< Previous20www.fdiforum.netEND OF YEAR SUCCESS STORIESInnovation fromTorishima(Europe) ProjectsThey say intelligence comes in many formsbut Torishima (Europe) Projects areconvinced they have uncovered the smartestway yet for food and drink companies toreduce their energy bills.The leading supplier of high quality, turnkey steam andhotwater engineering solutions has designed andmanufactured TEPICS – the Torishima (Europe) ProjectsIntelligent Control System. TEPICS is an automated system thatcan be applied to every aspect of a company’s boilerhouseoperation. Through its unrivalled monitoring capabilities, thisstate-of-the-art system increases the efficiency of the boilerhouseway beyond previous levels, leading to a reduction in fuel andlabour costs.Guy Forrest-Hay, Business Development Manager at Torishima,explains, “Torishima are able to help food and drink producersimprove the control and efficiency of their boiler houses andenergy centres. Our TEPICS system is a state-of-the-art controlsystem that can be retro-fitted into an energy centre and has theability to learn as it monitors every aspect of the boiler house. Itsneurological facility can constantly monitor the water quality inthe boilers for parameters such as hardness and dissolved salts, andadjust the water treatment accordingly in real time.“Energy savings are a key issue. The boilers are now 92-94%efficient when operating with economisers, bringing about a stepchange in energy efficiency from ageing assets which are typically70-80%. The intelligent control system will also optimisemaintenance regimes to ensure these efficiencies don’t drop off.”Condensed Heat Recovery is another energy-saving measurethat TEP’s expert team of engineers is bringing to the market. Guysays, “Torishima’s new package allows energy in the form ofexhaust gases that currently disappear up the flue stack to becondensed in a controlled manner, so another 6-7% of efficiencycan be gained and the flue stack can be reduced in height andmade of different materials, making the boilers 99% efficient – apreviously unobtainable figure.”For more information, visitwww.torishimaprojects.co.uk or email guyforrest-hay@torishima.co.ukFood for thoughtAs 2012 comes to a close many companiesare thankful to still be in business, as let’s faceit – it’s still tough out there. Having said that,it’s not all doom and gloom.It has been an interesting year for Clydebuilt Business SolutionsLtd, who began securing new business contracts at the start of theyear and business has continued in this vein. As well as acquiringnew customers Clydebuilt has been in involved in sizeableexpansion projects for existing customers who have leveraged theiruse of LocateIT WMS to help them offer and deliver more valueadded services.3PL providers usingLocateIT WMS haveattracted more foodmanufacturing companiesas clients. Such endcustomers need specificcontrols and track andtrace, especially where theyneed integration with theirback-office ERP. They are impressed with the flexible,knowledgeable and thorough services available.NOM Dairies were delighted to outsource their warehousing toSimmonds Transport. Rather than installing a terminal for NOMDairies back office system, SAP, and manually operate it, it wassuggested an automated real-time integration between LocateITand NOM’s SAP would keep operations consistent.Utilising Clydebuilt’s RF processes with the link, the WMSoperates virtually ‘dark’; staff at Simmonds virtually don’t have totouch the computers any more. NOM’s system sends and receivesEDI files to and from Simmonds LocateIT at all workflow touchpoints. These occur as a by-product of work being done by eachcompany on their own systems and everything else is automatic.Each system is always up to date as if Simmonds were adepartment of NOM.Clydebuilt Business Solutions, 6 Orr Square, Paisley, PA1 2DL Tel: + 44 141 847 1920 Fax: + 44 141 889 7962www.clydebuiltsolutions.com18-20:Layout 1 16/11/12 13:17 Page 3INNOVATION SPOTLIGHTwww.fdiforum.net21Despite the interest in heritagebrands, consumers continue tolook for new taste experiencesand more appealing products. Likewise,the increased demand for productintegrity, healthier options and absolutesecurity are just some of the issues facingmanufacturers.There has always been a tradition ofinnovation in the food and drinkindustry, but at a time when belts arebeing tightened and a sense ofconsolidation means smaller companieshave to try harder than ever before tomake an impact, it’s never been moreimportant to help research, develop andimplement new products, markets,services and processes. As organisationssuch as Datel point out, companies alsoneed to improve and innovate in theirmethods to improve the standards andprofessionalism of production, makingsure their products are of the highestquality and integrity.Companies that continue to innovatearen’t just benefiting from increasedinterest in their products. A host ofgovernment-backed schemes aresupporting companies on an internationalscale – aware that advancedmanufacturing techniques are a highlyvaluable commodity for a nation toexport. Businesses that can illustrate newThe Beneo-Technology Centre brings together thecompany’s food application and technical expertise toenhance and encourage product innovationThe future’s bright2012 has certainlybeen a successful yearfor many of theindustry’s leadingnames – butinnovation is key in thefood and drinkindustry.22 21-23:Layout 1 16/11/12 10:47 Page 122www.fdiforum.netINNOVATION SPOTLIGHTand innovative techniquesare therefore likely toenjoy huge incentives,allowing them tointroduce their ideasworldwide. It’sparticularly valuablefor food and drinkcompanies to emphasisetheir innovatory naturedue to the obviousrequirement to introduce newtalent to the sector.The existing employees in the food anddrink industry are, of course, highlytalented, but no industry succeeds bystanding still and a steady stream of newemployees are required to replace thoseretiring and bring newideas and concepts tothe sector. Schemessuch as the UK’sSee InsideManufacturing areemphasising theadvantages ofadvancedmanufacturing to awider audience andshowcasing it as a viable andvaluable destination for school leavers.As Melanie Leech, Director of theFood and Drink Federation, points out,“Food and drink businesses are workingwith young people to get them interestedin our sector. We know that to stayworld-class and to deliver our sharedvision with Government of 20% growthby 2020, we will need to attract the besttalent and FDF is tackling this throughour Taste Success – A Future in Foodcampaign and involvement in initiativessuch as See Inside Manufacturing.”Companies such as Nestle, Mars andBritvic are among those who haveorganised events and open days as part ofthe scheme.Indeed, many of our more innovativecompanies are cultivating strong linkswith educational establishments – andnot just to locate potential newemployees. Many are working with theirscience and technology departments tocreate new ingredients that can bringBritvic is one of the manufacturers involved in the UK Government’s SeeInside Manufacturing programme encouraging new talent to enter theindustry, and Minister Norman Lamb visited Britvic’s Robinsons factoryin Norwich along with schoolchildren to witness its workCompaniesthat continue to innovate aren’t justbenefiting from increasedinterest in their products. A host of government-backedschemes are supportingcompanies on an international scale21-23:Layout 1 16/11/12 10:47 Page 2INNOVATION SPOTLIGHTwww.fdiforum.net23ERP SOFTWAREIs traceability aheadache you’d liketo eliminate?Food and drink manufacturers across the UKare struggling to comply with retailers’challenging timescales for traceability – justfour hours in many cases. A recent survey of nearly 250 senior decision makers in theindustry showed that almost half find traceability a problem...* 26% of respondents cannot identify product recall itemswithin four hours* 11% would take over a day to supply the details * 10% are unable to identify product recall items at all The full report is available free of charge by emailingenquiries@datelgroup.com.How quickly could you provide full batch and lot backwardsand forwards traceability details on the products you supply, oractivate a product recall? Your commercial relationships andreputation will be irretrievably compromised if you can’t complywith a traceability request, while a badly managed recall couldcost your business millions. Ease the burden of complianceDatel helps food and drink companies to implement ITsolutions that automate the processes involved in meeting theirstatutory and commercial obligations around traceability. Datelinvite you to find out why they have been chosen by leading foodand drink companies such as Nichols, Jupiter Marketing, EuroFoodbrand Exports, Ruskim Seafoods and Xpress Fish. Visit Datel atwww.foodanddrinksoftware.com or call them on 0845 521 1875.new products onto thesupermarket shelves.One example of thesetwo sectors working togetheris the Food and Drink iNet,part-funded by the EuropeanRegional Development Fund, which co-ordinates innovation support for businesses, universities andindividuals working in the food and drink sector in the UK’sEast Midlands. It has developed an effective network toencourage the collaboration of academic expertise andknowledge, and local food and drink business innovationneeds.The iNet’s Innovation Awards for 2012 have just beenpresented and many of the nominees illustrate thiscollaborative spirit in action. For example, a collaboration ofthe Universities of Northampton and Nottingham alongwith Stichelton Dairy in Nottinghamshire focused on thearoma development and influence of secondary microflora inblue cheese production, with the aim to enable anunderstanding of the variants that can influence theconsistency of cheese production.Many major companies are reaping the benefits ofinvesting in innovation. Functional ingredientsmanufacturer Beneo, for example, have enjoyed greatsuccess over the last year or so with the creation of itsBeneo-Technology Centre, which brings together thecompany’s food application and technical expertise toenhance and encourage product innovation within thevarious sectors. It also co-operates with partners from acrossthe food industry, including machinery suppliers, flavourhouses, experts in emulsifiers and stabilisers to bring widerapplication knowledge to itscustomers.Its worth can be illustratedwith the herbal flavouredsugar-free candy it nowproduces using ISOMALTwith Stevia. By combiningthese two ingredients, Beneohas been able to achieve aproduct that has a roundedsugar-like taste and alsoprovides nutritional and healthbenefits. Specialists at the Beneo-Technology Centre have worked closelytogether to overcome the challenges related to formulationswith Stevia.Investment in innovation is the only guaranteed way toensure companies continue to succeed in 2013, and in manyyears to come. Blending new ideas with a company’s existingreputation for quality is an unbeatable combination.Manymajor companiesare reaping thebenefits ofinvesting ininnovationInvestmentin innovation is the only guaranteed way to ensure companiescontinue to succeed in 2013, and inmany years tocome21-23:Layout 1 16/11/12 10:47 Page 324www.fdiforum.netWAREHOUSING & DISTRIBUTIONCertainly, as the food and drinkindustry undergoes furtherconsolidation, the challenge is toprocess orders faster than ever before,while not compromising productintegrity, as well as often dealing in muchsmaller spaces without the productsthemselves becoming damaged or lost.The new breed of warehousemanagement and distribution tools,however, are ensuring completetraceability throughout the entire process.Each item can be monitored, traced andaccounted for at every step of the way –and records of all these transactions canbe easily made available, which is nowoften required by retailers in any case, aswell as customs and excise.Companies can therefore make use ofsolutions such as the LocateIT WMSfrom Clydebuilt Business Solutions. Thisis currently being used to help fulfil thecontract Premium Warehousing havelanded with Carlsberg. From the momentthe goods enter the warehouse, Premiumuse the monitoring tools within LocateITto keep track of BBE data, batch and theABV measures for each beverage. This isstored in a paperless system that updatesin realtime and can be interrogated bywarehouse managers and customers atany time.Companies such as System Logisticsalso provide valuable warehousemanagement solutions, and are alsoassisting companies in providing newautomated solutions to deal with theissues of space that can often proveproblematic for companies. At theforthcoming ProMat show in Chicago,they will be showcasing the latestaddition to the MODULA line ofThe RTITB’sOperator of the Yearcompetitionpromotes andrewards best practiceRunning smoothlyThe quest for improved warehouse management and effective distribution continuesThe complete truck at your serviceFor further information please call 01844 215501 or email sales@atlet.co.ukwww.atlet.co.uk24-26:Layout 1 16/11/12 10:23 Page 1WAREHOUSING & DISTRIBUTIONwww.fdiforum.net25Vertical Lift Modules, the Sintes1.Developed as a flexible and cost effectiveway to enhance picking and storageoperations, the module allows companiesto save up to 90% of their floor space. Itsflexibility allows for a seamless transitionfrom static storage methods to a fullyautomated, full featured vertical storagesystem.Energy efficiency is taking on increasedimportance for distribution facilities – inaddition to the benefits in terms of costsavings, many companies now requirethat their partners reach the higheststandards in this regard. A recentenvironmental survey by Atlet hasillustrated the changes that warehouseoperators can make to improve theirefficiency – and perhaps surprisingly, theactual production of the trucks beingused in warehouses is a less importantfactor, compared to how it is actuallydriven and operated.The study considered the truck’senvironmental impact throughout itscomplete life cycle and was performedaccording to the Eco Indicator 99method. The results that around twothirds of the truck’s impact on theenvironment is connected to energyconsumption during use, while transportrelated to servicing of the truck equatesto 29.5%. Håkan Ek, Business AreaManager at Atlet AB, says, “Our ownanalyses show that energy consumptioncan vary by up to 50% between different26 The four main accrediting bodies for fork lift safety in the UK – AITT,ITSSAR, NPORS and RTITB – have agreed to form the AccreditingBodies Association24-26:Layout 1 16/11/12 10:23 Page 226www.fdiforum.netWAREHOUSING & DISTRIBUTIONPremiumWarehousingPremium Warehousing hassecured a contract originatingfrom national brewer Carlsberg.LocateIT WMS from ClydebuiltBusiness Solutions has beeninstrumental in the deal, catering for the Excise requirements forHMRC.Storing up to 18,000 pallets of various products under bond,Premium will be doing all picking and distribution of goodsincluding to various retailers throughout the UK. From the moment the goods enter the warehouse Premium willuse the monitoring tools within LocateIT to keep track of BBEdata, batch and the ABV measures for each beverage. The fullrange of warehouse transactions are performed by Premium, andwhen the product is picked to fulfil an order for delivery to a non-bonded environment it will be released from bond. As a result, all associated paperwork is created automatically,including the daily W5D return and monthly W1. Not only willthe service provided by Premium delight the customer, it providesthe meticulous detail required by HMRC along with completetrack and trace - keeping the tax man happy too.Warehouse efficiencies and total accuracy is maintained via theLocateIT real time paperless warehouse processes operated by thestaff through the RF infrastructure. Electronic interfacing withthe customer’s back office system ensures minimal administrationon either side whilst giving instant visibility throughout thecontract enterprise.While many companies are still tightening their belts it isheartening to know that the users of LocateIT WMS arecontinuing to expand by winning new contracts. This illustratesthat thoughtful and careful investments with working solutionsprovide a real tangible return on investment.Clydebuilt Business Solutions, 6 Orr Square, Paisley, PA1 2DL Tel: + 44 141 847 1920 Fax: + 44 141 889 7962www.clydebuiltsolutions.comdrivers performing the same task. Our solution is to offerindividual truck performance settings and follow-up of how theenergy is being used.”These figures suggest that creating a more effectivelywarehouse layout and management system can make all thedifference. Atlet have contributed to this by assisting theircustomers with optimised warehouse layouts and drivingdistances. For example, they suggest that a simple measure likemoving a printer within a warehouse can lower truck energyconsumption by as much as 20%. Of course, ensuring the trucksare regularly serviced and that they are the most energy efficientavailable will make a major contribution to cutting costs andemissions – hence the move towards modular construction oftrucks that have as few moving parts as possible so maintenanceis minimised – but a more strategic view of the make-up andorganisation of the warehouse can provide instant savings withthe minimum of effort.Ensuring drivers are aware of their obligations will also have amajor benefit – not just in a more efficient approach but also toavoid potential safety flashpoints. Entries are now being soughtfor the RTITB’s Operator of the Year competition whichpromotes and rewards best practice, which will be a majorattraction at the IMHX show in Birmingham in March.Major companies are supporting the event, including Toyota,and Tony Wallis of Toyota Material Handling UK says, “Driveroperation is still one of the main causes of accidents and damageto goods and as which is a continuous cost to businesses. Theoperator of the year competition is a fabulous opportunity tocelebrate safe working and recognise excellence within ourindustry, among those that regularly take a backseat but withoutwhich, many business operations could not be completed.”Meeting best practice should be made easier in the future asthe four main accrediting bodies for fork lift safety in the UK –AITT, ITSSAR, NPORS and RTITB – have agreed to form theAccrediting Bodies Association. The agreement covers thestandards to which the training providers will have to adhere, themethods of monitoring to be applied by the relevant bodies, andthe future registration of operators by the training providers –with the aim to bring clarification for future training and testingof all workplace transport operators.Changes to warehouse management should ensure a faster-moving, more efficient sector that isn’t compromising on safety.Increasedconsolidationhas led towarehousesmaking moreeffective use ofspacePHOTO COURTESY TGW24-26:Layout 1 16/11/12 10:23 Page 3VISION, INSPECTION & DETECTIONwww.fdiforum.net27According to the UK’s Food StandardsAgency, there was an increase in thenumber of food incidents it investigatedlast year. These included reports of contaminatedor illegal food entering the food chain, with somepotentially harmful to the public. 1714 foodincidents were investigated by the FSA last year. No single reason has been identified for theincreasing number, but the FSA believes acombination of factors is behind the rise. Themost likely is improved monitoring andreporting, so at least companies’ standards aremarginally shifting.Tim Smith, Chief Executive of the FoodStandards Agency, says, “Keeping food safe isthe FSA’s priority and investigating foodincidents is a key part of that. Our annual reportgives a real insight into the vital role we play inprotecting the food chain from a wide range ofrisks. “The UK has some of the most robust foodsafety safeguards in the world. When suchincidents do occur the food industry, the FSA,other government agencies, and enforcementofficers locally, work quickly to isolate any risksand remove affected products from our shelves. Ihope this report gives consumers confidence thatour systems are working and working well.”One common problem seems to be metaldetection. Shards of metal can shear off olderequipment during the production process andeven microscopic grains can make their way intothe product. New machinery can detect even thesmallest particles and alert operatives to therejected products easily. Some systems can evenremove the product automatically, thus savingtime with use of magnets.These detection systems are increasinglybecoming more bespoke too. A one size fits allapproach rarely works in automation anddetection is no different. An oil bottling plant inKent recently had a line installed that includedsophisticated metal detection technology, but as29 Monitoring products, particularly if itis fresh, is integral to maintainingsafety and profit marginsPHOTO: JENTON INTERNATIONAL/ALAN HUNTER PHOTOGRAPHYOn closer inspectionContamination of products with foreign objects or irregular elements is unacceptable.Thanks to vision systems and other innovative technology, it is becoming easier to avoidcompromising products or entire batches.27-31:Layout 1 16/11/12 10:55 Page 127-31:Layout 1 16/11/12 10:55 Page 2VISION, INSPECTION & DETECTIONwww.fdiforum.net29the line dealt exclusively with glassbottles, breakages were aproblem when rejections weremade. As a result, the line wasdesigned to eliminate therisk of downtime caused bybreakage or spillage andfeatured a purpose-builtreject mechanism for thesafe handling of uncappedglass bottles filled with specialityoils and vinegars. This detection processwas seamlessly integrated between thefilling and capping process, meaningcontaminations were taken out at the lastpossible moment, wasting as little time aspossible.More metal detection machines arealso appearing which can deal with wetor more conductive products, meaningenhanced safety standards and betterlevels of detection. This is thanks toimproved methods that have almosteliminated what is known as the ‘producteffect’ where electrical signals picked upby the products previously interferedwith the incredibly sensitive detectiontechnology being used at present.X marks the spotPassing products through x-raymachinery has been common for yearsnow and there is noted investment indeveloping the technology. Findingcontaminants such as ferrous andnon-ferrous metal, glass, stone,bone, plastics and rubberwithin your products is aconcern, but being able tosee through the product ineffect can avoid anyunfortunate surprises onconsumers opening productsor foodservice clientssuffering embarrassing andcostly upsets. Newer x-raytechnology also means elements likefill level, seal integrity and packagingelements can be inspected. If a section ofpackaging is defective for example andhas already been filled, technology likethis could step in and remove potentiallyunsafe products.Getting the right lookOne interesting development withinvision systems is colour and packagingintegrity issues being addressed.Label legislation is becoming more fierceover time. There exists an increaseddemand not only from industry regulatorsbut also consumers to give informationthat clearly states nutritionalinformation, instructions onrecycling and facts on origin,price and allergies. With regards to this,more companies are usingtechnology that is able totrack barcodes and 2Dmatrix codes to improvetracking and tracingcapabilities. Knowingaccurately how many productshave left a facility with theirlabelling is integral should issuesarise further along the supply chain. Itmeans that logistics companies, retailersand consumers can be sure of where theproduct has come from and when. Thisnot only offers peace of mind, but cantighten operations too.Affixing vision or detection systemsto weighing equipment is somethingmore manufacturers are also takingColour disparity is somethingthat can damage a product’sreputation if it is notregulated, in-line camerascan help with thisPHOTO: COGNEX30 Sensors and label readers can track productseven at the palletised stage of a product’s life,not just in their individual packets.Newerx-ray technology meanselements like filllevel, seal integrityand packagingelements can beinspected.MASTER MAGNETS LTDIncorporating Metal Detection LtdBurnt Meadow Road, North Moons Moat, Redditch, Worcestershire B98 9PATel: +44 (0)1527 65858 Email: info@mastermagnets.co.uk27-31:Layout 1 16/11/12 10:55 Page 3Next >