ON THE SHELFWAREHOUSING &DISTRIBUTIONINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netDECEMBER2012 £3.50 STERLINGSweetsuccessSweetsuccessNEWS01:Layout 1 16/11/12 10:15 Page 102:Layout 1 16/11/12 10:15 Page 1ContentsContentsDecember 2012Cover photographs courtesy ofMain:www.shutterstock.com/VorobyevaTop: National FlexibleMiddle: RTITBBottom: Flowcrete2124ONTHESHELFWAREHOUSING&DISTRIBUTIONINTERNATIONALFood&DrinkFood&Drinkwww.fdiforum.netDECEMBER2012£3.50STERLINGSweetsuccessSweetsuccessNEWSWebsite: www.fdiforum.netEditor:Steve Fisher (s.fisher@blmgroup.co.uk)Editor’s PA:Angela SharmanJournalists:Steve Williams (s.williams@blmgroup.co.uk) Mike Shields (m.shields@blmgroup.co.uk)Elis Ballard (e.ballard@blmgroup.co.uk) Michael Fisher (m.fisher@blmgroup.co.uk)Sales Director:Teri CooperSales Manager:Becky RobertshawAssistant Sales Manager:Sam TrottSales:Nikki Logan • Tel: +44 (0) 1472 310302Accounts & Subscriptions:Dawn Cook, John DownesDesign & Production:Gary Jorgensen, Mark Casson, Rachel Green (studio@blmgroup.co.uk)Editorial:Tel: +44 (0) 1472 310305, Fax: +44 (0) 1472 310317Email:fdi@blmgroup.co.ukWebsite: www.fdiforum.netPart of the Business Link Magazine Group:Armstrong House, Armstrong Street, Grimsby, N E Lincs DN31 2QE EnglandAll rights reserved. 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FoodandDrinkInternational@fdiforumwww.fdiforum.netcompany/fdiforum4314News 4• General news• On the shelf - new products and initiatives• On line - production news• AppointmentsEnd of year success stories18 Businesses have reported an upturn in theirfortunes in 2012 – thanks to continuedinvestment and success in new markets• Clydebuilt Business Solutions• TorishimaInnovation spotlight21Innovation is key in the food and drinkindustry if it is to continue growth in 2013• DatelWarehousing and distribution24The quest for improved warehousemanagement and effective distributioncontinues• Clydebuilt Business SolutionsVision, inspection and detection 27Thanks to vision systems and otherinnovative technology, it is becoming easierto avoid compromising products or entirebatches• Stemmer Imaging• AutoCoding SystemsAnaerobic Digestion 33Government support and increased interestin energy efficiency mean anaerobicdigestion is becoming a more mainstreamproposition• WehrleMixing and blending 37A new generation of mixing and blendingequipment is enabling companies to deliverproducts in shorter lead times and to ahigher standard• Silverson Machines LtdeasyFairs Packaging InnovationsLondon40Record-breaking numbers attendedeasyFairs Packaging Innovations London -with a 27% increase on last year’s show.Bulk ingredients41When dealing with large amounts of rawingredients, storage can actually be a majorissue - not just in terms of space, but safetytooConfectionery43With more and more consumers turningtowards healthy alternatives, what is theconfectionery sector doing to win peopleback?• Sensient Food ColoursProSweets Cologne49It promises to be the best forum for theconfectionery industry with packaging,ingredients and automation takingprecedence along with the rest of theindustry’s best suppliers andmanufacturersEvents51Your chance to keep abreast of forthcomingexhibitions and food fairs from around theworldClassified52Food & Drink Diary5403:Layout 1 16/11/12 13:14 Page 1Trio celebrate sixtyyears of service withHygiene GroupThree employees of Hygiene Group arecelebrating twenty years of service with thecompany.Peter Laflin, site manager, Dave Maxwell,pest control manager and Simon Payne,mobile team account manager, have eachbeen presented with a wrist watch, acertificate and a bottle of champagne byHygiene’s managing director Steve Bailey.Peter has gained a large amount of experience of cleaning in the food manufacturing sectorduring his time with Hygiene, having worked with leading companies in the sector. Prior to joining Hygiene in 1992, Dave spent 13 years in the army as a corporal and started at HGspecialising in overhead cleaning and then worked with the mobile teams for various high-profilecustomers. Simon first started at Hygiene in 1986 and returned to the company in 1989. He also has vastfood industry cleaning experience and heads up work for some of Hygiene’s specialist contracts.4www.fdiforum.netCastell celebrates ninety years of industrial safetyCastell has celebrated ninety years ofprotecting people and assets worldwide.Its headquarters stand on the same north-London site that has served as home for thevast majority of the company’s life. Castell isstill protecting people in the workplace,although the company’s reach hasincreased dramatically. With operationsthroughout the world - from Shanghai toChicago and Chennai to Cologne - thebusiness is now truly global. This year also sees Castell’s longest-serving employee, Jim Dilks, complete 40years’ service with the company. Castellheld an awards ceremony in October tocelebrate this extremely rare event. During the ceremony, Castell also presented long-service awardsto a further five Castell colleagues: Mike Ganesh, Neil Thakor, Kishore Pisavadia, Chris McDonaldand Sheena Shah.Holfeld’s G81 punnetready to pack ‘em inwith a world beatingcarbon footprint rangeIn preparation for the new soft fruit growingseason, Holfeld Plastics is promoting its range ofstandard crate fit G81 punnets in five depths – headsealed or lidded and fully compatible withcompetitors SPS or the K37 size ranges.With pre-season prices available the range isbacked by 25 years’ experience, the G81 rangeoffers an enhanced venting solution increasingairflow and therefore shelf life, a substantial lowcarbon r-PET and an optimal ribbing design towithstand challenging packhouse conditions whilstoffering excellent product visibility. Holfeld manufacture their own supercleanedmaterial on site – they don’t rely on third partymanufacturers. This gives Holfeld absolute controlof manufacturing processes. Holfeld leads the wayin the use of recycled PET with some of the highestpost-consumer recyclate percentages in theIndustry at around 80%.Test device provides benefits forfood and drink producers3M’s Food Safety business has announced its Clean-Trace Water – Total ATP test device is tomove to an advanced, innovative formulation allowing for improved temperature stability andtest result accuracy. This aqueous test is designed to rapidly assess standards of hygiene, equipment sanitationprocesses and the efficiency of Clean In Place (CIP) procedures by detecting the presence oforganic contamination from microbial or product residues. The test gives an objective indication of cleanliness in water samples in seconds. By workingin real time, food and beverage producers can test rinse waters after each CIP cycle and re-clean immediately if ‘fail’ results are obtained.The device tip contains sample collection rings which are coated with a unique agent to aid inthe efficient collection and processing of a sample. Once the test is activated, the results aremeasured in the Clean-Trace NG luminometer from 3M and provided in Relative Light Units(RLU). The new and improved Clean-Trace Water Plus – Total ATP test now provides food andbeverage producers with the flexibility to store the product at their own convenience – roomtemperature (21°C - 25°C) for up to 2 months or refrigerated (2°C - 8°C) for up to 12 months. In addition, the test allows for lower background RLU levels, enabling food and beverageproducers to further improve their cleaning efficiencies as part of their continuous improvementprocess.04-12:Layout 1 16/11/12 14:20 Page 1KM Packaging seals launch of gourmet productAustralian Wholefoods has successfullylaunched its gourmet ‘Clever Cooks’ range oflasagnes in record time, thanks to KM PackagingServices.The company was chosen ahead of a locallidding supplier due to its extensive expertise inlidding film technology and global reputation.Shortly after the initial enquiry was made, KMPackaging visited the manufacturing facility inAdelaide, where a full site review allowed it to fullyunderstand the scope of the project. KM Packaging had no problem in carrying outintensive product trials at its facility in the UK. All product assessments benefited from being testedagainst the exact trays used in Australia, which ensured the chosen films and foil trays workedtogether. The first trial reels were delivered to Australian Wholefoods within a few days, which gave the company added reassurance that despite receiving stockfrom overseas, the despatch and delivery process would be prompt and hassle free.www.fdiforum.net5Kraft Foods saves time byupgrading to image-based barcodereadersIn regard to allergen management,Kraft Foods Canada scans eachlabel after it has been affixed on thepackaging line to ensure it matchespackage contents. The barbecuesauce product line at the plant inQuébec, produces 30 different stockkeeping units at a rate of up to 265bottles per minute. When the line ischanged over to produce a differentSKU number, the proper labels aremanually loaded into the fillingmachine.Their original laser-basedscanners were only capable ofreading codes located within a smallfield of view. When the labels are changed to a new SKU, the code may bein a different position depending on design. Cadence Automation, a Cognexintegrator recommended the Cognex DataMan 300 ID reader because its800 by 600 pixel image resolution was able to see the entire label and easilyread the code. Cold storeinnovation Aisle-Master’s new cold store truck hasbeen shortlisted in the Innovation Categoryfor the 2013 Fork Lift Truck Association’sAwards for Excellence. Combining the space saving capabilitiesof a narrow aisle forklift with the protectionoffered by a fully enclosed cold storespecification cab, the articulated Aisle-Master cold store model has beendeveloped specifically to withstand thissector’s exacting requirements. It enablesmaximum pallet density to be achieved inwhat is a very expensive environment andoptimises labour efficiency. The heated cab keeps drivers warmthroughout their shifts and ensures thehighest level of operator comfort, avoiding the need for regular breakswhich can have a negative impact on productivity.Low temperatures can have an adverse effect on battery performancebut Aisle-Master’s designers have counteracted this by fitting a powerful930 amp battery which enables extensive operational periods intemperatures as low as - 30°C.Kingspan bake a fresh batchGreggs have constructed anew £12 million regionalbakery at Gosforth Park inNewcastle, featuring 13,100sq m of Kingspan ControlledEnvironments’ KS1100 CSwall and ceiling panels, toprovide bread and buns toover 180 shops every day.The new 90,000 sq ft bakery, designed and constructed by Clegg Food Projects, not onlyprovides a significant improvement in technology, but also forms part of the company’s ambitiousplans to open and service an additional five hundred stores nationwide over the next few years.Kingspan’s KS1100 CS wall and ceiling panels were used across the bakery in differentthicknesses to meet all the varying requirements of the project.Peter Boughton, Group Project Manager at Greggs, says, “The KS1100 CS panel offered severalbenefits to the project including excellent thermal performance. We were particularly pleased withthe product’s enhanced walkability which will enable simple maintenance of the ceiling panels andmeet health and safety requirements.”Glen Scotia’s packaginga part of a global salesgrowth planA Whisky distillery is forging ahead with majorinvestment plans to expand its global operation.The Glen Scotia Distillery, producers of GlenScotia single malt whisky, has undergone a series ofcapital improvements in recent years as part of along term growth plan for the distillery itself and forthe premium range of single malts being sold in theGlen Scotia range.The Glen Scotia packaging has been redesignedand is being launched internationally in around 15countries. Opening orders are currently 141% aheadof last year’s 12 months’ sales. Leeds-based branding specialists, Brand Britain,were chosen to develop the packaging designs,working closely with Commercial Sales Director,Andrew Gray, and photographer Duncan Wood, indeveloping Glen Scotia’s new colour-coated bottledesigns. The packaging has been designed to cutacross language barriers and stand out from othersingle malt scotch whiskies. 04-12:Layout 1 16/11/12 14:20 Page 2Register NOW at www.easyFairs.com/PIUKDelivering tomorrow’s packaging innovations for today’s buyersVISITORS AT 201298% found the exhibition to be worthwhile or very worthwhile79% identified new suppliers Registration is open for the UK’s leading event for primary and secondary packaging. Visit www.easyFairs.com/PIUKOfficial Media PartnerSupported by04-12:Layout 1 16/11/12 14:20 Page 3Hygiene Group is the right ingredient for CereformHygiene Group, the contract cleaningspecialist, is working with one of the UK’s topbakery ingredient companies.Cereform manufactures ingredients for theUK baking industry with one of its key productsbeing bread improver, used by the country’stop bakeries on a daily basis to control thebaking process. 250 tonnes of bread improveris produced each week.Hygiene Group’s team was brought in tocarry out overhead cleaning work at the factory,which involved cleaning the cladded metalceiling.Robin Bailey, factory manager at CereformNorthampton, says: “We were very impressed with the team from Hygiene for several reasons. Theyhave the right certification and are clearly experienced in the cleaning of food manufacturingenvironments.”“Closing down production during cleaning wasn’t an option for us. We were able to move process areas around to accommodate the cleaning and theirflexible approach meant they were able to work around us to complete the job, without interruption.”www.fdiforum.net7Flowcrete project management serviceoffers seamless flooring deliveryFlowcrete UK’s project managementservice offers the complete solutionunderfoot for the food and beveragesector, Isocrete Project Management offersa single source route, extending from initialproject consultation process, through towarranty and aftercare. The management process offers abespoke service from initial consultation,product specification, product manufactureand logistics management, through toproduct installation from a trainedFlowcrete approved contractor - and allbacked by a warranty.Within the food and beverage sector, theprocess includes the installation of IsopolSBR polmer modified wearing screed,hygienic seamless resin coating,integrated drainage, coving and hygienic wall covering.Kevin Storey, managing director of Isocrete Project Management, says:“Isocrete Project Management only employs the services of Flowcrete UK’shighly skilled approved contractor network, offering our applicator partnersmore project opportunities in addition to the financial peace of mind thatcomes with a business model like this.”DuPont benefits UHT dairy with eco-friendly solutionsDuPont is enabling manufacturersof ultra-high temperature milkproducts to increase their processingcapacity, cut costs and benefit theenvironment. This is feasible thanks toFoodPro Cleanline, an effectiveenzyme from the DuPont Daniscoingredient range, that solves the age-old issue of fouling in UHT milkproduction.Fouling occurs when milk proteins,sugars and minerals caramelise insidethe UHT unit. The subsequent build-upof pressure in the system reducesheat transfer, necessitating frequent production shutdowns for cleaning. Bylimiting the frequency of cleaning cycles, the solution optimises processinguptime with no impact on final product quality. The subsequent reduced useof harsh and expensive cleaning chemicals contributes to a more eco-friendly production line. Aurélie Gammelin, DuPont global product manager for dairy enzymessays, “Trials have shown that a UHT processing unit can run for up to morethan twice as long between cleaning cycles when using FoodProCleanline.”Cognex image-based scanner boosts read ratesfrom 93% to 99.9%The West Liberty Foods plant in Utah, USA,processes turkey, pork, beef and chicken in arange of packaging options, which are boxedand moved on a conveyor line to arefrigerated warehouse. It is vital to havecomplete visibility as it moves out of onebuilding and into the warehouse. Previouslaser scanners only managed a read rate of93% and a 7% reject rate was unmanageable. “We tried the Cognex DataMan 500 codereaders on our existing linear barcodes andsaw an immediate improvement to a 98% readrate,” says Dave McDowell, Director of Information Technology for West Liberty Foods. “Based onthat improvement we decided to accept the recommendation and try 2-D Data Matrix barcodes. Aftersome further tuning, we were able to achieve 99.99% read rates. In the final installation, the decisionwas made to go with two DataMan 500 units to ensure 100% read rates.”KMS brew a newadhesive for packaginglinesKMS Adhesives have completed a project for ahigh quality blender and packer of teas, whowanted a universal adhesive for their sift-proofpackaging lines, wrap around case sealers andcase erectors.KMS’s research and development laboratoryresponded by developing Optimise H99 adhesivewith a unique formula which provides a longer opentime combined with a very sharp setting speed,high adhesion and grab.Carl Jarrad, KMS European Sales Manager, says,“Optimise H99 is like having several products inone – our client can use it for all of his packagingoperations, from sift-proofing to multiple applicationwrap around case forming.”Optimise H99 is effective for a wide range ofmachine speeds and its service temperature range(-30 to +70°c) ensures pack integrity. Adhesives inthe Optimise brand range are designed to keepproduction going with low consumption, no taint,low odour and thermal stability.Flowcrete UK’s project managementservice offers the complete solutionunderfoot for the food andbeverage sector – drawing on 30years’ experience in the flooringindustry and its extensive networkof approved flooring contractors.04-12:Layout 1 16/11/12 14:20 Page 4Be part of the fastest-growing market for72% of stands already sold.Book your stand today.Contact Alice DomenisTel: +44 (0)20 3377 3122Email: alice.domenis@informa.com26 - 27 March 2013 Transamerica Expo Center | São Paulo, BrazilNutraceuticals |Functional Foods |Pharmaceutical Ingredients |Portfolio includesJoin us onvitafoodssouthamerica.com/ad1fdiFunctional DrinksDietary SupplementsNutricosmeticswww.horiba.commt*EFBMGPSPOTJUFGPPERVBMJUZDPOUSPMt/PTBNQMFQSFQBSBUJPOt/POFFEGPSSFBHFOUt7FSZHPPEDPSSFMBUJPOXJUIMBCBOBMZTJTTo request your trial unit,contact:)03*#"6,-UE5FMFORVJSJFTIJM!IPSJCBDPN4DBOUPTFFUIFWJEFPEFNPOTUSBUJPO30 daysfree trialPocket salt meter forquick measurementof salt concentration.Easy to use: just placea tiny piece of sampledirectly onto the flatsensor to get an instant,accurate assessmentof your products’ quality.Also available: pH meterand ion meters (nitrate,sodium, potassium & calcium)04-12:Layout 1 16/11/12 14:20 Page 5Setting the seal of quality on retort film packaging A leading manufacturer is using a Mecmesinpeel testing device to reduce wastage resultingfrom seal adhesive defects and provide theircustomers with a safe, well-sealed, edibleproduct at minimum cost.Efficient, economic peel testing of the seals oftheir microwavable pots reveal the forcerequired for peeling and identify inconsistenciesin the adhesive layering between seal and pot.Using their Mecmesin peel test solution, they areable to observe materials performance andadhesive layer performance in detail, storemultiple tests, and overlay results forcomparison purposes. The results are costsavings through elimination of excess adhesion, reduced wastage, and greater batch consistency, which translate to fewer returns and fewer customercomplaints.Retort film is manufactured from multiple layers of laminate foil and withstands extensive thermal processing to heat seal and sterilise food contents. Thispackaging method provides the product with shelf-stability, while giving consumers protection from harmful microorganisms.www.fdiforum.net9Thermic is ultra light, ultra safe forolivesThe largest size Thermic Ultraretortable barrier jar from RPCContainers Corby – the 3.8 litreAmerican gallon – has proved the idealpacking solution for olive supplierAceitunas del Guadalquivir of Seville.The new jar has been specificallydeveloped to meet the needs of theolive industry. The Thermic Ultraprovides a pack format that combinessafety and ease of handling with longshelf life and the ability to withstand therigours of high temperature fillingprocesses, including hot fill,pasteurisation and sterilisation to 122°C.The polypropylene jar weighs just160g compared to around 1.7kg for themore traditional glass format. As well asease of handling and the elimination of breakages, the lightweight jars’reduced transport costs can make an important contribution to companies’carbon reduction targets.The six-layer structure incorporates EVOH to create an effective barrier tooxygen ingress which gives the olives a shelf life in excess of twelve months.“Outstanding” Linx CJ400 wins prestige awardLinx Printing Technologies has been presentedwith a prestigious award for the Linx CJ400continuous ink jet printer, described as“outstanding” by judges. The machine was namedas winner of the ‘Most Innovative Processing orPackaging Machine’ category at the PPMA GroupIndustry Awards.The award is presented to the machinerymanufacturer which has installed an applicationthat has dramatically improved productivity for thecustomer. Judges wrote that the Linx CJ400 hadbeen selected for “demonstrating that thoroughinvestigation of every component can bringoutstanding results”.Marketing Director Paul Doody says, “Linx is celebrating its 25th jubilee in 2012 and we areabsolutely delighted to mark that anniversary with this award. Looking forward, our aim is toproduce innovative, reliable, cost-effective coding and marking equipment which is simple to useand tailored to the needs of customers. The PPMA Group Industry Award recognises the successof the Linx CJ400 in doing precisely that.”R&D is key to growth forPFM after 25 yearsItalian manufacturer PFM Packaging Machinerycelebrated 25 years in the UK with an open day at itsLeeds headquarters.UK sales and operations director Chris Boltonsays, “Group strategy has been to continue toincrease investment in innovation as a means ofkeeping growth going at time of general economicslowdown. Over 3% of PFM group turnover is nowinvested each year in R&D.”This strategy had led to a sustained programme ofnew machine launches and contributed to anaccelerating rate of growth by the group, withturnover rising 6% in 2009/10 and almost 13% in2010/11 to reach around €80 million. Chris Bolton says, “Technical innovation over thepast three years from the thirty-strong R&D team atPFM group has covered both higher speeds forexisting packaging styles as well as new methods ofproviding enhanced presentation and reductions inthe use of packaging materials.”METTLER TOLEDOlaunch new industrialweighing catalogueMETTLER TOLDEO’s new IndustrialWeighing Catalogue has been launched,and is available now, ensuring you haveall the latest product information at yourfingertips.Combining a broad range of worldwideapproved and supported quality weighingsolutions, the catalogue includes:• Bench and compact scales • Counting scales • Floor and pallet scales • Weighing terminals • Weighing software • Weigh modules and load cells • Weighbridges • Transport and logistic solutions • Vehicle and train weighing • Checkweighing • Product inspectionMETTLER TOLEDO’s new products have been designed to improveproduct quality as well as accelerate and automate processes. You can alsobenefit from increased efficiency and regulatory compliance for your industry.To find out more, order your free copy of the catalogue and discover theright solution for your specific needs. Request your copy of the catalogue byvisiting www.mt.com/uk-ind-weighing-catalogue or call 0116 2345095.04-12:Layout 1 16/11/12 14:20 Page 6Next >