< Previous30 Food & Drink Internationalwww.fdiforum.netFRUIT AND VEGETABLESA clear view of the productInnovia Films understands the unique packaging requirements that fresh produce demands.Maintaining quality depends on the type of packaging and the product being packed. On the one hand, packs should slow down the natural breakdown process of the product, whilstmaintaining carbon dioxide and moisture vapour levels. On the other, they should have theappropriate oxygen transmission rate for the product. Achieving both these elements is essential to shelf life extension and can be complex. Anti-mistfilms are most commonly used in these applications to prevent moisture condensing on the inside ofthe pack so that excellent visibility of the product is maintained. Innovia Films has proven BOPP films - Propafilm™ RXP+ and RK+ that have excellent anti-mistproperties providing very high gas barrier and strong seal strength. They are also printable. If youhave a fresh produce application that demands superior gloss and clarity then Propafilm™ delivers. For more information, visit www.innoviafilms.com.These are bold and critical stepstowards changing the way in which weview our food and produce. But therising tide of food waste can’t bestemmed through ugly produce alone. Perhaps the biggest issue at play inthis argument is packaging, labellingand sell-by dates. Confusion over thelatter leads to consumers prematurelythrowing edible food and beverageproducts out, simply because the labeltold them too. Some of the worseaffected products here are meat, dairyand, you guessed it, fruit andvegetables. That may well be a thing ofthe past as the Consumer Goods Forumhas, of September, approved a call toaction to standardise food date labelsworldwide by 2020. As part of this callto action – which sees only one labelused on a product at a time –consumers will also be educated tobetter understand whatthese date labels mean.Educational efforts fromWrap, government and otherorganisations are also seeking to usherin a wiser, more informed consumer. Packaging is the sword and shield interms of protecting against food waste,especially when it comes to fruit andvegetables. Innovation in this area iscreating the next-generation ofpackaging aimed at preserving foodfreshness and integrity for longerwithout relying on chemicals. In thisfertile space, industry and academiaebb and flow, working together andindependently on the packaging of thefuture. A team of researchers at SabanciUniversity in Turkey have developed anew experimental type of foodpackaging made of a film that’s coatedin antibacterial clay nanotubes. Thisinnovation creates naturally occurringantimicrobial qualities from thecarvacrol essential oil incorporated intothe aforementioned tubes. This resultsin a defence against the over-ripeningof fruits and vegetables as well asstemming the growth of harmfulpathogens. In test conditions, freshfruits, vegetables and meat were shownto last as much as ten days longercompared to conventional polyethylenepackaging. This is packaging inpartnership with food, taking, as it does,a more active role in food preservation.As an added benefit, it also helpspreserve a more attractive appearancefor meat and fresh produce. Packagingof this kind could have a profound© shutterstock/279photo Studio29-31_Layout 1 25/09/2017 14:14 Page 2Food & Drink International 31www.fdiforum.netFRUIT AND VEGETABLESCentralHygiene LtdTel: +44(0) 1782 959909 Web: www.central-hygiene.co.ukEmail: sales@central-hygiene.co.ukCentral Hygiene Ltd are themanufactures of the ChessWashdown cleaning range.Established for 30 years, all ofits products are designedand manufactured inthe UK and to thehighest standards.Whether off-the-shelfor bespoke, CentralHygienic strives to findthe best solution.The company’s hygiene engineering knowledge and expertiseembraces the very latest technology to deliver workable, realisticsolutions that meet the most stringent of regimes. Chess Chemical Injectors, Dilutors and Foamers are designed tobe incorporated at water service outlets, they range from onechemical injector to multiple chemical satellite units incorporatingfoam, rinse and sanitise functions. Made from stainless steel andcovering operating pressures from 1 – 100 Bar, they are designed togive effective, long, trouble-free operation.Aerial Sanitisation can be easily achieved using Central Hygiene’sChess Fogjet systems. With no moving parts, using justcompressed air, the Chess Satellite Fogjets produce micronizedchemical solution to supersaturate the atmosphere in processingspaces, disinfecting large areas quickly and efficiently. effect on the war on food waste, given the extension itoffers to the life of fresh food. This means it can bestocked and sold for longer as well as lookingaesthetically pleasing over this duration. Yet for all these advancements at the end of thesupply chain, food waste needs to be tackled at all links.Avoidable waste is rampant during manufacturing wherepaperwork issues can have major knock-on effects.However, much of the blame lies with machinery andequipment or, specifically, the way in which they’re used.For example, manufacturers attempt to beat gravity, asit were, resulting in a loss of yield. Wrap advised thatproducers “use gravity by putting mixing operations at ahigher level than filling”, a simple solution, certainly, butone that could have an impressive cumulative effect. Good manufacturing practice – which describesprinciples under which products are consistentlyproduced and controlled according to quality standards –is a means through which manufacturers can avoidunnecessary food waste. For fruits and vegetables, thiscould mean less spoilage and loss of product. But it alsoascribes as much to the machinery employed by acompany. Relying on older, cheaper models won’t nearlybe up to the standard as their contemporarycounterparts. Automation and efficiency aren’t justindustry buzzwords, but rather a lens through which wecan explore and, ultimately, evolve the supply chain. Tostem food waste in the fruit and vegetables sector,manufacturers will need to embrace automation and thecutting edge technology. When combined withinnovative new packaging and working alongsidecampaign bodies, suppliers and consumers, then theindustry will have a rugged and reliable safeguard againstfood waste. © shutterstock/PressmasterPackaging Automaton hiringscheme connects producerswith packing processesPackaging Automation’shire scheme allowscustomers to automatepacking processes from dayone with minimalinvestment. It offers entrylevel machines on short termhire periods for seasonalproducts such as fruit with asealing tool for one packformat on hire for a fixedweekly hire rate. At the end of an initial six-month hire period, usershave the option to return themachine and stop makingpayments, keep the machineat a reduced weekly rate orupgrade for a small uplift in cost to a quicker machine with asealing tool to suit the same pack if demand for products isincreasing. Chicory Crops – a small business packing gooseberries andcherries in many different punnet types for Marks and Spencer,Waitrose and Booths – took advantage of PA’s hire scheme andworked closely with the company’s hire specialist Lesley Wakefieldwho helped them with a flexible solution to keep their costs down.For more information, visit www.pal.co.uk. 29-31_Layout 1 25/09/2017 14:14 Page 332 Food & Drink Internationalwww.fdiforum.netCONTROL & AUTOMATIONA combination of complex supplychains, large production facilities,changing legislation and the need togain a competitive advantage throughtechnological innovation are allcontributing to driving investment inautomation and control solutions. And,while manual set-up and recording ofproduction line outputs may haveserved the industry well in the past,many companies are being increasinglylet down by reliance upon these nowoutdated methods.Automation is one of the best waysto make savings in a manufacturingenvironment. Repetitive, time-consuming tasks that were traditionallycarried out by factory operatives cannow be completed quickly andefficiently by machines. As such,factory automation makes it mucheasier to meet large supply demands. Itmakes sound business sense to invest inthe latest automated solutions,especially for businesses operating on amassive scale.When using automation for food anddrink products the safety and reliabilityof the latest technology means thatcompanies can make significantchanges to the way their productionline flows. Automation allows operativesto utilise a greater range of skills on thefactory floor, and the additional capitalgenerated by switching to anautomated system can be re-invested inother cost and time-savingtechnologies, and even in new productlines.The good news for companies is thatautomated solutions are becomingcheaper and more flexible by the day.From basic assembly machines to leak-test fixtures and laser profiling devices,the latest innovations in automatedtechnology are helping businesses toreduce labour overheads and preventcostly wastage.In the past, no matter how skilled theoperative, there was always potentialfor error on the production line. Today,we are looking at the possibility of100% error and waste-free production,all thanks to factory automation. Take,for example, the hydraulic leak-testfixture, a once-niche technology that isnow commonly used in engineering andfood and drink production. Thesesimple-to-operate machines are used totest for flaws in hydraulic components,valves, pipes and so on. Pressure andflow measurement techniques areutilised in order to assess the integrityof each component – something that isespecially important if dangerous gasesor wastewater are being piped.Automatingthe processAutomation is a long termsolution to a number of foodand drink problems, so whyare more companies nottaking advantage?32-35_Layout 1 25/09/2017 14:17 Page 1Implementing AutomationImplementing an automation overhaul is a daunting task, and there are aspects to watch outfor. Here are ten points every company should keep in mind when making such a switch.* Never start an automation project without the end in mind. * If the project needs, due to financial or other constraints, to be partial in its implementation, then ensurethat it is part of the overall bigger picture.* Create a user requirement specification of the total project from the outset, even when the overall projectis to be implemented on a piecemeal basis.* Ensure that the chosen supplier has the capability (in house) to meet the total project objectives andguarantees to deliver the agreed results.* Ensure that the supplier will have the capability to train and coach your people during the changemanagement process, to ensure that the intended benefits are actually achieved and delivered.* Ensure that your supplier can back the whole project with after-sales service support, including hardware,software and training, on a 24/7 basis if necessary, with guaranteed, proven response and fix times.* Ensure that your intended supplier knows your business requirements well enough to take you the extramile. One example of this would be in Average Law where expertise from the supplier can ensure that yourmaterials utilisation is at least 0.5% better than your competitors, whilst making fewer process adjustments. * Make sure that your supplier has a healthy track record through which they can prove that they have donethe things that you are asking for and delivered the results you expect.* Don’t fall into the trap of believing that some newcomer can meet all your objectives just because theyare willing to say they can (at an attractive price) in their attempts to gain a valued order.* Make sure that your system is future-proofed and that when you return to the same supplier a few yearslater to complete your big picture automation, you don’t find that large parts of your investment to date arenow redundant and that you are consequently expected to stump up large additional costs for upgrading orretro-modification.© shutterstock/Semen LixodeevFood & Drink International 33www.fdiforum.netCONTROL & AUTOMATIONReadings are then transmitted directlyto integrated software. Although thesemachines need to be operated bytrained staff, the potential cost-savingbenefits are obvious: flawedcomponents equal waste, and wastecan be financially deleterious for bigand small companies alike. Quite simply, automated solutionshelp to speed up production. Productuniformity is absolutely essential withinthe food and drink industry, yet it isdifficult to achieve on a fast-movingproduction line. Automated laserprofiling devices provide a handysolution, with laser triangulationensuring that every surface of aproduct is inspected. The product’soverall mass can therefore bedetermined quickly and easily, and,34 ÁVersatile incremental encoders from SICKplug the technology gapSICK has launched the DUS60 incremental encoderand DUV60 measuring wheel encoder with DIPswitch programmability to provide users with aversatile and economical user-configurable motioncontrol sensor for packaging and printingapplications.The shaft-mounted SICK DUS60 rotary incrementalencoder can be installed and commissioned quicklyfor a wide-variety of conveying and rotationmonitoring applications in automated processing andproduction. For sheet or reel-to-reel measuringapplications, such as papermaking or printing or onlarge-scale logistics conveying, the SICK DUV60 usesthe same technology as the DUS60 combined withsingle or dual spring-mounted measuring wheels.The DUS60’s DIP switch programmability enablesup to 30 different resolutions to be selectedaccording to application requirements, as well assignal output and counting direction. Options of solid shaft, blind hollow and through hollow mechanical configurations are allavailable in the 60mm encoder housing. For more information, visit www.sick.com.© shutterstock/Vereschchagin Dmitry32-35_Layout 1 25/09/2017 14:17 Page 234 Food & Drink Internationalwww.fdiforum.netCONTROL & AUTOMATIONWe do more.Ergomodul#GermanBlingBling#Ergomodulmoreover, there are intelligentconveyer solutions on the marketthat can hasten the inspectionprocess even further withoutcompromising on quality.The food and drink industry is inparticular expected to benefit fromhigher levels of automation, thanksnot only to the stringent hygienerequirements which will be easier tomeet in an automated system. Butalso to the quantity of products thatmust go through a factory in anygiven day. Throughput oftennumbers in the tens of thousands, soeven the smallest saving on eachproduct soon adds up to substantialcost-benefits. There are those who argue thatfactory automation will bring about joblosses in the sector, and that the rightsof the individual employees should bebetter preserved, but current evidencesuggests otherwise. Investing in thelatest machinery will encourageproductivity and growth in the area,which in turn will lead to the creation ofmore jobs. Indeed, by utilising the latesttechnologies to speed up production,enterprising companies can use savingsas a platform to invest in otherdepartments, or further growth. Manual systems and manualrecording were fine when productionline speeds were typically 30 or 40packs per minute, but today, someproduction line speeds are ten timesthis amount and more. Coupled withthis has been the shift away from longbatch runs to shorter and shorter batchruns, brought about by increasedconsumer choice, leading todramatically increased productioncomplexity and frequent productchangeovers.Given this scenario, any companyrelying totally or largely upon paper-based systems faces huge risks inoperator error. In this highly chargedenvironment, with the need to maintainsome semblance of efficiency amongstthe increased complexity and frequentchangeovers, it is not so much aquestion of if something goes wrong,but when.One aspect that many automationspecialists are advising though, is thatautomation should not be undertakenwith a view as it being a quick fix – butrather that it is a long-term solution toa number of different problems. Manynew investors of automated systemshave done so not out of a desire tomake their supply chain more lean, butdue to external pressures or a singlefailing event such as a product recall. Inthese cases an automated system canbe a bitterly expensive pill to swallowfor a problem that could be handledusing other means. Automation shouldonly ever be undertaken with a clearend goal in mind, not to mention astrategy for how to best utilise the newsystem in an efficient manner. © shutterstock/Bluskystudio32-35_Layout 1 25/09/2017 14:17 Page 3Food & Drink International 35www.fdiforum.netPHOENIX HANDLING SOLUTIONSTel: 0845 265 7570 email: info@phs-uk.com website: www.phs-uk.com•De Palletising / Palletising•Pallet Stretch Wrap / Stretch Hooding•Shrink Wrapping Machines•Case Packing Machines•Pick & Place Machines / Tray Denesters•Complete Turnkey SystemsAutomation Experts for theFood and Beverage IndustryAll your End of Line Material Handling / Packaging Systems under ONE roof32-35_Layout 1 25/09/2017 14:17 Page 436 Food & Drink Internationalwww.fdiforum.netMIXING & BLENDING© shutterstock/Wattanachon KongthonThe global blending and mixing market is tipped forsteady growth in the immediate future. Food and DrinkInternational explores what’s driving this growth. Mixingthings up36-39_Layout 1 25/09/2017 14:25 Page 1Food & Drink International 37www.fdiforum.netMIXING & BLENDINGcompelling option. Given the diversityof ingredients that require mixing, thereisn’t a single option to suit everyingredient. Shaft mixers come witheither single or multiple options, withthe latter used mostly for viscousingredients. Operational efficiency canalso be improved here as multiagitators help reduce the pre-mixing orside mixing in a batch. A key trend in appealing to themillennial demographic is by makingfood customisable. Customisation hasalso become increasingly popular forfood manufacturers in regards to theirmachinery and equipment. Machinemakers and suppliers are morefrequently working alongside foodproducers on bespoke builds and set-ups, ensuring that the end productmeets a producer’s unique needs. Whata company requires from its productionline will doubtless differ from oneproducer to another. There is no onesize fits all approach, nor should therebe, and as well as gaining a set-uptailored towards a producer, it alsoprovides a competitive edge. Byworking alongside machinery makersfrom design and until delivery, aproducer will know exactly what theyneed and what they are getting.Of course, bespoke options can becostly, certainly when compared tosome of the other options open to foodmakers. One such avenue is factory andmachine rebuild. Keeping machinery intip-top condition is critical tomaintaining a cost-effective operation.So for companies whose machinery hasrarely seen preventative maintenance –or have a limited budget – the rebuildoption is an ideal option. Mixingtechnology maker, Admix, offers fullfactory rebuilds where it completelydisassembles a company’s equipmentas well as inspects all components andperforms a thorough failure analysis.Once complete, it will also provide adetailed report of its findings beforerebuilding the equipment and returningit in a like-new condition. No matter the machine, ingredient orend product, hygiene is at heart of allfood manufacturing. Contamination isA combination of market factors,new technologies and an increasingemphasis on customisability is ensuringa stable growth in the global mixingand blending market. The latestresearch has uncovered the growingdemand for processed packaged foodas the principal market driver. Althoughappetites in Britain and parts of Europehave more recently favoured clean-label and better-for-you products, anincrease in disposable income, awidening middle class and morefavourable economic conditions incountries such as China and India isseeing demand for processed foodproducts rise. As manufacturers targetthese growing markets, theirrequirement on reliable and efficientmixing and blending machinery is alsoon the up. The growth in bakery is heralding arise in the sales of packaged productsfrom bread rolls to sweet pastries. Thegluten-free trend shows little signs ofslowing down – Euromonitor forecaststhe market reaching $4.7 billion by2020 – as more manufacturers pursuealterative breads and pastries. Likewise,the bakery craze in Britain and thegrowing hunger for heritage andartisanal products has seen a myriad ofbreads flood the market. Given thedifference in flavour and textureprofiles, many of these breads need tobe processed differently which,unsurprisingly, requires differentagitators, speeds or mixers. Trends also point to what’shappening in the build, sale andfunction of the machines themselves.Currently trends in the mixing andblending market point to the growinguse of multi-mixer agitators. Althoughefficiency doesn’t necessary meandoing the same process as quickly aspossible, swiftness is certainly part ofthe equation. Quality machines shouldallow for a high throughput andfunctionality with little loss in yield.Manufacturers searching for quickermixing times have turned towardsthese multi-mixers agitators given theirability in reducing the time it takes tomix and combine food ingredients. As ameans of boosting product andreducing downtime, this can be a38 Á36-39_Layout 1 25/09/2017 14:25 Page 238 Food & Drink Internationalwww.fdiforum.netMIXING & BLENDINGan omnipotent threat on theproduction line, particularly fromcontact surfaces and from areas wherefood matter and dirt can accrue.Without a thorough washdown andsanitisation process between batches,blenders and mixers can be a majorsource of adulteration and could seethe transfer of food ingredients fromone batch to another. One eye-openingexample is with scrapers, which areused predominantly when highviscosity food ingredients are mixedtogether. During this process,ingredients close to the vessel wallstend move more slowly, which,obviously, affects the overall efficiencyof the mixing process. Scrapers aredesigned to come into contact with thevessel walls and pull the stickyingredients from the wall in order to bethoroughly mixed. But some particlescan become embedded around thescraper, creating abrasion on the vesselwalls which can lead to wear.Ingredients can collect on the scraperarm, indicating the importance of aregular and reliable washdown routine. Steady growth in the mixing andblending market is evidence of globalfood trends, with processed andpackaged foods becoming morepopular in countries with astrengthening economy and growingdisposable income. The greater needfor these machines, however, bringswith it the need for manufacturers toregularly clean, service and replace, ifnecessary, their production lines.Working alongside designers forbespoke options can provide a producewith a unique, tailor made solution. Butthis isn’t always affordable. Factoryrebuilds are the next best thing in thesesituations as many a manufacturer canattest. As ever, the need for efficiencyis having some of the biggest effectson the markets, as food producerspursue mixers and agitators that offerthe quickest times and most reliableprofiles. © shutterstock/Deyan Georgiev© shutterstock/Kartinkin7736-39_Layout 1 25/09/2017 14:25 Page 3AdvancedEngineeringMIDDLETON LTDmixingis our businesslInline High Shear Mixerl3 Stage High Shear MixerlDispersion MixerlFluid MixerslAdProlTop Entry High Shear Immersion MixerlBottom Entry High Shear MixerlSealed Bearing Mixermixerdesign and technologyUnit 5D Transpennine Trading Estate,Gorrells Way, Rochdale, Lancashire OL11 2PXtel: 01706 759003 fax: 01706 759004email: info@aemixers.comweb: www.aemixers.com36-39_Layout 1 25/09/2017 14:25 Page 4Next >