< Previous20 Food & Drink Internationalwww.fdiforum.netFORKLIFT & PALLET TRUCKSLatest electric X-Range lift truck fromNexen sets off for Three Oceans With application advice and support from itsYorkshire-based dealer MH Group, Nexen Lift Truckshas supplied a 3-wheel electric X-Range forklift toThree Oceans, a supplier of high quality white-fish tothe foodservice sector.Nexen was able to meet the requirements ofThree Oceans with its new electric-powered FBXT18 counterbalance forklift, which was supplied withadditional weatherproofing and IP protection toensure it could make trips between the customer’stwo processing facilities in Hull. To ensure zeroemissions and cope with the narrow aisles at thefacilities, a three-wheel electric forklift was essential,as was weatherproofing and IP protecting, as thecompany had been faced with substantialmaintenance bills for its previous electric forklifts. MH Group’s Andy Tuffnell said: “Working withNexen was a breath of fresh air, with the companygoing above and beyond to ensure that connectors,looms, motors and motor controllers were allprotected from the weather and operating environments.”For more information, visit www.nexenlifttrucks.com.company to make better use of limitedspace. Walkways and mezzanine floorscan be unnecessary if a distribution centreis set out properly. Remote forklifts are arather new option here, with the removalof the human element allowing them tobe even smaller. This is not a far cry fromAmazon’s current warehouse initiativeswhich use drones to select products fromwarehouse racks. Remote or drone-typeforklifts may well be the next step in thewarehouse itself, and one that could havefinancial, efficiency and safety benefits foroperators. Health and safety is a common concernwith forklifts, as the Health and SafetyExecutive (HSE) is unequivocal when itcomes to materials handling in theworkplace: comply with the regulations orsuffer the consequences. Companies areencouraged to adopt a three-point strategyto tackle safety issues around handling.According to HSE guidelines, they must“avoid the need for hazardous manualhandling, so far as is reasonablypracticable”; “assess the risk of injuryfrom any hazardous manual handling thatcan’t be avoided”; and “reduce the risk ofinjury from hazardous manual handling,so far as is reasonably practicable.”A recent HSE report showed that yetagain, the supply chain was a focus pointfor dangerous injuries and fatalities, raisingthe prospect of further safety checks in thefuture. Thankfully, manufacturers offorklifts and pallet trucks regularly keepthis in mind, and it is a rare vehicle todaythat comes without some kind of structuralshield around the driver, sometimes even acage itself. Rigorously designed and tested,these can help mitigate the impacts offalling pallets or products, ensuring thatthe driver is kept safe. Even the smallest accident in theworkplace can have a devastating effect,not only on those involved, but also theentire supply chain. Many workers willdown tools to come to the aid of anyonein danger, and the entire distributioncentre might be halted while the accidentis dealt with. PHOTO: SHUTTERSTOCK.COM/BALONCICIPHOTO: SHUTTERSTOCK.COM/TYLER OLSON18-21_Layout 1 29/07/2016 11:14 Page 3Food & Drink International 21www.fdiforum.net Reduce costs Double storage space Increase productivity Indoor/Outdoor operation AC electric or LPG 2,500kg capacity #$%$& 5 year/5,000 hours warrantyAisle-Master Ltd, Co Monaghan, Ireland !"The versatile articulated truck that does it allFORKLIFT & PALLET TRUCKSWhen it comes to training, advice from the HSE and also theFLTA (Fork Lift Truck Association) is that although there maybe no legal requirement for trained drivers to undergo refreshertraining, there is potential for experienced operators to becomecomplacent. Reassessment and refresher courses enableemployers the opportunity to both identify and address anylapses in attention before they lead to a serious incident. Forsome this may be a matter of course after a given period of time,perhaps every three to five years. But for many it is somethingonly considered after the fact, when the devastating results of anaccident have been witnessed. But this will only ever be as valid as the skills and abilities ofthe supervisor, who may require his own training courses,particularly as technology develops. What was known ten yearsago might not apply now, and it is far cheaper to send asupervisor on a course than it is to suffer losses in efficiency,compensation or in the workforce. Yet again, the advice is toconsider these aspects pre-emptively, and take steps to mitigaterisk. The upcoming IMHX exhibition will feature numerousexamples of new technology and innovation within the forkliftand pallet truck industry. The event takes place on 13-16th ofSeptember at the NEC in Birmingham, and will cover thelogistics and supply chain. Materials handling vehicles, includingforklifts, have long been a staple part of the event, withprofessionals and manufacturers coming from far and wide toexhibit their products. 18-21_Layout 1 29/07/2016 11:14 Page 422 Food & Drink Internationalwww.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTTrade shows, exhibitions and industryevents are significant dates that dot thecorporate calendar. They promote cross-pollination across all facets of the foodand drink industry, spawn fresh newideas, forge new contacts and offer a peekinto the latest machinery and equipmentinnovations. It’s fair to say that whateversubset of the sector a food or drinkbusiness inhabits, they’ll be reliant onmachinery and equipment to one degreeor another. So whether you’re a micro-brewery or a rival to the megacorporations, there’ll be a vestedinterested in the latest developments. Innovation, by its very nature, is arefinement of what has come before, bothbuilding on and expanding existingcapabilities and resolving many of theissues that plague current machinery.With each new generation, there is anoticeable, if subtle, difference to that ofits predecessor, meaning the productionline is constantly in flux. Some of theinnovations in recent years include thewidespread deployment of smart andinteractive touch screens, and theintegration of the internet and wirelesscapabilities. Both of these developmentsare in keeping with the growth of the foodand drink industry but also in context tothe wider manufacturing and productionsectors. As the capabilities of thisequipment continues to expand andevolve, so too will the industry itself,becoming ever more efficient, cost-effective and reliable. Innovation not only plugs the gap ofnecessity, but also offers machinerymanufacturers and suppliers a competitiveedge with their stock and offerings. Tothat end, manufacturers are closing theMore thanmachinesThe development of machinery and equipment for the food and drinkindustry is growing in tandem with software capabilities and drivingthe ‘smart factory’ concept. PHOTO: SHUTTERSTOCK.COM/VLADIMIR NENEZIC22-27_Layout 1 29/07/2016 11:19 Page 1Food & Drink International 23www.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTProduction gains from Oliver Douglas cleaning systemsApplication versatility and performance quality are both at the heart of the reputation builtby Oliver Douglas’s washing systems. Centred on a series of stand-alone equipmentdesigns, the company’s range helps to ensure production quality and hygiene standards aremaximised in installations that typically include catering establishments and food productionfacilities. John Glover, Sales Manager at Oliver Douglas - part of the Newsmith Stainless Group -draws attention to an example where two of the company’s designs – its Panamatic andRotary Jet systems – have both been installed to meet separate yet complementaryobjectives in this area. “It is a good example of performance as the installation has toaccommodate the regular changing of mixing equipment and parts for each individualproduct range,” he said. “Although this need had been fulfilled well by hand washing in the past, the opening of anew manufacturing extension at the site in northern England presented the ideal opportunityto enhance the process. For more information, visit www.newsmiths.co.uk. gap between IT and automation, whetherthat’s in the food and drink industry orotherwise. Industry 4.0 is the term coinedto describe the fourth industrialrevolution concept or, more specifically,the current trend for automation anddata exchange in manufacturingtechnologies. The deployment ofthis revolution is evident rightacross the food and drinksupply chain, reflected anddriven in the machinery andequipment it relies on.Understanding this concept is thefuture of the food industry, machinemanufacturer Krones has developedthe SitePilot range of softwaresolutions aimed exclusively at thefood and drink industry. Thepurpose of these solutions is toenable the workflows in specificparts of a company to be organised on astreamlined, reproducible and efficientbasis. It brings all IT products under theKrones Group together under a singleroof, boasting huge efficiency, cost-savingand production gains.In their SitePilot supplementarymaterial, Krones says: “It is only with thehelp of valid production data, transparentprocesses and networked communicationthat the quantum leap can be made forturning a production facility into a smartfactory.” The deployment of the smart factoryconcept is of course reliant on softwareand IT capabilities, but software alone isnot enough to drive forward industrialevolution. The physical equipment itselfneeds to work in conjuncture with itsdigital counterpart. Manufacturers arerefining their equipment not only to workalongside more advanced software, butalso to greater degrees of manufacturingprowess. One inevitably informs theother, so trying to differentiate betweenwho’s leading the other is much like theproverbial ‘chicken and the egg’ debate. Allen Coding, who provides industrialcoding solutions for thermal transfer,inkjet, hot foil printing and labelling, hasrecently launched the MLi, a new multi-head thermal transfer which offers foodproducers cost-effective, high-speed,multi-line and -lane printing of graphicsand barcodes on thermoformed packages. Featuring up to twelve print headsintegrated on one common platform, theMLi-TE prints multiple lanessimultaneously and quickly. The systemwas designed to combine industry-leadingspeed with reduced maintenance andenhanced flexibility compared toalternative technologies at a similar pricepoint, thereby filling a growing needamong food producers. High-resolution printing of static anddynamic information such as productidentification information, date/lot/batchcodes and company logos can be quicklyadded to packages such as sachets and25 ÁPHOTO: SACHMI22-27_Layout 1 29/07/2016 11:19 Page 222-27_Layout 1 29/07/2016 11:19 Page 3Food & Drink International 25www.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTNew carrot handling facility atPoskitts set to be the UK’s mostadvanced Carrot, potato and combinable crops producer, M H Poskitt Ltd has chosenleading handling equipment manufacturer Tong Engineering to design a newcarrot handling facility in-line with their business objectives of long-term growthDesigned to incorporate the latest optical sorting equipment, the new carrothandling facility is currently being installed on-site and is set to offer fullyautomated sorting of Poskitts’ over 1000 tons of carrots each week.The new Tong carrot sorting facility will handle Poskitts washed carrot cropand is designed and built over two levels, incorporating a specially designedmezzanine floor to ensure the complete sorting process can be completedwithin one building on site at Poskitts.Guy Poskitt, Managing Director of the family company says, “Tong Engineering really looked at our aims and objectives for the new sorting facilityand have custom-designed an advanced system that meets our requirements, all within one of our existing buildings on site. We are very excitedabout the capabilities of our new sorting facility from Tong.”www.tongengineering.com stick packs for a wide variety ofapplications including, making it ideal forthe food and beverage industry.The MLi provides indelible print on avariety of substrates at industry-leadingspeeds. Each print head can print atspeeds up to 70 mm/s, with multiple printheads handling multiple lanessimultaneously at this speed. It is up to130% less expensive than digital printsystems and comparably priced withTraversing CIJ and Traversing TTOtechnologies but offers significantlyreduced maintenance compared to allthree alternative technologiesLike a well-orchestrated symphony,Sacmi-designed bag-in-box packagingsolutions stand out on account of theirharmonious linearity, reliability and highlevel of automation. On innovative, Sacmifilling monoblocs every stage is designedto enhance both product quality and user-friendliness; this is achieved by usingadvanced, stainless steel filling valves andan automatic sanitising system thatensures perfect integrity of all producttypes plus outstanding output rates of upto 960 bags per hour in the 3-litreultraclean format. Case forming,aseptic/ultra-clean filling and bag closingare fully automatic and executed in asingle passage through the machine,making it the most efficient solution forone-step processing, from raw material tofinished product, sealed and ready forpalletisation.Designed to offer maximum flexibilityPHOTO: SHUTTERSTOCK.COM/BUDIMIR JEVTIC26 Á22-27_Layout 1 29/07/2016 11:19 Page 426 Food & Drink Internationalwww.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTof use on an ever-evolving market, the new range of KUBEmodular labellers is characterised by a hard-wearing, compactstructure (made entirely of stainless steel) to which labellingunits are connected outside the turret. This allows utilisation,in parallel, of different label application technologies (self-adhesive, hot glue and cold glue) with just one passage throughthe machine. On the new KUBE, unique levels of versatilityare combined with very easy use and maintenance thanks tothe modular structural configuration, designed to ensure easyaccess to vital machine parts.Machines and complete plants for the efficient, integratedmanagement of flexi packs: the Sacmi Packaging answer to amarket trend in which demand for such packs is growing at arate of nearly 10% a year Capable of compatibility with a broadrange of technologies – vacuum, gripper, side load etc. – toensure optimal handling of such packs, Sacmi’s plantengineering solutions range from filling to case packing, frompalletizing to end-of-line solutions.A high degree of process automation allows efficient controlvia Pick&Place robots plus effective pack handling, not tomention high output rates in the order of multiples of 150doypacks per minute in various formats. All stages – handling,case packing, palletisation – can be rendered fully automatedand efficient whatever the food pack type, from flexi packs toplastic cartons and glass jars, from doypaks to HDPE bottlesand yoghurt/dessert cartons.As the food industry continues to move more extensivelytowards to the automation-led Industry 4.0 concept, themachinery and equipment it is dependent on will becomealtogether smarter, more efficient, cost-effective and integrated.The software these machines are reliant on will likewisecontinue to evolve, encompassing even greater heights ofinnovation, meaning that the smart factory will become moreand more widespread across the food and drink industry. Nolonger is this merely speculation on the industry’s future, but atangible paradigm shift that is already taking place. Softwaremight be the unifying force in this changeover, but it is still thephysical machinery and equipment that is the key driving force. PHOTO: ROBERT KNESCHKE / SHUTTERSTOCK.COMMULTI-PACK WRAPPING Automatingmulti-packingwithout RobotsA.M.P-Rose’s revolutionary auto adjustable infeed system on the‘X-Pax’ flowrap machine, has been designed for multi-packwrapping, and combines the flowrapping machine with the verylatest in linear transport systems. The linear transport system, XTS, combines the benefits of rotaryand linear systems.In many instances the feed system can achieve the same result asrobots, where the packs are lined up ready for the flowrapper. Thecost savings can be significant but this is not the only benefit over arobot, it will also have a substantially reduced footprint on thefactory floor, and the energy consumption will also be reducedmassively.The revolutionary feeding system allows individual product size,number of pieces in the pack, number of product layers, and packlength to all be changed at the touch of a button. There are no chains or gears on the system so change over partscan therefore be eliminated entirely and downtime reduced to aminimum. The XTS has an electronically adjustable infeed pitch andloading pattern.A.M.P Rose can bespoke build the feed system to suit the type ofproduct that needs to be multi-packed, whether this is for food ornon-food items.Up to 4m/s can be achieved with the feed system, without anyjerking and still with maximum positioning accuracy.Synchronisation, stopping and starting can be accomplished at anyof the stations on the entire path.This machine will be on display at the PPMA/Total exhibition inBirmingham, on stand B82.For more information, visit www.amp-rose.com or email info@amp-rose.com, alternatively you can call +44(0) 1427 611 969.22-27_Layout 1 29/07/2016 11:19 Page 5Food & Drink International 27www.fdiforum.netMACHINERY & EQUIPMENT SPOTLIGHTMIXERSThe complete mixfrom AdvancedEngineeringWith in excess of forty years experience, AE Mixers areestablished as a leader in the design and manufactureof mixing equipment for fluid processing applications.Advanced Engineering manufacture mixers for the food,cosmetic, pharmaceutical, chemical, paint and eco-fuels industries.Their range of mixers include top entry batch, sealed bearing,bottom entry, single stage and three stage inline high shear rotorstator mixers and fluid mixers.Manufactured at their purpose built factory in the UK – staffedwith skilled operators trained for quality work – these mixers aredesigned to meet specific customer requirements and are availablewith a selection of precision interchangeable mixing heads toperform essential processes including homogenisation,emulsification, blending, dispersion, solids suspension, solubilisationand particle size reduction.Mixers can be supplied as individual units or integrated with skidmounted process vessels, lifting frames and control panels. It isimportant that the correct mixer is chosen for the job in hand andAdvanced Engineering therefore offer free on site trials withpurpose built test rigs. Design and manufacturing is carried out tothe highest engineering standards, ensuring total quality at all stagesof production.With off-the-shelf spares, machine repairs and on-site service, AEMixers provides dedicated support throughout the operational lifeof the product to all customers, small or multinational.For more information, call 01706 759003, email info@aemixers.com or visit www.aemixers.com.Advanced Engineering (Middleton) Ltd5D Transpennine Trading Estate,Gorrels Way, Rochdale OL11 2PXVisit us onstand G80 atTOTAL PPMAFILLERSBlock configurationfeaturing threemachinesThe trend towards combining several units to form a singlemachine continues unbroken, for quite a simple reason: theadvantages this offers to the users far outweigh the disadvantagesinvolved. In the shape of the 3Bloc, Krones’ subsidiary Kosme hasnow presented its first concept for a block configuration featuringthree machines available in two different variants: one for PET andone for HDPE containers.3Bloc for PET containersThis consists of the following three concatenated machines:lblow-moulding machine l filler l labeller• either for applying pressure-sensitive labels• or for reel-fed wrap-around labellingThis configuration is suitable both for cylindrical or square PETbottles and for special-shaped containers. The maximum output is16,000 bottles an hour.3Bloc for HDPE containersThis consists of the following three concatenated machines:l unscrambler l filler l labeller The unscrambler is tasked with putting the already-blow-mouldedHDPE bottles in an upright position before they reach the filler andhere takes the place of the blow-moulder needed for PET containers.This 3Bloc variant can handle up to 25,000 bottles an hour. The 3Bloc concept has been based on technically sturdycomponents, and when compared to a layout featuring individualmachines scores highly in terms of its substantially lower energyconsumption, its higher efficiency and its enhanced user-friendliness. Needless to say that the block configuration alsobenefits the machine’s footprint, plus the capital investment andoperating costs involved. No intermediate conveyors are needed,for example, and the times required for format change-overs andmaintenance routines are shorter as well.For more information, visit www.krones.comor call +44(0) 1942 845000.In the shape of the 3Bloc, Kosme haspresented its first concept for a blockconfiguration featuring three concatenatedmachines for PET and HDPE containers.22-27_Layout 1 29/07/2016 11:19 Page 628 Food & Drink Internationalwww.fdiforum.netVISION, INSPECTION & DETECTIONThe increasing demand for completeproduct integrity in the food and drinkindustry means that the productionprocess must now incorporate all-encompassing and effective inspection toensure potential contaminants are locatedand removed swiftly. Product consistency– in terms of size, shape and weight – isalso essential. However, the industry mustdo this while retailers and consumersdemand the supply chain moves fasterthan ever. It is no longer reasonable orviable to expect human inspection to be fitfor the task. The solution, as ever, lieswith technology. This feature examinesthe ways in which vision systems, IDreaders and sensors are being employed tocomplete these tasks as quickly andeffectively as possible.There is only so much that humaninspection can achieve in any productionenvironment. Given that food safety isabsolutely essential from both acommercial and an ethical standpoint, it isvital that any potential for error iseliminated. The human eye is a powerfulorgan, but with the advent of MachineVision Systems we are entering an entirelynew – and potentially flawless – world. Forthe most part, food and drinksmanufacturers use Machine VisionSystems to carry out tasks such ascounting large numbers units on theproduction line, reading product labels toensure they contain accurate nutritionaland allergen information, portion control,and testing for faults in the packaging of aproduct which could result incontamination or degradation. These systems are also employed duringthe initial stages of the manufacturingprocess to measure individual ingredients,so detailed information is available atevery step of the supply chain thanks totheir integration with ever-moresophisticated hardware. 100% qualitycontrol is the bottom line, and virtuallyevery process from harvesting to sorting topackaging is now using these technologies,significantly cutting down costs whilereducing the risk of contamination atevery stage. The options in this area are certainlybecoming more advanced, however –meaning contamination and mistakes canbe spotted almost immediately without therequirement of lengthy downtime or theneed to destroy a large number ofproducts. Of course, product recalls arealso something to be avoided, especiallysince they can fatally damage relationswith both customer and consumers.It is of course welcome news for thoseusing machine vision technologies, thatthey are becoming much more costeffective: multispectral cameras – arelatively inexpensive technology that isalready used frequently in other industries– are used to inspect large quantities ofInspectanddetectNobody is perfect but we demand such from food manufacturers.But in a world where a single gram out of place, or the slightest lapsecan spell disaster, how do manufacturers cope?PHOTO: ROBERT KNESCHKE / SHUTTERSTOCK.COMPHOTO: SHUTTERSTOCK.COM/BALONCICI28-31_Layout 1 29/07/2016 12:32 Page 1Food & Drink International 29www.fdiforum.netVISION, INSPECTION & DETECTIONRead The Dots SureDotNew! Matrox SureDotOCR™ Innovative OCR technology for reading challenging dot-matrix textLearn more about SureDotOCR www.matrox.com/suredotocr/fdiCombination checkweighing andoptical inspection – discoverCV3770 Discover an advanced inspection solution which combines bothcheckweighing and vision inspection in a single process, helping toprevent both label mix-up and ensure weight verification. The CV3770 is the first product inspection solution designed forcontinually detecting defective products, ensuring accurate weights,correct labelling and verification of critical prints. The system alsocomplies with BRC and IFS quality standards criteria, helping tomaximise product safety. Learn more about the CV3770 Combination Checkweigher andOptical Inspection system from Mettler Toledo by requesting productinformation. By immediately detecting label mix-up or irregularities includingexpiry dates or lot and batch numbers, manufacturers can minimisecostly product recalls and increase productivity by reducing re-work.Furthermore, the checkweighing function accurately verifies productweight and reliably rejects over and under filled products. This helpsreduce product wastage and maintain local weights and measurelegislation.For more information, visit www.mt.com/uk-cv3770.perishable harvested products such as fresh vegetables,which they sort according to colour systems, while lasertriangulation systems are employed to ensure that thevolume of each unit is consistent. The data is thenprocessed using the integrated hardware and anyundesirable products are rejected. The increasingavailability of these systems means that companies canensure maximum productivity whilst being sure of thequality of their products; swift production can nowtake place without cutting corners. We are now looking at a situation where themachinery can inspect over 3,000 small products perminute. If you’ve ever wondered how foodmanufacturers make the products you see onsupermarket shelves so consistent in size, shape,colour, and weight, and why there are now relativelyfew cases of food poisoning caused by pre-packaged,mass-produced products, Machine Vision Systemsprovide the answer. Supermarket retailers demandabsolute consistency of portion size, and lasertechnology is by far the most accurate way to achievethis. And there’s more: this technology can also beused to ensure that the best, most visually appealingexamples of a particular product appear at the top of a30 Á28-31_Layout 1 29/07/2016 12:32 Page 2Next >