< Previous30 Food & Drink International www.fdiforum.net MATERIALS HANDLING In the food and drink industry, the issue of materials handling comes close to home – especially within the difficult times of the COVID-19 pandemic. Both for within a manufacturing plant and beyond, in logistics and distribution centres, the efficient movement of material, ingredients or finished product, is paramount to a company’s success, and between efficiency, safety, accuracy and reliability, there is a lot to consider. Where possible, automation should be considered for handling requirements, particularly in manufacturing centres where large quantities of bulk material needs to be handled and processed. By using bulk filling and bulk handling equipment, the human element is minimised, improving safety and ensuring that manpower and manhours can be allocated elsewhere. One of the biggest difficulties in bulk solids handling is the measurement of flow properties – for as anyone in the industry will say, figuring out how to make bulk solids flow through a system Materials handling becomes an increasing challenge the more successful a manufacturer becomes, both in the manufacturing chain and the warehouse. with care Handling © Shutterstock /FUN FUN PHOT O 30-33.qxp_Layout 1 29/07/2020 11:14 Page 1Food & Drink International 31 www.fdiforum.net MATERIALS HANDLING is much harder than with any gas or liquid. Friction plays a clear part, as do a multitude of other problems which might lead to blockages, lost product or general inefficiency in the system. Most handling systems use gravity for this, simply put, the bulk material flows downward, but that’s only half the problem, with the interior of the equipment needing to be carefully designed for optimal results. This is an industry which is set to stay, however. According to new market research published by Credence Research, the bulk material handling equipment market was valued at a little over $38 billion in 2017, but will grow to over $56 billion by 2026, showing a compound annual growth rate (CAGR) of 4.5 per cent. Of course, despite all developments, the human element will always be an inevitable conclusion, and any materials handling solution must consider them in its design. While factories are moving 32 Á © Shutterstock /Mr . Kosal 30-33.qxp_Layout 1 29/07/2020 11:14 Page 232 Food & Drink International www.fdiforum.net MATERIALS HANDLING towards almost full levels of automation, within the warehouses it is still individual staff shifting goods about. Be it through forklifts, trolleys, conveyor belts or other materials handling equipment – the focus is on speed, efficiency and ultimately, safety. These three factors are more varied than they first seem, and in some cases can conflict with one another. Speed and efficiency are often mistaken for the same thing, and while it’s forgivable for a worker to attempt to fulfil an order by using a little extra haste, there can be risks involved, not only to personal safety, but also the operations of the warehouse. True efficiency is an improvement that comes about regardless of the individual effort involved. It is a passive component in many cases, one that will work as effectively for one employee as it will for another. Assuming the process is followed correctly, of course. When handling bulk material, the risks to health and safety become even more apparent. The weight of the material in bulk is often enough to crush a person, let alone the risk of someone being caught in the equipment or slipping on spilled material. Fully automated systems navigate this problem somewhat by working to remove the human element, but considering the available space in any given facility, this may not always be a solution. Better, perhaps, to have contingency plans in place and a rigid health and safety procedure that works hand-in-hand with any bulk solids equipment. The Health and Safety Executive (HSE) is unequivocal when it comes to materials handling in the workplace: comply with the regulations or suffer the consequences. Companies are encouraged to adopt a three-point strategy to tackle safety issues around handling. According to HSE guidelines, they must “avoid the need for hazardous manual handling, so far as is reasonably practicable”; “assess the risk of injury from any hazardous manual handling that can’t be avoided”; and “reduce the risk of injury from hazardous manual handling, so far as is reasonably practicable.” Because many industries in the manufacturing sector make use of hazardous or dangerous material, companies are seeking to minimise risk by employing machine handling equipment where possible. Because the latest robots on the market possess a degree of “hand-eye” co-ordination that far exceeds the capacity of human beings, hazardous and bulky loads can Uber extends food delivery dominance with $2.65bn Postmates buy Uber is extending its market reach in the booming food delivery segment with the $2.65 billion acquisition of San Francisco’s Postmates. Prior to the all-stock transaction, Postmates was a direct competitor of the Uber Eats food delivery platform. Following the deal, Postmates will continue to operate as its own app. Although coronavirus has led to a spike in food deliveries – with Q2 bookings on Uber Eats up more than 100% year on year – the pandemic has resulted in the company’s flagship ride-hailing businesses suffering a downturn. Uber said that the addition of Postmates boasts differentiated geographic focus areas and customer demographics, as well as “strong relationships with small- and medium-sized restaurants, particularly local favourites.” “Uber and Postmates have long shared a belief that platforms like ours can power much more than just food delivery – they can be a hugely important part of local commerce and communities, all the more important during crises like COVID-19,” said Uber CEO Dara Khosrowshahi. © Shutterstock/DELBO ANDREA 30-33.qxp_Layout 1 29/07/2020 11:14 Page 3Food & Drink International 33 www.fdiforum.net MATERIALS HANDLING Social distance products businesses safely 02476 420065 be transported from vehicles and to process machinery at a fraction of the risk. The risks to staff are kept to a minimum, and production is sped up – two things that could help companies save substantial amounts of money. Because society has become increasingly litigious worker-safety is now a top priority, and this is driving innovation in the field. From innovative pallet solutions to the latest and safest drum trolleys and tongs used to transport and lift hazardous substances, companies are taking giant steps towards avoiding costly law- suits. The canniest businesses are investing in Hand-Arm Vibration (HAV) meters, which are used to measure the physiological risk of handling a piece of equipment or transporting a material prior to an operation being carried out. © Shutterstock /Chaiwat Hemakom 30-33.qxp_Layout 1 29/07/2020 11:14 Page 434 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING Food makers already have many measures at their disposal which can be utilised in-house, such as ever more sensitive sensors that can be easily fitted into existing production lines. With advances in portable sensors, food makers are better able to detect the presence of foodborne pathogens such as E.coli, listeria and salmonella. Although some food companies, especially major global operators, will maintain their own in-house laboratory facilities for food testing, the majority simply can’t afford that expense or don’t have the space to spare. In these cases, companies will outsource to specialist food testing companies. Ensuring food safety and regulatory compliance during the discovery of a pathogen is already a protracted process, but with added wait times between testing, it only draws the process out which could be difficult for food makers to mitigate in an increasingly competitive market. Advances in rapid diagnostics, however, have led to ever more efficient, accurate and swifter tests being developed to detect pathogens and contaminants and validate authenticity. Turnaround times are quicker, downtime for food producers and operators is reduced, and companies can implement recall plans and investigations quicker and more efficiently. This helps to protect customers, curb potential litigious action and reputational damage, and keep costs down. If a pathogen is detected in the test sample, then undoubtedly the batch that sample was taken from will be destroyed. Detecting that pathogen as early as possible means that the source can be more swiftly identified. Once that’s discovered, the source can be better ascertained. If, for example, environmental swab testing reveals that the conveyor system was the source of the contamination, steps can be taken Securing the food chain There are myriad reasons why food and beverage operators would utilise testing and microbiological services, from mapping allergens and foodborne illnesses, to environmental swabs of production lines and DNA analysis and authenticity. As we’ll explore, the cost fallout from ignoring these services can be devastating. 34-37.qxp_Layout 1 29/07/2020 11:17 Page 1Food & Drink International 35 www.fdiforum.net MICROBIOLOGY AND TESTING to ensure its thoroughly cleaned or replaced and tested again to confirm whether production can resume. There will, of course, be production downtime during this process, but steps can be taken to ensure that no further batches pass through the same conveyor. Though testing is used during investigations in existing outbreaks, many food chain operators use it as a precautionary measure. It’s not that food makers are hoping to find contaminates or pathogens in their products, but rather want the peace of mind of knowing their products are safe. Should a pathogen then be found, they’re already in a better position to act. Routine testing is therefore advised, not only for ingredients and finished products, but for the premises and production lines themselves. Swabs can be taken of the entire production environment, from equipment, machinery and trucks, to the growers of raw ingredients. Testing is a key preventative measure for food makers, but it also has a valuable role to play in new product development. With the testing of ingredients and prototypes, companies can undertake shelf life determination and, as previously mentioned, discover nutritional information for labelling. Products are recalled for a variety of reasons, though most commonly because of the presence of undeclared allergens such as soya, peanuts and 36 Á © Shutterstock /Microgen 34-37.qxp_Layout 1 29/07/2020 11:17 Page 236 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING gluten. Rigorous testing before products hit shelves can help to prevent future recalls and they cost they incur. There are plenty of sources where contamination can occur, whether that’s raw materials coming into contact from soil, sewage and live animals, in the slaughterhouse where meat is concerned, or in transit where food is improperly cooled or heated. Improper storage temperatures are doubly concerning for high risk foods such as dairy products, seafood, cooked rice, meat and poultry and prepare fruits and vegetables. Contamination also occurs during production, where chemicals used to maintain machinery can mix with foods, or pathogens can develop on improperly cleaned machinery. A high-profile example of a microbiology outbreak ended in January this year after the US Centres for Disease Control and Prevention (CDC) announced it was safe to eat romaine Testing for Life For more information visit: www.eurofins.co.uk/food Or call: 0845 604 6740 Eurofins Food Testing UK, is a leading provider of food analysis offering a comprehensive testing portfolio. Our laboratories are reinforced by worldwide Competence Centres and our extended geographical reach is connected by our susbstantial fleet of collection vans. All of this is supported by our unrivalled purpose built IT systems. Our UK food laboratories are located in: • Wolverhampton • Acton • Grimsby • Galashiels 34-37.qxp_Layout 1 29/07/2020 11:17 Page 3Food & Drink International 37 www.fdiforum.net MICROBIOLOGY AND TESTING BOTTTLED & BBAGGGED MMEDIIA Manufacturer of prepared culture media and associated products for microbiology. Find out more at www.sglab.com BESSPOKKE MEEDIA MANNUFAACTUURE PLAATE MMEDIAA CONVENIENCE YOU CAN TRUST. lettuce from Salinas Valley in California, declaring the three-month outbreak over. Between September to December 2019, 167 people from twenty-seven states were sicken with E. coli after eating contaminated romaine lettuce, resulting in eighty-five hospitalisations nationwide. Though no deaths were reported, fifteen of those sickened developed a type of kidney failure. This most recent outbreak followed a similar one in 2018 from the same strain of E. coli from the Salinas growing region, and another the year before it. The issue arose because leafy greens like lettuce can become easily contaminated in the field by soil, water, animals and improperly composted manure. Contamination can also occur during handling, storage and transportation and after all that, consumers typically eat it raw and while washing at home removes some bacteria, it does not eliminate E. coli. Last year also saw the outbreak of listeriosis in Spain, the biggest in the country’s history. In all more than two- hundred people were taken ill, of which three died, after eating branded chilled roasted pork. Though the outbreak began in mid-August, and was declared over in October, arrests were made after the Spanish Civil Guard and law enforcement agency Europol found individuals were aware since December 2018 that some food products contained listeria but did not inform authorities and continue to sell them. Last summer, six people died from listeria infection after eating pre-packaged chicken sandwiches in hospitals in England. Through thorough testing, meat from by distributor North County Cooked Meats was discovered to contain the outbreak strain of listeria. Along with sandwich producer The Good Food Chain, North County Cooked Meats went into liquidation and ceased trading. For the former, it was because the impact of suspending production during an inquiry was too great for it to remain viable, demonstrating the potentially huge costs that companies can face during outbreaks. Testing of any kind is no silver bullet, but rather one important part of a wider efforts to ensure consumer safety and regulatory compliance. By regularly testing their suppliers, distributors, production line and products, companies can help to ensure they remain on top of any potential contamination and are better prepared to act should an outbreak occur. © Shutterstock /Microgen 34-37.qxp_Layout 1 29/07/2020 11:17 Page 438 Food & Drink International www.fdiforum.net MICROBIOLOGY AND TESTING - ASTELL SCIENTIFIC Q&A Why are autoclaves traditionally so energy intensive? The basics of how an autoclave uses energy are pretty fixed. An autoclave sterilises by heating objects in their chamber to typically 121°C for 15 minutes or more. (There are hotter, faster sterilisation cycles, but 121°C is the norm). This combination of temperature and time is shown to destroy anything biological: bacteria, spores, viruses, prions etc. If the temperature drops below 121°C during this time, sterilisation cannot be assured, so the process has to be repeated. Heating objects using just air is inefficient, so autoclaves use steam containing a specified quantity of liquid water droplets (5% by mass). This mixture is perfect for carrying heat without making the load in the autoclave too wet. The problem with using water is that, Q&A Astell Scientific Ltd. The food and drinks sector has long been aware of the importance of ensuring its products reach the highest standards of microbiological quality. With electricity- hungry autoclaves sterilising items across the food and beverage industry, from the laboratory to the processing plant, we ask Astell Scientific Ltd. if this key piece of hardware can be made more energy efficient. at room pressure, it boils at 100°C. The autoclave produces conditions where water boils at 121°C by creating a sealed, pressurised environment of above 2.068 Bar(a). Filling the autoclave chamber with 121°C steam at 2.068 Bar(a), and maintaining these conditions for 15 minutes is fundamental to what an autoclave does, and accounts for the majority of its energy use. So, steam generation takes the lion’s share of energy consumption, but how can process become more efficient? Turning water to steam is a process governed by the laws of physics. At the pressure required for sterilisation (2.068 Bar(a)), water needs 2,201 kJ/kg of energy to boil. For each kilogram of water heated, this process creates enough steam to fill a 0.841m3 space. There are some claims that using a lower wattage heating element will mean an autoclave uses less energy. This isn’t true – the autoclave will still need to add 2,201 kJ/kg of energy to turn water into steam at 2.068 Bar(a). If you half the size of the heating element, you double the time it takes to boil the water. By heating the water more slowly, you increase the opportunity heat has to escape the autoclave, increasing energy loss and overall energy use. One change that cuts energy use is reduce the amount of 38-39.qxp_Layout 1 29/07/2020 11:18 Page 1Food & Drink International 39 www.fdiforum.net MICROBIOLOGY AND TESTING - ASTELL SCIENTIFIC Q&A water the autoclave heats to make steam – halve the volume of water you are heating, and you halve your energy use. We applied this rule first on our heaters-in-chamber models, which have now up to 16kw heating elements in a smaller volume of water, while our autoclaves with integral steam generators have up to 72kw heating elements. Autoclaves come in many shapes and sizes. Which is the most energy efficient? The autoclave’s chamber, and the vessel that contains it, are the biggest determinants of the shape and size of an autoclave. The shape of the autoclave chamber is important to saving energy, but there is no simple answer to which is best. Because its shape distributes pressure more evenly, a cylindrical chamber allows you to use thinner metal for the vessel. This thinner construction takes less energy to heat. The problem with a cylindrical chamber is that there is less usable space inside it. If you have a cylinder on its side as your chamber, you have a rounded base and rounded walls. This means you need to build a shelf to compensate for the round floor, and you can’t fill all the space beside the walls because they curve away from the floor. This can result in 36% of the chamber space being empty, and a 36% increase in wasted energy. The alternative to a cylindrical chamber is a cuboid one. With a flat floor and flat sides, filling a cuboid chamber is much easier; the fuller the chamber, the less energy is wasted. The problem is that you need thicker walls than with a cylindrical chamber to hold the pressure. The thicker your walls, the more energy they take to heat. We have companies asking for all kinds of cuboid, horizonal cylinder, and upright cylinder chambered autoclaves. By discussing how their operators use the autoclave, we can help find the most energy efficient chamber for each organisation. What other steps can be taken to further reduce energy use? We often recommend a heating and cooling jacket is added to the autoclave. A jacket wraps around the outside of the vessel, and can be filled with hot or cold water. This allows for better temperature control, and reduces the chance of fluctuations below the sterilisation temperature. Such temperature fluctuations can cause the sterilisation process to be invalid. If sterilisation is invalid, the process needs running again, doubling the energy use. Regular servicing, calibration, and validation are also very important to make sure the autoclave is running efficiently, at accurate temperatures, and that its loads sterilise fully and correctly. Where specifically can the biggest energy savings be made? Making sure the autoclave is only used when it is full to capacity is the best way to make energy savings; If your autoclave can hold thirty Duran bottles and you only autoclave one bottle, around 97% of your potentially useful energy is wasted. This also highlights why you don’t want an autoclave that is too big for your needs. At the other end of the spectrum, if the autoclave is too small you might need to run more loads; More loads mean more energy is wasted heating and cooling the autoclave. In short, organisations need autoclaves that are designed to meet their specific requirements. The more “one size fits all” the design of the autoclave, the less it has been designed for the company’s needs. The less the autoclave is designed to fit a business’s specific needs, the greater the possibility of inefficient use. This is why we provide so many variations in models, options, and chamber sizes. To find out more, visit www.astell.com, email info@astell.com, or call +44 (0)20 8309 2031. 38-39.qxp_Layout 1 29/07/2020 11:18 Page 2Next >