< PreviousWAREHOUSE MANAGEMENTUpgrade toLocateIT improvesManageability A new release of LocateIT WMS will be available from ClydebuiltBusiness Solutions Ltd in the coming weeks. With a commitment tocustomer satisfaction, Clydebuilt has taken feedback from existingusers of the system and made changes that reflect the needs of thediverse customer base. Including some visual changes to the main screens in LocateITthe new release focuses on simplifying the Goods In process, ascomplete accuracy at this stage also means that all subsequentwarehouse functions follow easily, and are more manageable andtraceable. The system is suitable for both raw materials and finishedproduct warehouses and enables users to serve a multichanneldistribution network. LocateIT can manage bulk, pallet and pickand pack operations concurrently, automatically updating thecorrect delivery channel and producing the correct despatchlabelling and paperwork. With tried and tested integrations intomost back office systems, LocateIT can provide a capable Best ofBreed solution for manufacturers, giving more functionality thanstandard inventory management.BBE date, batch management and track and trace ability isinbuilt, meaning that a complete audit trail is compiled with everytransaction. This level of detail is paramount within manufacturingsites, giving confidence that the right quantity of product will bepicked at the right time, with the intelligence of the system dictatingthe most efficient and profitable way of doing so. The backgroundchanges in place for this new release make the system even moreflexible and functional, especially when dealing with high volumes. Tel: 01418 471920 Fax: 01418 897962www.clydebuiltsolutions.com 20 Food & Drink Internationalwww.fdiforum.netSUPPLY CHAIN SPOTLIGHTstresses and strains of afood and drinkwarehouse, ensuringslips and falls are cut toa minimum and forkliftscan work across asmooth and bump-freesetting.When examining ways to avoid contamination – both from theoutside world permeating the warehouse, and vice versa – Rubbaircan help with their range of impact traffic doors. The Quantumdoor, for example, offers excellent means for safely expeditingmaterial flow and personnel movement. It has a 50% increase inthickness at critical areas, which can prove particularly importantin case of impacts from forklift and pallet trucks. They also havevery good noise and thermal insulating properties, making themideal for noisy sites, while their superior resistance to penetrationby moisture, dust and chemicals are of particular value in food anddrink warehouses where hygiene is paramount.These innovations at every link of the supply chain are ensuringthat money and energy is saved without any decrease in the qualityand security of the products being transported. It’s the best of bothworlds for manufacturers, retailers and consumers alike.One of the most effectivemethods of ensuringabsolute product integrity inrecent times has beenwarehouse and trafficmanagement softwarePHOTO: SHUTTERSTOCK.COM/ MARCIN BALCERZAK15-20:Layout 1 18/10/13 11:29 Page 6Food & Drink International 21www.fdiforum.netPROFILE ON PACKAGINGPackagingwrapped upThe packaging industry has alwaysbeen the most diverse and forward-thinking within the food industry. Withmore options for manufacturers andproducers than ever, it’s often hard tokeep track of changes and newproducts. However, the ones that aremeeting the challenges head on andmaking real strides are the ones we’refocused on here at Food & DrinkInternational.Can do attitudeOne challenge that has always beendifficult due to a huge market and amaterial that is, in essence, finite isbeverage cans. In particular, finding waysto label them in a way that catches the eyeand stands out has always been key. Withaesthetics being an important part, thelaunch of thermochromic printed endsPHOTO: SHUTTERSTOCK.COM/GEMENACOMChina is now set to overtake theUSA in being the world leader inpackaged water.23 The multiple challenges that thepackaging industry faces -sustainability, efficiency, designand cost reduction - are beingmet in a number of ways. FDIlooks at the way the industry ispulling together the manystrands and coming up withinnovative solutions.Packagingwrapped up21-29:Layout 1 21/10/13 09:43 Page 1A BUNDLE OF PACKAGING SOLUTIONS FOR THE DAIRY AND FOOD INDUSTRIESA BUNDLE OF PACKAGING SOLUTIONS FOR THE DAIRY AND FOOD INDUSTRIESwww.oystar-group.comOYSTAR, one of the world’s leading providers of packaging machinery offers solutions to the packaging challenges of the dairy and food industries with state-of-the-art thermoform, fill and seal machines (FFS) for cups and stick packs, fill and seal machines (FS) for preformed cups, tubs and bottles as well as wrapping machines e.g. for butter and margarine. With flexible packaging machinery and complete customized systems that include multi-packing, cartoning, case packing and palletizing we successfully meet the industry’s constantly changing market demands. Benefit today from our experience to develop your packaging solutions for the future.21-29:Layout 1 21/10/13 09:43 Page 2operations here in Poland. Together, we’reworking to implement new systems toimprove packaging traceability and furtherincrease the efficiency of our business.”Over the coming years, PLS will workwith Can-Pack on the conversion of itsentire packaging requirements fromcardboard and wood to plastic. This willenable the delivery of a more robustproduct, as well as improving hygienestandards and plant performance.Jon Graves, General Manager of PLS,says, “Can-Pack recognises the benefits ofusing plastic packaging to ensure a morerobust delivery platform goes into thesupply chain; our remit is to help themdrive these improvements forward. “We see significant opportunities totake our packaging expertise into newEuropean markets, at the same time weare working to increase the productoffering to include plastic pallets, cratesand IBCs.”This comes after the recent commentsmade by Defra’s Lord de Mauley atRecoup’s annual plastics conference,where he pledged support to Recoup’sFood & Drink International 23www.fdiforum.netPROFILE ON PACKAGINGand photochromic ink must be awelcome development.Editions is a new printing techniquedeveloped by Rexam’s business in SouthAmerica. It allows manufacturers toproduce up to 24 designs of the samelabel simultaneously on a single pallet.This printing innovation allowscustomers to deliver several designs toone single filling line, creating increasedmarketing opportunities for brandsusing beverage cans and improvingefficiency in the filling process asdesigns are already mixed on the samepallet.The ink changes colour indicating thecan is perfectly chilled and ready forconsumption. It’s available in 12different colours and on 200 and 20225 With under a two billion litredifference recordedin 2012, by the endof 2013 China is forecastto be one billionlitres ahead ofthe USRecoup announced their ‘Plastic Matters’campaign at their annual conference, roping inleaders from the food and drink industry.ends. The thermochromic indicator ishighly visible to consumers whilst the canis stored in the fridge door or horizontallyon the shelf.Reuse, reinvest, recycleThe use of plastic for equipment usedover and over again is seeing a rise at themoment. A recent example is returnablepackaging specialist PLS. Havingexpanded its European footprint aftersecuring a significant five-year contract inPoland with beverage can manufacturerCan-Pack, the deal covers the supply of allof the company’s plastic layer padrequirements on a managed rental basis. The company has invested more than€1.5 million in establishing the newventure which is based in Katowice,southern Poland, where staff work a two-shift system, five days per week, managingmore than three million plastic layer padmovements a year.Robert Skoropad, Group Planning andProcurement Manager at Can-Pack’sworldwide headquarters in Krakow, says,“PLS continues to impress our UKcolleagues, so the next logical step was toinvite them to service two of our main21-29:Layout 1 21/10/13 09:43 Page 324 Food & Drink Internationalwww.fdiforum.netPenn Packaging LtdHarkstead Hall Barn, Harkstead, Ipswitch, Suffolk, IP9 1DBTel: 01473 893990Email: miles@penn-packaging.co.uk www.penn-packaging.co.ukPenn Packaging, working with their European specialist partners,supplies a wide range of primary and secondary packaging equipmentto customers in the Food, Beverage, Household Products and PersonalCare industries.SN Maschinenbau offers high quality pouch packing systems for 3 or4 side seal pouches, doy packs, stand up pouches, shaped pouchesand more.SN now also offers highly efficient FFS-machines for hot-filling liquidproducts into pouches at 95°C, opening up the market for everyone.Today form/size and filling capacity of the pouch can be chosen freely.Every possible addition, such as a straw-applicator, re-sealable corner/centre spout can be realised. There is no end to marketing creativity.The SN Liquid Pouch is produced directly from a film roll. It is formed,filled and sealed with precision and accuracy. The Liquid Pouch machinesare designed for 60, 120, 240 and 500 pouches per minute and canhandle cost-reduced composite films. Material consumption is significantlyreduced in comparison to former methods. Thus the SN Liquid Pouchtechnology offers critical ecological and economic advantages.FRIPTel: 01455 638630www.frip.co.ukCompany ProfileFRIP (Foil Ribbon &Impact Printing) Finishinghas over forty years’experience in providingprocesses, special effectand traditional finishingservices. It has expandedfrom being the industryspecialist for hot foilstamping and embossinginto a leading decorativeprint finisher providing awide range oflaminations, coatings,finishes and specialtypapers and boards.Product ProfileA first for the UK market, window lamination is a revolutionary new wayto show off your product whilst keeping your packaging as eco-friendlyas possible. Window lamination can be applied both internally andexternally to any pack and has a number of benefits over more traditionalstyle window patching.When applied internally the film creates a food safe barrier betweenthe board and product so eliminating the need for bags, PE board orwindow patching. When applied externally the film decoratively enhancesthe pack and gives added protection to both product and packaging.For further benefits, visit FRIP’s website.Logopak International LtdEnterprise House George Cayley DriveClifton Moor Industrial Estate York YO30 4XETel: 01904 692333Email: info@logopak.netwww.logopak.co.ukLogopak are theleading manufacturerand supplier of printand apply labellingmachines. Reliable androbust, its machinesdeliver the longevity andreliability required tomeet the demands ofmodern industry.Logopak have been themajor innovator in printand apply for over 30 years, and continue to lead the way with the launchof Vericoder, the integrated verifier.Retailers, manufacturers and distributors demand barcode labellegibility at every point in the supply chain. Verification is an essentialfactor to ensure this legibility and avoid penalty fines for illegiblebarcodes.Logopak’s new integrated verifier ‘Vericoder’ makes manual verificationa thing of the past, with 100% quality guaranteed. This new systemcontains a unit licensed exclusively from verification experts Axicon, andintegrates verification with print and apply, allowing labels to be checkedin real time. Only a verifier to ISO/IEC 15426-1, can give the qualitygrading demanded by retailers. Verification is carried out automaticallyremoving the need for calibration, controlled lighting conditions andmanual intervention.Kliklok InternationalWestern Drive,Hengrove Park EstateBristol BS14 0AYTel: 01275 836131Email: sales@kliklok-int.comwww.kliklok-int.comCompany ProfileFor over 60 years,Kliklok has held anenviable position atthe forefront ofpackagingtechnology, withparticular emphasison the food industry.The company has aproud history ofinnovation in machinery design and manufacture, investing itsexperience, skills and knowledge into researching and developingcapabilities in packaging applications.Product ProfileKliklok’s range of durable and efficient packaging equipment offers topload carton/tray forming and closing, horizontal end load cartoning,automatic product handling, wraparound sleeving, and end of linemachinery. With expertise and focus on core industries such as frozenand chilled foods, confectionery, cereals, snack foods and bakery –Kliklok is able to meet the growing needs of today’s demandingconsumer market. From hand-pack machines to fully automatic turnkeysystems, Kliklok’s complete range of packaging machinery providesquality, performance, reliability and efficiency. 21-29:Layout 1 21/10/13 09:43 Page 4Food & Drink International 25www.fdiforum.netPROFILE ON PACKAGING‘Plastic Matters’ campaign.The initiative, launched by RecoupCEO Stuart Foster, will develop plasticrecycling communications tools andguidance to provide support to localauthorities to increase the collection ofplastic packaging for recycling, and delivermore consistency of information. Byproviding clear messages and minimisingconfusion, this will help consumers totake the right actions and ultimately leadto more plastic being recycled.Together with Defra, the foundingsignatories of this initiative include Marks& Spencer, Kent Resource Partnership,Unilever, WRAP, Coca Cola Enterprises,Nestle Waters, RPC, Veolia, Closed LoopRecycling and Valpak. Both the ministerand Recoup called for more organisationsto come forward and support thisPHOTO: SIMON KING26 “Understandingconsumer behaviour isthe key to changingconsumer behaviour, and assuch the first activity underthe new initiative will be an indepth plastic recyclingconsumer insight study tobuild on existingknowledge”Stuart FosterPLS is an example of companiesthinking about switching to plasticfor dealing with packaging,making the equipment involvedas sustainable as the products itis delivering.21-29:Layout 1 21/10/13 09:43 Page 526 Food & Drink Internationalwww.fdiforum.netPROFILE ON PACKAGINGBefore you make itreal, make it rightAn optimal packaging design will lead to the perfectshopping experience. New technology now allowscustomers to live this experience and translate it intoreality with Smurfit Kappa’s 3D Store Visualiser. The unique Smurfit Kappa Shelf Viewer can analyse yourproduct’s on-shelf challenge today. The Store Visualiser allowsaccess to thousands of interchangeable optimisation scenarios,pictures, movies and live demos of segment brands and customerspecific packaging options, all projected on a giant 4.5m x 2.5mhigh-resolution screen.The Store Visualiser is the latest step in Smurfit Kappa’s range ofInnotools and consolidates our market positioning with innovationthat works. The Store Visualiser gives customers a clear competitiveadvantage as the impact of packaging design in a shopper’sexperience can be tested before it goes into the market.The secure and confidential environment the Store Visualiserprovides for brand research is the best way to guarantee the mostsignificant impact at that First Moment of Truth, when shopperscome into contact with the brand. This is a step further in SmurfitKappa’s leadership in researching the optimisation of packagingdesign for customers.Tony Smurfit, Smurfit Kappa’s Chief Operations Officer, says,“The Store Visualiser proves our leadership in uniting technologywith unique packaging insights. This way we ensure that when ourcustomers are designing and testing their packaging, before makingit real, they make it right.”For more information, contactMelina Ekic on +31 (0) 528 231302,email Melina.Ekic@smurfitkappa.com or visit www.smurfitkappa.comworthwhile initiative.Stuart Foster says,“Understandingconsumer behaviouris the key tochanging consumerbehaviour, and assuch the firstactivity under thenew initiative will bean in depth plasticrecycling consumer insightstudy to build on existingknowledge. From this work, the steeringgroup made up of the founding signatories will develop theconsumer facing campaign and will aim to launch the consumerfacing tools before the end of the year.”Bottled competitionIt’s not just about resuse either. Reports are increasingly beingpublished that suggest China is going to overtake the US when itcomes to packaged water. Canadean have suggested that this sectoris skyrocketing and sees no sign of slowing yet. In just seven yearsChina has doubled its share of the global market and by the end ofthis year, is forecast to topple the US from the leading position. With under a two billion litre difference recorded in 2012, by theend of 2013 China is forecast to be one billion litres ahead of theUS. In per capita terms, however, the picture is very different.Canadean’s latest research shows that China is running well belowthe global packaged water average of thirty litres per head, and atonly around one-fifth of that of the US. More recently, a notable shift to mineral water is emerging asconsumers become more aware of the health benefits ofconsumption. Producers are increasingly mindful of this new trendand are seeking out high quality natural mineral water sources inorder to underline the image of their brands, particularly when itcomes to packaging. PHOTO: REXAMThermochromic ink is set to improvethe look of drinks cans in the futureA notableshift to mineral water isemerging asconsumers becomemore aware of thehealth benefits ofconsumption21-29:Layout 1 21/10/13 09:43 Page 6Food & Drink International 27www.fdiforum.netPROFILE ON PACKAGINGThat’s especially the case in Europe. Nick Brewin, Sales andMarketing Director for Europe and Asia, says, “We are now part ofa wider food packaging family and our new colleagues in SilganMetal Packaging and Whitecap have made life easier for us byintroducing us to different customers and markets. We have recentlysecured supply contracts in the Czech Republic, the Ukraine andTurkey, and we’re also pleased with business growth in the UK.“Our products are all about making life easier for the consumer– we supply packaging for long shelf-life, typically 18 to 24 months,ambient, convenience foods such as soups and ready-meals thatcan be microwaved and eaten ‘on the go’. We have a unique in-line manufacturing process, Rotary ThermoForming, which offersour customers both superior technical performance and commercialadvantages. Our range of 99mm, 83mm and 73mm bowls, for500ml to 100ml, can be processed and double-seamed closed onconventional canning lines. We also have a range of stock heat-sealed containers.’’Three recent UK product launches have involved well-knownbrand names that have used Silgan PFC products to re-energisefamiliar products and help meet a new generation of consumers.Fray Bentos®Meat PuddingsThis classic British meal has historically been packed in atraditional metal can, to be opened with a can-opener and cookedfor 45 minutes in boiling water. These famous meat puddings arenow being relaunched using Silgan PFC’s new lightweight plasticbowl. It is opened using an easy-open metal end and cooked in themicrowave for three minutes – easy!Hormel STAGG®ChiliUsually packed in a metal can, these flavoursome chili meals haveto be tipped into another container before cooking. However, thisclassic ambient product is now also available in Silgan’s high-barrierplastic containers, decorated with a carton-board sleeve and isperfect for putting straight into the microwave and eating directlyout of the container – easy!Hormel 200g Spam®This iconic chopped pork and ham product wasfirst introduced in 1937 in metal cans, but in 2013, a market trial isbeing conducted using a high-barrier, rectangular, plastic cup madeby Silgan PFC. The pack, with a clip-on lid, easy to remove heat-seal membrane and tapered shape, makes product removal easy,especially for the elderly or infirm, and any unconsumed productcan be hygienically put back into the lidded container and stored inthe fridge until required – easy!For more information, contact Nick atnick.brewin@silganpfc.com orcall +44 (0)1432 851722.Silgan helps tomake life easyJust over a year since Silgan Inc’s acquisition of Rexam’s high barrier food container business,Silgan Plastic Food Containers is going from strength to strengthNick Brewin says, ‘’Silgan PFC is here to make life easierfor our customers and the end-consumer and we are eagerfor more opportunities to help’’.21-29:Layout 1 21/10/13 09:43 Page 728 Food & Drink Internationalwww.fdiforum.netPROFILE ON PACKAGING - SUCCESS STORYThat was not all - two existingproduction facilities had to be shut down,most of the equipment installed thererelocated and combined with newmachines and lines, an absolutelymammoth job. In Auckland, Lion operated the KhyberPass Brewery, with around 150 years ofhistory and a capacity of about 1.5 millionhectolitres of beer. Lion also ran theContract Bottling Company in Auckland,which had concentrated on fillingalcoholic beverages from the firm’s ownportfolio and on contract-bottling, and adistribution warehouse. Today, the firmemploys 7,500 people in Australia andNew Zealand, and owns some of theleading brands in the fields of beer,spirits, wine, milk, juice, cheese and soy-based drinks. Ambitious targets“In 2007, we discontinued operationsat the Khyber Pass Brewery and plannedto build a new multi-beverage plant withwarehouse on a greenfield site to thesouth of the city”, explains Duncan Field,who as the Capital Project Director wasshouldering principal responsibility.Lion set itself ambitious targets: theplant was required to meet risingexpectations in environmental protection.While upgrading product quality,productivity levels were simultaneously tobe increased by 40% and beer lossesreduced by 30%. But first of all, a name had to be foundfor the new plant. In an internalcompetition, “The Pride” emerged as theepitome for what Lion’s staff could bejustifiably proud of.The third Steinecker brewhousein successionThere had been Steinecker brewing kiteven at the Khyber Pass Brewery, since1975. This tradition was to be continuedin “The Pride”. Krones installed a four-kettle brewhouse comprising mash tun,lauter tun, wort copper and whirlpool,plus a vapour condenser and an energystorage tank with an installed capacity of600 hectolitres per brew.The brewhouse is controlled from acentral process room through the Botec F1system from Steinecker. Botec alsocontrols the supply of raw materials. Fermentation tanks from existingbreweriesThe brewhouse is supplied from sixmalt silos, each with a capacity of 150tons. Krones’ job package included eight200-hectolitre yeast tanks and new spent-grains silos. 18 fermentation tanks camefrom the dismantled Khyber PassBrewery, and four from the CanterburyBrewery. 24 new storage tanksmanufactured in New Zealand by NDAwere supplied by Krones. The twelvebright-beer tanks were purchased by Lionitself, with Krones responsible for theirinstallation. For filtering its beers, Lion opted formembrane and separator technology, tothe exclusion of diatomite. The yeastpropagator, too, was taken over from theold Khyber Pass Brewery, and Lion had itsubsequently automated by Krones.What’s more, Lion centralised most of thecleaning in a single big CIP kitchen,which serves the brewery’s process-engineering operations, plus beverageproduction, and even parts of the bottlingprocess. One single hall for all fillinglinesThe 24,000 square metre filling andpackaging hall accommodates two glasslines, one canning line, a line forcarbonated drinks, a spirits line and aIn a manner of speaking, building a new brewery on a greenfield site is downrightsimple. But “The Pride” multi-beverage plant of New Zealand’s food andbeverage conglomerate Lion was unlike any other project. Not only did it involvesetting up the multi-beverage plant, plus a warehouse, with a brewing capacity of1.8 million hectolitres, it also stipulated the installation of lines and systems formaking and filling wine, spirits, cider and ready-to-drink beverages. A pride of lions21-29:Layout 1 21/10/13 09:43 Page 8Food & Drink International 29www.fdiforum.netfour-lane kegging line. This 150-metre-wide hall bay rests on only two rows ofpillars, so as to minimise obstacles forintra-plant logistics. It’s in this hall thatall beer varieties, and also the otheralcoholic beverages are filled. Themachinery installed offers an enormouslyvaried spectrum of end-of-line packaging,including two cans on top of each other inone pack. Krones’ job package included therelocation of the most importantcomponents of the existing bottling line,the canning line and the kegging line fromthe Khyber Pass Brewery. After havingbeen moved to the new premises, thebottling line (Line 1) was refurbished withnew conveyors, a pasteuriser andpalletiser to bring it up to the latest stateof the art. Line 1 is a multi-purposeinstallation handling beer, RTDs andcider. The second bottling line, rated at54,000 bottles an hour, contains almostexclusively new machines. This line offersas a special feature the ability to handletwo different types of end-of-the-linepackaging in parallel. In all, the lineshandle a total of more than 220 differentSKUs. A highly complex projectIt is imperative that this complexconfiguration, comprising as it does sixfilling lines of various types with severaldisparate fillers and the option of runningseveral different products in parallel onone line can be run with maximisedoperator-friendly efficacy. To ensure this,Krones has integrated an LMS linemanagement system. The LMS wasdesigned to be absolutely production-determinant, in regard to both order andmaterials management. The ordermanagement function processes the fillingorders imported from the ERP system,and reports back to this system thefinished articles, plus the materialsconsumed for making them, accuratelyreflecting the production batch concernedin each case. The materials managementsystem utilises efficient interfaces to theclient’s warehouse management system tomake sure that materials are in factavailable in the right quantities when andwhere they are needed, and reports backthe finished articles on an order-referenced basis. “The first brew, a “Steinlager”, wasproduced in September 2009 and with itshighly product- compliant results exceededexpectations”, says Duncan Field. First-time bottling (on Line 2) took place amonth after the first brew, in October2009. “But the biggest challenge of allonly came our way as from January 2010,when three plants were being operated inparallel: the brand-new “The Pride”, theold Khyber Pass Brewery, and CBC, thecontract bottler for the alcoholic drinks.Production at Khyber Pass then had to bediscontinued by mid-2010, and fillingoperations at CBC by mid-2011.”Earthquake reshuffles the cardsAs if all that hadn’t been enough, on22nd February 2011 at 12.51pm,everything suddenly changed yet again forLion. The devastating earthquake on NewZealand’s South Island affected theCanterbury Brewery in Christchurch soseverely that at a stroke productioncapacities of 210,000 hectolitres of beer and6,000 tons of malt extract had been wipedout. Up to this date, Lion had been lookinggood in New Zealand - in the very south ofSouth Island, the Speight’s Brewery hadbeen brewing around 45,000 hectolitres ofbeer. In the middle of South Island, theCanterbury Brewery in Christchurch hadbeen brewing 210,000 hectolitres of beerand also producing malt extract. The new“The Pride” brewery in the north of NorthIsland had primarily been earmarked for bigbatches. There was nothing for it but torestructure Lion’s operations as quickly aspossible. Speight’s in the south wasexpanded to handle all of Canterbury’s maltextract operations, plus the kegging of over100,000 hectolitres of beer. In the spring of2013, moreover, the Speight’s Brewerycommissioned a new Steinecker brewhousefor 150 hectolitres of cold cast wort. Beerproduction, at more than 200,000hectolitres, was swiftly relocated by Lion to“The Pride” brewery in Auckland. Tel: 01942 845000Email: mark.heath@krones.co.ukwww.krones.com21-29:Layout 1 21/10/13 09:43 Page 9Next >