< Previous20 Food & Drink Internationalwww.fdiforum.netSOFTWARE & HARDWAREminimising on mistakes a more traditional system mightmake. Removing the human element where possible canhelp to not only ensure that all data is correct andaccurate, but that there are no unnecessary paper trails totry and work through. Automation is king, both on theproduction line – and when it comes to software packages.One area where this is of particular value is in the supplychain, specifically in distribution centres – which might seeproducts coming in from multiple manufacturing sitesacross the country, before being sent out to variouswholesale or retail outlets from that one warehouse. Anydelays at this crucial part of the process can becatastrophic, as it is distribution centres which commonlydeal with directly with the final client – introducing thatage-old risk of failing to satisfy and thus losing a keycontract. With the food and drink retail market dominated by afew very powerful retailers, manufacturers can ill-afford tosuffer any lost confidence with these major clients. Because the warehouse is the final port of call from themanufacturer to the customer, systems which monitor andhandle traceability are of key importance. Shouldsomething go wrong and require a recall – as recent high-profile cases have seen happen – then the retailer will needto assuage the doubts of their own customers. To do this,they will always come back to the manufacturer, askingthem to isolate and identify where the batch wascontaminated and how – usually within a period of nomore than 72 hours. Some larger retailers such assupermarkets may provide even less time, of which thefailure of meet the target might result in a lost contract.And it is this traceability that continues to placepressure on many within the supply chain today. In fact arecent survey of 250 companies in the UK food and drinkindustry suggested that 26% of those surveyed wouldn’tbe able to identify product recall items within thattimescale, while 11% would need at least a day and 10%wouldn’t be able to carry out those requirements at all.That would inevitably mean that they would have littlechance of winning contracts from blue chip companieswhose traceability requirements often go far above andbeyond the recommendations of food safety bodies andgovernments.Warehouse Management Systems work to minimise thatrisk, by accurately recording all products that enter thefacility – where they came from, and what their finaldestination will be. From that point they are trackedthrough the warehouse until they are dispatched, allowingOperations Managers to not only save time on the tasksthey need to do, but also stay informed as to any© shutterstock/branislavpudar19-21_Layout 1 21/08/2017 12:52 Page 2Food & Drink International 21www.fdiforum.netSOFTWARE & HARDWAREMobile solutionsto speed upyour business Every industrydemands mobiletechnology –solutions thatspeed up yourbusiness processes,allowing yourcompany to savetime, to decreaseglitches and toincrease ROI. Butwhat is theproblem about it?To find a solutionthat perfectlymatches yourneeds.Kalipso Studio is a mobile development platform thataddresses this problem. How? By being a low code platformthat does not require you to be an expert developer, Kalipsofocus on the purpose instead of focusing on the code, invitingevery person to develop its own applications. Easy create anapplication by simply drag and drop actions alreadyestablished, with no need of coding it by you. Save time – bydelivering solutions faster with certified quality.With customers around more than 70 different countries,several application examples might be found – integratingemergent technologies such as barcoding, RFID, NFC, GPS ormobile printing. Here are some reasons why you should chooseKalipso Studio:•Code abstraction with an easy and intuitive interface;•Development to multiple OS (Android, Windows 10,Windows Mobile, Windows CE, iOS);•Multi-language – develop your APPs with the languagesyou need, translating it at the same time you are building it;•Several updates and upgrades;•Integration of several SDKs from different hardware manufacturers (this is particularly important when it comesto barcoding or RFID apps, because you won’t need to integrate an SDK by yourself);•Phone and E-mail support;•Personal training, as well as online tutorials;•Unlimited deploy of different apps for different devices (noroyalties).For more information,visit www.kalipsostudio.com,email marketing@sysdevmobile.com,or call +35(0) 1 234 188 027.fluctuations in stock incoming – be it an unusually largeone-off order, or a more long-term change in stock levels. What the results show clearly is that despite the need fortraceability being well-known, many companies continue togo without a proper software system that can monitor it.While trust in employees and facilities is admirable, it onlytakes one instance of bad luck to cripple the reputation ofa company beyond all measure. The use of software has been so ingrained in theproduction process over the last few years that it’ssometimes hard to imagine how some parts of the industrycoped without it. The next stage is for this software tobecome even more intuitive, explicit and effective –creating an even more efficient supply chain.That said, companies will only be able to reap thebenefits of these advancements, so long as they continueto invest in keeping their systems up to date. It can be easyto believe the improved traceability that comes about as ause of WMS should be something to look into whensomething goes wrong – but many large retailers will noteven consider a company as a potential client unless theyprove they can retrieve data within a four hour period. In the competitive world of the food and drink industry,can any manufacturer afford to be complacent about suchthings?19-21_Layout 1 21/08/2017 12:52 Page 322 Food & Drink Internationalwww.fdiforum.netDUST CONTROLThrough preventative measures, afood manufacture can help circumventthe inherent dangers of this multi-faceted and fast moving sector. Humanerror, unsafe machinery and myriadother circumstances mean thataccidents still frequently occurthroughout the global supply chain.Although injuries – life-changing andotherwise – are most common, workerdeaths are far from a rarity. The majority of these injuries relate tospecific equipment, be them forklifts,mixing machines or conveyor systemsetc. One of the single biggest dangersto any food production facility is one ofthe most seemingly innocuous, nearinvisible as single particulants. Dust inany form presents numerous health andsafety concerns to manufacturers. Itcan be a clear indication that itswashdown services and overall sitehygiene is failing. It might also meanthat there has been a product spillage,or that an aspect of its production linehas been compromised. Or it could bean environmental issue, with theintegrity of the facility itself the routecause. As with the potential origins ofdust contamination, its effects can alsobe expansive. It only takes one particle coming intocontact with a food product oringredient to contaminate it, leading tospoilage and putting consumers at risk.Given dust can be made up of metal,dirt, food matter, as well as skin andhair, manufacturers are obviously keento keep any potential contamination toa minimum. Dust can also causemachinery to perform below standardor fail altogether. A build-up of particlescan compress together and harden,impairing moving parts and sensorequipment. Should this occur, acompany’s output can be seriouslyaffected. Moreover, the downtimeneeded to repair or thoroughly serviceand clean affected equipment can besignificant. Perhaps the most profound dangerarising from dust is explosions.Almost all dust particles areexplosive, with somemixes more potentthan others. Some ofthe products thatcomprise dust clouds are not normallythemselves explosive, but can becomeso if the particles are the right size.Explosions occur when the dustconcentration in the air falls withinthese specific limits. Although mixturesof dust and air within these limits arecapable of exploding, they will not doso unless exposed to an ignition ofsome kind. Ignition in a manufacturing contextcan arise from a number of origins,from a hot surface or an electricalspark, to a mechanically generatedfriction spark. Given manufacturingfacilities are defined by theirequipment, theaforementioned sparkscan all frequentlyoccur. Dust cangather withoutever exploding© shutterstock/KITSANANANMatter of dustDust brings with it numerous threats to a food manufacturing facility, fromthe effects on machinery, to causing explosions. There are, however, anumber of safeguards at a company’s disposal. 22-24_Layout 1 21/08/2017 12:53 Page 1Food & Drink International 23www.fdiforum.netDUST CONTROLif there is not an ignition, andmachinery can spark without causingcombustion if there is no dust to spark.However, when an explosion doesoccur, the results can be catastrophic,both to a company’s facility andbottom line, but also to its workers. A recent dust explosion in Americabrings home the reality of the situation,that manufacturers still liveand work alongsidethis threat.And thatdust explosions are still one of theindustry’s many spectres. Powdered foods are endemic in thefood industry, as enhancers, additivesand as products in their own right.Although a manufacturer can employ arugged hygiene and washdown routine,and utilise the best in chutes andguards to minimise the build-up of dust,particles can still escape and congestover time. As previously mentioned,products that might not otherwise beflammable can become explosive in aparticular particle size. Therefore,products including sugar, corn starch,coffee and, increasingly, whey powders,can all be potentially hazardous. Otherproducts, such as powdered custard,are already well documented as beinghighly flammable. One of the surest defences againstdust clouds at a manufacturer’sdisposable is air filtration systems andother clean air solutions. Thesesolutions also have the dual purpose ofprotecting manufacturing facilities fromoutside contaminates, such as airbornebacteria. It’s interesting to note that, inmany ways, air is an antagonistic forceto the food industry. Preservingprocesses, such as freezing, vacuumsealing and drying, all serve tosafeguard products from thedetrimental effect of air (or, specifically,the combination of air and water).Airflow itself can bring in outsideparticles into a facility, but it can alsoaccumulate dust throughout a facilityand lead to dangerous build-ups.Constantly filtering and cycling air isintegral to preserving the overallintegrity and safety of any facility and,by extension, the supply chain. Manufacturers can choose from avariety of air filtration options, includingbagged filters which act in a similar wayto a vacuum cleaner, albeit on anindustrial level. There are also air© shutterstock/BLACKDAY24 Á22-24_Layout 1 21/08/2017 12:53 Page 224 Food & Drink Internationalwww.fdiforum.netDUST CONTROLDustcontrol brushes designed withfood industry in mind Dustcontrol UK’s Good For Food brushes are designed specifically with the food industryin mind and tailored to suit its requirements, offering a unique combination of properties. Antistatic and ESD certified, they can be used in Atex Zone 22, where dust explosions canoccur. They are also approved for food surface contact, being both FDA compliant and theEuropean equivalent.The brushes are colour coded, covering five handle colours and two interchangeablebrush colours, which allows their use for different applications in the factory, different areasor even for different days of the week depending on need. In addition, their materialcomposition makes them detectable via metal detector as well as being autoclavable up to121 degrees Celsius, allowing for high pressure saturated steam cleaning. The brushes can work in conjunction with Dustcontrol UK’s high-quality extractionequipment, ensuring food hygiene areas are the cleanest they can be – keeping thepotentially serious side effects of dust to a minimum.For more information, visit www.dustcontroluk.co.uk.cleaners, which take in potentiallycontaminated air, remove particles andsend it back out again on a constantcycle. Then there are specific dustextraction systems. These can beaffixed to specific machines on theproduction line, concentrating theircapabilities on the likeliest source ofcontinuation – such as the pouring ofpowdered foods. Although dust can ignite and affectmachinery, workers are themselves alsoat bodily risk. Breathing in particles canseriously affect worker health andlungs, leading to a variety of conditionsand complications that could impactworkers or lead to libellous action. Asimple means of countering this threatis with personal protective equipment(or PPE, for short). Breathing apparatus,mouth covers and other masks exist forthe sole purpose of preserving workerhealth in environments where theycould come into contact with harmfulmaterials. Although a price can’t be puton the lives of workers, many PPEsolutions are relatively low-cost andform a keystone in any manufacturer’shealth, safety and hygieneresponsibilities. Although the headlines are mostoften dominated by news of lifechanging injuries suffered by workersoperating cutting or other processingmachines, dust remains one of the mostprofound obstacles for the foodindustry. Given the right conditions,dust can explode leading to downtimeand a loss of profit at best. It can alsoimpair worker health and compromisefood and beverage products.Fortunately, there exists a variety ofrobust options for manufacturers toexploit and a number of PPE options tokeep workers safe. © shutterstock/Sergey Butin22-24_Layout 1 21/08/2017 12:53 Page 3Food & Drink International 25www.fdiforum.netBAKERY & CONFECTIONERYThe bakery and confectionaryindustries may not seem to have somuch in common at first glance, butboth face many of the same problems,from automation to packing, and evenfocus on their propensity for highcalories. In a world where weight gainand obesity are in the media – andGovernment – eye, how can the twoindustries cope?It hardly helps when one considershow difficult consumers can be in thesetwo sectors. Consumers search forproducts that appear to have beenmade in a traditional manner, makinguse of natural ingredients and withinteresting tastes and textures. However,this goes hand in hand for the need forincreased automation, higher qualityand healthier products – and those twoaspects come across as opposites. The demand for artisan, hand-craftedgoods and easily-manufactured andsafe produce is something that has leftmany scratching their heads – and isperhaps one of the few areas in whichwe can definitively say consumerdemand is contradicting itself. That’snot to say the demand will go away, ofcourse, and manufacturers are going tohave to adapt to these demands nomatter how unusual they might seem.On top of this, consumers aredemanding healthier foods and higherlevels of transparency, which has placedmore pressure on the industry to tryand conform. This has not been madeeasy, particularly in the confectionaryindustry, which – in all honesty – is notthe healthiest of foodstuffs. Many companies are able to ensure allthese needs are met with theintroduction of new ingredients andproduction methods. In the case ofingredients, many are looking towardsfat replacers that can offer the samequalities as the ingredients they’rereplacing.The confectionery sector is, inevitably,continually under scrutiny as consumersconsider potential health problems, butcompanies such as BENEO haveproduced a range of tooth-friendlychildren’s confectionery productconcepts to try and help with this. Theirbubble gum and chocolate lentilconcepts have successfully undergonescientific testing with plaque pHtelemetry, making them tooth-friendly,thanks to the inclusion of theircarbohydrate Palatinose, which27 ÁNot sosimplefoodThe bakery andconfectionaryindustries face a slewof demands fromconsumers, many ofwhich would seem atodds with one another.Despite this, they’reexpected to meetthem all.© shutterstock/Evgeny Karandaev25-29_Layout 1 21/08/2017 12:54 Page 126 Food & Drink Internationalwww.fdiforum.netFi EuropeFi AsiaFi RussiaFi VietnamFi South AmericaFi IndiaHi ChinaHi EuropeHalal AsiaHi JapanFi IstanbulHi South East AsiaHi Korea 28 - 30 November 2017Frankfurt, Germany @Fi_GlobalSearch for Food ingredients Find your perfect ingredients partner at Fi Europe & NiScan this QR code to step in the exciting world of Food ingredients eventsSign up now for your free visitor pass at: www.fi-europe.eu/barterSource the latest ingredient innovations from leading ingredient suppliers at the world’s largest global food ingredients show! Get to know 1,800+ leading suppliers and their latest solutions, build your network with 25,000+ food and beverage professionals from across the globe and get the latest insight on food and beverage trends from 86+ free presentations and tours.Find your perfect ingredients supplier for flavourings, proteins, colours, aromas, bakery, functional foods, dairy, gelling agents, gums, fibres plus many more – all under one roof at Fi Europe.1,800+ leading ingredient suppliers under one roof!25-29_Layout 1 21/08/2017 12:54 Page 2Food & Drink International 27www.fdiforum.netBAKERY & CONFECTIONERYIf you think you’ve seen this before, you’re wrongAsk us for a sample on 01274 68 55 66 or email marketing@nationalflexible.netSchär gluten-free launches four newproducts Schär, the UK’s fastest growinggluten-free brand, has launched aselection of new bread andbiscuit products into stores for2017. The new products include agluten-free Deli Style SourdoughBread, Hamburger Buns, ChocChip Buns and Viennese Biscuits.The latest launches address thegrowing consumer appetite forbaked goods with bread currentlythe number one sector in gluten free and Schär bread the most often bought in thecategory. Inspired and developed by Schär’s master bakers, the new products are made usingtraditional recipes and only the best quality ingredients. Dedicated to providing qualityand choice for those with special dietary needs for over 90 years, Schär ensures gluten-free shoppers have no need to compromise on taste. Since 2015 Schär has contributed 14% to gluten free growth (£8 million), which is 21⁄2times more than the contribution of the next biggest growth brand in the category. For more information, visit www.schar.co.uk completely replaces sucrose.New technology is also allowing formore efficient and effective production.On a large scale, modern vacuumtechnology can play a major role in theconditioning of industrial bread baking.At atmospheric pressure, water boils at100°C, but decreasing the atmosphericpressure decreases the boiling point. Ifthe pressure is at 42 mbar, the waterevaporates at 30°C and the energynecessary for baking stems from thestill warm oven-baked product. If bakedgoods are subjected to vacuum cooling,this can be done in under six minutes,with the steady withdrawal of watercontent preventing possiblecondensation and gelatinisation withinthe product.This vacuum-based technology offerssignificant advantages for both bakersand consumers. While customers cannow purchase perfectly baked productsfaster than ever, manufacturing anddistribution channels are saving money,as significant cost reductions arepossible in logistics, plant foot-print andin streamlining work economics. Indeed,depending on the plant design, costreductions may reach 50%.Other technology is also improvingthe speed and efficiency of baking andconfectionery production. Hygiene hasoften been a top priority and there arenumerous potential flashpoints. Forexample, checkweighers can createproblems are the transitions betweenin-feed, weighing and discharge belts. Inthese cases, dough remnants can fallfrom the conveyor belt and collect inthe system. The belt is narrower thanthe belt body, so dough accumulates onthe belt body next to the belt and couldre-enter the production flow.The treatment of ingredients duringproduction is also a factor. Companiesin the sector frequently require a mixing28 Á© shutterstock/Chamile White25-29_Layout 1 21/08/2017 12:54 Page 328 Food & Drink Internationalwww.fdiforum.netBAKERY & CONFECTIONERYi2r unveils stylish black ‘tuxedo’ tulipmuffin wrapi2r Packaging Solutions has released anew black ‘tuxedo’ range, providingcustomers with an elegant premium look.The company continues to expand itsoffering, manufacturing a ‘family’ of wraps tosuit all requirements. From the dinky ‘bite-sized’ micro wrap to a recently released‘perfect for sharing’ stepped mega tulipversion at 175mm x 175mm x 60mm, alongwith a number of sizes in between, i2rcontinue to develop their baking division tomeet increased and varied demand.Manufactured in i2r’s FSC and BRCaccredited factory, all muffin wraps are available in printed sheet and in a variety ofcolourways.i2r’s Guy Rowledge said: “The ongoing growth of our tulip muffin wraps and paperproducts continue to keep pace with the increasing demand in this sector, particularlywith food-to-go. And with ongoing investment in new tooling, we will continue to innovateand further enhance our product offering.”For more information, visit www.i2rps.com.Holchem devise cleaningsolutions for clients Holchem’s Cath Chapman said: “Managing the hygiene of a facility producingbread – whatever the size of the plant is critical to ensuring the quality of theproduct, assuring produce is sent out meeting consumer expectation and deliveringtaste and consumer satisfaction.“During the baking process, foreign body controls, mould controls and allergenmanagement are integral to the hygiene management system ensuring the endproduct is not spoiled. Bakeries that handle dairy products such as cream haveadditional hazards to consider, with the control of pathogens crucial in qualitycontrol and delivery.“Bakeries are most commonly managed through dry cleaning such as vacuuming,brushing or sweeping of dry materials. Equipment that is used throughout thebaking process needs to be deep cleaned on a routine basis to stop potential infestations. We work with clients in the sector to deviseCleaning in Place systems that are often used to clean yeast holding tanks and delivery mains.”For more information, visit www.holchem.co.uk.system which can mix ingredients quickly,give an even, homogenous blend, while atthe same time providing a very gentlemixing action so the product isn’t reducedto a homogenous, unidentifiable lump. Forexample, fruit pieces are relatively fragileand usually can’t be damaged by the mixerbecause they’re expected to be obviousand noticeable in the finished product.Companies are increasingly using mixerssuch as the bladed mixers. Their bladedesign and slow rotational speed combinewith a short length to diameter ratio togive a fast gentle mix with low powerconsumption – which provides significantbenefits over conventional ribbon or spiralmixers.Automation is the name of the game,particularly with rising wages set to forceefficiency in what is already a tight market.Industrial fillers and depositors are valuablewithin these industries, particularly in themanufacture of baked products whichcontain fillings. With hygiene and speed ofutmost importance, the age-old task of anemployee filling each individual product arelong gone, and need to stay that way. Suchtasks are time-consuming and wasteful,and because it is only the filling itself whichis done by such a machine, the product canstill be considered artisan and hand made.In essence, whether the filling is inserted viaa machine or by an employee holdingcontainer over the product, it is the samething – just thousands of times quicker, andwith added hygiene. In the quest to meet consumer demand,improve efficiency and reduce costs, it isclear that even an industry with thousandsof years of history needs to keep movingwith the times. But with global demand setto continue growing, and the globalpopulation increasing, it’s an industry setto succeed.© shutterstock/Sorbis25-29_Layout 1 21/08/2017 12:54 Page 4Food & Drink International 29www.fdiforum.netDynamic process scale CWPmaxx Bakery100% control of dough in the bakery industry from BizerbaDue to it’s particularly robust design, the CWPmaxx bakery checkweigher is ideally suited for use in the hygienically sensitive environment of the bakery industry. The hygienic design required for this industry is exemplary. The open construction facilitates cleaning & minimises the formation of product residue.No or few parts designed to wear: a continuous belt, no deflection rollers, no bearings. A long lasting drum motor provides reliable propulsion. Optimise your lines’ efficiently and increase profits with fill quantity and process control.Highlights:Throughput: up to 250 products/minWeighing Ranges: 50 - 6000gProtection Class: IP 65Optimised weight and fill quantity control with tendency controlInterface to Bizerba’s data management solution _statistics.BRAIN01908 682740 info@bizerba.co.uk www.bizerba.comCWF maxxOptimum quality assurance of packaged goods for food processing companies.Additional metrologically approved checkweighers:CWE maxxStandard checkweigher for middle and high performance settings in the food industry and non-food areas.CWD maxxEntry-level model for dry areas and non-food applications.Tel: +44(0) 330 223 0400Web: www.vegware.com Email: info@vegware.co.ukCompany profileVegware, the only completelycompostable packaging companyoperating globally. That the global brand suppliesindependent cafes through to theworld’s largest contract caterers anddistributors is testament to its qualityproducts and competitive prices.Established in Edinburgh in 2006,Vegware has operational bases inHuntington Beach, Sydney and HongKong, with distribution throughoutEurope. Product profileVegware’s award-winning catering disposables are made fromplants, not plastic.Its extensive range of eco catering disposables offers qualityenvironmentally-friendly products at competitive prices.The award-winning hot and cold drink cups, takeout boxes andfood containers are low carbon, made from renewable or recycledmaterials, and designed to be commercially composted with foodwaste where facilities exist.People love the look and feel of its premium eco materials, andthe feel-good factor of being part of a sustainable economy.Vegware – good for your food, good for the environment. RAPS GmbH & Co.Tel: +49(0) 9221 807-0Web: www.raps.comEmail: info@raps.comCompany profile For more than 90years, the ingredientmanufacturer hasstood for first-classquality, taste,innovation,technology and rawmaterialcompetence. As areliable solution provider,RAPS supplies segment- and customer-specific services, andprocesses approximately 1,100 raw materials from all over theworld for the food, meat, catering, dairy and bakery industries. Product profileWith ‘RAPSolution Salt Control CT’, RAPS offers the idealsolution to reduce salt in formulations such as bakery products.The same level of salt perception can be achieved using up to20% less salt. In toast, for example, the coated salt grains formirregular, concentrated “salt spots” in the dough, resulting in goldstandard salt perception. As no masking solutions are required,this approach is particularly cost-effective. RAPSolution SaltControl CT is suitable for a wide range of bakery products andsnacks, as well as for frozen convenience meals such as pizzadoughs. RAPS is also an expert in developing individual,customer-specific solutions.25-29_Layout 1 21/08/2017 12:54 Page 5Next >