< Previous30 Food & Drink Internationalwww.fdiforum.netPLANT MAINTENANCEConducting oil sample analysis can help to prolong the lifespanof machinery and should be carried out on a routine basis.Acoustic vibration monitoring technology, which costsrelatively little, can also be employed to check the condition ofmechanical parts. Industrial rotors, for example, will emithigher-frequency sounds if they sustain any damage. By using anAcoustic Emission (AE) sensor to detect early signs of friction,companies can address problems before they become causeproduction to grind to a halt.It is vital to keep machinery as clean as possible – especially inan environment where food and drink is being produced.Products such as milk and cheese can be difficult to removefrom hard surfaces if they are allowed to burn, and caramelisedbuild-ups will inevitably make machines and pipes lessfunctional. In order to remove potentially hazardous blockages,manufacturers are investing in UHP pipe-cleaning technologieswhich employ water pressure to achieve a more powerful clean.The latest products on the market are able to clean lengths ofpiping over 1 km long, and because many of them featuresophisticated rotary heads that increase water propulsion, theyare also able to clean around bends. But what about health and safety? According to the Healthand Safety Executive of the UK, machinery causes nearly fivePHOTO: SHUTTERSTOCK.COM/KZENONCK Foods opens £5 millionproduction plant in BradfordFamily-owned foodmanufacture,CK Foods, isofficiallyannouncingthe opening ofits purpose-built £5 millionstate-of-the-artfoodproductionfacility inYorkshire, UK. CK Foods, which has specialised in the manufacturing andprocessing of pizza cheese of a number of years, is now introducingpoultry products to our portfolio as part of its ongoing expansionprogram. A gap in the market for locally sourced halal poultry products wasthe inspiration behind the opening of the new facility, which receivedover £800,000 funding from the Leeds City Region. Omar Bhamji, Managing Director of CK Foods, explains: “We sawthere was an opportunity within the market for locally produced poultryproducts, with a close UK supply chain, which wasn’t being catered for.Most of the products coming in were from the Far East or EasternEurope.”29-31_Layout 1 19/10/2015 11:51 Page 2Food & Drink International 31www.fdiforum.netPLANT MAINTENANCEhundred accidents per year in the food and drink industry,including over 30% of fatal injuries. Poorly maintained and/orsupervised conveyors are the biggest culprits, but food mixers,thermoform machines and wrapping machines also account for asignificant percentage of the total. These figures make grimreading, but, thankfully, most companies are beginning toimplement well-thought out measures to ensure the health andsafety of their staff. Eliminating hazards at the design stage is by far the best wayto prevent machine-related accidents, but this is not alwaysviable, and no method of checking is 100% fool-proof.Therefore, where particularly dangerous, heavy machinery isbeing used, companies should institute a permit-to-work systemto ensure that, a) only highly-trained operatives have access tothe machinery, and b) that no individual is required to use apiece of machinery for longer than is absolutely necessary. It is similarly vital that machines are positioned in unconfinedspaces on the factory floor. This not only reduces the risk ofgetting trapped in the moving parts of machine, but it alsolessens the chances of an operative inhaling the dust that is aninevitable by-product of many food manufacturing processes.Dust inhalation and other issues such as eye and skin irritationcan also be prevented if companies provision their staff with thecorrect safety equipment and take the trouble to install high-quality exhaust ventilation systems.With automation on the rise, plant maintenance has neverbeen more important to food and drinks manufacturers. Takingthe right steps now could mean increased profits in the long-run.Contact our sales team today for more informationvisit resinsurfaces.co.uk or call 0161 483 1232The Resuthane range is the UK’s leading flooring solution for the food and drink industry.Moody Plc Celebrates 40 YearsSupplying the Food ProcessingIndustriesFrom humblebeginnings workingout of Chairman PaulMoody’s garage athome, Moody’sbegan by trading inpre-owned foodprocessingmachinery. MoodyProcess Equipment isstill selling top qualitynew and pre-ownedfood and beveragerelated machinery including packaging equipment, tanks, heatexchangers, homogenisers, pumps and valves today. The Moody Group, based from headquarters in Retford,Nottinghamshire, has grown substantially over the years and is nowmade up of seven divisions including process and packaging spareparts, service, turnkey projects, electrical engineering, automation, assetvaluation and asset disposal services. The Moody Group has alsoacquired a number of brands such as Alfred & Co, the well- known icecream equipment business. “We have had many challenges and successes over the past 40years. We have constantly adapted our approach to the ever changingmarket to fit our customers’ needs. For example, we developedMoodybid our own in-house online auction platform enabling onlineauctions as opposed to an ‘in the room’ sale. Developments such asthis have given our customers flexibility in a busy and sometimes hecticFMCG industry.”29-31_Layout 1 19/10/2015 11:51 Page 332 Food & Drink Internationalwww.fdiforum.netWATER TREATMENTWater is integral to food anddrink production. Hugeamounts are used bymanufacturers every day, and with food-borne diseases an ever-present concern, itis vital that it is kept as pure as possible. For some time now, manufacturers havebeen purifying their water by harnessingthe natural process of “reverse osmosis”(RO). Semipermeable membranes madefrom carbon and/or composite materialsare used to filter out unwanted particlesand bacteria. This is by far the cheapestway to purify water, and reverse osmosistechnologies are highly effective atremoving contaminants. However, around70% of the water is wasted using thismethod, and as a consequence companiesare beginning to turn to energy-efficientsolutions that allow wastewater to be re-used.The longer a filtration product staysfunctional, the less waste it produces. Assuch, innovation in the field has primarilybeen focussed on developing filtrationmembranes that have a longer life-span.Companies across the globe areexperimenting with materials such assilicon carbide – a mixture of silicon andcarbon traditionally used as an abrasive –to create water filters that allow morewater to pass through whilstsimultaneously sifting out morecontaminants. Materials such as siliconcarbide can stand high-temperature steamcleaning, which means it is no longernecessary to use potentially harmfulchemical cleaning products that could endup in the food or drink, defeating theobject of the operation. Another highly versatile innovationthat is proving increasingly popular is theSpinClean filtration system. The systemhas an exclusive modular design and usesa grooved disk to guarantee maximumefficiency. As a result, SpinClean isparticularly effective at removing fibrousmaterials and organic contaminants suchas algae from the water, preventing thebuild-up of solids, and the system can becan be used in tandem with rain-waterharvesting technologies, making it a cost-effective green option.Water re-use is becoming increasinglyimportant to the industry. As the dualimperative to go green and cut costsbecomes ever-more pressing, companiesare investing in the latest water recyclingsolutions to stay ahead of the game. Agreat deal of research is being done intothe potential of harnessing natural by-products of the food manufacturingprocess such as condensation andcontaminated wastewater to create greenenergy that can then be used to powermachinery, or re-used as a component infood and drink products.The key question is how best to achievethis. Given that water must be de-contaminated before it is recycled, severalcompanies are experimenting withUltraviolet (UV) disinfection techniquesin order to eradicate potentially harmfulmicrobial elements that render the watereffectively useless. This approach hasseveral advantages: using ultraviolet lightas a disinfectant is cheap, safe and easy toimplement. The technology has beenaround for years, and because there are nodangerous by-products associated with UVtreatment, this method is especially goodfor the environment. Another way food and drink producerscan recycle wastewater is by using it tofacilitate the very earliest stages ofproduction. Where hazardous chemicalcontaminants are not present, mostwastewater can be used to irrigate soil,Waste not,want notWater re-use is becoming increasingly important to theindustry. As the dual imperative to go green and cut costsbecomes ever-more pressing.32-33_Layout 1 19/10/2015 11:52 Page 1WATER TREATMENTPHOTO: SHUTTERSTOCK.COM/ZORABCFood & Drink International 33www.fdiforum.netwhich has a remarkably high impuritythreshold. Therefore, wastewater from theproduction line can be used to help growraw produce – a great way of cutting costs,especially in countries where the climateisn’t conducive to heavy agriculture. Other simple measures companies cantake include re-using rinse water in theirboiler facilities (which should destroymost contaminants), using cleaning-hosesthat have a low flow so as to cut downwastewater in the first place, andemploying the latest inexpensiveanaerobic pre-treatment technologies toproduce reusable bio-energy. Contaminated water can cause hugeproblems for food and drinkmanufacturers. Fortunately, however,water treatment systems are becomingincreasingly sophisticated, and with oneeye on green issues as well, the industry isclose to guaranteeing a sustainable future. PHOTO: SHUTTERSTOCK.COM/ZAMUEL32-33_Layout 1 19/10/2015 11:52 Page 234 Food & Drink Internationalwww.fdiforum.netFROZEN FOODS AND READY MEALSAdvances in technology have seenmanufacturers of frozen andready meals expand their productportfolios in recent years. With consumersdemanding convenient, high-quality foodin increasingly large quantities,manufacturers are drawing upon newtechnologies that allow them to vary theirrecipes and create better quality produce.Extending the shelf-life of food productshas also become a major concern for theindustry, so innovations in refrigerationtechnology are of the utmost importance.As a consequence of changes in theglobal economy, the public are spendingless on perishable foodstuffs. This haspresented opportunities to manufacturersof cheap frozen foods and ready meals,but there are challenges, too. Marketanalysis suggests that today’s consumers,particularly young people, are demandingexperimental frozen foods that go beyondthe bog-standard pies, chips and peasorthodoxy of yesteryear. As people travelmore they are being exposed to newflavours, and this is one factor that isdriving product diversification within theindustry. Another is healthy living. This is not just the case inside the UKeither, as the cold chain market in Chinais expected to grow at a compound annualgrowth rate (CAGR) of 24% between thedates of 2014-2019, according to a detailedreport by research firm TechNavio. Theycite the growth as a result of an increasingdemand in Asian countries forconvenience food with health or well-being benefits, which is creating atangential demand for refrigerated storageand distribution technology – as retailersrush to take advantage of the demand.The key questions for manufacturers,then, are how to make production moreefficient, and how to introduce newproduct lines without increasing costs?The answer lies with innovativerefrigeration technologies. Manufacturersare using Individual Quick Frozentechnology (IQF) to ensure the freshnessand taste of their products. Eachcomponent of a ready meal is sprayedwith a stabilising agent (usually acombination of Guar gum and XanthanOn iceThe frozen foods and ready meal sector has been booming overthe last few years, and the trend is set to continue. Campden BRI shows superchilling cansafely extend shelf life by 120%Research carried out by Campden BRI has shown that superchilling can safely extend theshelf life of chilled foods without any loss of sensory quality. Superchilling reduces the temperature of food products to around -2°C so they becomepartially frozen. The products are stored at that temperature until being released into the chillchain. The greatest extension in shelf life was achieved with prawns. The lab research showedthat superchilling could increase the shelf life of cook-chill prawns to 22 days. This offers apotential 120 per cent increase on the 10 day chilled shelf life subject to the protocol beingimplemented commercially. Campden BRI also looked at the effects of superchilling onpoultry and gammon. Dr Greg Jones, a microbiologist at Campden BRI and the project coordinator, says: “Superchilling is not a novel technique. It is used on an ad-hocbasis to build stock in times of high demand, such as Christmas or a ‘barbecue’ weekend. Up until now there has been little data to support its usemore widely and little information on the impact of its wider use on product safety. Our research shows that it can be used to extend shelf life withoutcompromising the quality or safety of these products.” 34-38_Layout 1 19/10/2015 11:54 Page 1Food & Drink International 35www.fdiforum.netFROZEN FOODS AND READY MEALSImprove climate conditions from inside cold stores to:Prevent ice Improve safety Protect quality Reduce defrosts zzzzIceDry™gum) prior to freezing. Liquid nitrogen, which is far morepowerful than conventional refrigerants, is then used to freezethe product. IQF can be used to safeguard the freshness of anyproduct line, but it is especially useful in cases where exoticcomponents that have already travelled a long distance formpart of a ready meal. One of the most unusual new approaches to freezing food,known as Acoustic (or “Stirling”) refrigeration, involves theuse of sound waves to modify the pressure in refrigerant gases– fluctuations which in turn cause changes in temperature.Although it is still in development, this technology is likely tobecome popular in the future as companies look for moreflexible ways to freeze their products; flexibility during thepreparation stage being the key to a diversified product line. For companies dealing in frozen fruit and vegetables,dehydro-freezing is a great option: large quantities of water areremoved from a product before it is frozen, which helps toWhat is your Christmas turkeygoing to look like this year?Ideally your Christmasturkey will be succulent andcooked to perfection.However, for many homechefs when the proudmoment arrives their turkeyfails to impress. Digital foodthermometer company ETILtd has been working withCelebrity Chef Nick Nairn toreassure home chefs andhelp them to cook theirChristmas turkey toperfection, with theminimum amount of fuss.By using the fastresponse temperatureprobe of a Thermapen foodthermometer they can knowinstantly (three seconds),whether the turkey breastmeat is cooking too fast or the legs need a bit longer, and adjust thetemperature accordingly – or use foil to cover the breast. Celebrity TV chef Nick Nairn says, he routinely uses the Thermapenat his cookery school in Aberdeen; “Thermapen thermometers totallytake the guesswork out of knowing when your Christmas turkey isready. The way to check is by inserting the Thermapen into the centreof the thickest part of the breast and also the thickest part of the thigh.Both should give a reading of 75˚C or above.”PHOTO: WWW.EPICSCOTLAND.COMPHOTO: KUNAL MEHTA / SHUTTERSTOCK.COM36 Á34-38_Layout 1 19/10/2015 11:54 Page 2www.etiltd.comdigital thermometerSuperFast Thermapen 4®NEW‘With a number of new innovative features including a 360° self-rotating display, auto intelligent backlight,sleep mode & waterproof to IP66/67’36 Food & Drink Internationalwww.fdiforum.netFROZEN FOODS AND READY MEALSconcentrate its flavour and speeds up thefreezing process. In terms of ready meal packaging, weare beginning to see a subtle shift fromthe use of rigid, inflexible containers toflexible solutions such as re-sealablepouches and bags. These types ofpackaging represent cost-effective, space-saving solutions that are also better forthe environment. Moreover, there are now a wealth ofenvironmentally friendly display andstorage options available that can helpfood and drinks companies achieve thethreefold aim of saving energy, savingmoney and ensuring food safety. Syntheticrefrigerants such as R404A and R22 aretraditionally used to cool food storage anddisplay cabinets, but these substances areliable to leak, causing untoldenvironmental damage. To combat thisproblem, manufacturers are developingchiller cabinets that employ alternativerefrigerants for each different temperaturezone, which means a diverse array ofproducts can be chilled at the correcttemperature within the same unit. Temperature controls are alsoparamount when frozen food products arein transit. Care must be taken to ensurethat the optimum temperature ismaintained for each individual product orcomponent. Even when they are notdestined to be part of a frozen meal,perishable products such as fresh meats38 ÁPHOTO: SHUTTERSTOCK.COM/FINEART134-38_Layout 1 19/10/2015 11:54 Page 3 Innovation. Knowledge. Expertise. It’s What’s Inside. Ingredients make up the food we eat, the beverages we drink, and the supplements we take. But what makes some ingredients fresher, tastier, and safer than others? It’s what’s inside that matters. Open the door to DuPont Nutrition & Health and you’ll see a team of solvers, providing the most innovative solutions in the food industry. We start with an ingredient portfolio that’s wider and deeper than most, but what truly sets us apart are the ingredients you can’t see – our consumer insights, breadth of research, and scientific capabilities. Want to see what else we can bring to the table? Come find out what’s really inside DuPont Nutrition & Health. Visit dupont.com/itswhatsinside to learn more. Welcome to the Global Collaboratory.™hh.DuPontNutrition & HealthCopyright © 2015 DuPont or its affiliates. All Rights Reserved. The DuPont Oval Logo, DuPont™ and all products denoted with ® or ™ are registered trademarks or trademarks of E.I. du Pont de Nemours and Company or its affiliated companies. 34-38_Layout 1 19/10/2015 11:54 Page 4need to be chilled at low temperatures – usuallybetween -0.75 and -1.25?C – to stop themdegrading, which should give some indication ofhow vital temperature controls are in the readymeal context. Discarding produce is likethrowing money down the drain, so from abusiness perspective it is ill-advisable topersevere with traditional refrigeration systemsthat can only chill food at a single, statictemperature. Temperature controlled storage anddistribution remains one of the most powerfulindustries in the food and drink industry, withthe cold chain accounting for roughly 9% of the£187 billion of sales in the food and drinkindustry. In fact, in the month of October 2014,figures show that approximately 41p of every £1spent in the retail industry was in food stores,with a large share of the goods moving throughthe cold chain.What is clear to the cold chain industryhowever is that the demand from consumersacross the globe is not decreasing. What newinnovations the industry will design to combatthis is unsure, but it is an opportunistic time forthe temperature control industry.It is never easy to improve quality, guarantee food safety andcut costs at the same time, but with a raft of new refrigerationtechnologies, safer temperature controls and storage optionson the market, it is fast becoming a realisable goal. Varicon Metal DetectorVision System BVSXRE Product Inspection The Bizerba BVS has a high-resolution camera with automatic height adjustment and ultra-fast data transmission via a GigE interface. The automatic height adjustment makes it unnecessary to adjust the camera for different products. Combined with the industrial software _statistics.BRAIN and _dataMaintenance.BRAIN, this multi-functional inspection system is an impressive addition to many fields of quality management.Using the XRE product inspection system enables all foreign objects that absorb x-rays more or less effectively then the surrounding product due to their density, chemical composition or mechanical dimensions to be detected. Other product defects such as cracks, tears or air pockets in tubes and tins can also be detected. The highlight - any foreign objects that are designed to be present, for example aluminium clips at the end of sausage packaging can be simply ignored.The varicon metal detector quickly and reliably detects all ferrous and non-ferrous metals in packaged and unpackaged unit goods. For automatically separating packaging containing metal, the pusher separator system with separator container is available as an option. Thanks to an extensive range of accessories from Bizerba, it is possible to create some 200 different, entirely customised systems for your specific needs.01908 682740 info@bizerba.co.uk www.bizerba.com38 Food & Drink Internationalwww.fdiforum.netFROZEN FOODS AND READY MEALSThe Collective launches newgingerbread yoghurtGourmet yoghurtbrand, TheCollective isspicing things upin the dairy categorywith the launch of adelicious and warmingnew GingerbreadLimited Edition, thatcaptures Britain’sfavourite seasonalflavours throughoutAutumn and Winter(RRP £2.39 for a 500gtub). Gingerbread is a traditional treat in the colder months and is aconsumer favourite during Halloween and Christmas where it is usedfor making edible seasonal decorations and conjuring images ofHansel and Gretel. By creating this new edition, The Collective isbringing an innovative new product to market that will have significantappeal to shoppers and retailers alike. This seasonal edition will allow the business to tap into significantconsumer demand around Halloween and Christmas, which, alongsideEaster, are two of Britain’s three biggest buying occasions.PHOTO: SHUTTERSTOCK.COM/VLADIMIR NENEZIC34-38_Layout 1 19/10/2015 11:54 Page 5Food & Drink International 39www.fdiforum.netPPMAThe PPMA Show 2015 returned to theNEC from the 29th September - 1stOctober, with more than 1,000 leadingpackaging and processing machinerymanufacturers represented at the showand providing a platform to showcase thelatest technological innovations anddiscuss key business opportunities withmore than 7,500 visitors.The exhibition saw prominent figuresfrom across the manufacturing sector taketo the stage as part of the shows seminarsessions with former Sainsbury’s CEOJustin King CBE, providing the headlinediscussion, addressing the future formultiple retailers and how the growingmarket share of discount retailers willaffect the supply chain.Show features also included a Roboticand Industrial Vision zone whichshowcased the latest inventive and quirkyuses of robotic technology includingrobots that could dance, pour drinks andeven play golf.Visitors were able to view first-handmany of the latest innovations on themarket with exhibitors including the likesof Riggs Autopack, who presented theGuinness World Record winning Series 1micro-fill depositor, which was recentlyused to produce 35,000 cupcakes for theworld’s largest cupcake mosaic. Returning as headline sponsors of thePPMA Show 2015, Lloyds BankCommercial Banking offered valuableexpertise from their manufacturingspecialists, including guidance on day-to-day banking requirements and funding forexpansion, as well as supportingbusinesses in their plans to invest in newplant and machinery.David Atkinson, Head ofManufacturing, SME, at Lloyds BankCommercial Banking, said: “The PPMAShow is a major landmark in themanufacturing calendar and this year’sevent was bigger and better than ever.Many businesses were keen to share theirexperiences, taking elements of bestpractice from across the industry to betterunderstand how they can achieve theirgrowth aspirations.” Mark James, Product MarketingManager, RS Components said: “We’re afirst time exhibitor and the show has beenvery good. Overall organisation and thequality of customers is up with the best ofthem. The show meets the needs of endcustomers and compared to other shows,communication is very slick, and theorganisers produce good looking materials.”The Ones to Watch award alsoreturned, celebrating the contributions ofthose people under the age of 35 to thepackaging and processing industries withReiser engineer Cesare Bove the recipientof this year’s Gold award. Cesare was awarded the title by a panelof judges having demonstrated his talent,and dedication to the industry. He wasalso praised for the progress he’d madeduring his time working with Reiser,having started as an apprentice, beforemoving into the field as a service andinstallation engineer.An opening keynote speech from LordDigby Jones, former Minister of State forTrade and Investment, set the tone for theinformative Seminar Sessions which tookplace at the show, with a number of keytopics addressed by industry figures duringthe course of the exhibition. HannahWall, Graduate Project Engineer, Nestleand Sam Kelly, Electrical EngineeringApprentice, PepsiCo, took to the stage todiscuss the opportunities available toyoung people to get into the engineeringindustry. In front of a packed audience ofstudents, Hannah and Sam spoke abouttheir own experiences in the industry andthe type of projects they’d worked onduring their careers. Success atthe PPMAProcessing and packaging professionals converge on NEC for mostsuccessful PPMA Show in recent history39-41_Layout 1 19/10/2015 11:56 Page 1Next >