixoneurope.co.uk24 Food & Drink Internationalwww.fdiforum.netENGINEERING AND COMPONENTSLorien supports expansion at historicPolish brewery Lorien Engineering Solutions issupporting the construction of anew bottling plant for one ofEurope’s oldest breweries.Namysłów Brewery makes beersat its factory near Wroclaw and cantrace its brewing history back to1321. Lorien is an engineering designand project management firmbased in Wroclaw, Poland, andBurton-on-Trent, UK, with a clientportfolio that includes some of thebest-known manufacturers in eithercountry.The new Namysłów Brewerybuilding will contain a high capacitybottling line and additional warehousing facilities, offices and laboratories.Lorien has been commissioned to provide engineering services from concept throughto detailed design for the building. Łukasz Kolendowicz, Managing Director of Lorien Engineering Polska, said: “We willensure that the new building can be seamlessly integrated with Browar Namysłów’sexisting manufacturing facilities while ensuring that it meets all planning regulations.”Initial concept studies started in late 2017 with Lorien’s work set to be completed inJuly.For more information, visit www.lorienengineering.com.reduce waste but still be necessarystandards. Staff might also being overcautious when it comes to quality checkingand throwing out perfectly good product.In this regard, it’s worth ensuring that staffconform to the same quality standards. Automating the supply chain Consumers are exponentially demandinghigher quality products and in increasinglylarger quantities, leaving the industry tryingto find new ways to increase productivity.The challenge, however, lies in doing sowithout extending timescales or rampingup costs. Needless to say, this isn’t an easyendeavour. The deployment of new andever more innovative technologies ishelping to hasten the production processwithout comprising quality or resulting inmore wasted product. Realistically, there’s only one way ofachieving this goal – automation. Thoughautomated and even semi-automatedprocesses have long been part of theproduction line, many companies,particularly those operating on a smallerscale, still use manual processes. Cutting,cleaning and other tasks that were typicallyundertaken by human workers can all nowbe achieved with greater speed, proficiencyand precision with automated processes.Likewise, more modern procedures – suchas the emulsification and de-gassing offood and drinks products – can also beundertaken more efficiently withautomated technologies. Fortunately,companies like SMC Pneumatics, whichoffers solutions from air preparation,instrumentation, through to vales andactuators practically covering every step inthe automation process, exist to assist andaid food and beverage companies. The next logical step in the on-goingautomation of the production line is withburgeoning new technologies such asartificial intelligence, augmented reality andthe internet of things. These and othersolutions promise to create a moreharmonious, interconnected supply chainhelping to ensure safety, transparency and,above all, efficiency. 20-25.qxp_Layout 1 25/06/2018 12:38 Page 5We do more.Ergomodul#GermanBlingBling#ErgomodulENGINEERING AND COMPONENTSSensing the future Sensor technology is becoming moreand more sensitive, creating a morerobust and efficient production line. Notonly can sensors help to provide peaceof mind for manufacturers andconsumers alike, but the reduction gainscan be nothing short of profound.Companies are investing in high-techsolutions such as barcode readers andother ID readers which can spotmislabelled products on the productionline. This can help put a stop to apotential product recall, most of whichare down to product labelling errors. While these solutions – known asOptical Character Verification (OCV)devices – have long been part of theproduction process, they have come onin leaps and bounds in recent years.OCVs can now operate at incrediblespeeds and are sensitive enough tocatch even the smallest errors. There’ssimply no comparison with the humaneye. Sensor technologies also offer ameans of minimising food waste,bringing us full circle. For example,companies are investing in anddeveloping systems which allow them tomonitor the temperature and humidityof perishable goods. Fluctuations ineither of these factors, or too high atemperature and humidity, can casemould and deterioration, rendering aproduct inedible. Perhaps mostbeneficial of all is that thesetechnologies can be used duringproduction and while the product is intransit. It used to be that basictemperature controls on the productionline (never mind during transportation)were unreliable. Now, however,companies rely on hyper-sensitivemonitoring systems and sensors whichare boosting efficiency and minimisingwaste by preventing productdegradation. Innovations in engineering are havinga huge impact on the industry. Processeswhich were once carried out by handcan now be completed using the latesttechnology. Great strides are beingmade to improve the individualcomponents that make up thesemachines, all with the aim of improvingproductivity and reducing waste. Thebenefits afforded by these solutions willundoubtedly shape the production offood and drink in the years to come.© Shutterstock/Max Maier20-25.qxp_Layout 1 25/06/2018 12:38 Page 626 Food & Drink Internationalwww.fdiforum.netMEET THE EXPERTS‘From field to fork’ is a buzzwordbeloved of the media for its ability toencompass the food and drink supplychain. But doing so does a disservice tothe industry, downplaying thecomplexity of the supply chain and themassive number of players workingwithin it. Almost all stages of this supply chainare reliant on water, either to growproducts, for washdowns or as anintegral ingredient in its own right. Allof that water needs to be responsiblymanaged, disposed of and measuredwith companies working tirelesslybehind the scenes to do so. Flow measurement is anotherimportant aspect of the production andprocessing process as without thiscrucial element, manufacturing couldbe plunged into chaos. Detection is critical in ensuring thatfood and drink products are free fromcontaminates, pathogens and any otherharmful additives that may haveentered along the supply chain. Metal isa common contaminated andcompanies must utilise metal detectionmethods to ensure their products aresafe. Magnetic separation is a reliablemeans of maintaining product integrityand safety. As well as testing food,laboratories are also at the cutting edgeof food trends, with the rise innutraceuticals and nutrition-addedingredients. Ensuring that food and beveragemakers stay up to date with the latestinnovations in processing andpackaging equipment is critical. To thatend, suppliers of such equipmentperform a key role in the supply chain,ensuring companies keep up with thetimes and remain competitive. The following page showcases thebest across all aspects of the supplychain, truly from field to fork andeverything in between. Send in theEXPERTS Over the next page we illustrate the huge array ofsuccessful companies that exist across the food anddrink industry and invite them to share their expertise. © Shutterstock/Pressmaster26-27.qxp_Layout 1 25/06/2018 12:33 Page 1Food & Drink International 27www.fdiforum.netMEET THE EXPERTSEriez Europe Greenway, Bedwas House Industrial Estate, Bedwas, Caerphilly, CF83 8YG, UK Tel: +44(0) 29 2086 8501 Email: info-europe@eriez.com Web: www.eriez.euCompany profile:Eriez Europe is a specialistmanufacturer of magneticseparation and metal detectorsdesigned to eliminate metalcontamination in processindustries. Their extensiveproduct range includesmagnetic separatorsincorporating ferrite and RareEarth magnets, as well as metaldetectors for in-line and end-of-line quality control and inspection.Product profile:Typically, magnetic separators are installed prior to the metaldetection stage with multiple variations available, specifically suitedfor different applications. The Eriez Prograde® range includesmagnetic tubes, grates, liquid line traps and grate-in-housings andoffers the ultimate in ferrous contamination removal. These all-stainless-steel units feature a fully welded, sanitary construction andare available in the Xtreme™ Rare Earth magnetic strength withgreater holding force, higher Gauss rating and improved separationefficiency.Metal detectors and separators safeguard against both ferrous,non-ferrous and stainless steel metal contaminants. Detectors arepositioned at different locations throughout the process line fromraw or bulk material through final package inspection, typically atcritical control points identified by the customer.MAGNETIC SEPARATIONRotronic Instruments (UK) LtdCrompton Fields, Crompton Way, Crawley, West SussexRH10 9EE. Tel: +44(0) 1293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.ukCompany profile: Rotronic is a global companymanufacturing instruments for the precisemeasurement of water activity, humidity,temperature, CO2, process pressure andairflow. Rotronic devices are specifiedthroughout the food and other industries.Experienced engineers can providemeasurement solutions for any application.Rotronic has UKAS / ISO 17025 accreditation forTemperature, Humidity and Dew Point calibration.Product profile:Rotronic manufactures water activity analysers to determine thefree moisture within food products - a good indicator of productstability and shelf life. Controlling the moisture present improvesproduct quality. Analysers provide measurements in typically less thanfive minutes. The wide product range includes the AwTherm analyserwith full temperature sample control; the HygroLab C1 laboratoryanalyser for up to four probes, handhelds for making spot-checks anda PC-based solution which is ideal when visiting suppliers’ sites. Thesensors can be calibrated to confirm performance. Full technicalproduct information is available on the website.WATER ACTIVITYOsprey House, 1 Percy Road, Huntingdon, Cambs PE29 6SZTel: +44(0) 1234 686100 Email: swilcox@alpheus.co.ukWeb: www.alpheus.co.uk Company profile:Alpheus is a leadingwater and wastewater assetmanagement companyspecialising in themanagement of largewastewater treatmentplants in the public andprivate sector. A subsidiaryof the Anglian Water Group, Alpheus combines technical andcommercial expertise delivering tailored O&M and process solutionsthat are cost-effective, sustainable and deliver value. Product profile:Imminent implementation of tighter environmental regulationse.g. the Industrials Emissions Directive will have a major impact onthe compliance and cost of emissions and effluent treatment offood and drink producers raising concerns in the sector.Alpheus operates and manages some of the largest industrialwastewater sites across the UK including the food and beveragesector. Our strength sits in our capability to understand the specificsector needs to deliver robust wastewater process solutionsconsidering clients’ operations and how these are affected byupcoming environmental regulation. Alpheus are expertly placed toadvise on the best effluent technology available for your business. WASTEWATER TREATMENTPremier Mill, Brunswick Street, Nelson, Lancashire, BB9 0HUTel: +44(0) 1282 440040 Email: info@riggsautopack.co.ukWeb: www.riggsautopack.co.uk Company profileRiggs Autopack Ltd is an award-winningBritish manufacturer of high-qualitydepositors and filling machines, transferpumps and automatic conveyor filling lines.Based in Nelson, Lancashire, the companyis a UK market leader with an excellentreputation, and supplies its equipment tothe food production industry.Product profile Riggs Autopack Ltd is able to provideFull Servo controls for its depositors and filling machines. Benefitsof using this type of control system include:Product Recipe Control* Reduced downtime on set-up between product changeover* Automatically sets fill speeds and weights to suit each productand container size* Possible interface into third party HMI for one point of controlGreater Control* Slow start / ramp up / slow finish control to increase productionon difficult food applications* Feedback and automatic adjustment via a check weigher* Automation synchronisation of individual pump speeds onmulti-pump applications* Different viscosity products have no effect on individual weightsat the same volumePROCESSING EQUIPMENT26-27.qxp_Layout 1 25/06/2018 12:33 Page 228 Food & Drink Internationalwww.fdiforum.netPOUCH PACKAGINGOne might be forgiven for thinkingthat while there has been muchinnovation in the packaging industry interms of materials, machinery andenvironmental impact, that there hasnot been much in the design sector – orat least in developing new designs of© Shutterstock/lighthunteralpPacked in apouchPackaging has long been a sector on the move, but pouch packaging is an innovation sprinting to successpackaging itself. We thought for thelongest time that we knew all there wasto know, and thus the food and drinkindustry soldiered on, content in itscertainty. Pouch packaging isn’t technically anew or emerging design factor, but itwas one slow to take off in the humanfood sector. No longer, however, as ithas taken over numerous brands andlooks set to continue its meteoric rise. From some of the largest brands tothe smallest, including Kraft Heinz andMars, pouch packaging has started totake over the shelves of supermarketsas manufacturers and retailers promoteits attractive design, functional shapeand environmental benefits. There’s noclaiming this is new technology, nomatter how much we might wish.Pouch packaging has been ubiquitousto the point of dominant in certainindustries, with pet food being onesuch example. It’s harder now to findcat food served in a can than it is apouch, and the industry has been thisway for years. Whatever the reason ittook human food to catch up, itcertainly has done so. Confectionary28-31.qxp_Layout 1 25/06/2018 12:32 Page 1Food & Drink International 29www.fdiforum.netPOUCH PACKAGINGand sweets, particularly multi-packs, arenow almost all sold in stand-uppouches, while ready meals seem set togo the same way.There are many reasons for thischange. Firstly, the lack of rigidity in thepackaging is a big selling point. Cans,cardboard and paper packaging are allvery susceptible to damage and harmbecause they need to conform to arigid shape and so cannot flex whenpressure is applied. This leads to cansbeing malformed in transit orcardboard being punctured. Pouchpackaging is typically made ofpuncture-resistant laminated film, andmany layers of it. This allows thematerial to flex and bend, taking onwater-like properties to avoid beingdamaged. While it does not offer thesame protection to the food inside,certain foodstuffs such as soups, readymeals or rice, do not fear being jostledor malformed. They will simply flowback into shape. All of this workstogether not only to reduce the chanceof damage, but also to offer longershelf life and ensure the productremains attractive on the shelf anddoes not fade or become misshapen.Stand-up pouches can also be madefrom 100% recycled materials, addingan environmental appeal to the design.As consumers become ever moreconscious and demanding when itcomes to sustainability, this is anattractive and easy way to minimisepoor exposure. This can have knock oneffects to other parts of the company.Take drinks for instance, which are stillmostly in bottle form, but some ofwhich are moving towards pouches.Bottles, plastic or otherwise, are rigidand do not offer much freedom ofmovement. They need to be carefullystacked in supported boxes when beingtransported to a distribution centre.This requires a lot of space. The sameisn’t true of pouches, which can bemore liberally stored in containers andcrates, in the knowledge that thepackaging will be unharmed and willeasily flow back into shape at the finaldestination. This means that wereseveral lorries might be needed for athousand or more bottles, a single onemight only be necessary for pouches,saving road miles – and offering yetmore environmental benefit. Printed design is easier on pouchpackaging as compared to unusuallyshaped boxes or cartons. As can beseen from any of Mars’ multi-packs,© Shutterstock/AlenKadr30 Á28-31.qxp_Layout 1 25/06/2018 12:32 Page 2Next >