< PreviousMACHINERYwww.fdiforum.net2931 which can be used by organisations to gainfingertip control of regulatory complianceand quality assurance programs, drivecontinuous performance improvement andaccomplish strategic change – whilelowering the cost of operations.More companies are also introducingpredictive maintenance techniques whichcan be used to create the most cost-effective repair and review programme.The techniques make use of the detailedservice data that the greater automation infactories can now provide and analyse it toascertain its working environment, thespeed at which it runs and the number ofhours, as well as the specific duties of themachine – so two identical machines maywell have different requirements based onthe products they produce. This can thenhelp predict the correct service interval foreach machine and ensure they remain intop condition for optimum performancewithout excessive downtime caused byunexpected failures.The value of machinery produced to thehighest standards of hygiene also cannotbe overestimated. Companies such asKluber Lubrication are part of theEuropean Hygienic Engineering & DesignGroup which promotes effectiveapproaches to engineering. Europeanlegislation does, of course, require thathandling, preparation processing andpackaging of food is done using hygienicmachinery and the EHEDG aim to make itparticularly simple for businesses toadhere to this by purchasing machinesthat have been designed with an array ofspecial hygienic features. This is ofparticular value in the issues of depositingand pumping and Kecol Pumps are amongthose companies that prioritise hygienicsolutions that cut down on downtime.Companies such as Bizerba are alsoemphasising hygiene in their latestmachinery. Their latest checkweighers, forexample, have been designed to ensurethat bacteria doesn’t collect in places suchas the edge of the machine or under thedisplay – thanks to the introduction oftubular structures so that water flows offtheir sloped sections and nothing getstrapped at any point. As well as adheringto the EHEDG standards, they are alsocompliant with protection class IP69k,which is resistant to dust, high-pressurewater jets and aggressive cleaning agents,and is available in several designs to suitany set-up their customers may have.Of course, downtime can also beimproved by introducing the highestquality machines to the productionprocess, and many companies are nowoffering bespoke and effective solutions tomeet all requirements. Heat and Control,for example, have formed a newpartnership with Food Process Systemsthat means FPS’ coating applicators, oftenused for coating meat, poultry, vegetablesand many other products, are nowavailable alongside Heat and Control’smachinery systems. James Padilla of Heatand Control points out, “FPS’ approach tocoating application has been largelydeveloped by listening to andunderstanding the needs of processors. ForCOURTESY BOSCH REXROTHMinister Norman Lamb visiting Britvic’sRobinsons factory in Norwich along withsome pupils from Sprowston High Schoolas part of the UK Government’s SeeInside Manufacturing campaign whichaims to illustrate the career optionsavailable in the industry26-32:Layout 1 17/8/12 15:09 Page 430www.fdiforum.netexample, they have successfully integrateda vibratory conveyor and a breadingapplicator to create a simple, reliable, andversatile applicator and aligner for manytypes of coatings.”These machines emphasise accuracy –which thanks to the latest packagingguidelines that require labelling to beabsolutely correct and the potential wastecaused by excessive product giveaway hasStevens Vantage RFScan control theweighing accuracy ofingredients used tomake up processedmixesRockwell Automationhave established anindustrial automation,motion control andsafety laboratory atIstanbul TechnicalUniversity – emphasisof the increasedimportance ofautomationnever been more important. Prima FoodProcessing Solutions offer an array ofoptions from DWS such as the multi-headweigher which is particularly suitable forfruit. Emphasising the current interest inflexibility, this is available in a mobileversion, which can move easily from line toline for those companies that operateseveral machines at different times or atmultiple sites.The main attraction for companieslooking for new machinery now is thecomplete package – a total factory processcontrol system that can control andmanage the manufacturing process fromraw material received to finished product,and that’s often the case with the newbreed of automation options.Stevens Group, for example, canintegrate their Receiving Software with anMRP system which allows cross-referencing with purchase orders to ensuresupplier compliance while providing priceinformation for later job costing analysis.The software allows full control of use ofingredients throughout the factory process,saving money through ingredient rotation.The company’s clients have often installedthis alongside Stevens Vantage RFS tocontrol the weighing accuracy ofingredients used to make up processedmixes.The machinery now available in thefood and drink sector is setting newstandards in user-friendliness, accuracyand efficiency – matching the innovationand dedication to quality of the leadingmanufacturers.MACHINERY26-32:Layout 1 17/8/12 15:09 Page 5MACHINERYwww.fdiforum.net31State-of-the-artlubricants contributeto economic successRegarding the lubricant as aninvestment in economicefficiency rather than just acommodity pays off in manyways. If synthetic high-performance lubricants tuned tothe particular application areused, the total cost of operationdecreases, even though theirpurchase price is higher. Yousave in standstill costs,maintenance, energy, spareparts, storage, disposal andlubricant consumption.When it comes to bearinglubrication, speciality greasesalso ensure extendedmaintenance intervals. Onerecent example is the waterpump bearings on a productionunit where it was vitalprocessing was almostcontinuous. In previous years,the bearings on the waterpumps had been unreliable andeach failure resulted in lengthydowntime. The customerchanged their lubricant to thePAO- based Kluberfood NH114-261, providing excellentwater resistance and wearreduction characteristics thatwould enable longer bearing life.Another important savingfactor is energy costs. Oftenspeciality lubricants decreaseconsumption compared tostandard lubricants, especiallywhen used for the lubrication ofcompressors or gears. Theefficiency increase can amountup to 18%, leading directly tolower operating costs.KlüberAssettSupport deliversthese exceptional lubricants in apackage designed to managelubrication across site. With theunrivalled expertise andexperience in lubricationmanagement offered, linked tothe highest standards ofproduction and product quality,Kluber Lubricants are anintegral part of machine safetyand reliability.Partner with your lubricantsupplier and once the perfectsolution is found, significantsavings can be made.Be it the lip of a tool, rolling or plain bearings,compressors or gears, taking a close look atlubrication and the potential of specialitylubricants always pays off. 26-32:Layout 1 17/8/12 15:09 Page 632www.fdiforum.netMACHINERYWeighing andBagging solutions Since its humblebeginnings over 30years ago A.M.P-Rosehas developed into oneof the world’s leadingsuppliers of new, usedand rebuilt machines tothe chocolate andconfectionery industries,with 80% of it’sproducts being exportedto more than 80countries world-wide.The Company currentlyemploys over a hundredpeople in a well-equipped and modernfacility inGainsborough, England.A.M.P-Rose has seen inrecent years that customers areincreasingly looking forcomplete solutions to theirweighing and packagingproblems. AMP-Rose is wellequipped to supply baggingmachines with completepackaging systems.Complete packaging systemsinclude suitable feeding system,multihead weighers, bucketelevator, rotary packing tablesetc. All new equipment comeswith after sales support andspares in stock from AMP-Rose;new equipment is alsoaccompanied by acomprehensive 12 monthguarantee.The ‘Cyclone’ range ofvertical form fill and sealmachines are engineered toexacting standards and use onlythe highest quality components.They are hand-built by skilled,experienced packaging machineengineers. Maintenance anddown-time are kept to aminimum and this makes themachines cost-effective to ownand operate.A wider range of multiheadweighers and other feedingsystems has also increased thevariety of products the baggingmachines can pack, this includesconfectionery, chocolate, fruit,frozen foods, vegetables,hardware, snacks, powders,liquids, rice, coffee, pasta,cereal, sugar and many more.Tel: 01427 611969Heapham Road North,Gainsborough, Lincolnshire,DN21 1QUEmail: info@amp-rose.comwww.amp-rose.com Fresh ideas from PrimaFood Processing SolutionsPrima Food Processing Solutions arespecialists in equipment for the freshpreparation of fruit, salad and vegetables inthe growing fresh cut industry. Together with PND srl ofNaples in Italy, Prima are readyto offer a solution to all yourprocessing needs, by discussingyour requirements and wherenecessary demonstrating theequipment, either in the UK orat European manufactures orcompanies by appointment.Not long introduced to theUK market, PND srl arespecialists in fruit and vegetableprocessing machinery. To peel,cut and slice raw materials toindividual serving sizes, themachines are efficient inpreventing wastage by higheryields and reduction in labour.This means firms can increasecapacities and ultimately savemoney on the productionprocess as a whole. PND srloffer machines able to handlelarger fruit such as pineapplesand melons as well as less hardyfruits such as oranges, apples,pears, mangos and kiwi fruit.The machines have beendesigned to extract themaximum amount of saleableproduct from each piece offruit, increasing yield andreducing the amount sent towaste. Using the automatedcutting machines such as thesealso presents safety levels notnormally attainable when usingemployees to cut fruit by hand.As the blades are enclosedwithin protected enclosures,accidents are rare.For more information on what Prima can offer yourbusiness, visit www.primafps.co.uk or call them on01775 841664.26-32:Layout 1 20/8/12 10:16 Page 7New OPTi+ refractometer provides wide ranging measurement capabilityThe new OPTi+ series of digital hand held refractometers launched by Bellingham + Stanley extends the measuring rangeof the successful half Brix OPTi models. Covering the Brix range, a number of scale derivatives are available making the OPTi+a perfect instrument for a wide range of applications, whether measurement is required in the field or as a support instrumentwithin the factory or lab. Bellingham + Stanley has combined 95 years’ of experience with design innovation to produce the OPTi and OPTi+.Injection-molded stainless steel has been specifically chosen for the sample dish material not only for optical rigidity butalso to facilitate rapid temperature stabilisation that when combined with product specific temperature compensation,ensures reliable results no matter what the sample or environmental conditions. New software has been developed for the OPTi+ to improve measurement performance but also to enhance the userexperience by offering a number of special features such as the unique “AG verification mode” that allows the use of long-life non sucrose based certified reference materials to check calibration as well as touch-of-a-button temperature displayin either Celsius or Fahrenheit.Tel: 01892 500400 E-mail: sales.bs.uk@xyleminc.com www.bellinghamandstanley.comOptical mini-encoder NOE1 for compact applicationsHigh-precision position measurement for NEMA8 and NEMA11 small BLDC and stepper motorsAlldrives & Controls, Nanotec`s UK representative, is introducing the NOE1, the first rotary encoder in a new productseries of optical encoders. Due to its compact size, it is ideal for applications that require accurate positioning of smallstepper, or BLDC motors. In addition to the motor and the proprietary DSP SMCI controller range, the NOE1 encoder isthe essential component completing the loop, when accurate, high-resolution positioning is called for. In response, to applications in Medical, Food & Drink technology, and other fields which require small sizes, drivespecialist Nanotec developed the 3-channel Optical “NOE1” encoder, which fits small NEMA8 and NEMA11 step-per and BLDC motors, with compact dimensions of just 20x26x10 mm. The NOE1 has 800, 1000, or 2000 pulses per revolution, Quadrature increasesthe maximum resolution to 8000 increments per revolution, which corresponds to 40 increments per 1,8° step for a standard stepper motor. For stepper motors, the NOE1, in conjunction with Nanotec`s closed-loop DSP control deliver performance Beyond MicroStepping, and opens up new fieldsof application in areas where precision positioning with high torque is required.For BLDC motors, the NOE1 is ideal for use when high-resolution positioning isrequired. The high resolution makes it possible to measure the commutation angle in field-oriented control operation with sine commutation and synchronisation,even at slow speeds. The line driver for higher interference immunity is also integrated into the housing.Tel: 01543 271899 Email: emily@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.ukwww.fdiforum.net33CONTROL & AUTOMATION SHOWCASEDavall Stock Gears offers stainless steel gearboxesDavall Stock Gears introduce smooth, full stainless steel housing gearboxes, designed for the harshest ofenvironmental applications. The gearboxes are ideally suited for food or drink preparation sites. Both ranges are constructed with a stainless steel housing (304), and designed to be close coupled to a B14face mounting stainless steel AC motor accepting either IEC or NEMA frame motors, and are availabledimensioned in either metric or inch. These gearboxes are available in two gear geometries, either in-line helicalreduction (co-axial) or worm and wormwheel reduction (right angle). The gearboxes are designed to ensure a minimum maintenance regime. The worm unit has two bearings onthe worm line and two bearings on the wheel (output) line, to ensure maximum power transmission capacity.The two styles of gearboxes have a choice of reduction ratios available, worm gearing from 7:1 up to 100:1, andhelical gearing from 3:1 up to 60:1, and power ratings from 0.18Kw, up to 4Kw.The high efficient in-line coaxial helical unit is fitted with a stainless steel output shaft, and the worm unit is available with a stainless steel outputfemale sleeve, with an option of a plug-in male shaft.Tel: 0800 626028/01707 283131 Email: dsg@davall.co.uk www.davall.co.ukControl and Automation ShowcaseAs the PPMA Show will illustrate, the food and drink industry is among the most advanced of them all,and increased automation is allowing for increased innovation. Indeed such is the importance of advancedmanufacturing that many governments are prioritising the sector as a major revenue earner.Companies that can illustrate they have embraced new technology to ensure a swift and secureproduction line are well-placed to land valuable contracts. Indeed with the requirements now for increasedtraceability and absolute product integrity, businesses that are slow to introduce automation are highlylikely to miss out.Along with automation comes the requirement for staff to be effectively trained in its operation.Schemes such as See Inside Manufacturing, which the UK government has pioneered, introduces thesector to young people as a viable career option. Employment Minister Norman Lamb marked the schemeby visiting Britvic Soft Drinks in Norwich with a group of pupils to examine how the plant is usingtechnology to excel.33:Layout 1 17/8/12 10:55 Page 134-35:Layout 1 16/8/12 15:07 Page 1PACKAGINGwww.fdiforum.net35The UK food and drink industry handles enormous complexity every day. Allsupermarkets in constant competition for market share try to outdo each other withnew products, flavours, special offers and lower prices.Only rarely do supermarkets agree to pay higher prices for their products, whiledemanding consistently high quality levels, on-time deliveries every time, insmaller batches. The supermarket suppliers, on the other hand, are faced withhigher raw material costs, higher salaries, higher energy costs, short batch runsand more frequent product change overs.This means that if suppliers continue to do what they have always done in themanagement of such increasing demands and complexity, they are likely tocontinue to get more quality issues, more non-conformances, higher reject rates,more batch rejections, more waste, reduced efficiencies and punitive fines fornon-compliance. Clearly, they have to find ways to guarantee total compliance100% of the time, including on-time deliveries, but at lower manufactured cost. Roy Green, Managing Director of Harford Control, says, “We believe theseconverging dynamics can only be cost-effectively achieved where the productpackers are prepared to look at doing things differently in order to minimise risk,reduce wastage and reduce the overall cost of their manufacturing operations.This is often talked about but very little in evidence, principally because it meansa radical change away from paper-based systems and significant investment inautomation, real time information management, prioritisation, visualisation andinformation distribution.“Without such investment operators, faced with the day-to-day management ofsuch complexity, will continue to make costly mistakes. During the last five years,we’ve seen an increase in the use of integrated and automated systems which willlargely remove the incidence of operator error by automatically setting up wholeproduction lines and, through the same system, analysing and prioritising actualline performance in real time. Making real time information highly visiblethrough powerful modern metrics including OEE headlines the top productionlosses and helps drive continuous performance improvement. The net result istotal compliance, 100% of the time, at lowest manufactured cost.“Where we have helped companies to achieve these objectives, we have seencomplete transformations in the elimination of coding and labelling errors,increased quality consistency, improved operational discipline, reduced materialswastage, better manpower and materials utilisation and improvements inefficiency/OEE by as much as 40%. One client told us that by directly actingupon the prioritised information generated within the system, they were able toreduce product changeover times from one hour and 28 minutes to just 26minutes!“All our evidence suggests the successful management of complexity, coupledwith sustained performance improvement is highly dependent upon real time,accurate information, made instantly visible to all stakeholders. When thishappens and operational personnel begin to see the benefits in action, the all-important buy-in for such systems accelerates and quickly becomes the newstandard. When this happens, paper-based systems permanently become a thingof the past and forests are saved, while companies reduce their operating costs.”For more information, call Harford Control on +44 01225 764461,email sales@harfordcontrol.com or visit www.harfordcontrol.com.They are also at the PPMA Show on Stand E60.Complexity simplified in FMCGTop losses by timeTop losses by costProduction schedule downloaded from ERP34-35:Layout 1 16/8/12 15:07 Page 236www.fdiforum.netPACKAGING38 The whole packageThe quest for packaging that is cost-effective and safe as well as appealing onthe shelf continues. And, a host ofexhibitions this autumn ever-moreimpressive products look set to appear.One style of packaging which has gonefrom strength to strength in recent timeshas been corrugated and its manyadvantages have ensured a rise in use.Retail ready packaging is fast becoming anincreasing necessity for food and beveragemanufacturers and according to a recentsurvey commissioned by the Confederationof Paper Industries this looks set tocontinue.The survey found that in a time whereenvironmentally-friendly and attractivepackaging is demanded, corrugated isleading the way as a tool for optimising theappearance and performance of a varietyof branded products. A poll of 100 companies found that 79%of respondents rated corrugated retailready packaging as their first choicepackaging material and 83% agreed withthe statement that it ‘helps promoteproduct or brands in store’. Green issues also came to the fore in thesurvey, which revealed that a majority ofthose contacted believed corrugated iseither very or extremely helpful in meetingcorporate or government targets onenvironmental issues. CPI believes these statistics confirmcorrugated cardboard as the completesolution for transit and point of salepackaging, making it the ideal and mostsustainable material for fulfilling logisticsexpectations throughout the food anddrinks supply chain. Andy Barnetson, Director of PackagingAffairs, says: “Protection of goods and costalso score highly in the CPI survey as keyadvantages for using corrugated packaging.This clearly demonstrates the need for theUK Corrugated Industry to remain at theforefront of innovation by continuing toproduce sustainable, retail ready packagingwith quality printing that makes productseye-catching at the point of sale. “To meet the expectations of the foodand drinks industry the corrugatedpackaging sector in the UK is pioneeringpackaging solutions that bring increasedsustainability to the supply chain as well asinvesting significantly in new equipment.”The results of this survey indicate thatthe industry appears to be getting thebalance right between functionality andpresentation.Coding for the futureCoding and marking is obviously anintegral part of the packaging process, andplacing custom coding onto packaging onthe line is often essential. Directlyapplying the codes to products is oftenmore cost effective than placing adhesiveson after be it through traditional or laserprinting. Use of software which allows access toremote web interfaces to monitor andcontrol printers via PC or smartphones isPackaging is an ever evolving medium. This isespecially true for the food and drink industry, whereconstant refining and perfecting leads to innovationsand improvements for manufacturers, retailers andconsumers alikeCorrugated packaging offersstrength and comes with shelf-ready optionsCoding can now be controlled remotely thanksto software linked to smartphonesPHOTO: LINX PRINTING TECHNOLOGIES36-41:Layout 1 17/8/12 11:35 Page 136-41:Layout 1 17/8/12 11:35 Page 238www.fdiforum.netPACKAGING41 now available. With a few keystrokes on aremote computer connected to theinternet, an operator can start, pause orstop printers, change messages from pre-stored selections and download messagesfrom a PC to a printer with manypackages. Users can also lock the printerkeyboard to prevent changes being madeon a line and reducing coding errors.Embracing smartphone technology is alogical step, and with the amount ofinnovative apps appearing week afterweek, it was only a matter of time until itmade its way into the packaging industry,where monitoring is nigh-on essential.From these apps there is the ability tocheck the current status printers, forexample viewing the current message,print count, ink and solvent status, andtime to next service, meaning that evenoffsite and nowhere near a screen, progresscan be tracked. This would be useful forthe engineer who covers multiple sites orworks in a large, sprawling foodmanufacturing plant.Convenience rulesOne survey which has delved deep intowhat consumers want and expect in thenear future has revealed a desire for mealmobility and a need for more single-portioned products. This all points to anexisting and on-going trend which hasbeen part of the food and drink packagingindustry for years, the concept ofconvenience. Products launched in thelast few years include more innovativeclosures for both soft drinks andconvenience foods in general. Flip-top andshaped closures on plastic jars andcontainers mean airtight seals whichensures food stays fresh for longer.Adding fused foil to these closures meanseven more guarantees of freshness too.Australia has just seen the launch of clear,plastic pots containing fresh fruit which isa prime portion-control opportunity aswell as being mobile. It’s not just for consumers thatconvenience matters. Retailers alsoincreasingly look to stock innovative andpractical on-shelf packaging solutions.Innovative answers to packaging whichappeals to both retailers and consumersare constantly being sought. Glass actingas a traditional material for wine is fastfacing a challenge from other mediums.Supermarkets are now turning to otheroptions, including pouches. This solutionnot only offers a lighter material thanglass, which saves on space and loadweights for supply chain management, butalso provides the consumer with choice. Itfeatures a re-sealable closure which meansit can be taken outdoors for use atbarbecues, festivals and other socialoccasions. This kind of design is also lessimpactful on the environment, taking upjust 20% of the carbon footprint a winebottle might.In Thailand, the issue of materials usedto house drinks has been addressed withthe launch of a flexible pouch that replacesthe traditional drinks can. Mxx Drink’srange of fruit-flavoured drinks is in a can-shaped package that stands up on its own.The containers have a year-long shelf-lifethanks to a very thin aluminium wallinside and with the materials used, theoutside walls can be customised too.Problems with sealing technology meanthe company are looking to more effectiveoptions for its second generation of thisproduct, but it is an interestingdevelopment nonetheless.A good film…Resealable packaging also means portioncontrol is available to the consumer and insome cases actually reduces packaging size.Recent lidding technology has meantpackaging for pasties and pies that featuresresealable snacking options. This is notonly a boon for consumers who want toRe-sealable closures meanconvenience for those whowant to exercise controlover portioningPHOTO: BAPCO CLOSURES36-41:Layout 1 17/8/12 11:35 Page 3Next >