< Previous30www.fdiforum.netVISION, INSPECTION & DETECTIONwww.olympus-ims.com/en/hsv-products/Olympus is pleased to introduce the Cyclocam high-speed video camera which is ideal for the manufacturing industry. See the effect of adjustments to your production line process live in high-speed.Functions include:ŘLive slow motion playback of the high speed eventŘPortable and easy-to-use, with built in displayŘAdvanced trigger techniques for different applicationsinfo@olympusindustrial.euadvantage of. In some cases they are also purchasingweighers with such equipment fitted as standard, shrinkingthe space taken up by the separate machines. Weighers thatcombine precise weighing, marking and vision verification ofbatch and bar codes are incredibly useful. They often usesmaller versions of existing vision systems which can alsooffer productivity reports, giving live feedback on howproduction processes are progressing and the option tocompare with previous sessions.Colour inspection cameras fitted in-line can also flag uppotential mistakes. Take a product to market that ismarkedly different from previous batches in terms of colourtone and vitality and it could negatively impact not only onimmediate sales, but reputation with both retailers andconsumers alike. Colour verification systems often havepalettes that run to thousands of shades of colour so if thecorrect pantone can be ascertained, then alerts will flag upmistakes in colour or shade that might exist. Often thesesystems also allow for light changes, meaning that evendisruptions in natural light or different light sourcesentering the area do not affect the detection of the correctcolour for your brand. In relation to light too, light curtains are one element thatplay a part in safety on the detection side. Manufactured bymost of the inspection companies, they are often used toprotect workers from potentially dangerous situations wherethe risk of being caught up in moving machinery or extremeX-ray technology now means that even products likecheese can be inspected safely and with more accuracyPHOTO: METTLER TOLEDO27-31:Layout 1 16/11/12 10:55 Page 4VISION, INSPECTION & DETECTIONwww.fdiforum.net31A smart wayto inspect foodThe BOA from Stemmer Imaging’s rangeof smart cameras is an ideal vision systemfor food inspection applicationsCompletely self-contained, BOA hasall the hardware andsoftware needed toproduce and processhigh quality images,make measurementsand output the resultsinto a process controlsystem – all in real time.This makes it ideally suitedfor single point inspectionapplications.With a choice of monochromeor colour sensors, sensor resolution and a range of differentsoftware capabilities, BOA can be used to improve productquality and prevent substandard items passing to the next stage ofproduction.Applications can involve checking parameters such as shape,size and position. For example, for cooked and processed foodssuch as biscuits, flour tortillas and pizzas, smart cameras can beused to check for incomplete product, diameter, size and shape,edge defects, holes, burnt product, the correct presence anddistribution of pizza toppings and more.However, BOA is not restricted just to measurements on foodproducts themselves, it can also be used for product label andmarking inspection. Code-reading capabilities allowmanufacturers to combine 1D and 2D tracking with otherinspection tasks, such as character reading and featureverification, to ensure all product markings are correct when theyleave the factory floor. Simple integration into the factoryenvironment is guaranteed through built-in ethernet and RS-232connectivity, discrete and expandable I/O and vision lightingcontrol.In addition, at just 44x44x39mm, it can fit into very smallspaces with mounting holes on all sides for maximum flexibility.The IP67 rated housing makes it suitable for washdownenvironments without a protective enclosure.For more information, call +44 1252 780000,email info@stemmer-imaging.co.uk or visit www.stemmer-imaging.co.uk.CWF CheckweigherPerfect weighing ofpackaged goodsCheckweigherCWEMetal detectorBVS (Bizerba VisionSystem)A camera supportedinspection system toensure product safetyProduct InspectionSystem X-RayBizerba UK Limited, 2-4 Erica Road, Stacey Bushes, Milton Keynes, MK12 6HS01908 682740 info@bizerba.co.uk www.bizerba.comscan using yoursmart phone or visitwww.bizerba.comtemperatures is present. A recentboost in sensitivity means that evena finger in the wrong place cancut power immediately toharmful machinery. The‘curtains’ work by surrounding amachine with a veil of light orsensors, being fed informationabout the products’ shape, sizeand dimensions. Not only areoperatives limbs and bodiesprotected, but anything extraneousand unwanted within or attached toproducts can be flagged up before beingwrapped or palletised.The key element that food and drink manufacturers need totake away is that no amount of pre-checking can be too much.The compromises far outweigh the inconvenience of installingsuch machines. A product recall is PR death for most companiesand the fines that can be imposed can be hugely damaging toyour bottom line. Small companies risk losing importantcontracts and larger firms are distinctly more visible to the pressand public eye, so it pays to be extra careful. With productionrates being as fast as they are, often producing thousands ofunits per hour, letting a significant amount leave withoutadequate checks could well be foolish and result in long-lastingharm to both perception and profits.The keyelement thatfood and drinkmanufacturersneed to take awayis that no amountof pre-checkingcan be toomuch27-31:Layout 1 16/11/12 10:55 Page 532www.fdiforum.netVISION, INSPECTION & DETECTIONDairy Crest, Davidstowproduces over 48,000 tonnes ofcheddar cheese per year in 20kgblocks, 80% of this being thewell-known Cathedral Citybrand. The 20kg blocks arevacuum sealed to prevent airleaking into the cheese prior tothe 12-18 month maturationcycle.The AutoCoding visionsystem identifies vacuum failureson the sealed 20kg blocks. Thesystem comprises a cameradriven software application thatanalyses the reflected light fromthe surface of the vacuum sealedcheese block and rejects theblock if it doesn’t meet thedefined criteria. Reports aregenerated which give the totalnumber of blocks through thesystem, the number of sealfailures and an analysis of theefficiency of the sealing process.This enables Dairy Crest tomonitor and identify potentialproblems with the sealing andpacking process.The AutoCoding visionsystem replaced the original “inhouse” system that had beenrunning in the factory for almostten years. With over 120 tonnesof cheese going along the lineeach day, the system had to beproduct. We now have anefficient and reliable systemwhich gives us meaningfuland useful data which allowsus to continually improve oursealing and packing process.In addition, we have beenable to refocus one of ourProduction Line Operators onother tasks rather thanchecking for failed seals.“Having worked onprevious successful projectswith AutoCoding Systems, wehave built up a strongbusiness relationship and wewere, therefore, confidentthat they could deliver thequality and reliability werequired with this newsystem.”For further information, visitwww.autocodingsystems.comor call 01928 790444.The image captured by the camera compared to the actual cheese. This pack would passsuccessfully. If the number of green highlighted areas drops below a defined threshold, thepack would fail as it would indicate that the seal had broken and air had entered the packGreat vision fromAutoCoding Systemsand Dairy Crest,Davidstowefficient because even a smallpercentage of cheese blocks withbroken seals would result inmould growth during thematuration period. Theresulting cost of recovering anycontaminated cheese would bequite significant. Based on previous successfulprojects with AutoCodingSystems, Dairy Crest approachedthem again to help develop asystem based on the obsoletemethod.Initially, AutoCoding facedchallenges such as variations insize, colour and surface textureof the cheese blocks making itdifficult to adjust the camera andimage processing to capture alldefects, whilst not resulting in afalse alarm for good seals.Achieving the correct balancebetween success and failure wascritical.Neil Flood, AutomationEngineer at Dairy Crest, says,“We are already reaping thebenefits of the system in termsof cost savings. Any blocks ofcheese with faulty seals thatslipped through our old systemand were stored for maturationwould result in us having todowngrade contaminatedThe 20kg cheeseblocks pass througha stainless steelcamera housing andare photographedThe camera ismounted in astainless steelhousing AutoCoding Systems and Dairy Crest, Davidstow are nostrangers when it comes to developing applications to meetspecific requirements. They have recently worked together todesign a vision system which analyses and identifies vacuumfailures on sealed packs of 20kg blocks of cheese.32:Layout 1 16/11/12 10:24 Page 1ANAEROBIC DIGESTIONwww.fdiforum.net33As waste management is a relativelyhot topic in the food and drink industryand is likely to come under increasedscrutiny. The industry is responsible for ahuge amount of the total waste producedand is therefore most at risk from finesand poor publicity caused by ineffectivewaste management.Many companies are taking theopportunity to make better use of theirwaste products rather than simplyoffsetting the responsibility of its removaland management to a third partycompany. In the latter instances,companies are charged for the removal ofthese materials, the manufacturer has noaccountability and the waste couldpotentially end up in landfill. A farbetter option is obviously to introducemore effective waste management policieswhich not only reduces resources sent tolandfill, but can also provide foodmanufacturers with income – and that’sespecially the case with anaerobicdigestion. Indeed, landfill tax onbiodegradable waste is increasing – in theUK it is currently £64/t – making gatefees for AD more and more competitive.The subject will be debated at thismonth’s Anaerobic Digestion and BiogasAssociation’s National Conference,which will feature numerous illustrationsof the benefits companies have receivedfrom the recycling of their wasteproducts. In anaerobic digestion,microorganisms break downbiodegradable material and turn it intoenergy, and governments are emphasisingthis as an ethical and effective way ofmaking money with saving energy. It is ofparticular relevance to the food and drinkindustry as the cost of anaerobicdigestion drops with increasing scale ofoperation, so it is most cost effective forlarger manufacturing facilities whichproduce many tonnes of food waste eachday.The introduction of AD throughoutthe industry has been rather slow,however, and Charlotte Morton, theChief Executive of ABDA, says, “Theindustry has suffered from a lack of R&Din key areas to date. Recognising thedifficulties facing the sector we decided towork with our members and the widerindustry to put together an AD R&DStrategy to help drive focused ADresearch and development and identifyThe Anaerobic Digestion andBiogas Association, organisers ofthe successful UK AD and Biogasshow, will be considering thecurrent state of the sector at thismonth’s National ConferenceAD energises the industryGovernment support and increased interest in energy efficiency mean anaerobicdigestion is becoming a more mainstream proposition35 33-36:Layout 1 16/11/12 13:19 Page 1Corrugated tube heat exchangers Scraped surface heat exchangersTurnkey processing plants Plate Heat Exchangers Piston PumpsTube in tubeTriple tubeMulti tubeScraped surface PlateFOOD SYSTEMS:HRS is able to combine its products into complete processing plants.Thanks to our experience of over 20 years in the market we can offer ourcustomers a wide range of modular system solutions, suitable for the mostcommon scenarios.The core of the system solution that HRS offers is the thermal treatmentsection: any kind of heat exchanger combination can be used for obtaining the best result for the pasteurisation or sterilisation process. Theheat treatment sections can be combined with other process steps such ashomogenisation and deaeration. Efficient system integration of pumps,tanks, heat exchangers, aseptic fillers, piping, controls and other equipment lead to complete solutions for the food processing industry.The HRS scraped surface evaporator forconcentration of environmental waste aswell as juices, fruit and other food productsContact Michael Adkins at HRS for more informationT: 01923 232335 michael.adkins@hrs.co.uk www.hrs.co.ukENVIRONMENTAL WASTE EVAPORATION-CONCENTRATION:Evaporation is an effective way of reducing the impact of environmentalwaste. It is a Thermal process where energy is invested to separate waterfrom the effluent, thus reducing its volume. The evaporated water, whencondensed, can be reused again. In environmental processing the effluentis often a fouling substance. Normal Evaporators would have a limited operation time between stops for cleaning. HRS has overcome this problemby applying the Unicus scraped surface evaporator. The scraped surface means constant removal of fouling which maintains theconstant evaporation capacity. The Unicus can evaporate to very high levelsof concentration.www.digestateprocessing.cominfo@digestateprocessing.comHRS Heat Exchangers offers a wide range of heat exchangers for hygienic processing in the food industry:33-36:Layout 1 16/11/12 13:19 Page 2ANAEROBIC DIGESTIONwww.fdiforum.net35and fill gaps in knowledge, avoidrepetition, provide better return on R&Dinvestment and allow better exploitationof existing knowledge.”The UK government’s AnaerobicDigestion Strategy and Action Plancontinues to monitor the state of playand reports a large increase over the pastyear in plants that treat food waste –with a total of 78 AD plants operating inthe UK in June of this year. The strategydoesn’t set any targets but instead offersbest practice advice to interested parties.The plants are often the result ofcollaboration between business and localauthorities and many are offering obviousbenefits to both manufacturers and thewider community.For example, the Agrivert plant inOxfordshire treats food waste from theOxford Waste Partnership – apartnership between six local authorities– as well as waste food from bothretailers and manufacturers. Agrivert’s45,000 tonne capacity site generates2.1MW of electricity, enough to power4200 homes in the local area.Meanwhile, the Blackmore Vale Dairysite in Dorset is an example of a foodprocessing business seeing the financialbenefits of using AD to treat the wastegenerated on site. Manufacturing dairyproducts from over 35 million litres ofmilk every year, BV Dairy chose to usean onsite AD plant to reduce the highcosts of discharging waste liquids to thesewer. Now the load has been lightenedat the local water treatment works,freeing up capacity for new housing inthe area, and BV Dairy are enjoyinggreatly reduced energy bills.AD is certainly considered to be amarket with great growth potential, andit’s likely to become an increasingmainstream proposition, with localauthorities and commercial operatorsbeing more competitive on gate feeswhile also stimulating investment intothe sector by offering longer termcontracts. Companies such as Wehrle are alsooffering a number of exceptional systemsto major companies in the sector. Theyare supplying a state-of-the-art solidsseparation and digestate treatmentsystem to AgriGen using its MembraneBioreactor technology. AgriGen’s currentanaerobic digestion facility processes40,000 tonnes of maize per annum andtheir plans are to expand this to 60,000tonnes in the next two years. In thefuture, the AD system will produce 2.5MW of renewable energy.Commissioning of the plant will takeplace in the first quarter of 2013.The introduction of anaerobicdigestion can make a large impactalthough its individual results will varydepending on the system and its use. Forexample, at Heineken Spain’s brewery inSeville, a change was made to theanaerobic digestion process as, initially, itdidn’t perform as well as expected – theinoculated sludge developed an unusualappearance and didn’t grow. The brewerstherefore used the analytical servicesupplied by Omex Environmental toevaluate the composition of thewastewater. In the case of breweries, there isusually an excess of carbon, hydrogen,oxygen, sulphur and the macronutrients,36 At Heineken Spain’s brewery in Seville, a changewas made to the anaerobic digestion process as,initially, it didn’t perform as well as expected33-36:Layout 1 16/11/12 13:19 Page 336www.fdiforum.netANAEROBIC DIGESTIONand the latter two may have to be removed by a separate process.There is often a shortage of others such as minerals and essentialtrace elements – those elements required as cations in minutequantities but indispensable to the proper function of themicroorganisms. Sometimes these elements aren’t present in thewastewater, so trace element addition is a usual practice forindustrial anaerobic effluent treatment in Europe.Safeguarding tomorrow’s food and energy securityFood and drink businesses interested in learning more aboutthe versatile renewable can find out more at the AnaerobicDigestion and Biogas Association’s National Conference, held atOne Great George Street in London on Wednesday 12thDecember, which focuses on “AD: Safeguarding tomorrow’s foodand energy security”.Including discussions on AD’s role in creating a closed loopeconomy and the best use of resources, the conference’s morningsession addresses the key drivers for AD and its importance tosectors such as the food and drink industry.Following the morning’s high level debate, delegates will havethe opportunity to join topical discussions in four breakoutsessions, covering the value of food waste, the use of biomethaneas a transport fuel, gas to grid and creating markets for digestate.For any food and drink business already involved or looking toget involved in AD, this event provides the opportunity to learn,influence and network with the who’s who of the AD industry.At the event, Steve Wallace, Director at Aldersgate Group,discusses “A closed loop economy: the best use of resourcesthrough reuse and recycling of food waste”. Justin Laney, GeneralManager Central Transport at The John Lewis Partnership,considers biomethane as a transport fuel, and the BBC’s JulianO’Halloran introduces “Making the most of limited resources:delivering the ‘huge increase’ in a deficit constrained economy”.There will also be a panel discussion on the value of food wastebetween Richard Barker, Chief Executive of Biogen, StuartHayward-Higham, Development Director of SITA UK and BillElliott, Business Development Director of Tamar Energy.Find out more about this event at www.adbiogas.co.uk.Professor Martin Tangney is Director ofthe Biofuel Research Centre in Edinburghwhose aim is to assist wherever possiblein introducing sustainable biofuels andbioenergy from renewable resourcesModular design andintegrated processesfrom WEHRLEOver the past decade, the food and drink industry has identifiedthe value inherent in its waste and wastewater and has movedtowards more sustainable technologies, such as anaerobicdigestion, which harness this value and provide a source ofrenewable energy. Since the early nineties, WEHRLE, along with leading researchinstitutions, have been continuously developing a suite oftechnologies to extract the maximum value from waste andwastewater. The company’s Kahlenberg anaerobic digestioninstallation was the first of its kind to utilise extended solidsretention, reducing reactor sizes and maximising biogas output. With tighter regulations, a need to reduce carbon footprints andsoaring energy prices, WEHRLE’s modular designs have beenproven as Best Available Technology by many environmentalagencies worldwide. Over fifty highly skilled engineers cancombine a range of technologies to offer individually tailoredtreatment concepts, which not only meet current demands but alsohelp avoid future problems.WEHRLE has been recognised as one of the world’s leadingproviders of turnkey wastewater treatment systems. More thanthirty years of project management experience ensure WEHRLE arean ideal partner to help end users extract maximum value from theirwaste and wastewater. WEHRLE have extensive process experiencein maximising biogas yields, water recycling, nutrient recovery fromdigestate, heat management and membrane filtration. With over 180 installations worldwide, WEHRLE havesuccessfully deployed its comprehensive range of treatmenttechnologies across all food and drink sectors. From Kelloggs andUnilever in the UK, to Ambev in Brazil, to Fonterra in NewZealand, WEHRLE have been providing unique processes to helpcompanies achieve their environmental commitments. For more information, visit www.wehrle-umwelt.comor call +44 1865 733 36033-36:Layout 1 16/11/12 13:19 Page 4MIXING AND BLENDINGwww.fdiforum.net37Findingthe rightblendA new generation of mixing andblending equipment is enablingcompanies to deliver products inshorter lead times and to a higherstandard.Technical innovations in the mixing and blendingoperation has continued at a pace. Smoothness ofconsistency and texture through a product is oftenthought of as standard, but the innovation behind this isfascinating. Use of methods such as aeration and usingcombinations of rotors and stators to ensure every lastmolecule is mixed perfectly ensures uniformity of product,not least in the bakery sector. As a sector that has huge production runs, a product usingliquid or mixes that do not have properly-producedproperties can taint a whole batch. Precise measurement andtiming is essential, so the mixture needs to be perfect oncethese elements have been delivered by dosing or weighingmachinery. With pastry or cake products in particular, thechallenge is often in the suspension of ingredients such asfruit or chocolate chips. Because the batter used for thesekind of products is prepared in liquid form, creating aconsistency where particulates such as the fruit do not dropto the bottom of the mixers used is a real problem. Creatinga batter sufficiently thick as to suspend these elements, butnot so thick that it will be tough and hard to eat, can becombatted with adequate aeration and using shears atdifferent points.Microscopic differenceGetting down to a microscopic level within mixing and38 A cutaway of a batchmixer, featuring an in-tankhigh shear mixerPHOTO: SILVERSON37-39:Layout 1 16/11/12 10:59 Page 138www.fdiforum.netMIXING AND BLENDINGblending is important. Having an impact ondigestibility can depend on how a product isengineered during the mixing process. Theways in which products full of starch areprocessed can have an impact on theirmechanical properties and the way they aredigested after eating. A study by the Pontificia UniversidadCatolica de Chile has suggested thatdifferent mixing or shearing rates producedifferent gluten microstructures. What thismeans is that the different structures canhave effects on the physical or nutritionalproperties. Higher levels of mixing werefound to promote higher levels of disruptionof the gluten by starch in products such aspasta or dough, giving the starch a moreeven or uniform distribution. This might seem elementary, butscientific proof on such an intimate levelillustrates that processing products in thisway is beneficial, both for the consistency ofFruit suspended within bakery products needs to be mixed to a good level of viscosity that allows thefruit to be even distributed and not stuck in machinery or destroyed altogetherPHOTO: ANNCOO JOURNAL BLOGmixingis our businessCreamsandOintmentsPaintsandResinsGelsSoupsandSaucesSalsaandDressingsEcoFuelsHigh Shear Mixersand Agitators37-39:Layout 1 16/11/12 11:00 Page 2MIXING AND BLENDINGwww.fdiforum.net39the product and the way in which it is digested. Those who canlatch onto health benefits or claims about digestion couldpromote a marketable element in their products. Along similar lines, scientific studies on the viscosity ofchocolate and investigating ways in which fat can be reduced insuch products has often taken into account the issue of mixing.Chocolate is often mixed during the cooling process to ensurean even consistency and this is a point at which chocolate withreduced fat can often become too viscous to work with. Theaddition of limonene, a citrus-flavoured oil, means fat content isstill kept low during mixing and shearing processes but viscosityis kept at an optimum level. A liquid solutionWhen blending liquids, balancing ingredients together is oftendifficult in vast quantities, but ensuring quality is becomingeasier. There are problems associated with blending someelements. One problem is the use of artificial sweetener, whichis small batches can be added simply to liquid and dissolved, butin large-scale outfits, some may not dissolve right away andheating might be required to avoid clumps of powder remainingwithin the liquid. Also, very fine powders might behavedifferently within water or other liquids, forming floatingparticles or ‘rafts’ on top of the liquid it is meant to be beingcombined with. Technology in the mixHighly adaptable mixing machinery seems to be the emergingtrend helping companies to innovate. From gentlehomogenisation of the most sensitive of bulk materials to thepre-dispersion of pigments and similar elements, mostmachinery providers will be able to deliver a bespoke machine,with only general purpose machinery left to more basicoperations. Use of small, high-speed rotating paddles, morecommonly known now as intensifiers, can also mean smallerquantities of liquids, waxes or chemicals can be seamlesslyblended into large powder bulks. Another impressive feature is integration of jacketed walls,meaning cooling or heating product as it is mixed is possible.Combined with a receptacle that is easily cleaned, this is surely aboon for those looking to maximise space. Use of these jacketedwalls can also mean the installation and use of vacuum dryingtoo, so wet or moist products that require drying can beprocessed along with other ingredients in the same rotation.This not only saves space, but also time ensuring you canamalgamate the process into fewer steps.It seems that any option is available thanks to adaptabletechnology for those wanting to streamline their productionprocesses or produce their own recipes on a large scale. Lookinginto this area could well be a huge opportunity to cut costs ifpre-mixed ingredients are being purchased and the option tomix or blend ingredients on site presents itself.Supremeefficiency inmixingIncreasing pressureson the bottomline call forefficiency savingsacross the board.The mixingprocess, centralto so much offoodmanufacturing,offers significantopportunities to reducecosts. Silverson high shearmixers are supremely efficient and can dramatically cut mixingtimes when compared to conventional mixing equipment. Thisadvantage stems from the positive mixing/shearing action of thedesign which draws materials into the work head, subjects them tointense high shear forces then projects them back into the body ofthe mix. In a short mixing cycle the entire batch will passthrough the workhead many times, ensuring a consistent,homogeneous product is rapidly achieved. The efficiency of Silverson mixers extends beyond the speed ofoperation, although this in itself reduces energy consumption.Many processes that are usually carried out at raisedtemperatures, or that require overnight soaking can be done atambient temperature, reducing heating costs and process time.An example is with sugar solutions, where a Silverson mixer canachieve a 66 Brix solution at ambient temperature; likewise manygums and thickeners that would otherwise require holding atraised temperatures until fully hydrated can be processed morerapidly with a resultant saving in energy costs. In-Line mixers offer additional advantages because whereas anin-tank mixer has two duties to perform – firstly the mixing taskitself and secondly circulation of the entire contents of the vessel –with an In-Line mixer, all the energy is concentrated on the smallvolume of product being mixed within the workhead area at anygiven moment. This means a relatively small mixer can process abatch that would otherwise require a more powerful in-tank unit.Silverson Machine Ltd.Waterside, Chesham, Buckinghamshire HP5 1PQTel: 01494 786331 Fax: 01494 791542Email: sales@silverson.co.uk37-39:Layout 1 16/11/12 11:00 Page 3Next >