< Previous30 Food & Drink Internationalwww.fdiforum.netVISION, INSPECTION & DETECTIONOvercome the challenges of dot-matrix text with Matrox SureDotOCR™Matrox SureDotOCR™ is the first OCR technology specifically designed to overcome thechallenges of using inkjet-printed, dot-matrix text in vision inspection applications, particularly onpackaging lines in the food, beverage and healthcare sectors. Existing solutions for reading dot-matrix product identification information such asmanufacturing date, expiry date, lot size and product number are limited because they involvecase-specific image pre-processing to form solid-stroked text prior to using traditional OCR. SureDotOCR requires simply specifying the expected dot size and dimensions of a boxframing the entire text of interest. The software handles non-uniform dot spacing; deformed,skewed and touching characters; rotated text strings; varying contrast; uneven backgroundsand other anomalies. SureDotOCR also accepts grammar rules such as letter only, digit only, specific letter(s),specific digit(s), specific punctuation mark(s) and other designations at each character positionto further enhance reading accuracy. Matrox SureDotOCR™ enables more efficient producttraceability and recall management. For more information, visit www.matrox.com/suredotocr/fdi.SureDotmultipack or crate. Some vision systemscan even be used to aid the assembly ofmulti-part products such as pizzas andcakes if the machinery is pre-programmedwith the correct information andintegrated with the required robotics onthe production line.With traceability also a key concern, theadvent of Optical Character Verification(OCV) has been a huge boon for theindustry. OCV is principally used to ensurethat products are labelled correctly. Use-by-and best-before dates must match theactual product, and the information printedon a product’s packaging must be 100%legible in case of product recall and otherworst-case scenarios. Most OCV devicesused in food manufacture are font-basedID-readers that are pre-programmed torecognise particular details such as specificallergen advice and nutritional information.In cases of poor legibility, the device willautomatically reject the product, ensuringabsolute quality control and removing theneed for a costly and time-consuming re-evaluation of the kind traditionally carriedout by human operatives.Product safety – an absolute must in aquality-driven environment – can also beguaranteed through the use of MachineVision Systems. For example, lasertriangulation devices similar to those usedto measure size, weight and consistencycan be employed to ensure the overallintegrity of a product’s packaging. Toguarantee maximum freshness and preventpotential contamination, it is vital that anyseals, lids, bags and bottle-tops arechecked for flaws or signs of tampering.Triangulation devices will do a muchbetter job than older 2-D imaging systemsbecause they are able to capture a fargreater level of detail, identifying even thesmallest imperfections. The otheradvantage of using a 3-D system, ofcourse, is that it will pick up flaws onevery side of a unit of packaging or rawproduct and not just on its immediatelyvisible surfaces. Manufacturers are also focused onreducing the impact of their systems onthe manufacturing process as a whole.While hygiene and safety are important,the efficiency and profitability of a site stillneeds to be a major concern – as even theslightest interruption can prove costly.Global manufacturer VEGA is one suchcompany, who’s 80GHz Bluetooth sensorscan be operated by engineers from saferlocations, possibly even outside cleanrooms in the food industry. No covers areremoved or wires connected to thesensors, so in some cases `hot work`permits may not even be necessary. Aswell as keeping the engineers safe, thisalso prevents possible contamination byallowing a worker into the clean roomduring the process. Even during the nascent stages of thefood production process, such as wheneggs are checked to see if they aredeveloping at the desired rate, MachineVision Systems can play a key role.Traditional methods of checking eggs weretime-consuming and laborious, involvingcandles and, of course, a pair of humanhands. But we now have automatedcandles and candle-simulators which, likethe other technologies described in thisfeature, can be integrated with hardwareand programmed to sort and discardflawed examples of the product, ensuringthat no underdeveloped eggs find theirway onto the factory floor. This is yetanother example of how the technologycan be used to increase productivity andprevent health risks. It is clear that Machine Vision Systemswill shape the future of the food anddrinks industry in a variety of ways.Automated systems can help save time andmoney at every stage of the productionprocess. They can also be used to ensureproduct safety, which, in a quality-driveworld where reputations are constantly onthe line, is a highly desirable outcome. PHOTO: SHUTTERSTOCK.COM/EKATERINA_MINAEVA28-31_Layout 1 29/07/2016 12:32 Page 3When it comes to contactless level measurement of liquids in small containers, smaller is better. With the smallest antenna of its kind, VEGAPULS 64 is simply the greatest! With its excellent focusing and insensitivity to condensation or buildup, this new radar sensor is truly exceptional. Simply world-class! www.vega.com/radarThe ultimate for small tanks!The future is 80 GHz: a new generation of radar level sensors 28-31_Layout 1 29/07/2016 12:32 Page 432 Food & Drink Internationalwww.fdiforum.netENGINEERING & COMPONENTSAt one time, veganism was a nearinsignificant niche in an otherwise meat-dominated market. Although there havebeen impressive inroads into thevegetarian subset over the decades, withQuorn in particular positioning itself as acredible and cost-effective alternative tomeat, veganism hasn’t fared nearly aswell. That is until the last few years, andnow the meat-free market is booming,driven by the growing number ofconsumers adopting a vegan diet, and thegrowing trend for meat eaters to cut backon their consumption of animal protein.The rise of ‘flexitarianism’ is also playinga role, indicating, perhaps, the diet bestsuited to responsibly manage andmove away from carbonintensive animal farming. It’s a fair observation that the meat-free sector is one of the food industry’smost interesting markets, as much forwhat’s happening at the consumer levelas on the production side, namelyengineering. Lab grown meat has beentouted as the future of food productionalongside insect protein, both of whichhave become media mainstays over thelast few years. There’s a growing weighton both sources of protein as the globalpopulation is forecast to keep rising atan astonishingrate. Genetically modified vegetables arearguably more controversial now thanthey have ever been, with the debatemost recently aimed at GMO labellingon food products. At best, people thinkof GMO fruits and vegetables as twee, asin the case of the square watermelon, ordownright dangerous. If indeed this isthe direction the food industry isheaded, then there is an increasedresponsibility on the abilities andskillsets of engineers. The central ethical dilemma thatsurrounds lab-grown meat is thatPHOTO: SHUTTERSTOCK.COM/SIMON BOOTHSend in the engineersFood engineers hold the key to feeding our rising population, reducing our reliance on carbon intensivefarming and making us altogether healthier. 32-33_Layout 1 29/07/2016 11:29 Page 1Food & Drink International 33www.fdiforum.netENGINEERING & COMPONENTSif this kind of protein can be producedwithout killing an animal, therebyremoving the ‘cruelty’ aspect from theequation, will it be embraced by vegans.Israeli start-up Super Meat, with theirvegan co-CEO Koby Barak, thinks so. Thecompany produce a cultured meat productthat is grown from chicken stem cells inlabs originating from a painless biopsy.The research team is headed up byProfessor Yaakov Nahmias, an expert inthe field of tissue engineering andnanotechnology at Hebrew University.Barak and Nahmias together endeavour tocreate a sustainable, cruelty-free chickenproduct, which will grow in a nutrient richslurry in a meat-producing machine, in arestaurant and/or in the home. Todemonstrate the consumer demand forsuch products, and indeed the growingsocietal need, the company’scrowdfunding campaign met its fundinggoal in only eight days. Super Meat is building on the successof its predecessor, with the Dutch teambehind the world’s first lab-grown burgerhoping to have a product on sale in aslittle as five years. Peter Vestrate,consultant and food scientist, ProfessorMark Prost, who developed the originallab-grown burger, and MaastrichtUniversity are to establish Mosa Meat, anew company which will look at ways ofmaking the lab engineered burger appealon a more sensory level and make itcheaper for consumers – two crucialhurdles that must be overcome for lab-grown meat protein to have any realimpact. The company will employ up to25 scientists, lab technicians, managersand engineers with a key aim oftroubleshooting how to mass producethe meat. Another key aspect of thisresearch will be in utilising 3D printing(see May 2016 issue) to discover ways ofmaking chops and steaks, something thatis likely to take much longer tocommercialise. Tissue and genetic engineers will have agreater role to play in the food industry ifindeed our future diet is supported by labgrown protein. As the population risesand the carbon footprint of livestockbecomes more of a concern, it serves tofollow that genetically engineered meatwith a dramatically smaller landmass andcarbon requirements would be the mostlogical successor. PHOTO: SHUTTERSTOCK.COM/VALENTYN VOLKOVPHOTO: SHUTTERSTOCK.COM/VANYAIVANOVA32-33_Layout 1 29/07/2016 11:29 Page 234 Food & Drink Internationalwww.fdiforum.netPACKAGING MATERIALS & DESIGNPackaging has long been thedetermining factor in the success of manybrands and this has changed little inrecent years. Consumers may now bemore conscious of what they desire, butscience still shows that aestheticallypleasing packaging catches the eye. Thetrick now is in ensuring that once thecustomer’s attention is caught, they do notput down the product. Consumer demands and expectationshave led to an increased level ofinteraction, first with labels and caloriecounts, then with ever more specificinformation on RDA’s and information onwhere the product was sourced from. Ontop of that, conscientious consumers aredemanding that packaging have as small anenvironmental impact as possible. All ofthis must be done without compromisingthe integral elements of appearance,strength and design. Hence, food packagingneeds to be engineered for increasedstrength, using less material, and alwaystaking into account the cost element.This has led to major overhauls of thepackaging process in many companies –and some find this a challenge. Investmentcosts for regulation and legislation willalways be a difficult factor, especially withvarying standards across the EU. Theseare necessities that cannot be avoidedhowever, and as labelling is one of thefastest-changing sectors when it comes tochanges in legislation, it is something thatmany are forced to quickly adapt to.Considering the large quantities offinished products that go through amanufacturing facility in any given day,there is also a necessity for a flawless andefficiency system that can work withbatches of well over 10,000 individualproducts. All of this with minimaldowntime, efficient energy usage andunparalleled accuracy.This provides problems both within themanufacturing facility itself, but also thewarehouse and distribution sector –specifically in end of line packaging. Onesolution to this is to automate the systemas much as possible, but to adapt forvaried product lines by having some formof off-line automation. By having aseparate automation machine, as opposedto one that is part of a specifiedproduction line, changes can be made tosettings based on what is needed at thetime. This is particularly useful for pallet-wrapping in warehouses, as it allowspallets of different sizes to beaccommodated. In addition to this, the vast majority ofcompanies in the food and drink sector arehaving to measure and report on theenvironmental performance of theirpackaging. In fact, some companies areeven taking a more proactive approach byusing packaging assessments at the designphase, which can offer an opportunity toreduce costs in their supply chains whilealso reinforcing their corporate socialresponsibility activities and brand image.All this obviously has to come in additionto the packaging remaining secure androbust throughout the supply chain.Many packaging specialists have boostedtheir research and developmentdepartments to emphasise this newapproach, and focus is now on packagingthat is made from plant, food or otherwisesustainable material. One packaging concept that has provenparticularly popular in recent years is thatof corrugated. With a wide range ofbenefits, including an inherent flexibility,corrugated can be modified for differentcrops and misshapen produce, therebyreducing the potential for bruising andEver-conscious consumers aredriving packaging innovation,with many companies adaptingto new trends to stay atop themarket. Wrapped upWrapped up34-37_Layout 1 29/07/2016 12:29 Page 1Food & Drink International 35www.fdiforum.netPACKAGING MATERIALS & DESIGNInnovia clearly focussed on BOPPEarlier this year Innovia announced the sale of its cellulose films business. Now threemonths later with the deal closed, Innovia is refocusing its strategy clearly upon buildingand strengthening its specialty biaxially oriented polypropylene (BOPP) films business. They are concentrating their efforts into primary global core markets – highperformance advanced polymer solutions for labels, packaging, tobacco, and securityfilms. Internally, Innovia is restructuring to ensure that their BOPP focus is fully alignedthroughout the business, people, service and systems.Joe Piccione, Managing Director, Innovia Films, said: “We have always been aspecialty films business which represents over 80% of our sales. In addition to ourunique and bespoke bubble extrusion process, one of our core strengths is surfaceengineering. We are experts in tailoring films to our customers’ requirements whetherthat is barrier, thickness, printability, shrink tightening, squeezability or fast sealing filmsfor optimised performance.” For more information, visit www.innoviafilms.com skin damage that can sometimes occurwith rigid packaging.Because over 80% of corrugated isrecycled, while new boxes are madefrom recycled material, theenvironmental footprint is very low.Where new fibre is used, it comes fromsustainably managed forests. Thiscommitment to responsible forestmanagement has made a hugecontribution to the increase in the sizeof Europe’s forests – up by 30% since1950. Although it has been used inone form or other for many years, thecorrugated packaging industry iscontinually investing in newtechnologies to ensure it retains its toptable place.Innovative technology is improvingin-store performance as well throughPHOTO: SHUTTERSTOCK.COM/ADISAi2r expandsmuffin wrap range Telford-based i2r Packaging Solutions Ltd haverecently expanded their range of tulip muffin wrapsto include both stepped and micro sizes. The movefollows increased demand for their baking products,which includes greaseproof papers.Launched in April at this year’s Farm Shop andDeli Show, i2r’s new baking division aims to providethe industry with a one-stop-shop for bothaluminium foil containers and FSC accredited tulippaper products direct from a UK manufacturer.i2r Baking’s Guy Rowledge said: “The newlaunch of our tulip muffin wraps has been fantasticwith a number of key supply contracts beingsecured in the UK and export markets. We continueto work very closely with our customers to look atnew products and grow this very exciting part of ourbusiness.”The stepped and micro muffin wrap sizes areavailable in printed sheet and coloured options,using FSC accredited paper.For more information, visitwww.i2rps.com/baking. 36 Á34-37_Layout 1 29/07/2016 12:29 Page 2We have the UK’s leading B2B ecommerce website, offering 2,500 stock products. 36 Food & Drink Internationalwww.fdiforum.netPACKAGING MATERIALS & DESIGNTransparent packagingmade from Bio-PETThe company Seufert offers a newmaterial, Bio-PET, which allowsproducing resource-savingtransparent packaging atnearly the same costs astraditional clear packaging.Bio-based PET(polyethylene terephthalate)is partly manufactured fromrenewable resources (30%),thus conserving fossilresources. Bio-PET may betransformed into clear foldingboxes and transparent sleevesin the same way as standard PET.And it can be recycled together withconventional PET. “Previous vegetable based materials had one big drawback - price, “says managing director Thomas Pfaff and explains: “our packaging fromBio-PET is now available at nearly the same price as transparentpackaging from traditional PET”. Until the end of the year, the Germancompany has a special offer for those, who would like to try Bio-PET: CO2emissions resulting from manufacturing of packaging from Bio-PET willbe compensated through a carbon neutral scheme free of charge for thecustomer.www.seufert.com better print capability. High Quality PostPrint has transformed corrugatedpackaging from protective transitpackaging into multi-functional, colourfulretail ready packs, without compromisingproduct integrity. Liners and coatings arealso being developed for corrugatedmaterial to provide even greater foodfreshness and, with the advent of moderncorrugated processes, such as new flutingsthat offer up to 23% storage space saving,it also offers more efficient logisticsmanagement through better use of pallets,resulting in fewer vehicles on the road.Digital technology has certainlyprovided more flexibility for packagingdesign, especially as legal requirementshave required much more information ison packaging that was previously the case.Many companies have introduced QRcodes on their products to allow customersto receive promotional material and muchelse, while it also has value when it comesto traceability.Combined with this, though, thechallenge for products more than everbefore is to stand out on the shelves – sothe importance of a distinctive, highquality package is emphasised. Howeverthis distinctive nature has to go hand inhand with convenience in distribution anddisplay. While creativity is all-important,PHOTO: ROBERT KNESCHKE / SHUTTERSTOCK.COM34-37_Layout 1 29/07/2016 12:29 Page 3Visit our website for more information about our creative combination packaging solutions and our wide range of sustainable food packaging:BRITISH FOOD PACKAGING DESIGNER & MANUFACTURERwww.colpacpackaging.com enquiries@colpac.co.uk | +44 (0) 1525 712 261Food & Drink International 37www.fdiforum.netPACKAGING MATERIALS & DESIGNNational Flexible’sgrab bag grabsattentionNational Flexible had several new packaging formats on showat the Packaging Innovations Exhibition but were surprised whenmost visitors simply wanted to talk about the new flowwrap grabbag. It was undoubtedly the star of the show.The pack is formed using standard flow wrapping machinerywith few modifications. It is essentially film on the reel which dramatically reduces the labour costs associated with packing by hand, whilst alsoimproving manufacturing efficiencies at speeds of up to 30 packs per minute.Currently available in a paper or lacquered finish, the film has no pre-creasing and the window aligns 100% every time. Extra benefits of this thinnerfilm are it not only saves packaging waste but gives perfect ‘on shelf pack presentation.’ The combination of this upright laminate pack, on anautomated machine has already been recognised as a breakthrough for sandwich pack manufacture and presentation. For more information, visit www.nationalflexible.co.uk. products that require distributors to obtainnew pallets, retailers to invest in new displayunits and consumers to rearrange theirkitchen shelves are unlikely to proveparticularly popular at any stage in thesupply chain.The packaging of many of the products onretailers’ shelves remain in the iconic anddistinctive designs they have kept for manyyears – but while their look hasn’t changed,the materials used often have to create moreeffective, efficient and secure packaging. Toachieve higher shelf spacing is the challengefacing all producers. This is particularly soin convenience stores where space is evenmore limited. The use of mixed tray systemstherefore has great merit, allowing morevariety, choice and range of products. Withan assorted range of products there’s agreater chance of seeing something whichwill catch the eye. For smaller outlets, theseassorted product trays provide a creative wayfor retailers to offer a wider product range ina smaller space.Consumer demand leading to a rise insingle serve packs and varied size packs hasalso driven innovation in the packagingsector. For instance Colpac, one of the UK’slongest established manufacturers of foodpackaging solutions, has expanded theirrange of Combione packaging in directresponse to this – particularly to fuel theincreasingly popular `food-to-go` market.This surge in demand is consistent withthe growing requests Colpac havewitnessed for more varied pack sizes, inparticular smaller sizes to suit healthconscious customers looking for tighterportion control. Neil Goldman, ManagingDirector of Colpac explains: “OurCombione® packs have been extremelysuccessful and the new, reduced volume,pack will suit smaller sized portions but willalso enable retailers to up sell with sideportions of salad or fruit to accompanymain meals, catering to this growingmarket segment.”All of this rapid adaptation is the reasonfor the vast number of packaging showsand events that take place around theglobe. A number which seems to eclipsethat of many other industries, fromingredients to processing and even retail.To many, packaging is first and foremost inthe food and drink industry – and as timegoes on, there may be even more challengesfor the sector.Many politicians, business people andmembers of the public often ask what acountry, an economy or even a sport willlook like in 10-15 years’ time. Perhaps thebig question should be, how unrecognisablewill the packaging industry become in thattime? PHOTO: SHUTTERSTOCK.COM/JANTHIWA SUTTHIBORIBAN34-37_Layout 1 29/07/2016 12:29 Page 438 Food & Drink Internationalwww.fdiforum.netFROZEN & CHILLED FOODSThe rise of frozen and chilled foods hasremained constant in recent years, withsteady growth within the UK and EU, andrising growth in Asia and further abroad.In fact the cold chain accounts for roughly9% of the £187 billion of sales in the foodand drink industry. At the end of last yearfigures showed that approximately 41p ofevery £1 spent in the retail industry was infood stores, with a large share of thegoods moving through the cold chain. As a consequence of changes in theglobal economy, the public are spendingless on perishable foodstuffs. This haspresented opportunities to manufacturersof cheap frozen foods and ready meals,but there are challenges, too. Marketanalysis suggests that today’s consumers,particularly young people, are demandingexperimental frozen foods that go beyondthe bog-standard pies, chips and peasorthodoxy of yesteryear. As people travelmore they are being exposed to newflavours, and this is one factor that isdriving product diversification within theindustry. Another is healthy living. The key questions for manufacturers,then, are how to make production moreefficient, and how to introduce newproduct lines without increasing costs?The answer lies with innovativerefrigeration technologies. Manufacturersare using Individual Quick Frozentechnology (IQF) to ensure the freshnessand taste of their products. Eachcomponent of a ready meal is sprayedwith a stabilising agent (usually acombination of Guar gum and Xanthangum) prior to freezing. Liquid nitrogen,which is far more powerful thanconventional refrigerants, is then used tofreeze the product. IQF can be used tosafeguard the freshness of any productline, but it is especially useful in caseswhere exotic components that havealready travelled a long distance form partof a ready meal. One of the most unusual newapproaches to freezing food, known asAcoustic (or “Stirling”) refrigeration,involves the use of sound waves to modifythe pressure in refrigerant gases –fluctuations which in turn cause changesin temperature. Although it is still indevelopment, this technology is likely tobecome popular in the future ascompanies look for more flexible ways tofreeze their products; flexibility during thepreparation stage being the key to adiversified product line. For companies dealing in frozen fruitand vegetables, dehydro-freezing is a greatoption: large quantities of water areremoved from a product before it isfrozen, which helps to concentrate itsflavour and speeds up the freezingprocess.There is a wealth of developmentwithin the frozen and chilled foods sector,particularly with the recent upturn inrefrigerated ready-meal sales. As such,new technological advancements intemperature control are being focused onby many, with developers looking at newways of achieving old tasks. PHOTO: NILOO / SHUTTERSTOCK.COMA coolchallengeThe frozen and chilled foods market has boomed in recent years, andlooks set to continue doing so. But what challenges facemanufacturers within the industry – and how are they navigatingthese? The cold chain accounts for roughly 9% of the£187 billion of sales in the food and drink industry38-42_Layout 1 29/07/2016 11:33 Page 1Food & Drink International 39www.fdiforum.netFROZEN & CHILLED FOODSThe Cold ChainWith the demand for food and drink inthe UK rising by 3% year on year,according to the ONS, many food retailersand supermarkets are facing difficultquestions on whether they should increasethe size of their temperature-controlledtransport fleet, or whether they shouldlook to invest in more temperature-controlled storage facilities closer to home. For many in the industry the choice isnot a simple one. While investing in alarger transport fleet at first might seemthe cheaper choice, it does carry the biggerenvironmental impact and of course hascosts dependent upon the price of oil. Onthe other hand, storage facilities require alarger amount of initial capitalinvestment, and would also require morestaff to man and maintain. In addition energy consumptionremains a key concern for many in theindustry, not only due to the increasedtravel lengths associated with the food anddrink industry – but also increasing costsin the case of keeping a storage facility ata certain temperature. It’s easy for thecosts of temperature control systems toquickly scale out of control. Therefore it’simportant at all times to focus on methodsof efficiently maintaining temperaturelevels, with as little ambient loss oftemperature as possible. At the end of theday, it’s far more expensive to keep aircool, then it is to warm it up.Ultimately however, it becomes adifficult balance between energy savings,40 Á38-42_Layout 1 29/07/2016 11:33 Page 2Next >