SUPPLY CHAINMANAGEMENTSPECIALITY AND FINEFOOD FAIRSLICING, DICING ANDCUTTINGINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netAUGUST2012 £3.50 STERLINGThegreensceneThegreenscene01:Layout 1 20/7/12 11:42 Page 102:Layout 1 20/7/12 11:42 Page 1ContentsContentsAugust 2012Cover photographscourtesy of:Mainwww.shutterstock.com/PicsfiveMiddleArla FoodsIngredientsNews 4• General news• On the shelf - new products and initiatives• On line - production newsD S Smith Packaging9 Continued success for D S PackagingVitafoods Asia15 Vitafoods Asia on track to double in sizeImport and export16 With so much going on in the British Islesthis year, we take a look at how the UK andIreland are fairing in food and drink exportsSupply chain management19Regardless of the trend towards a greenersupply chain, for many the major factor inreviewing and revamping their logisticsoperations is the cost• Lakeview • Clydebuilt • PD PortsTemperature monitoring and control24The perils of losing stock through inadequatemonitoring and control of temperature mustbe obvious to many, but what technology isout there to prevent losses?Control and automation26Automation is commonplace in the industry– and the next stage is to gain a vitalcompetitive edge with ever more advancedprocesses• AutoCoding Systems • Stevens GroupSlicing, dicing and cutting 30Slicing, dicing and cutting machinery cannow deal with the most delicate ofingredientsSustainable packaging31Be it praised, criticised, redesigned orminimised, food packaging is always in theheadlines and sustainability is top of theagenda1924Website: www.fdiforum.netEditor:Steve Fisher (s.fisher@blmgroup.co.uk)Editor’s PA:Angela SharmanJournalists:Steve Williams (s.williams@blmgroup.co.uk) Mike Shields (m.shields@blmgroup.co.uk)Elis Ballard (e.ballard@blmgroup.co.uk) Michael Fisher (m.fisher@blmgroup.co.uk)Sales Director:Teri CooperSales Manager:Rebecca RobertshawAssistant Sales Manager:Sam TrottSales:Nikki Logan • Tel: +44 (0) 1472 310302Accounts & Subscriptions:Dawn CookDesign & Production:Gary Jorgensen, Mark Casson, Rachel Green (studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317Email:fdi@blmgroup.co.ukWebsite: www.fdiforum.netPart of the Business Link Magazine Group:Armstrong House, Armstrong Street, Grimsby, N E Lincs DN31 2QE EnglandAll rights reserved. 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FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforum375Water treatment 37Water treatment is vital for food and drinkproducers looking to cut their bottom lineand ensure safety with the use of innovativetechnology and new methodsAnaerobic Digestion40Turning waste into energy is somethingboth agriculture and industry are lookinginto in a big way, with estimates the sectorwill swell by unprecedented levelsUK AD & Biogas43This year’s UK AD & Biogas Expo andConference has been hailed a success byexhibitors and visitors alike and was thebusiest event yetSpeciality and Fine Food Fair45This year’s Speciality & Fine Food Fair, takingplace at London Olympia on 2nd to 4thSeptember, looks set to be bigger than everEvents47Your chance to keep abreast of forthcomingexhibitions and food fairs from around theworldClassified48Appointments 5003:Layout 1 20/7/12 12:08 Page 104:Layout 1 20/7/12 12:08 Page 1New catalogue facilitates customer productunderstanding and selectionIndustrial safety specialist Castell haslaunched a 72-page product catalogue forits main product range of trapped keyinterlocks, typically used with machineguarding and in the switchgear industry. Thecatalogue is designed to facilitate product,and system, understanding and selection.There are three factors to consider whendesigning a trapped key interlockingsystem: the power source being isolated,the number of access points there are andthe type of access. The layout of the catalogue reflects this selection process.An application example is provided for each product, clarifying the product’s functions and uses.The catalogue also features new products, a map of Castell installations worldwide, product overviews and a glossary.Castell’s product range has been developed over 90 years to provide industry with interlocks of high quality and integrity. All products are welldocumented via the recently updated data sheets and catalogue.www.fdiforum.net5Anglia Business Solutions offer a fresh approachMinor Weir & Willis, handlers of freshproduce, has selected the Microsoft Dynamicsbased LINKFresh solution from Anglia BusinessSolutions to manage its fresh produceoperations.The 70+ user LINKFresh solution will replacelegacy Sage Line 100 and Access solutions.Starting in August, LINKFresh will be deployedacross all its UK operations at its various sitesin the Midlands, South East and East Anglia.The project will utilise Microsoft Dynamics NAV2009 R2 with the Role Tailored User Interface,LINKFresh modules for Supply Chain and Operations, LINKFresh mobile applications forWarehouse Operations, Dispatch and Quality Control and the LINKFresh Touchscreen Silverlightinterface for factory floor management.Speaking about the project, Rajinder Gill, Finance Director at Minor Weir & Willis says: “TheLINKFresh solution will provide MWW with a single solution, making financial reporting andinformation sharing much easier. We will have streamlined paperless business processes and areal-time view of our inventory.”Goplasticpallets.com secures soleUK distribution of HyRackGoplasticpallets.com has gained soleUK distribution rights of the popularHyRack pallet following Belgian palletmanufacturer IPS’ acquisition of themoulds and machinery from DS SmithKaysersberg in France.Well known for its enhanced rackingperformance and durability, the HyRackpallet has a static load capacity of 7000kg,a dynamic load capacity of 2000kg and iscapable of supporting up to 1000kg inbeam and edge racking systems, makingit the racking pallet of choice for a diverserange of industries.Moulded as a single piece measuring1200mm x 1000mm, the HyRack pallet’sopen flow-through top deck has nointernal cavities where mould, dust and other contaminants can collect andis easily cleaned, hence its popularity with food ingredients companies.The design also incorporates lead in ramps on the internal edge of thebase runners, rounded block sections, optional edge lips and anti-skid plugsand can be personalised through moulded-in logos or screen printing.The drinks are on TorishimaHaving added a leadingsoft drinks manufacturerto its portfolio of clients,Torishima (Europe)Projects Ltd is building upa head of steam in thefood and drink industry.Torishima has beenchosen to refurbishboilerhouse and steamsystems, leading to adouble-digit energysaving in this area of thecompany’s London plant thanks to increased boiler efficiency, heat recoveryand associated practices. The project will deliver robust processes tosupport the anticipated peak production period during the Olympics.Long after the Olympic flame has died down, Torishima will continue toprovide gold-standard energy centres to the water/waste/renewables, food,health and process sectors. All capabilities - including design and projectmanagement and engineering disciplines - are maintained in house.Business Development Manager Guy Forrest-Hay says, “During thesechallenging times, companies are focusing on steam and hot water systemsto future proof their businesses against fuel costs, improving efficiencies aswell as reducing their carbon footprint.”New coffee jarsdelivered in an InstantWhen coffee producer Little’s needed to source anew jar for its range of flavoured instant coffees glassmanufacturer Beatson Clark was able to step in witha new lightweighted jar.Little’s was looking for a UK manufacturer toprovide glass containers, working closely withpackaging specialist Rawlings to guide them throughthe manufacturing process. Beatson Clark was able toprovide the premium solution. It was a bespoke, high-quality, low-cost product which appealed to Little’s asit was lighter than the jar they had previously used.“The Beatson Clark solution ticked all the boxesfor Little’s quality brand and the speed to productionhas been incredible” said Thomas Wood, ManagingDirector at Rawlings.“Our main focus was consistent supply,” said WillLittle.“We were really impressed with the competitiveprice was and quality of the product. We really likedthe lightweight option the cost and environmentalbenefits.”05-11:Layout 1 20/7/12 12:11 Page 105-11:Layout 1 20/7/12 12:11 Page 2Bart set to show it can do more than spiceup your lifeBart Spices has re-launchedas ‘The Bart IngredientsCompany’. The Bristol-basedcompany will be building on itsheritage of supplying herbs andspices to become a leadingsupplier of a range of cookingingredients. The business has grown tobeing only 65% herbs and spices to a wider range of ingredients. Supported by LangholmCapital, the rebranding activity will include a new logo, innovative packaging, a revampedwebsite and Facebook page. As David Collard, Chief Executive explains: “We recognised the potential in the brand to stretch beyond the herbs and spices fixture; but it was also timefor us to bring some new creative and thinking to the brand. It is very exciting to be able to talk about it for the first time.” “We have a lot in the pipeline for the next few months not only for the brand but our ranges and packaging.” www.fdiforum.net7Checkweigher’s display technology minimiseseye strain and operator fatigueThe ZQ375 is designed to meet the hygiene requirements of the foodindustry, minimising the growth of microorganisms on the scale andlimiting food trap areas where bacteria can thrive. In addition to itshygienic design, the ZQ375 features a durable IP69K-rated enclosurewith Gore Vent technology, to prevent moisture build up. Darren Waplington, Product Manager at Avery Weigh-Tronix, explains:“The addition of a Gore Vent membrane allows air and other gases topass through the enclosure while also keeping moisture out.This makes the product completely resistant tocondensation build up and water ingress that areproblematic for electronic equipment.”The ZQ375 has high-speed value capturingcapabilities of up to 80 times per secondand provides users with a range ofconnectivity options - includingEthernet, USB and wireless -simplifying the transfer of weighingdata and statistics.A grand designLaunching a new brand can be a fragmented, costlyprocess requiring a heavy investment in time andresources. A well-known manufacturer of leading FMCGsauce brands chose to commission a partnership withdesign specialists, NXL Design and packaging filmsuppliers, National Flexible to bring own-brand productsto market.NXL‘s Design Manager Phil Parkinson says: “Wewanted to give a strong brand identity, immediatelyhighlighting the products cultural origins.”“We used bold colour schemes and photographyacross the range, making use of the foil film base to pickout detail, the effect was enhanced by use of a spot mattlacquer.”Completing the design with an end film productionprocesses in mind, National Flexible were then ideallypositioned to supply the film, working from print-readyartwork.The collaboration between NXL Design and NationalFlexible ensured the development costs for the entireproject were significantly reduced and the speed tomarket increased.No more nightmare night doorsA quiet revolution is making adifference in cold rooms acrossthe land. The Green Door is themost energy saving cold roomdoor with the longest life andminimum servicing requirementavailable on the market – and theGreen Door is installed without anight door.Brian Seymour, Chairman ofSeymour Manufacturing anddeveloper of the Green Door,says, “Our driving objective is todesign products that not onlysave our customers significantamounts of money and reducetheir carbon production, but whichare also appealing to the enduser.“Our research has shown the night door, so often considered essential, isone of the most hated pieces of equipment in current use. The experience ofthose already using it verifies the Green Door’s credentials – it really can beinstalled without a night door and that in itself could be one of the biggestdevelopments in the sector for a long time.”Moody Direct launch PasTest2000Moody DirectSpares & Service haslaunched PasTest2000,a non-destructive leakdetection testingservice for pasteurisersand plate heatexchangers.PasTest2000 is apatented testingmethod which canrapidly detect smallleaks in plate heatexchangers without theneed to open the plate pack and has been tested by Campden BRI.Periodic testing using the PasTest2000 system will reassure customersabout the integrity of their plate heat exchangers, and could reduce thepossibility of a product recall where product is heated or cooled by a plateheat exchanger. This rapid, accurate test allows several heat exchangers tobe tested in a single day, which will reduces production downtime.Paul Gregory, Managing Director of Moody Direct Spares & Service, says,“PasTest2000 produces rapid, accurate results and will provide ourcustomers with the peace of mind, and the necessary documentation thattheir heat exchanger plates are without defect.”05-11:Layout 1 20/7/12 12:11 Page 3Brand owners to benefit from print equipmentinvestment bySeufertLeading European packaging supplierSeufert Transparente Verpackungen GmbHhas invested in a new, advanced UV-offsetprinting machine from Koenig & Bauer AG,continuing its dedication to innovation.STV, the packaging company thatpushed back boundaries when it firstlaunched its 85% recycled R-PET plasticpackaging and biodegradable PLA, cannow offer Europe’s brand owners even higher quality, faster printing with a smaller carbon footprint.The new high-speed 3B-format machine allows printing of six colours, a varnish and the whitecolour needed for the transparent background to be achieved in a single pass. The faster printcycles and energy saving technology result in lower overall energy consumption. Once printed, the plastic films are transformed into transparent foldingboxes and sleeves for the packaging industry, and into promotional items for brand marketing.8www.fdiforum.netHigher efficiency with new multifunctionaljoystickWith the introduction of Ergologic,Swedish truck manufacturer Atlet isoffering reach truck operators the chanceto effectively control all on-board hydraulicfunctions with minimal strain. Ergologiccomplements Atlet’s new Tergo range andis a big leap towards improved ergonomicsand increased operational efficiency.The design of the Ergologic joystick control considers the natural position and movements ofthe hand and fingers. Ensuring support for relaxed operations, the control allows the driver tohandle it in a predetermined ergonomic way, without locking the hand into a static position. Toavoid fatigue and increase efficiency, the driver can vary his or her hand position and control allhydraulic functions in the most intuitive way. Up to seven functions can be incorporated in onecontrol and it fits drivers, whatever their hand size.Jan Callderyd, Product Manager at Atlet, says, “By providing well-designed ergonomic tools likeErgologic, operational efficiency can easily be increased and secured.”FiFo accumulation tablefor pouchesNetherlands company Polyketting has launched anew FiFo accumulation concept for flexible packages.Based on their long experience in accumulationtechnology, they have developed a 100% first in firstout horizontal accumulation table especially for drinkand spout pouches.Polyketting provides accumulation and conveyortechnology for the food industry, especially for thedairy, beverage and soft drink sectors. In the mid-nineties, they were the first company to develop ahorizontal first in first out accumulation concept, andtheir experience has seen their products used bymultinationals like Elopak, Tetra Pak, Unilever andmany others. An efficiency increase of more than 10%has been reached in several production lines.The FiFo tables are designed for handling drinkcartons, PET and glass bottles, plastic trays andcontainers, and can now also be used for flexiblepackages like pouches. Polyketting accumulationequipment is well known for its open but safe design– easy to operate, inspect, clean and maintain.Mecmesin ensures top quality capsfor mineral waterPortuguese mineral water companyÁgua de Luso is using five MecmesinTornado digital torque testers to ensurethe quality of the tamper-evident capson their PET bottle packaging.At their bottling plant in Luso, bottlesare routinely tested for correct closuretorque. Capping machines must capbottles at a torque that provides aquality-assured, leak-preventing sealbut allows consumers easy access tothe bottle’s contents.A quick, easily performable torquetest provides an effective solution.Mecmesin’s 10N.m Tornado digitaltorque tester is a compact, portable, easy-to-use instrument that offerspackaging manufacturers such as Água de Luso, line-side pass/fail andtamper-evident (slip and bridge torque) testing capability. Previously, torque testing of bottle caps was performed using a lessaccurate, analogue gauge-based manual testing device. The Tornado’sdigital torque capture technology combined with clear intuitive controls,easy-to-read pass/fail parameters and an on-board memory to keepstatistical results offers far greater accuracy.Castell and Traka produce intelligentloading bay safety systemIndustrial safetyspecialist Castell andaccess control expertTraka have joined forcesto create DockSafe, anintelligent loading baysafety system.DockSafe usesTraka’s immobilisersystem to controlaccess both to theloading bay and Castell’s Salvo Susie mechanical locking device. Thisensures only authorised users can gain access to loading bay equipment.Access is granted through the intelligent Traka iFob, which allowsCastell’s Salvo Susie to be released and fitted to the articulated trailer’sexposed emergency airline coupling. A Castell key is subsequently releasedfrom the Susie and inserted into the Salvo Control Panel, enabling the baydoors to be opened. This ensures the trailer is immobilised while loading orunloading takes place.David Hughes, global sales director at Castell, says, “The ability to trackand control who is accessing equipment delivers increased safety, improvedefficiency and a complete end-to-end audit trail. I believe this presents themarket with a unique solution.”05-11:Layout 1 20/7/12 12:11 Page 4an anti-slipcoating toprevent productslippage. Thismeans the bottlestays firmly in placefor the product labelto be ‘on view’ to theconsumer.Branding is visibleon the sides and topof the pack foridentification and thepack features an easyopening device for therecipient of the delivery. TerryMorgan, Market Development Director, DS Smith Packaging, says,“This is a great example of supply chain efficiency coupled withimproved presentation. It’s innovation tailored to the customers’marketplace and fundamental to what we do at DS Smith. Theawards are a recognition of the hard work and talent of our designand technical teams”.Zorba dips into thebenefitsZorba have packed a great deal in their ten years working withDS Smith Packaging. Zorba Delicacies is a specialist food companythat has continued to expand ever since 1976, thanks tosupermarkets’ high demand for premium dips, spreads andsandwich fillings.Tony Foster says, “We’re proud to have worked closely withZorba Foods for such a long time. Our focus has been on optimumperformance and on developing packs and automated packingsystems for Zorba’s state-of-the-art production facility.”The breadth of the DS Smith offering means the two companieshave enjoyed many successes from major installations of six trayerectors and two robotic packers, to development of retail readypackaging formats and several primary sleeves recognised as aleading pack style in the chilled product category. It’s clear whileZorba “bring flavour to life”, DS Smith Packaging “Make IdeasHappen” for their customers... from factory floor to retail store!DS Smith Packaging, Beech House, Whitebrook Park, 68 Lower Cookham Road, Maidenhead, Berkshire, SL6 8XY Tel: 0845 260 70 80 Email: sales.support@dssp.comwww.dssmithpackaging.comContinued success forDS Smith PackagingAwards continue to flow intoDS Smith Packaging withthe recent presentationof Gold, two Silversand a highlycommendedaccolade from theEuropeanFlexographicIndustryAssociation.The Gold went toDS Smith PackagingClay Cross for a highlyimpactful Jaffa Yard packdisplayed in the majorsupermarkets during the Christmas period. The wide web fourcolour pre-print on clay coated paper used water based inks and aregistered varnish.DS Smith Packaging Featherstone picked up a Silver awardwith a visually striking effect for Seabrooks Crisps. The fivecolour print replicates a superb product shot and backgroundtexture that depicts a traditional potato sack. It demonstrates DSSmith’s R-Flute board is capable of being post printed in fivecolours to the highest standards.Tony Foster, Sector Director, says, “It’s always a great honourto receive awards on behalf of our customers and their brands.We have lots of skilled people making good use of our PackRightbusiness tools, turning ideas into commercial innovations. At DSSmith Packaging we’re focused on helping customers succeed atthe point of sale, while reducing cost and carbon in a sustainablemanner. It’s how we Make Ideas Happen.”Award for Excellencefor DS Smith PackagingDS Smith Packaging also received the Starpack Award forExcellence for a presentation pack designed and produced forLaithwaite’s Wine to package their Hugh Johnson wine selection.The 100% recyclable pack came as a result of Laithwaite’s requestfor a postal pack for fulfilment and supply of wine for internetsales.The pack specifically developed to replace wood, provides spaceefficiency and excellent presentation of six wine bottles. Thebottle is protected by the corrugated fitments which incorporateD S SMITH PACKAGINGwww.fdiforum.net905-11:Layout 1 20/7/12 12:11 Page 5Next >