< PreviousMATERIALS HANDLING 20 Food & Drink International www.fdiforum.net dŚĞh<ΖƐůĞĂĚŝŶŐƉĂĐŬĂŐŝŶŐƐƵƉƉůŝĞƌƚŽƚŚĞ ĨŽŽĚĂŶĚĚƌŝŶŬŝŶĚƵƐƚƌLJ͕ŽīĞƌŝŶŐĂǁŝĚĞ ƌĂŶŐĞŽĨƉĂĐŬĂŐŝŶŐƉƌŽĚƵĐƚƐŝŶĐůƵĚŝŶŐ͗ ŝƌ^ŚŽĐŬďŽƩůĞƉĂĐŬƐ WĂůůĞƚǁƌĂƉΘƐLJƐƚĞŵƐ ŽdžĞƐĨŽƌďŽƩůĞƐ >ĂďĞůƐ an employee-owned business sector and boosting safety is heightened levels of automation. Our industry faces the major challenge of fast paced, frequent changes in consumer desires, and those transporting goods in facilities throughout the industry must be able to make sure movement of products is uninterrupted to keep up with this. More must be done in less time with less resources. As human labour becomes increasingly hard to find in the materials handling sector of the food and drink industry, automating materials handling as far as possible is vital. While material handling across food facilities is still mostly completed by employees, new technology set to replace them, that for now works alongside staff, is certainly on the way with automated conveyors and lift trucks etc. already in use. Automated equipment continues to be beneficial as it reduces chance of injury by removing workers from dangerous roles and can work without human interference 24/7. In addition, by removing the manual elements involved materials handling that frequently suffer from human error and mishandling, one can avoid damage to goods and resulting losses, as well as avoid the need for training and retraining employees and new recruits. Automated pallet trucks are one innovative piece of equipment worth considering that are proving highly Stertil fast-action doors provide sweet access solution One of the UK’s leading food and confectionery manufacturers relies upon a pair of Stertil FlexiEdge fast- action doors to provide access to a fork truck drivers training facility and a store area within its manufacturing and distribution complex in York. Stertil’s FlexiEdge range comprises 16 models including internal and external doors, all- weather doors, cleanroom and freezer/coldroom doors plus emergency exit doors incorporating breakthrough curtains. Standard models are available in widths up to 11 metres and heights of 5.5 metres whilst bespoke and special sizes may be specified. The door curtain is fully flexible with a soft bottom edge which self-adjusts to seal on an uneven floor and eliminates any possibility of causing injury to users. In addition, the incorporation of an infra-red photocell, fitted 300mm above floor level, supported by a bottom edge wireless detector ensures instant halting of all door movement in the event of sensing an obstruction. For more information, visit www.stertil-dockproducts.co.uk. 16-21.qxp_Layout 1 23/07/2019 11:44 Page 5MATERIALS HANDLING Food & Drink International 21 www.fdiforum.net • Plain / Printed Labels • Thermal Transfer Ribbons • Lasersheets • Fanfolded Labels • Barcode Labels Self adhesive labels and labelling Tel: 01482 506560 • Email: sales@datamarkuk.com • Website: www.datamarkuk.com useful, such as Phoenix Handling Solutions’ compact AGV ‘Nipper’. With this technology, intelligent software communicates over Wi-Fi with the pallet truck, and after a command is taken, Nipper performs the action independently and safely, even in workspaces with active people. Robotic trucks such as these allow repetitive tasks like loading and moving pallets to be completed in a cost-effective manner, leaving employees to concentrate on tasks such as picking, packing and other value adding activities. They can also be integrated easily with wider automation such as robotic palletising systems. The popularity of automated guided vehicles (AGV) like these pallet trucks is on the rise, after previously being thought of as untrustworthy, as they make the movement of materials and products effortless and remove operator error that causes many accidents, being able to detect objects from several feet away and move between people and other machines. While the idea of autonomous forklifts for instance is well established, improvements in navigation, adaptability, flexibility of technology and decreasing costs has seen the equipment become more of a reality. Removing the human element from this equipment has been highlighted as beneficial in avoiding the over 8,000 accidents involving forklifts reported annually in the UK alone. Once restricted to fixed routes across warehouse floors, AGVs are now guided by lasers and cameras, or by measuring their environment. With the use of IoT devices and AI programs, multiple AGVs can be deployed at once in a facility, are able to communicate with each other, avoid colliding and can relay information to one another. They are also able to adapt to changes in warehouse layouts and are helpful in reducing loss from misplaced products as every movement they make can be tracked. Further, when connected to the IoT, software can be used by managers to monitor AGV traffic and optimise it. A main barrier to AGV adoption in materials handling is the initial capital investment, though in the long run, AGVs are shown to be more cost-effective and efficient than employee-controlled equipment. Warehouse management systems (WMSs) are also now being recognised more for their importance in improving materials handling, in streamlining how one handles products and are being used alongside AGVs. This interest in WMSs has come as managers look to optimise capacity and boost efficiency of warehouses as well as reduce human error with a system that can program paths used in picking. WMS programmes can organise how pallets are loaded and built based on factors such as expiration date, and direct product movement from its entrance to departure from a warehouse. A WMS is also useful in managing recalls due to its tracking features, allowing one to discover where a product is, if it has been shipped, and who to, or if it is still within a warehouse. © Shutterstock/ Chesky 16-21.qxp_Layout 1 23/07/2019 11:44 Page 622 Food & Drink International www.fdiforum.net VISION AND INSPECTION W ith supply chains and food processing now moving quicker than ever to satisfy demand, food companies must ensure that their products still meet consumer and retailer expectations for quality and safety. Key to this, and in preventing the nightmare of costly, reputation damaging recalls, is efficient equipment and software that allows for the accurate inspection of goods, such as machine vision systems, X-ray systems and metal detectors. Inspection and detection equipment and software are also essential in reducing contamination, ensuring the integrity of packaging and can be used to boost quality, traceability, cost savings and reduce food waste, which is poignant as currently a third of food produced across the globe is wasted and does not see a human mouth. Boosting the utilisation of this equipment is an increasing recognition of the need for preventative controls to avoid contamination and defects which has seen facilities add inspection systems earlier in the production line so that problems can be found and dealt with sooner, before for instance a contaminant is spread into numerous products, helping reduce wider waste and as a result save money. Employing inspection equipment throughout and earlier in the production line also allows firms to improve facility efficiency by making problem ingredients, products and processes easier to locate. Alongside this, inspection equipment is becoming more of a necessity throughout production as humans are being removed from the production line in favour of automation in a bid to reduce labour costs, make operations more productive, and embrace the smart factory of the future, meaning there are less eyes to identify potential problems. Long gone are the inefficient error-prone days when food inspection involved trained inspection employees looking over conveyor belts to discover defective goods. When considering the inspection of one’s products for contaminants, a metal detection system is frequently the first line of defence chosen, especially as metal is the most likely contaminant in processing due to contact exposure in cutting, grinding and mixing for instance. Despite the popularity, concerns with metal detectors surround the chance of false positives as the technology can be tricked by moisture and high salt contents, meaning unnecessary waste is created – in fact false rejects can cost manufactures up to £14,000 per year per line. Improvements, however, have seen the equipment adopt multi- frequency/multi-scan technology which has reduced false rejects that cause product loss. © Shutterstock/SeventyFour Essential for quality and safety Vision, inspection and detection technology are indispensable in quality assurance and food safety plans and will only grow in importance as food recalls and contamination scandals frequent the front page. Essential for quality and safety 22-25.qxp_Layout 1 23/07/2019 11:46 Page 1Food & Drink International 23 www.fdiforum.net VISION AND INSPECTION Exemplary of these innovations in metal detection, Fortress Technology have launched a food metal inspection ‘world first’ with a metal detector that inspects low profile, high value products vertically and horizontally concurrently to achieve high sensitivity. The Interceptor DF (Divergent Field) is believed to be the first ever multi- orientation, multi-scan food metal detector. The conveyor-style metal detector, rather than scanning a select number of frequencies, inspects raw, cooked and packaged products using multiple field directions. To increase food safety, the Interceptor DF system addresses several previous limitations - notably orientation, size, geometry and position of metals. It’s especially reliable at detecting very thin flakes and foils that could be introduced to premium foods in the mixing, rolling, cooking, scoring, moulding, slicing or baking processes. The Fortress system uses multiple coil sets to instantaneously drive the electromagnetic fields in different directions. Rather than missing a metal contaminant because it hasn’t aligned with a specific field, the Interceptor DF looks for signals over a broad spectrum, from multiple angles. The stronger disturbance from one field compensates for the weaker signal from another. This increases the probability of identifying and rejecting products containing non-spherical metals by over 100%. Also recognised as key in ensuring food safety are X-ray inspection systems, which are increasing in popularity due to their ability to discover a diverse range of contaminants, from glass, to bone, to plastics and stone, which can all be detected through tins and aluminium foil no matter the temperature or salt Backward compatible food metal detectors Exceptional sensitivity and ROI … guaranteed Tel: +44 (0) 1295 256266 www.fortresstechnology.co.uk Email: sales-uk@fortresstechnology.com 24 Á © Shutterstock/FUN FUN PHOTO 22-25.qxp_Layout 1 23/07/2019 11:46 Page 224 Food & Drink International www.fdiforum.net VISION AND INSPECTION A Jenton Group Company sales@dimaco.co.uk 01234 851515 ASK US ABOUT MAP LEAK DETECTION! Everything has changed Combination label ]LYPÄJH[PVUJOLJR ^LPNOPUN_YH` TL[HSKL[LJ[PVU NOW VERIFIES DATA EMBEDDED BARCODES (DEB)! PPMA TOTAL STAND A50 content of products. Engineers are also making X-ray machines easier to operate and machine learning is being integrated so that machines can quickly learn how to improve inspection. With this detection equipment one can also assess whether defects or contamination occur more during certain shifts. X-ray systems are used in further instances too for quality control tasks like checking seals, inspecting fill levels - which can identify whether products are being overfilled and thus when addressed can lead to potential savings - and finding broken items. However, X-ray can be an expensive investment, and is typically more costly when compared to metal detectors to acquire, install and run. Of course with this inspection technology, no matter what one uses, one must also have the correct software to manage the data your detection machinery produces. Further, when used with automated rejection systems, contaminated or unsatisfactory ingredients and products can be removed from the production line without stopping the production process. Food manufacturers often use a combination of inspection equipment to discover the wide range of contaminants that goods face, to assess quality and achieve fully automated traceability in response to tightening regulation - using metal detection for instance in conjunction with vision systems with which one can study the appearance of products through its combination of hardware and image analysis software. Vision systems, which have risen in popularity, have become more robust with equipment manufacturers developing systems to respond to strict demands. Frequently integrating AI, patterns can be analysed, and data collected on ripeness, colour, spoilage and internal temperature as well as internal makeup which is used Only thermal coder with built-in print checking proven to help business improve OEE Two years ago, coding and labelling specialist Clearmark Solutions launched its next generation thermal transfer overprinter (TTO), with a built-in print checking system, capable of reporting on the quality of each code it produces, largely removing the need to invest in costly add-on vision systems in order to meet increasing demand from retailers for code quality checks. Clearmark says the ICE Zodiac Hawk TTO has helped numerous businesses achieve improved Overall Equipment Effectiveness (OEE) by being the first coder that can report on all three elements of OEE, with quality now included alongside performance and availability. Equally important, the coder’s ability to provide early warning of any potential loss of code quality will help to minimise production disruption and downtime, as well as reduce the risk of customer complaints or the possibility of a product recall, with its cost implications and potential damage to brand reputation. To find out more, visit www.interactivecoding.co.uk/hawk. © Shutterstock/Baloncic 22-25.qxp_Layout 1 23/07/2019 11:46 Page 3Food & Drink International 25 www.fdiforum.net VISION AND INSPECTION to conclude the status of an item objectively and consistently within a second. Vision systems can, beneficially, be implemented across production to assess everything from raw ingredients to whether a product has been undercooked or overcooked and can have the extended use of inspecting the hygiene of processing equipment. Smart machine vision inspection systems and their associated software are also key for assessing packaging defects, that devalue products, at high speeds as well as checking printed coding on packaging and labels for quick and easy error proof inspection of dates and batch numbers to ensure legibility and that they are correct. With the rise in need for traceability in response to numerous high-profile recalls, investments are being made into barcode readers, optical character recognition technology and smart cameras in particular for their sophisticated vision technologies. Machine vision systems can be used to track ingredients and goods through the production process, which is useful for producers receiving foods from others in an industry with heightened concerns over traceability. Vision systems, with their applications across food production, allow for strong quality control and minimise risks. In depth inspection of one’s products is an essential part of responsible food production. As recalls plague the news more frequently, now is the time to invest in detection and inspection technology to allow for higher levels of quality control. AutoCoding Systems takes a different view of vision using 4Sight The global partnership between AutoCoding Systems and SICK has resulted in the development of a new innovative solution for automatic print inspection and packaging recognition. Incorrect, illegible or missing codes on consumer products can cause serious and expensive problems for manufacturers, but typically reading and inspecting of printed codes, particularly on high speed lines, has always been challenging due to the many application specific variables. 4Sight is a dedicated solution for automatic print inspection and packaging verification which radically simplifies and automates the set-up and ongoing execution of vision applications using smart software. Using innovative techniques, the patent-pending vision solution has revolutionised the complicated, inflexible and often challenging process of print inspection and packaging recognition. The 4Sight software is powered by SICK AppSpace and is resident on the SICK camera. The software communicates directly with the printing equipment and understands the intended message for printing. 4Sight’s automatic set-up means there is no requirement for operators to configure features or regions of interest, no need to “teach” the camera what to look for or train the camera with the printer’s font. Using this advanced method of inspecting code and packaging artwork, 4Sight has already reduced configuration time and speed of processing in a number of factories. By looking at the process from a completely different perspective, 4Sight has made vision a cost-effective option for a variety of applications. The solution is already being launched globally both by AutoCoding Systems and SICK. To find out more, visit autocodingsystems.com. © Fortress Technology 22-25.qxp_Layout 1 23/07/2019 11:46 Page 426 Food & Drink International www.fdiforum.net PROCESSING SPOTLIGHT During the last half century the industry has seen many changes, mainly in the complexity, demands and power of the supply chain, but has the manufacturing side been able to keep up? T here was a time when a dedication to the highest standards would have been considered a USP but retailers and consumers alike now demand these as a matter of course. The challenge for manufacturers is to ensure standards don’t slip at a time when retailers are looking for increased efficiency on the supply chain, costs need to be kept down at every stage as new products and production methods are introduced. In many cases, this will require the highest degree of operational discipline, excellent interdepartmental communication, far greater awareness of issues and current production status, together with automation, wherever possible, to minimise the risk of operator error. All responsible manufacturers will have carried out in depth risk assessments, and realised how easy it is, within such high pressure environments, to get something wrong. Errors in component handling, out of date ingredients, coding and labelling errors, compromised pack seals and inaccurate Part of the process Part of the process 26-29.qxp_Layout 1 23/07/2019 11:48 Page 1Food & Drink International 27 www.fdiforum.net PROCESSING SPOTLIGHT weights are just a few things which negatively impact delivery schedules and the bottom line in food manufacturing environments where short batch runs and frequent product changeovers have become the norm. One obvious benefit of the rise of automation in the processing sector is the ability to ensure complete accuracy. That’s absolutely vital with increasingly stringent regulations on labelling – not to mention the huge expense that can be engendered by excessive product giveaway. This has in turn led to an increase in the levels of traceability present within the manufacturing and supply chain – with companies able to find out exactly who the suppliers were of any ingredients used in a given batch of completed products – within a few hours. This improved accuracy, and the reduction in human error that comes with it, has proven itself very valuable for the packaging industry as well. Particularly when dealing with the stringent legal requirements of the labelling, coding and marking aspects of the packaging process. The quantity of goods that passes through a single production line continues to grow as technology improves, with up to 25,000 units passing through a packaging line in a short frame of time. Correct and accurate label application needs to keep up with the increased demand, and with many manufacturers now exporting to other countries as well, the process has only become more difficult. During the last half century the industry has seen many changes, mainly in the complexity, demands and power of the supply chain. There is a very real fear that the internal changes in food and drink manufacturing haven’t kept pace with the changes in the supply chain. That is where much of the risk comes in for problems, and in many cases can be a result of outdated systems not being replaced – simply because nothing has gone wrong yet. An automated processing system is more however, than just a preventative tool to problems. It is also a tool to increase efficiency in the manufacturing process. One issue is that the UK food and drink industry is falling far behind other countries when it comes to automation and the adoption of robotics into the food industry. These were the findings of a recent study into robotics within the food and drink industry, which found that even within Europe, the UK is ranked 15th in terms of robotics usage. To give an idea of what that means, the UK is behind countries such as Germany, Sweden and France – but also now falls behind Slovakia, Slovenia and the Czech Republic. The bigger problem still is that the changes in robotic investment within the UK are some of the lowest in the bloc, with many food manufacturers not seeking to make changes and instead relying on outdated and expensive labour models. With the introduction of the National Living Wage this has to change, but there are some who fear it could already mean UK manufacturers cannot compete with their rivals. Corbion plant preps for more organic foods growth As the market for organic foods continues to expand, global ingredient solutions leader Corbion has earned organic certification for its plant in Blair, Neb., where the company manufactures vinegar- and lactic acid- based ingredient products for the food industry. The move enhances Corbion’s ability to manage production and increases the security of supply for makers of organic foods. Ruud Peerbooms, Senior Vice President, Food Ingredient Solutions at Corbion, said: “Organic options are an important part of the food industry’s future, and we want to make sure our customers can count on us to help them meet that demand.” Corbion’s broad portfolio of sustainable and clean-label solutions leverages its expertise in natural fermentation processes and applying them solve some of the food industry’s most pressing challenges, such as reducing food waste and increasing safety in the global food supply. For more information, visit www.corbion.com. © Shutterstock/ Romaset 29 Á 26-29.qxp_Layout 1 23/07/2019 11:48 Page 2FOR MANUFACTURING IN FOOD, BEVERAGES, PHARMACEUTICALS, TOILETRIES, COSMETICS AND MORE… 1-3 OCTOBER 2019 NEC, BIRMINGHAM THE COMPLETE PRODUCTION LINE EVENT ppmatotalshow.co.uk OWNED & ORGANISED BY FREE TO ATTEND REGISTER NOW 26-29.qxp_Layout 1 23/07/2019 11:48 Page 3Food & Drink International 29 www.fdiforum.net PROCESSING SPOTLIGHT A big problem is that this phenomenon of the UK falling behind is actually quite limited to the food and drink industry. As an example, the UK is still highly competitive in the automotive industry, despite robust competition from other countries, and lo and behold, the UK automotive industry is a huge investor in robotics and automation equipment. With capital expenditure budgets remaining tight, increasing numbers of processors are seeking operational improvements that deliver cost savings, increased production levels, enhanced product quality and reduced plant downtime without the financial implications of new equipment. As well as the requirement to speed up processes, the new techniques that are now used can also ensure complete traceability at every part of the lengthy supply chain, allowing inefficiencies to be pinpointed. The food and drink industry is in particular expected to benefit from higher levels of automation, thanks not only to the stringent hygiene requirements which will be easier to meet in an automated system, but also to the quantity of products that must go through a factory in any given day. Throughput often numbers in the tens of thousands, so even the smallest saving on each product soon adds up to substantial cost-benefits. Manual systems and manual recording were fine when production line speeds were typically 30 or 40 packs per minute, but today, some production line speeds are ten times this amount and more. Coupled with this has been the shift away from long batch runs to shorter and shorter batch runs, brought about by increased consumer choice, leading to dramatically increased production complexity and frequent Algae products proven to boost grape yield and quality Wine producers could significantly boost grape health, yield and taste by adopting a holistic approach to soil and foliar nutrition. Olmix-Micromix introduced its full SAGA range to the UK at the Viti-Culture Event in July, offering a complete package of plant care with scientifically proven benefits. With foliar nutrition, biostimulants and soil improvers now available to British producers, they can improve productivity and taste, while also protecting against stresses like drought. “Produced at Olmix’s cutting-edge laboratory in France and using proven algae-based biotechnology, the SAGA range protects and enhances crop health at every growth stage,” says Sales Manager Chris Gamble. “From the biological soil activator Geo2 – which speeds up the production of organic matter and improves soil structure – to SeaMel Prevent, which alleviates stress at fruiting – growers have a full package of crop care at their disposal.” The SAGA programme was designed to answer the sustainability challenges facing producers. For more information, visit www.micromix.com. © Shutterstock/ yanik88 product changeovers. Given this scenario, any company relying totally or largely upon paper- based systems faces huge risks in operator error. In this highly charged environment, with the need to maintain some semblance of efficiency amongst the increased complexity and frequent changeovers, it is not so much a question of if something goes wrong, but when. 26-29.qxp_Layout 1 23/07/2019 11:48 Page 4Next >