< Previous30 Food & Drink International www.fdiforum.net VISION AND INSPECTION pizzas and cakes if the machinery is pre- programmed with the correct information and integrated with the required robotics on the production line. Product safety – an absolute must in a quality- driven environment – can also be guaranteed through the use of Machine Vision Systems. For example, laser triangulation devices similar to those used to measure size, weight and consistency can be employed to ensure the overall integrity of a product’s packaging. To guarantee maximum freshness and prevent potential contamination, it is vital that any seals, lids, bags and bottle-tops are checked for flaws or signs of tampering. Triangulation devices will do a much better job than older 2D imaging systems because they are able to capture a far greater level of detail, identifying even the smallest imperfections. The other advantage of using a 3D system, of course, is that it will pick up flaws on every side of a unit of packaging or raw product and not just on its immediately visible surfaces. Manufacturers are also focused on reducing the impact of their systems on the manufacturing process. While hygiene and safety are important, the efficiency and profitability of a site still needs to be a major concern – as even the slightest interruption can prove costly. Machine Vision Systems will shape the future of the food and drinks industry in a variety of ways. Automated systems can help save time and money at every stage of the production process. They can also be used to ensure product safety, which, in a quality-drive world where reputations are constantly on the line, is a highly desirable outcome. © Shutterstock /Microgen Dimaco launches combination label verification, checkweighing and metal detection system Dimaco – part of the Jenton Group of companies – has launched a fully integrated combination label verification, checkweighing and metal detection system. Offering major space saving and traceability benefits, the exciting new machine is capable of verifying multiple parameters in a single pass in high care food production environments, helping reduce waste and improve carbon footprint. Using one-third less line space than installing individual machines, the new label verification, checkweighing and metal detection system is specially designed to offer multi-parameter product verification within the smallest physical footprint. Using Dimaco’s Veri-CENTRAL database, it also allows easy data capture, storage and analysis. Dimaco has developed a single machine incorporating its label verification system, CEIA metal detector and Starflex checkweigher within an extremely compact design and which is capable of sharing both product specification data and real-time results in line with increasingly stringent audit requirements. For more information please visit www.dimaco.co.uk 26-31.qxp_Layout 1 28/08/2020 08:26 Page 5Food & Drink International 31 www.fdiforum.net VISION AND INSPECTION Sparc Systems and Fortress Technology have together developed and launched a brand new modular, high performance combination metal detector and checkweighing conveyor system. A breakthrough development, the Raptor Combi combines months of R&D, drawing upon Sparc’s exceptional engineering prowess and Fortress’s market presence. Featuring a single swipe touchscreen HMI and paperless audit software with unlimited pre-programmed Codes of Practice, Raptor captures all the data required to guarantee absolute traceability. Phil Brown, Managing Director of both companies, picks up the backstory of this long-term partnership, which was formalised last year and how the development of the flexible, fast and affordable Raptor Combi overcomes several limitations in high-care food inspection environments. What are the synergies between weighing and inspection systems? They are complementary technologies. While they may be used for very different applications, many of the functionalities are common to both. Combining the two technologies offers food factories cost savings in a smaller footprint, due to the better utilisation of common elements, such as the drives. Innovative common fixings and connection features, such as jigsaw style panels at the metal detector infeed and checkweigher outfeed, give manufacturers the option to rotate the equipment around to suit a specific production layout, while maintaining the metal detection and checkweighing sequence. How does the Raptor Combi offer premium inspection? Specifically designed to inspect high- care food applications, the Raptor Combi features advanced hygienic and cleanability features, including a unique motor release. A design concept developed by Sparc, operatives can unclip and disconnect the conveyor motor in a matter of seconds, removing the conveyor and releasing the belt for maintenance and cleaning. By introducing Sparc’s tight fitting, smooth surface conveyor, the Raptor eliminates belt noise which affects a checkweighers’ accuracy Inspecting and checking up to 150 packs per minute, the Raptor Combi can handle pack sizes of up to 400mm and weights of up to 8kg, calculating Average Finished Weight Variance. Modifying Sparc’s tried and tested precision weight check software and electronics to reduce product giveaway and meet legislative weight requirements, the Raptor checkweigher also sends a controlled feedback signal to upstream automation equipment used to portion food products. This signal specifies when to increase or decrease fill quantity. More machine in less space Minimising the overall footprint of the combined units was a key consideration during the design process. Raptor’s universal design gives manufacturers the option to purchase a standalone Raptor checkweigher and attach a complimentary metal detector at a later date to meet different phases of their production and inspection investment strategy. Combining the technologies and utilising a pneumatic reject system, the Raptor Combi isolates weight and metal contamination rejects into two separate lockable BRC-approved reject bins. How does the Raptor Combi assist with COP conformance checks? Through our work supplying inspection equipment to multiple European food factories, we have garnered an extensive knowledge of retailer COPs. All of the latest COPs are integrated into a single COP test routine, which can be instantly updated when new COPs are introduced. Operatives simply select from a list of pre-programmed retailer COP parameters, and the product being inspected. Reminders for tests are issued, alerting QA Managers when a test is overdue. By using automation to follow the test principles, it’s impossible to bypass a step in the test process. In turn increasing the transparency and traceability of machine performance audits. Taking traceability to a new level… together sparc-systems.com www.fortresstechnology.com Phil Brown, Managing Director of Fortress Technology and Sparc Systems Both Fortress and Sparc recently merged their R&D to unveil the Raptor Combi, a flexible metal detector and checkweigher The system utilises Sparc’s unique unclip conveyor concept, designed for ease ofmaintenance and cleaning 26-31.qxp_Layout 1 28/08/2020 08:26 Page 632 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS T he importance of loading bays and doors in the food industry should not be underestimated. The first line of defence, they are vital for securing facilities, goods, and environmental conditions. Loading bays however are accident prone areas and one of the busiest locations in food and drink facilities. They must therefore be optimised to run smoothly and efficiently, handle high volumes of traffic, and meet health and safety standards. There is a lot to consider in the selection, construction, and upgrade of loading bay solutions, from dock shelters to access doors, dock bumpers, dock levellers and lighting. Diversity of fleet will also impact choices. A key issue at loading bays is the presence of small gaps around a trailer. This bleeds money every day due to heating and air conditioning escaping, while gaps allow the ingress of unwanted elements, from dust to wind and bugs - major contamination threats. This can quickly create an uncomfortable climate for employees, contribute to product damage and effect inspections. With hardy dock shelters and seals, goods and employees can be protected from the elements, such as rainy weather and subsequent staff slips in the loading area, while a firm seal maintains precisely set building temperatures when doors are open for loading and unloading. By forming a seal between loading bays and vehicles, dock shelters bolster hygiene, insulation, and safety. Inflatable dock shelters are often regarded as the peak in thermal insulation, sealing a facility’s environment with cushions filled with high volume, low pressure air, maintaining steady contact to provide a tight seal and reduce ingress of contaminants. A particularly hazardous area no matter what the season or weather - frequently witnessing costly damage to products and equipment and workplace injuries - solutions must be employed to mitigate risks in loading bays. Vehicle creep for example can occur while loading, when equipment jolts a vehicle, extending the gap between the vehicle and bay, possibly causing goods or machinery to fall. Automatic vehicle restraints can be utilised with the push of a button to prevent this, alongside issues like premature drive off. Unplanned movement is stopped with the restraint system wrapping around a trailer’s rear impact guard or wheels to secure it to the dock. An extra layer of safety can be added with automatic sequence control integrated with other loading bay equipment. Here operating sequences are secured as dock levellers and doors cannot be operated until a vehicle is restrained. The vehicle can then not be released until the dock leveller and door are back in position. Other pieces of equipment key in the loading bay include A critical line of defence Though essential in the movement of goods, maintaining climate control and ensuring the security of products and facilities, loading bays and doors are often overlooked. 32-36.qxp_Layout 1 27/08/2020 13:50 Page 1Food & Drink International 33 www.fdiforum.net LOADING BAYS AND DOORS wheel guides which ensure vehicles are in the correct position, properly aligned for loading and unloading, and prevent staff injury and damage to dock equipment, vehicles, and buildings. Dock buffers meanwhile reduce impact damage between buildings and vehicles which often collide as a result of suboptimal visibility for drivers. Furthermore, traffic lights are commonplace, informing drivers of when it is safe to pull off from a bay or that a trailer is secure for a forklift operator to begin loading/unloading. From the above, the loading bay may seem relatively unchanged over recent years, especially when compared to innovations inside food factories and warehouses. However there have been a plethora of improvements to loading dock technology and ergonomics that are making the loading bay a safer and more efficient place, while a general change is seeing the increase in double deck dock shelters, due to the growing use of double deck trucks in supply chains. Recent developments have seen motion activated sensor systems used in the dock, such as those which display blue light onto a leveller when activity is occurring inside a trailer, to inform workers that equipment or staff could be on their way out. This prevents accidents including forklift and 34 Á © Shutterstock /Worldpics 32-36.qxp_Layout 1 27/08/2020 13:50 Page 2Tel: 01142 889464 Email: sales@dpdoorsandshutters.co.uk Website: www.dpdoorsandshutters.co.uk Aluminium Support Legs and Head meaning easier and quicker installation. Built in integral Windbar system giving excellent wind resistance, no need for additional add on wind bars. Designed for external door locations where wind resistance is Key. Variety of activation options available, from basic push button, to remote handsets, movement detectors, pull chords and induction loops. Safety features as standard, Multi Light beam and electronic safe edge. High Speed Doors 34 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS Registered In England No 3428508 pedestrian collision or crush injuries. When integrated with advanced control boxes, vehicle restraints can be locked until activity ceases to ensure drivers do not pull away when a worker remains in the trailer. Restraints themselves are also being improved further, with external motion sensors stimulating visual and audible alarms to warn staff outside the dock when a trailer is backing in, and traffic light systems have been upgraded with highly visible LED lights at the upper corners of dock doors for increased visibility and safety. Ergonomic loading docks meanwhile are helping mitigate the painful crossing between loading dock floor and trailer, lessening whole body vibration. Levellers are smoothing the crossing to help workers and diminish damage to products and equipment, with some making use of a constant-radius rear hinge to reduce gaps at a levellers rear, two point crown control and an optimised lip chamfer up front to minimise the bump felt when crossing. Outside of developments boosting health and safety, as firms look to improve loading dock operations alongside facility management, new variations of equipment are coming to market. For instance hydraulic dock levellers are being integrated with radio-frequency identification (RFID) technology, for the no-contact recording of goods as they cross the dock leveller, streamlining loading processes. Moreover, developments are seeing in depth yard management systems created to monitor and manage trailer movements and bolster communication. In a system now used by Nestlé, drivers input their details when arriving on site, wait in a designated area where they can see a flight board detailing the status of their load and when they can return to 36 Á Investment in AGV’s in the warehouse can save time and money There are several benefits of deploying AGV automated technology in warehouses. AGVs can help to boost employee development and job satisfaction by performing many of the low value, repetitive and long-distance tasks that, until now, had to be performed by employees. This gives employees more time to focus on the higher-level tasks that will enable them to become more skilled and develop professionally. Safety is another key benefit. AGVs have built-in safety features to protect pedestrians, such as 360-degree scanners which detect obstacles and cause the vehicle to slow down or stop when necessary – all Linde’s AGVs have a PL-d safety level. AGVs also reduce the number of pedestrians needed on the warehouse floor, which in turn reduces the risk of accidents and will be key for many businesses. Getting employees on board is vital to the success of mobile automation. There’s a common misconception that mobile automation is a threat to job security, but in fact studies have shown that the opposite is true. Companies that adopt mobile automation technology generally thrive and grow, eventually employing more staff. Once the technology is in place, employees generally welcome the change. As once the more mundane activities are taken care of by mobile automation, employees can progress to higher level and more rewarding tasks, leading to greater job satisfaction. The average cost for purchasing an AGV system on a seven-year capital only lease works out at around £4 per hour. This means that the equivalent hourly rate of an automated truck on a longer- term lease can be significantly lower than the cost of a manual truck and operator. For more information, please visit www.linde-mh.co.uk 32-36.qxp_Layout 1 27/08/2020 13:50 Page 3Food & Drink International 35 www.fdiforum.net LOADING BAYS AND DOORS Innova Adva aion nced Co old Logi TRIANGLE’ IN ‘L CILITY O A F -FR N E DEEP stics O G I Ă 9 V 0 21 CORB O PENS R EEZE E W ISTI CS Y rustT Autom Innov mation atio Q4 2 0 Agility or– W NewCold Contact: Jon Miles + E: jon.miles@newcold y rking with Our Customers +44 7740 924 695 d.com alue and Qualityto Add V e 21st Century Cold y in the Chain www.newcold.com © Shutterstock /PriceM 32-36.qxp_Layout 1 27/08/2020 13:50 Page 436 Food & Drink International www.fdiforum.net LOADING BAYS AND DOORS Union Industries acts fast on supply of rapid roll freezer door Union Industries, the UK’s leading manufacturer of high- speed industrial doors, has supplied and installed one of its innovative Eiger fast acting rapid roll freezer doors within three weeks of receiving the order. The company was called into action by Oakland International after experiencing problems with an existing door from another supplier. The door was facing increasing high temperatures in the recent hot weather, causing snow and ice to build-up in the cold store, which led to the poor performance and subsequent failure. Having previously installed an Eiger door at one of its other facilities, Oakland International made the decision to invest in the same technology for its Corby depot, and the door was installed less than three weeks later. The Eiger door is the first automatic, rapid roll freezer door to operate at high speed, allowing areas to remain working effectively at temperatures of up to -25°c. The cable-operated door features a unique dehumidified air circulatory system to prevent ice forming around the door frame and boasts the ‘Crash-Out & Auto-Reset’ feature, which allows the door to remain operable even after an impact to the bottom beam. Lee Whiting, Regional Director for Oakland International said: “We were very impressed with the speed at which the Eiger door was supplied and installed by the team at Union Industries. At a particularly challenging time for the industry, we needed a quality of service that we could rely on. Having previously installed an Eiger door at our Redditch depot, we were confident that the Eiger was the best solution for our Corby site.” For more information or to see how Union Industries can help you visit www.unionindustries.co.uk, email enquiries@unionindustries.co.uk, or call +44 (0)113 244 8393 the vehicle and leave. Mobile capabilities are also being added to dock equipment wherein a tablet can be used to view dock status across a facility to see if a restraint is engaged, door is open or leveller in place. This information can then be shared with supervisors to make docks safer for staff. When it comes to doors, well insulated, fast-action options are at the root of conversation for many in the food and drink industry. Saving time, allowing more efficient movement of people and equipment and quicker product flow, high speed doors, by opening and closing quickly, additionally reduce pollution - noise and odour - and much like dock shelters and seals help control indoor environments, maintaining temperature by minimising potential heat loss and gain, and prevent pests and entry of the elements. This is particularly important in the loading bay, where doors are the barrier to the next section of the supply chain. When selecting doors for food facilities one should look for those with tight seals and that accommodate hygienic design, to avoid bacteria build up and dust, liquid, and debris collection. Doors should also be made of corrosion resistant material like stainless steel and hold HAACP certification. With flawless door operation essential in keeping operations moving, regular maintenance should be planned. A malfunction can see costly downtime, bottlenecks, surrounding areas unprotected and exposed, biosecurity risked and render a loading dock unusable until fixed, pausing operations. Through regular maintenance, small problems can be detected and rectified before becoming a larger issue, reducing potentially expensive repairs if a door fails and extending the lifespan of doors. Stertil’s Retro Dock accommodates multi deck vehicles By converting a series of existing loading bays with the installation of its innovative Retro Dock, Stertil Dock Products has enabled a leading high street retailer to load and unload multi deck vehicles. The novel design of the Retro Dock system eliminates the need for any civil works to be carried out. Instead, by utilising the external skeletal frame of the dock leveller it replaces, the new platform and cylinder can be simply installed within the empty space. Each of the six docks now comprises a 6000kg capacity telescopic dock leveller, type XF 30-20, plus a WIS 300 Series inflatable dock shelter, featuring an inflatable head curtain to accommodate a wide range of vehicles from 7.5 tonne rigid lorries through to 4.8 metre-high double-deck trailers, and a set of highly durable PE dock bumpers. Finally, to ensure the safe movement of vehicles, Stertil Dock Products installed ultra-bright LED traffic lights. For more information, please visit www.stertil- dockproducts.co.uk 32-36.qxp_Layout 1 27/08/2020 13:50 Page 5Food & Drink International 37 www.fdiforum.net BAKERY AND CONFECTIONERY W hen COVID-19 first hit, there was a surge of people making homemade bread across the UK and other countries, which some thought might persist after lockdown and potentially impact the bakery industry. The sales of bread within the UK seems to suggest this hasn’t been the case however, as people coming back out of lockdown were eager to move back to normal life as it was before, even after saying they enjoyed the simple pleasure of baking. It’s hard to argue with convenience, however, as we all know. New tastes, new demands and ever-more critical consumers are looking both at ingredients, health benefits and the ecological impacts of the food they eat. Gluten-free, vegan, dietary requirements, low calorie and so much more have both made the bakery market a harder place to work in but also expanded the range of potential customers manufacturers can sell to. The confectionary industry is facing challenges of its own. As obesity continues to rise within many countries, the US and UK especially, legislators are locking sights on snack and junk foods with targeted advertising bans. There are many who believe this won’t work – some within the industry themselves – and this may well be even worse news, because if it doesn’t work then the governments will be forced to look into other options, which could include taxes like the sugar tax, or even a calorie tax. It doesn’t help that consumer trends are constantly evolving, either. Consumers look out for products that appear to have been made in a traditional manner, making use of natural ingredients and with interesting tastes and textures, and yet also want those traditional products to not have traditional ingredients that might go against their diet or lifestyle choices, leaving those behind the design of recipes scratching their heads. Flavourings can help in a pinch, and alternative ingredients are the aim of the day, substituting where possible without compromising flavour or texture. That’s easier said than done of course, especially when the goalposts can be so arbitrary. Many companies are looking to ensure these needs are met with the introduction of new ingredients and production methods. In the case of ingredients, many are looking towards fat replacers that can offer the same qualities as the ingredients they’re replacing. New technology is also allowing for more efficient and effective production. On a large scale, modern vacuum technology can play a major role in the conditioning of industrial bread baking. At atmospheric pressure, water boils at 100°C, but decreasing the atmospheric pressure decreases the boiling point. If the pressure is at 42 mbar, the water evaporates at 30°C and the energy necessary for baking stems from the Back to basics 38 Á © Shutterstock /Pinkyone Lockdown saw dramatic changes in people’s eating habits, but even the slightest easing saw figures return to normal. As people come out of lockdown, they’re going to be looking to the food and drink sector for that touch of nostalgia, something the bakery and confectionary industry can provide. 37-41.qxp_Layout 1 27/08/2020 13:52 Page 138 Food & Drink International www.fdiforum.net BAKERY AND CONFECTIONERY still warm oven-baked product. If baked goods are subjected to vacuum cooling, this can be done in under six minutes, with the steady withdrawal of water content preventing possible condensation and gelatinisation within the product. This vacuum-based technology offers significant advantages for both bakers and consumers. While customers can now purchase perfectly baked products faster than ever, manufacturing and distribution channels are saving money, as significant cost reductions are possible in logistics, plant footprint and in streamlining work economics. Indeed, depending on the plant design, cost reductions may reach 50 per cent. The treatment of ingredients during production is also a factor. Companies in the sector frequently require a mixing system which can mix ingredients quickly, give an even, homogenous blend, while at the same time providing a very gentle mixing action so the product isn’t reduced to a homogenous, unidentifiable lump. For example, fruit pieces are relatively fragile and usually can’t be damaged by the mixer because they’re expected to be obvious and noticeable in the finished product. The packaging game has also seen a shift in recent years, especially in the confectionary industry. While see- through packets are still popular, especially with jelly and other sweets, there has also been a shift towards fully-enclosed pouch packaging. From some of the largest brands to the smallest, including Kraft Heinz and Mars, pouch packaging has started to take over the shelves of supermarkets as manufacturers and retailers promote 40 Á © Shutterstock /Vladimir Mulder www.kanegrade.com Tel: +44 (0) 1438 742242 Email: info@kanegrade.com NATURAL FOOD INGREDIENTS 37-41.qxp_Layout 1 27/08/2020 13:52 Page 2Intelligence that transforms the world. ndc.com/food 50 years of expertise goes into every one of our in-process and at-line gauges to help you transform process data into knowledge and knowledge into intelligence. Our solutions measure and control: Ź Moisture Ź Fat/Oil Ź Brownness Ź Protein Ź Fat Ź Sugar Ź Degree of roast 50 Years of Infrared BAKERY AND CONFECTIONERY Rotronic Rotronic Instruments (UK) Ltd Crawley, West Sussex RH10 9EE E: instruments@rotronic.co.uk T: 01293 571000 Measure water activity with up to 4 product samples, simultaneously or separately. Simple, fast and repeatable! • Reliable AW Quick mode for rapid results (typically 4 - 5 mins) • Up to 4 interchangeable measurement probes • Automatically generated measurement reports • Remote access with a PC or Tablet • Large touchscreen and 4 USB ports The New Laboratory Measurement Device for Water Activity, Humidity and Temperature Rotroni HygroLab NDC Technologies – 50 Years of NIR Measurements In September 1970, Dr Rodger Edgar and Dr Peter Hindle developed a pyrometer for a breast cancer clinic in Lewisham, UK. They quickly developed a non-contact measurement device using near infrared (NIR) reflection technology to measure the moisture content in a variety of applications. The accurate and reliable measurements using the same NIR principles are still seen in today’s NDC Technologies’ products. Only now they are capable of not only measuring moisture, but also key constituents in a vast array of applications including fat/oil, protein, degree of brownness, sugars, nicotine, total volatiles, coatings, film thickness and much more. Coinciding with this 50-year celebration is the launch of NDC Technologies’ 9th generation of in-process NIR gauges – the aptly named Series 9. This unique, next-generation gauge uses the half-century expertise of the organization, while also offering a future-proof platform that is scalable and integrates easily into any manufacturing process. For more information on NDC Technologies and the Series 9 gauge, visit www.ndc.com 37-41.qxp_Layout 1 27/08/2020 13:52 Page 3Next >