< Previous20 Food & Drink Internationalwww.fdiforum.netCAPS AND CLOSURES52% of the market by 2017. Theadvantages of using plastics tomanufacture caps and closures aretwofold. Plastic closures are much moreconvenient because, unlike metal ones,they do not usually require the use of asecondary implement (e.g. a bottle- or tin-opener) to operate. This means, of course,that they are easier to use on the move.Moreover, many can be repeatedly re-sealed. But the big advantage formanufacturers is that widely-used plasticsand polymers such as polypropylene andhigh-density polyethylene (HDPE) aremore malleable than metals and cantherefore be put a greater variety ofpurposes. They are also more lightweightand easier to recycle, so manufacturerscan pitch to the green market as well. So, which innovations have been mostsuccessful? One hugely innovative designthat is revolutionising the sports bottlemarket is the Smartseal Flex spill-proofcap. The sophisticated cap incorporatesvalve technology which closes by itselfwhen the consumer stops drinking,eliminating spills entirely. The product isostensibly leak-free and easily adaptable toa wide range of bottles, making it one ofthe most attractive products on today’smarket. Another leader in the field is the GCSPicasso flip-top sports closure. ThePicasso is equipped with a double hinge,which makes drinking from the bottle alot easier, and an integral tamper-evidentband which the manufacturers claim is“inviolable.” The product is made fromtranslucent material so consumers caneasily see any evidence of tampering.Product safety is a major concern formanufacturers and consumers alike, soinnovations like the Picasso canautomatically add value to a productrange. Sales are likely to increase ifconsumers are reassured that the drinkthey are buying is safe. But how else can manufacturersincorporate the latest caps and closuresinto their existing product range withoutramping up costs? The good news is that these productsare becoming cheaper by the day. Becausemajor multinational companies areordering the latest caps and closures inhuge bulk (nearly 300 billion units peryear, in fact) prices are dropping, makingit viable for smaller businesses to get onPHOTO: SHUTTERSTOCK.COM/CHONESboard. Furthermore, plastic caps andclosures are compatible with plasticbottles, cartons and metal and glasscontainers, so companies who usuallypackage their products using the latterdon’t have to shell out on new packagingmaterials or designs. Finally, there areGlobal caps and closures market to grow at a significant paceduring 2014-2019Research and Markets has announced the addition of the “Global Caps and Closures Market 2015-2019” report to their offering. The global caps and closures market to grow at a significant pace during 2014-2019, posting a CAGR of 4.07% in terms of volume and6.35% in terms of revenue.Caps and closures are essential elements in the overall packaging of products, enhancing both the aesthetics and functionality of theproducts. They protect packaged products such as foods and beverages from spoilage, dust, pollutants, and evaporation. They keep thecontents fresh and make handling convenient. Today, caps and closures are also used for product differentiation and brand building.They are generally made of metal, plastic, rubber, or combinations of these materials. Some types of caps and closures are threadedcaps, snap caps, hinged caps, stoppers, corks, roll-on closures, twist-off closures, lug caps, and canning lids. They are used in varioussectors such as food and beverage, pharmaceuticals, home care, health and beauty, chemicals, paints, personal care, and automotive.This report covers the present scenario and the growth prospects of the global caps and closures market for 2015-2019. To calculatethe market size, this report covers revenue generated by the various segments of the market, which has been divided based on the rawmaterials used. The market has been divided into the following segments: plastic, metal, and rubber/cork. The report, Global Caps and Closures Market 2015-2019, has been prepared based on an in-depth market analysis with inputs fromindustry experts. The report covers the end-user segment distribution of 2014. It also presents the vendor landscape and acorresponding detailed analysis of the top eight vendors in the market. PHOTO: CRISTI180884 / SHUTTERSTOCK.COM19-21_Layout 1 18/09/2015 11:04 Page 2Viscose supplies and manufacturers...Flat & Sport Plastic Caps, Aluminium ROPP’s, Crowns, PVC & Polylaminate Capsules and Shrink Sleeves.www.viscoseclosures.com@viscoseclosuresFood & Drink International 21www.fdiforum.netCAPS AND CLOSURESfresh marketing opportunities thatcompanies can exploit should theychoose to invest in the latest products.Zip-seal closures may appeal to elderlyconsumers and parents with youngchildren, for example, as they can beopened and re-sealed at one’s leisure –ideal for people who are unable (orsimply don’t want) to consume aproduct in one go. Caps and closures are becomingsafer, easier to use, and mostimportantly for manufacturers,cheaper and more flexible than everbefore. Convenience is paramount,and the latest raft of innovativeclosure solutions are delivering it inbuckets. Suero Oral® Inc. Expands its Market Reach byAdding New Beverage Concentrate PackagingSuero Oral® is a functional beveragecontaining electrolytes that replenish thebody’s fluids lost either through exertion orthrough fever or vomiting due to illness. It isbased on a traditional Latin American homeremedy used by generations of mothers totreat their children losing fluids due toillness, as its name, which translates as“oral serum,” suggests.As it was evaluating the new packageconcept, Suero Oral also consulted withTricorBraun, which sources its traditionalbottles, and which has also done its ownresearch into the new concentrate packaging. But where Suero Oral’s research had been into themarket, and involved talking with distributors and retailers, TricorBraun had conducted consumerfocus groups in which it explored consumers’ preferences regarding the new packaging. It then usedthose results–including preferences for convenient size, dispensing functionality, and leak resistance–to create unique beverage additive package designs. “This was an important decision for us,” Perez says. “In all, it was a 16-month process ofevaluating the market and the package, re-formulating products to deliver the same result in aconcentrated form, etc.”From the concentrate bottle designs that TricorBraun had created, Suero Oral chose a fluid, subtlyasymmetrical two-ounce squeeze bottle with a flip-top closure for its convenient size and dispensingfunctionality. Each bottle is decorated with a full body shrink sleeve label carrying an image thatreflects the image on the larger bottle of the product. 19-21_Layout 1 18/09/2015 11:04 Page 322 Food & Drink Internationalwww.fdiforum.netSUSTAINABILITY SPOTLIGHTThe concept of sustainable developmentis interpreted in different ways bydifferent companies. Some believe thatsustainability is about caring for theenvironment and little else. However, thisoverlooks the substantial cost-benefits ofadopting a green strategy. Indeed,sustainable development in the food anddrink industry is much more far-reaching.It is not simply about creating a so-called“greenwash” statement or “being seen tobe doing it.” Energy efficiency is drivinginnovation in the field, and it can givecompanies a competitive advantage intoday’s eco-friendly market.Carbon emissions, water efficiency andthe impact of harmful pesticides are allvital concerns for producers of food anddrink. In order to address these issuessuccessfully companies must adopt aholistic approach that considerssustainability at every stage of the supplychain. Energy efficiency is essential all theway through from the farmer’s field to thepacking and transit stages. Quick fixes willnot do. Global warming is a long-termissue, and, as such, it is more profitable toplan ahead.So, what are food and drinks companiesdoing to become more energy efficient? Inrecent years the use of locally-sourcedproduce has been one of the mostpervasive trends within the industry. Theadvantages of going local are twofold.Sourcing from local producers meansfewer environmentally-unfriendly “foodmiles,” so carbon emissions can bereduced during transit. Transporting foodand drink over shorter distances alsomeans that there is less chance of productdegradation. Because consumers arecontinually demanding better quality,ethically-sourced produce, this approach isproving to be increasingly lucrative.Reducing energy consumption on theproduction line is a must for eco-friendlycompanies. Virtually all food and drinksproducers use refrigerators to keep raw,perishable produce as fresh as possible.Refrigeration technologies are relativelyexpensive and require a lot of energy tofunction, but thankfully there aremeasures companies can take to keepcosts to a minimum. Painstakingmaintenance is vitally important toguarantee optimum functionality, andchecking for leaks is crucial. If arefrigerator is leaking it is likely to warmup, which means that the produce insidewill degrade more quickly. Nobody wantsto lose money like this, and what’s more,most refrigerants are dangerousgreenhouse gases – to let them escapecould spell serious reputational damage. This level of diligence can be appliedelsewhere. For example, money can besaved by ensuring that the machinery usedto manufacture and pack produce is well-maintained (indeed, automation itself, asa means of increasing efficiency on theproduction line, can be a key part of aGoingGREENAll companies aim to be sustainable, but what steps are thosein the food and drink industry taking? 22-25_Layout 1 18/09/2015 11:07 Page 1Food & Drink International 23www.fdiforum.netSUSTAINABILITY SPOTLIGHTsustainable strategy). A well-thought-out maintenance plan can helpcompanies achieve the dual aim ofkeeping costs down whilst hittingenergy-efficiency targets.Water efficiency is an important partof the drive for sustainability.Fortunately, a raft of innovativewastewater treatment and recyclingsystems are revolutionizing industrypractices. The latest advances inAnaerobic Flotation Reactor (AFR)technology, for example, are helpingcompanies to separate the solids andliquids in wastewater more effectively.The advantage of these reactors is thatthey can recycle water and produceNestlé waters and the Wildlife Trusts launchnational campaign to `get better with nature`Nestlé Waters, the numberone bottled water companyworldwide, and The WildlifeTrusts, have announced thelaunch of a community basedcampaign to help conservethe environment and raiseawareness of the benefits ofnature, with a focus on waterin the landscape.This coincides with a LancetCommission on Health andClimate Change report thisyear, which called ongovernments to promotehealthier, greener lifestyles incities. Nestlé Waters and TheWildlife Trusts have joined forces to help improve the health and wellbeing of the UK population byworking with communities to conserve their natural environment, both in the countryside and inurban areas.The ‘Get Better with Nature’ campaign has taken steps over the last year to help improvecommunity awareness of the benefits of nature around Nestle Waters’ facility in Buxton, Derbyshireand build local stewardship of the natural environment as part of a pilot programme. It will nowextend its work nationally to target more inner-city areas, starting in Slough, through a partnershipwith the Berks, Bucks & Oxon Wildlife Trust. The campaign will also extend to Hertfordshire andMiddlesex in partnership with the Herts and Middlesex Wildlife Trust.PHOTO: TAINA SOHLMAN / SHUTTERSTOCK.COMPHOTO: JAMESBOX / SHUTTERSTOCK.COM24 Á22-25_Layout 1 18/09/2015 11:07 Page 2biogas. This gas can be used to fuel production at little extracost to the company. Even at the initial stages of food and drink productionwhere vast quantities of water may be required, companiescan go green – and save money – by investing in the latestrainwater harvesting technologies. Water is collected viagutters and down-pipes, filtered and then stored insubterranean tanks, before being pumped throughoutcompany premises. It can then be utilised as part of theproduction process.Another common aspect manufacturers are focusing on istheir packaging requirements – both in terms of the retailpackaging used for the finished product, and the end of linepackaging used more commonly in the supply chain. Smallsavings made on an individual level can soon multiply as acompany works with larger volumes of goods. What’s more,efficiencies in packaging are relatively easy to make and assuch remain one of the most common forms of improvingsustainability. 24 Food & Drink Internationalwww.fdiforum.netSUSTAINABILITY SPOTLIGHTResearchers toinvestigatecreatingbiodegradablepackaging fromagricultural wasteImperial College London scientists arejoining a European consortium that willassess how waste agricultural productscan be used to make biodegradable packaging. The environmental drive to move away from plastics made from fossil fuels has, over thepast few years, generated a number of innovations in bioplastics, including the process ofextracting the biosuccinic acid - a chemical building block used in producing bioplastics –from corn and wheat grain. The ADMIT BioSucclnnovate Consortium will investigate the use of agricultural wastesand residues, such as wheat and maize straw as well as low-maintenance energy cropsElephant grass and willow, as the raw materials to produce biosuccinic acid. The consortium is aiming to produce biodegradable packaging for consumermarkets, in association with the UK retailer Waitrose and food tray producerSharpak. In addition, it will create a toolkit called the Integrated SustainabilityAssessment Tool (ISAT). This should help industries get to grips with thetechno-economic issues associated with products made from theagricultural waste streams, as well as understanding theenvironmental impacts across the whole of a product’slife cycle.PHOTO: SHUTTERSTOCK.COM / MATTHIJS WETTERAUW22-25_Layout 1 18/09/2015 11:08 Page 3Food & Drink International 25www.fdiforum.netSUSTAINABILITY SPOTLIGHTImprove plantperformance, reduceenergy use and lowercosts with Spirax SarcoSteam is widely used within the food and drink industry as anestablished, reliable and sterile heating medium capable of meetingever-more demanding energy efficiency requirements. Innovations from Spirax Sarco’s comprehensive product range canbe applied to new and existing steam systems to reduce energyconsumption, lower emissions and improve plant performance, forexample: EasiHeat™–replace traditional hot water systems with an on-demand system to deliver energy savings of up to 20 per cent. Nowincorporating the Spirax Intelligent Monitoring System (SIMS), itenables companies to make informed energy management decisions. Reverse Osmosis (RO)– a clean water supply is the starting pointfor any efficient steam system. RO significantly reduces the need forboiler blowdown, delivering significant energy and water savings. Arecent RO installation at Westons Cider saved the company £44,000in annual fuel costs. Flash Recovery Energy Management Equipment (FREME)–recovers energy from returned condensate and flash steam and feeds itback in to the system, achieving energy savings of up to 26 per cent. Turflow– a heat exchanger which manages the heating and coolingof industrial fluids. The corrugated tube design delivers an economicand efficient solution for heat transfer in the food and drink industry. Heat Pipe Heat Exchanger– recovers energy from industrialexhaust gases, enabling companies to reduce fuel demand, CO2 andcarbon emissions and increase process efficiency. For more information visit www.spiraxsarco.com/uk,call 01242 521361, e-mail ukenquiries@spiraxsarco.com or tweet us @Spirax_Sarco_UKAn outward-facing strategy is vital to maintaining aprofitable, sustainable food and drinks business. In order todemonstrate their green credentials to shareholders andcustomers, companies must act as transparently as possible,providing clear information about what they are doing andwhy. Customers tend to respond positively when companiesare open about their energy-efficiency targets andperformance. This isn’t window-dressing, but an exercise inbuilding consumer trust that can only have a knock-on effecton profitsEffective communication is key, and this applies to the waycompanies treat their employees as well. If workers aretrained to be “on-message” Vis a Vis a company’ssustainability strategy, energy efficiency is likely to improve asstaff learn to use lighting economically, not to waste waterand so on. With reputations and profits at stake, sustainability isbecoming the watchword of the food and drink industry. Longmay it continue.PHOTO: SHUTTERSTOCK.COM/WK1003MIKE22-25_Layout 1 18/09/2015 11:08 Page 4GUARANTEED PERFORMANCE IMPROVEMENT througha SINGLE INTEGRATED SOLUTIONThe Harford END to END Manufacturing Execution SolutionAutomated coding &labelling verificationto meet retailers' codes ofpracticeOptimisedAverageQuantity LawRoving quality audits,H&S checks,engineer lineattendance, HACCP Automatedline efficiency& OEEIntegrated productionperformanceimprovementOn-lineVisionReal timepaperless qualityAutomated Short Interval Controlon factory monitorsIf you missed us at PPMAcall us today for yourFREE site audit26-29_Layout 1 22/09/2015 13:17 Page 1Food & Drink International 27www.fdiforum.netINSPECTION AND DETECTIONEnsuring a product is free from anyhazardous materials or harmful pathogens, isa crowning priority through its life cycle andright across the supply chain. The recentspate of product recalls, which has affectedproducts as diverse as alcoholic beverages toconfectionary, demonstrates not only theimportance of quality assurance, butreiterates that food manufacturers are in aconstant battle to ensure the best end result. Pathogens might be the most harmfulcontaminates found in food products, butthe most common is metals. From metalchips off of processing equipment, to heavymetals such as mercury and lead, thepresence of metals in foods presents asignificant health and safety risk toconsumers all over the world. Metalcontaminates can often be minute, which isa particular challenge for quality assurance.A group made up of researchers andscientists from Japan’s Department ofEnvironmental and Life Sciences atToyohashi, however, have developed a noveldevice which allows for precision detection ofmetallic contaminates in food. The device,which is made of nickel-alloy, has asignificant advantage over the traditional X-ray radiation method in that it can detectmetals smaller than 1 millimetre in size andbe used in conjuncture with dairy products. Japanese-owned Shoda Sauces, which arebased in Abertillery, Wales, specialise in themanufacture of oriental sauces from soy,oyster and hoisin, to blackbean, yellowbeanand chilli sauces. Despite shipping its saucesacross the UK and Europe, its commitmentto food safety is the same regardless ofcustomer or destination. Subsequently,Fortress Technology installed its fifthPhantom metal detector at Shoda Sauces. The in-line inspection system is currentlythe most sensitive method available forscreening piped sauces of varying viscosities.Detecting metal With the enduring popularity of oriental sauces and the boom of healthy snacks in the UK, we look at whatproducers in this area are doing to ensure their products are free from metal contaminates. 28 ÁPHOTO: SHUTTERSTOCK.COM/FOREWERPHOTO: FORTRESS TECHNOLOGY / WWW.CHRISNORMANDALE.COM26-29_Layout 1 22/09/2015 13:17 Page 228 Food & Drink Internationalwww.fdiforum.netINSPECTION AND DETECTIONAssurances alone aren’t conclusive; theproof is always in the results. Sincepurchasing its first Fortress equipment in2004, Shoda hasn’t received a singlecustomer complaint or report relating tometallic contamination from any productsleaving its factory. Shoda EngineeringManager, Gareth Law, was especiallyproud of the companies hygiene longevity,commenting: “If we look back over thelast eleven years, since we started workingwith fortress, we can honestly say we havehad zero incidents with metal. Fortressmetal detectors are like the ‘Fort Knox’ ofthe inspection world – nothing gets pastthem; they are completely failsafe.”The detection system in question, thePhantom pipeline, detects metalcontamination in pumped liquids andpastes conveyed through a non-metallicpipe. As with previous purchases, thelatest detection system was intended foruse in the company’s vat room, with theintention of screening liquids as they arepumped into 1,000 litre intermediate bulkcontainers (IBCs), pallecons, jerry cansand buckets. There are two overriding advantages tousing pipelines for this application. Firstly,pipelines are in-process detectors; they donot occupy any additional floor space orincur and labour costs. Secondly,inspecting in-line achieves far greatersensitivity than passing packaged productthrough a conveyorised detector head asthe aperture is far smaller – the smallerthe aperture, the better the sensitivity. Companies like Fortress, who providedetection systems and quality assurance,are duty bound to respond to challengesand changes in the food and drinksmarketplace. In the UK, the increasingdemand for healthy convenience such asenergy sports bars and on-the-go breakfastreplacements are shaping the snacksmarket. The demand is so great that it isexpected to reach £3.8 billion by 2016.Given the increasing demand, snacksproducers are turning to efficiency drivenautomation and utilising the latestmachinery to deliver consumersatisfaction and maintain safe, highquality products.Typically, snack manufacturers willhave more than one metal detectorbetween the beginning and end of theproduction and packing process,corresponding to identified CriticalControl Points (CCPs). Many will installa system as close as possible to the end ofline after primary packaging, typicallybagging with snacks. If that isn’t feasible,then installing a system just before thebagging stage is also effective. In thesesituations, loose product such as chips orcrisps can be channelled through a vertical‘throat’ detector. It’s also likely that manufacturers willwant to check incoming ingredients beforethey reach the processing stage. Thismight be advisable for a number ofreasons. Firstly, snack producers will wantto identify the source of any metalcontamination, which may of courseinclude raw materials. Secondly, thesensitivity achieved at this stage may behigher than with finished or packagedproduct. This may come down to theaperture of the metal detector or therelative sensitivity obtained withunprocessed and processed ingredients. So why choose metal detection ratherthan x-ray? The answer will depend onthe application. X-ray remains the moreexpensive option, both in terms of capitalcost and running costs. Depending on theapplication size and complexity, expect topay in the region of £35,000 to £40,000to install x-ray, compared with £4,000 to£18,000 for metal detection. Integrating ametal detector into a snack processing orpacking line is relatively straightforward.Consideration needs to be given to‘product effect’, although with today’stechnology this ‘phasing’ or calibration isan automatic process. In recent years, retailers have becomePHOTO: FORTRESS TECHNOLOGYPHOTO: SHODA26-29_Layout 1 22/09/2015 13:17 Page 3Food & Drink International 29www.fdiforum.netINSPECTION AND DETECTIONmore risk-averse when it comes to food safety and quality,increasingly imposing their own stringent protocols and standardson suppliers. As well as ensuring that the required form ofinspection is in place, to the necessary specification, the retailer‘safety net’ will also often include assurances about regular systemchecks to ensure that all QA systems – including metal detection –are functioning correctly. As one might expect, the sensitivity of metal detector systemskeeps improving which enables snack processors to detect ever-smaller metal contaminants. Some retailers may pressurise suppliersto invest in x-ray contaminant detection. Being able to demonstratethe reliability and improved sensitivity of metal detectors installedwith FM software, for example, may strengthen the case for snacksuppliers. Before selecting inspection equipment, snack manufacturersshould carefully research potential sources of contamination. Ifpotential contamination is mostly metal-based, then it makes senseto consider metal detection as the principal option. If thecontaminate risks are wider ranging, or predominantly non-metal bynature, it may be worth examining the benefits of x-ray in moredetail. One thing worth considering is even the latest x-ray systemsare not fool proof. Some have trouble detecting the smaller particlesand low-density metals – such as aluminium – that metal detectorswill pick up as a matter of course. In fact, the reliability of x-ray inidentifying a range of potential contaminants has been questionedover the years.When it comes to brand reputation, consumer satisfaction iseverything, and contaminant detection is critical for maintainingproduct trust. With the future of snacks looking strong andhealthier variations enter the market, now’s the time to exploreinspection options to help make product recalls a thing of the past.Find out what’s in food withpocket sized mini scannerConsumer Physics, an Israeli-based start-up, has launched apocket-sized device which instantly analyses the composition ofmedicines and other objects. As Dror Sharon, co-founder of the firm explains, the device is “thefirst molecular sensor that fits in the palm of your hand.”The device was launch with the financial aid of a crowd fundingcampaign (through popular site Kickstarter, where it raised 1,381 percent of its funding coal within 24 hours) with a total 13,000 customersalready placing orders for the device. The SciO, doesn’t need to make any contact with the material orsubstance being tested. It works by using near-infrared spectroscopyto interact with every molecule to create a unique optical signature ormolecular fingerprint. Used in conjuncture with a smartphone ortablet, and Consumer Physics database of matter, this signature, likea barcode, which reveals the given object’s chemical properties fromfat to sugar content. Bizerba InspectionSystems:Perfectioncreates qualityEnsuring safe products due to quality assurance is top priority formanufacturing companies, because foreign bodies and contaminantsin food constitutes enormous risks for consumers which can lead toexpensive recalls. This can seriously jeopardise a company’sreputation.We are a full-range supplier for inspection systems ranging fromforeign body detection and weight control, up to package endcontrol. Our equipment supports the high quality standardsrequired from production processes. They are installed on criticalcheck points in the process for state-of-the-art monitoring.Moreover they conform to leading standards such as IFS(International Featured Standards) and BRC (British RetailConsortium) as well as legal regulations such as FIR (FoodInformation Regulation).Metal Detection:Metal detectors find metal residues whichentered a product during production – all types of ferrous and non-ferrous metals in packaged and unpackaged piece goods. Separationsystems may be connected in order to remove contaminatedpackages from the operator side.X-Ray Inspection:X-Ray inspection systems detect metalcontaminants and other foreign bodies in products such as glass,ceramics, stones or plastic. They also ‘see’ incomplete goods.Within milliseconds they evaluate an image. The devices quicklyreject affected packages.Optical Inspection:Optical inspection systems (vision systems)ensure perfect packaging and a high-quality appearance of theproducts. The devices find and quickly sort out packages whichwere incorrectly labelled, improperly sealed, have the wrongpackaging or unreadable barcodes.To find out more visit www.bizerba.com or call 01908 682740, alternatively you can email info@bizerba.co.uk 26-29_Layout 1 22/09/2015 13:17 Page 4Next >