< PreviousContact Michael Adkins at HRS for more informationT: 01923 232335 michael.adkins@hrs.co.uk www.hrs.co.ukThe HRS scraped surface evaporator forconcentration of environmental waste aswell as juices, fruit and other food productsENVIRONMENTAL & FOOD WASTE EVAPORATION & PASTEURISATIONEvaporation is an effective way of reducing the impact of environmentalwaste. It is a Thermal process where energy is invested to separate waterfrom the effluent, thus reducing its volume. The evaporated water, whencondensed, can be reused again. In environmental processing the effluent isoften a fouling substance. Normal Evaporators would have a limited operation time between stops for cleaning. HRS has overcome this problemby applying the Unicus scraped surface evaporator. The scraped surface means constant removal of fouling which maintains theconstant evaporation capacity. The Unicus can evaporate to very high levelsof concentration.HRS THREE TANK BATCH PASTEURISER SYSTEM WITH THERMAL REGENERATIONCombining the HRS stainless steel tube in tube heat exchangers utilising the HRS developedheat transfer enhancing corrugated tubes we can provide a continuous 3 tank batchpasteuriser. This allows for a constant raw-feed and pasteurised supply of sludge,which allows for easy and continuous energy usage onsite compared to singletank fill-and-drain systems.This innovative continuous-batch system also utilises thermalregeneration of heat from the raw and pasteurised sludge to reducerunning costs. The HRS continuous 3 tank batch pasteuriser process can handle awide range of feed stocks and can be placed pre or post pasteuriser toallow for site flexibility. ASK US ABOUT THE NEW HRS - ROTEXROTATING SCRAPEDSURFACE HEAT EXCHANGERCorrugated tube heat exchangers Scraped surface heat exchangersTurnkey processing plants Plate Heat Exchangers Piston PumpsHRS Heat Exchangers offers a wide range of heat exchangers for hygienic processing in the food industry:Scraped surface PlateMulti tubeTriple tubeTube in tube29-31:Layout 1 25/7/14 09:30 Page 2Food & Drink International 31www.fdiforum.netWATER & WASTEinformed decisions when purchasing a greenproduct.”Environment Minister Dan Rogerson says,“Green technologies are important for theenvironment while also providing a huge growthopportunity. The ETV scheme will helppurchasers to identify British innovation and bringour green technologies to market sooner,benefitting both businesses and the environment.”Got the bottle for Africa?Health concerns towards the lack of safedrinking water across many African countries,combined with rising consumer incomes, hasdriven the packaged water market in the region togrow faster than that of Europe and the US. The African packaged water market has seenstrong growth in recent years, largelyoutperforming developed Western nations,according to Canadean’s latest soft drinksresearch. Rising incomes across the region has meant that morepeople can afford packaged water as a solution for clean and safedrinking water. In the last five years, growth levels have remained consistentlyhigh across the continent, with double-digit increases posted in anumber of countries. A compound average growth rate of 10% inAfrica has largely been driven by the Nigerian market. Nigeriamakes up two thirds of the region’s packaged water contribution.Although growth in Nigeria has slowed in recent years, per capitaconsumption continues to increase and is still well above theregional average. Africa’s high growth rate is driven by a lack of safe drinkingwater. In developing markets such as Nigeria, Tanzania and Ghana,consumers are increasingly turning to packaged water as analternative to public water supplies. As Canadean analyst Chris Strong says, “Although many Africanstates are now benefiting from rising levels of GDP and anexpanding middle class, the availability of fresh drinking watercontinues to be a problem. Rising prosperity and increasing healthconcerns have helped drive consumers towards packaged wateroptions.” Satisfying the demand for safe drinking water in a historicallypoor continent has meant that cheaper sachet packaging has tendedto dominate the market. A market share of 54% was recorded forthe pack type in 2013, most of which was contributed by Nigeriaand Ghana. Sachet packages are generally more affordable forconsumers on low incomes and are very cheap to produce, whichhas enabled soft drinks companies to build market share in thesecountries. In the coming years the African packaged water market isexpected to continue its growth, with public water supplies stillremaining rather limited or unreliable. The rate of growth is,nonetheless, forecast to slow between now and 2018 to a CAGR of5%.This reflects concerns over the quality of infrastructure acrossthe continent, as well as uncertainty about the introduction of moreexpensive PET bottles in the key Nigerian market. Balancingconsumer demand with the right price point will therefore becritical for African packaged water companies in the near future. Such figures explain why the water and waste sector is set toenjoy a comfortable future. With the hygiene of water used beingBottled water sales in Africa areset to increase as they are asource of clean drinking water.under such scrutiny and such great technology being available, it’sno surprise to find that those wasting water or not disposing of itcorrectly are becoming a rare instance indeed. With a level-headedapproach to both use and disposal, the responsible are bound tosucceed. If that’s a message that’s spreading throughout the industryas a whole, it is to be commended. PHOTO: SHUTTERSTOCK.COM/GILLES PAIREa breath of fresh air inodour control?OSILAir Pollution Control +Fully independent company with a proven trackrecord for delivering odour and air pollution solutions to the waste, recycling and associated sectors.Consultancy OSIL are recognised for having some of the leading minds with over 70 years’ collective experience in odour and air pollution abatement.Asset & Scoping Studies Site Refurbishment Full Design and New Build Turnkey ServicesSector Leading Service and Maintenance support. Proven in-house teams of Process/Mechanical/Electrical and Project Delivery Engineers as well as in-house steel and plastics fabrication. Passionate focus on long-term client relationships based on partnership,innovation and trust. Start preparing for tomorrow, today!www.osiltd.com29-31:Layout 1 25/7/14 09:30 Page 332 Food & Drink Internationalwww.fdiforum.netMACHINE VISION SYSTEMSProbably the most important task formanufacturers is ensuring consumers haveabsolute confidence in their products.Certainly, brands that have beenconnected with contamination scares havefound it extremely difficult to recovermarket share as consumers decide theycan’t be trusted.In today’s production facilities,however, it’s not just important that workis done to address this – it’s also vital thatthe work is seen to be done and records oftheir success can be easily acquired. Thisdoesn’t just provide peace of mind to themanufacturer that the introduction of thesystem has been justified in both savingdowntime and avoiding flashpoints, butalso helps provide the information thatclients now often demand to provideassurance they are reaching the higheststandards.Machine vision systems have thereforeproven totally invaluable formanufacturers in recent years. Machinevision uses image capture and analysis toautomate tasks such as inspection,gauging and counting, in addition toreading barcodes and optical characters.While human inspectors can visuallyinspect parts to judge the quality ofworkmanship, machine vision systems useadvanced hardware and softwarecomponents to perform these functions athigher speeds, reliably, and with greaterprecision. This opens up possibilities inquality assurance that were previouslyimpossible to implement, both in terms ofinspection of the product and itspackaging, and in tracking andtraceability.All products on a production line,rather than just a representative sample,can now be reviewed in real time and anyissues immediately addressed – usuallywith little if any downtime. In addition afull record of any incidents can be madeavailable to those who require theinformation. The food and drink industry nowbenefits from extremely high qualitysystems that deal with the particularrequirements of the sector. StewartJackson, Technical Sales Manager atBytronic, says, “The main thing we’reseeing at the minute is that the bigcompanies need to double check that thepackaging they’re using for the products isthe right packaging – it’s got the rightlabelling and the right artwork. Using thesystems we offer, companies are now ableto inspect 100% of their products, runningat high speed, as opposed to simply doinga batch check of one in every hundred orevery thousand.”Bytronic’s self-contained, industrial-grade vision systems, for example,combine advanced vision tools with high-speed image acquisition and processing.Their ability to inspect parts, identifydefects or guide robots is contained withina range of compact, durable housingoptions suitable for a wide range ofenvironments. The company is a preferredintegrator for Cognex, using Cognex In-Sight smart camera vision systems for itsmachine vision projects which set thestandard for automated inspection andproduct quality assurance across a broadspectrum of industries.There are various options availabledepending on the tasks that are intendedto be carried out. For jobs that requiremany inspections before the items can bepassed, a number of standard camerasoften do the job more effectively thansmart cameras. For simpler tasks, theChecker vision sensor – an all-in-oneindustrial sensor with a built-in camera,processor, lighting, optics and I/O – canprove highly valuable.One advantage of the new machinevision systems for the food and drinksector is that they deal with the specificrequirements of the industry – which hasits own unique challenges. As JörgSchmitz of Stemmer Imaging points out,A clearvisionMachine vision systems for the food and drink industry offertotal peace of mind for manufacturers and consumers alike32-34:Layout 1 25/7/14 10:00 Page 1Food & Drink International 33www.fdiforum.netBizerba Inspection Systems for the Food IndustryPut an end to costly customer complaints. The multi-functional BizerbaBVSmaxx inspection system is integrated into labelling lines and automaticallychecks the label position, text, foil colour and seal, ejects faulty samplesfrom production with a pusher and classifies products into different gradesdepending on their fat content.Every pack is 100 % quality controlled 01908 682740 info@bizerba.co.uk www.bizerba.comcasan for nimation- Camera with ultra-fast data transfer via GigE Interface- Pack inspection from above and below in the smallest space- Text inspection by means of OCR/OCV via high-resolution camera: Best before date; Price; customer information; product description; recommended preparation etc.; Position and legibility of company logo (brand protection)- 1D and 2D barcode verification- Seal inspection using a laser process to check that the packaging is airtight- Automatic height adjustment obviates the need to move the camera for different products- Integration with _statistics.BRAIN and_dataMaintenance.BRAIN“Vision systems in thefood industry are inpart subject to extremeenvironmentalconditions. Thecomponents andsystems used musttherefore be extremelyrobust mechanically orplaced in suitable protectivehousings. Another factor is thatthe processes where vision technology isapplied as a rule cover several different production stages. Here itis useful to be able to react to the multitude of tasks involved witha high performance software library, regardless of the hardware.“A special challenge for machine vision in the food industry isthe inspection of raw materials – for example, process-safemeasurement, classification and grading of meats or baked goods.Another frequently occurring task is the objective inspection ofnon-measurable product features, for example, the look of pizzatoppings.”Stemmer Imagining have created a number of vision systemsusing 3D vision which allows for extremely effective production.The LMI Gocator 3D smart camera, for example, carries out 3Dprofiling on blocks of cheese with the resulting volumetricmeasurements used to control the position of the cutting knife forslicing. Cameras sensitive to near infrared radiation, meanwhile,enable fill level determination of liquids as they can “see through”the bottle, as well as checking the correct alignment of the cap.34 PHOTO: SHUTTERSTOCK.COM/ROBERT KNESCHKEAll productson a production line,rather than just arepresentative sample,can now be reviewed inreal time and any issuesimmediately addressed –usually with little if anydowntime32-34:Layout 1 25/7/14 10:00 Page 2CAM__SC=735.296CAM__SC=847.394x=10,5 y=10,5 z=2,75CAM__SC=162.274395,472⌄423,746VISION SOLUTIONSFOR THE FOOD, BEVERAGE AND PACKAGING INDUSTRYPhone 01252 780000www.stemmer-imaging.co.ukCAM__SC=352.893 SORTING & CLASSIFYING LOCALIZATION & IDENTIFICATION READ & VERIFY MEASURE & COUNTExplore state of the art vision systems and smart cameras from Europe's largest provider. Discover how we combine leading products with out-standing competence and service to make you stronger!Imaging is our passion.ExpExpExpExplorlorlorlore se se se stattattattateoeoe of tftfttfhe heheheheheartartartartartvi vi vivivsiosiosioon nn nSORSORSORSSOTINTINTINTING &G &G &G &CL CL CLCASSASSASSASSIFYIFYIFYIFYINGINGINGING34 Food & Drink Internationalwww.fdiforum.netMACHINE VISION SYSTEMSMany other products present their own unique challengeswhen it comes to detecting potential contaminants. Frozenproducts have always been an issue and ice cream, forexample, can often prove tough to inspect because theconductive signal varies according to the temperature of theproduct. The requirement is therefore to combat anyunexpected rises and falls in the ambient and make thenecessary fine adjustments to ensure consistent sensitivity tocontaminants.Bizerba also offer an exceptional range of inspection systemsand, as with many solutions, they can be integrated intolabelling lines. Their Bizerba BVS automatically inspects thelabel position and the text printed on it, as well as the colourof the foil. Packaging sizes and barcodes can also be verifiedusing the system, and defective packages are segregated fromproduction by a pusher. It has a high-resolution camera withautomatic height adjustment and ultra-fast data transmissionvia a GigE interface. The automatic height adjustment makesit unnecessary to adjust the camera for different products.Innovation in packaging has gone hand-in-hand withinnovation in inspection and detection systems that haveconsistently kept up to date with challenging new materialsand trends. No company wants the embarrassment andexpense of a product recall, but the new inspection anddetection systems provide a clear vision for a more efficientproduction process.PHOTO: SHUTTERSTOCK.COM/TEREKHOV IGOR32-34:Layout 1 25/7/14 10:00 Page 3Food & Drink International 35www.fdiforum.netTRACEABILITYThe very nature of traceability haschanged over recent years. As NickMartin from Trace One suggests,“Traceability has typically meant retailersand manufacturers using technologies likeExcel and email to hold and shareinformation on products. “Yet these methods are slow and error-prone: making critical actions such asproduct recalls harder to facilitate. Thisleaves the industry unable to provideconsumers with the transparency theyincreasingly demand; as well as posingincreased risks to consumers, retailers andmanufacturers alike from dangerous orcontaminated products.”All the time spent trying to findinformation and conducting product recallsin a matter of days rather than hoursimpacts on companies’ bottom lines anddistracts from driving new innovativeproducts to market.Nick continues, “As consumersincreasingly demand more information onthe origin and contents of food products,being able to verify information andconvey this across the supply chain cansave countless man hours. With visibilityto consumers being championed,traceability is becoming a key issue whichwill looks to be gaining more focus.Retailers and manufacturers can gain anadvantage now by improving ways ofworking to anticipate these demands.”Seamless integrationSometimes traceability works best whenadded to a host of other improvements.For example, Europa Worldwide Logisticsand e-business company Naked Winesentered into a partnership from the startof their operations in 2008. Europareceives and stores goods for NakedWines at Europa Northampton in aHMRC warehouse. Consumers orderwines online before 5pm and receive theirselection of wines at home the followingday.However, in 2011, Naked Winesforecasted a record 90,000 orders,triggering a radical re-engineering ofwarehouse and administration processesand a completely new warehouse layoutdesign. A bespoke warehousemanagement system was introduced toTracing progressIt’s sometimes mind-boggling how food and drink manufacturers keep track of such large volumes ofstock. However, technology at every turn seems to be ensuring a smooth operation for many.Naked Wines hasincreased capacity ofits operations and as abi-product hasincreased traceability.37 35-39:Layout 1 25/7/14 09:39 Page 135-39:Layout 1 25/7/14 09:39 Page 2Food & Drink International 37www.fdiforum.netTRACEABILITYsegregate orders by case size, making it easier totrack stock balance, manage cash flow, calculateduty and generate HMRC reports and customerinvoices. Having a joined-up approach to matterscan sometimes make all the difference. It’s also value that traceability adds, as DuncanMoir, Product director of process manufacturing,at Epicor Software explains, “It doesn’t matterwhich area of the food or beverage processingindustry you are involved in, the importance oftraceability throughout your products has neverbeen greater, not just because of recent highprofile scares, but because of the requirementsput in place by retailers – after all, it is theirname, not yours, that gets plastered across themedia when problems arise.”When it happens, speed is of the essence. Ifyou cannot give complete confidence in theaccuracy of your traceability, products can bepulled, at your cost, not to mention any supplierfine that might be imposed, or range reviewexclusion. Equally the longer it takes to identifyaffected batches the greater the risk to thepublic, and more chance a blanket pull willhappen.Duncan adds, “Ultimately we all have toask ‘Can I, in under five minutes, identifyevery ingredient or component delivery, batch,storage location, machine, person, quality test,process and destination that has been involvedin a finished product’s life and at what point intime?’“Fully ERP integrated traceability not onlyremoves risk and administrative burden, itincreases confidence, margins and enables staff tofocus on making fantastic products. This is onlypart of the value-add of effective traceability - wehave seen customer revenues increase,relationships improve and in some cases evenprocessors mandated for other parts of a retailerssupply chain.”All quality and production managers dreadcustomer audits or recalls, but having all theinformation at your fingertips allows quickreactions and minimises risks to business andcustomer relationships. Similarly, having adaptable equipment toprocess a wider range or size of product makesmanaging traceability alongside other elementsBenders Paper Cups haveincreased their traceabilitywhen it comes to theirenvironmental credentials.38 easier overall. A recent example is the twin-head metal detection unit from LomaSystems, which is allowing TendercutMeats to inspect frozen meat packagedin both foil and plastic on the sameline. This gives flexibility toaccommodate changing customerdemands and offers a space-savingsolution. Following the launch of a newproduct range by one of its keycustomers - a frozen food retailer - themeat processor replaced an existingferrous-in-foil metal detector with aflexible twin-head system.Is your site compliant with Product Inspection? Call the experts...E enquires@loma.com www.loma.com / www.lockinspection.comT+44 (0)1252 893300 35-39:Layout 1 25/7/14 09:39 Page 338 Food & Drink Internationalwww.fdiforum.netTRACEABILITYThe original ferrous-in-foil detectorinspected purely foil-packaged products,such as sliced lamb in gravy. With thenew product range, plastic oven-readybags were introduced. The two materialsneeded to pass through the same machineon the same production line, but requireddifferent metal detection capabilities. Loma advised Tendercut Meats on theiroptions, recommending a combined twin-head unit, including an IQ3 system toinspect products wrapped in plastic, and aferrous-in-foil detector. By flicking aswitch, the operator can change betweenthe two heads instantaneously. Tony Bryant, UK sales manager atLoma Systems says, “There is a financialand a space saving benefit to installing atwin-head system rather than runningtwo units independently on separateconveyor belts. The advantage stems fromthe fact the heads ‘share’ a conveyor anda reject system.” Environmental efficiencyIt’s not only for product quality thatfirms are investing in traceabilitysolutions. Sometimes it can be to reduce acarbon footprint or to improveenvironmental impact, especially wherepackaging is concerned. For example,Benders Paper Cups has consolidated itsenvironmental position in the market withChain of Custody accreditations underboth Programme for the Endorsement ofForest Certification and ForestryStewardship Council. These certifications guarantee that allpaperboard used to make Benders cupscomes from sustainable managed forestry.Independently verified, the certificationsrubberstamp this across all Benders’ cupsranges giving assurance to customers andendorsing the company’s reputation.In future, all Benders cups will officiallybe recognised as meeting the requirementset out by either PEFC or FSC and, as themanufacturing process of the Bendersfactory facility has been Chain of Custodycertified, that means that the origin of thecup board is fully traceable.It seems that traceability is now notonly a watchword for making sure allproducts reach their destination on timeand intact, but also a reputation-sealingand altogether consolidating term forcorporate responsibility. The requirementsset by the industry may seem stringentand strict, but this is translating intocompanies seeking out new levels ofresponsibility and culpability in all formsof their daily operations. This can only beseen as a good thing, with environmental,fair trade and transparency all beingpleasant side effects of this fascinatingsector of the industry.PHOTO: PARTNER LOGISTICSOperations need to work hand in handwith supply chain services to ensuresmooth delivery of products, no matterwhat volume. ERP Solutions for the Fresh Food Industrywww.linkfresh.com35-39:Layout 1 25/7/14 09:39 Page 4Food & Drink International 39www.fdiforum.netTRACEABILITYAs Wilkin and Sons expanded theiroperations, the jam producer andfruit grower sought METTLERTOLEDO’s expertise to ensureappropriate capture of weighing datafor better quality control and toreduce product giveaway. Thecompany gained more than justtighter weight control – colorWeight-enabled “traffic light” scales are alsohelping productivity.Wilkin and Sons are manufacturers ofpremium quality foods, and their exclusive“Little Scarlet” strawberries have beencelebrated for generations. Their 125thanniversary was marked by a visit fromHer Majesty The Queen. When Wilkinand Sons found themselves seeking toexpand their existing fresh-fruit pack-house capacity by introducing anadditional line, it seemed natural for themto improve their overall efficiency at thesame time.The primary issue was a need to havemore visibility over the performance oftheir packing facility, in particular theirweight control and compliance withcustomer specifications. They were hopingto gather this data from in-use scales andconsolidate it centrally to allow forreporting and analysis, which could helpthem to maximise the efficiency of theiroperation. It would also give them a betterview to operators’ performance and providethe statistical data to allow the company tomaintain certain productivity rates.Local METTLER TOLEDO weighingexperts Bernie Gately and Phil Tylersuggested the installation of ICS449colorWeight-enabled scales. Thesehygienic scales’ LCD screens register withan unmistakable backlight of red or greenafter settling. Red indicates that thebalance contents are not yet in anacceptable tolerance range, and greenindicates an operator’s ability to “goahead” and move onto the next weigh.This has increased the production processby almost 25%.Central Review Enhances ProductivityThe scales were further equipped withMETTLER TOLEDO UK’s ScaleMonitordata capture software and customer-specific SQL Server Reporting Servicesreports and dashboards. These enableeasier central productivity reviews andbetter decision-making to maintainprocessing standards. This has allowedmore precise ongoing weight-monitoringof Wilkins and Sons’ punnets.Andrey Ivanov, Wilkin and Sons’ farmmanager, says, “We’ve had a very goodexperience and excellent support andservice from Bernie and Phil. The ‘trafficlight’ system on the ICS scales hasmaintained and even improved ourproductivity, while easier data capture hasallowed better overall quality control onoutgoing products.”PHOTOS: WWW.PETERALVEY.CO.UKTo learn more about how easy-to-use METTLER TOLEDOscales and intuitive reporting software can improveaccuracy and productivity in your weighing operations, visitwww.mt.com/uk-scalemonitor.British fruit grower enhancesthroughput with easy-read scales35-39:Layout 1 25/7/14 09:39 Page 5Next >