< Previous40 Food & Drink Internationalwww.fdiforum.netVISION, INSPECTION AND DETECTIONRandom sampling ... Product Inspecon ... 100% Packaging Control...scan using your smartphone or visitwww.bizerba.comProduct InspeconSystem X-RayCWF CheckweigherPerfect weighing ofpackaged goodsBVS (Bizerba Vision System)A camera supportedinspecon system to ensure product safetyCheckweigher CWEMetal detectorBizerba UK Limited, 2-4 Erica Road, Stacey Bushes, Milton Keynes, MK12 6HS01908 682740 info@bizerba.co.uk www.bizerba.commaking a difference insuch places and we maystart to seeimprovements on thesupermarket shelvesas a result.Making it clearFood manufacturersare increasinglyinvesting incontaminant-detectionequipment to enhanceproduct safety and qualitycontrol. However, deciding whetherto purchase a metal detector, x-ray inspection system or both canbe confusing.Mettler-Toledo have recently released a white paper dispellingthe myths surrounding the two technologies and simplifies thechoice between them. By doing so, it helps manufacturers selectthe most appropriate contaminant-detection solution for theirspecific application and budget.The paper also describes how metal detectors and x-rayinspection systems work and explains their capabilities andlimitations. Knowing the strengths and weaknesses of thetechnologies helps readers understand why one may performbetter than the other at different points on a production line.The paper goes on to review the performances of thetechnologies across a range of applications and makes it easy forreaders to pinpoint the detection solution that is right for theirapplication by taking them step-by-step through the variouscombinations of product, packaging and contaminant they arelikely to encounter.To have this advice handy is helpful, but obviously eachautomated setup is not the same. This is the case even acrossdifferent production facilities under the same company banner.Regulation should always be kept to, but overegging the vision,inspection and detection pudding is sometimes needed as in thesesituations. Being safe really is better than sorry when you considerthe damage one rogue batch of product could do to not only yourreputation, but your bottom line.Below: Hygiene and being able to clean equipment quickly has beenaddressed with impermeable seals being added to many inspectionsystems, meaning they can withstand even pressure washesRight: Vision systems have become so advanced they simply don’thave to take up any room at allPHOTO: CAMOCHEMICALPHOTO: COGNEXSomesystems we’veseen recently havesolved the problem oflengthy conveyor beltchanges too byintroducing a quickrelease mechanism,mounted for operatorsafety38-41:Layout 1 15/11/13 11:00 Page 3Food & Drink International 41www.fdiforum.netVISION, INSPECTION AND DETECTIONNew infraredcameras fromSTEMMER IMAGINGSTEMMER IMAGING has boosted its range of infrared(SWIR & NIR) sensitive cameras with the addition ofnew models from Xenics, Allied Vision Technologies,IDS GmbH, JAI and Teledyne DALSA.These cameras provide a wide choice of resolution, sensitivity,waveband and other functionality, but it is their enhancedperformance in imaging light from the NIR region of the spectrum(700-1050 nm) and for the Xenics product SWIR (1um-3nm), thatallows them to reveal information in food inspection that cannot beobtained using conventional imaging.Infrared imaging is particularly important in the inspection offoods such as fruit, vegetables, nuts and meat, because NIR andSWIR radiation allows features below the surface of the object to beviewed, whereas standard cameras can only show surfaceinformation. This allows checks to be made for early signs of decay,mechanical bruising and pest damage below the surface. Thissubsurface imaging capability also offers the added benefit of beingable to check the contents under printed packages, giving allowing afurther quality check even after a product has been packaged.The new additions to the infrared camera range include both areascan and linescan models together with a choice of vision datatransfer interfaces and a rich array of features. This allows easyinterfacing into existing processing lines and ensures that the mostappropriate camera to be chosen for the particular application. For more information on all of STEMMER IMAGING’s products,call +44 1252 780000, email info@stemmer-imaging.co.uk orvisit www.stemmer-imaging.co.uk.Bytronic achieveCognex GoldPartner SystemIntegrator statusMidlands-based Bytronic Automation Ltd are celebrating beingnamed as the UK’s first Cognex Gold Partner SystemIntegrator. The award was achieved in September and Bytronicare only the 19th company worldwide to attain this status.The award, for partner involvement and performance, is based onthe commercial actions taken by Bytronic to reach their goals andturnover target and recognises the company’s advanced knowledgeof Cognex hardware and software offerings. Bytronic’s innovativevision system project planning and singular approach, together withgreat results and high standards, has enabled them to expand andcontribute to Cognex’s global success. To date, Bytronic have soldin excess of 100 Cognex systems during a partnership that hasspanned over eight years.Cognex is the leading machine vision systems manufacturer,offering complete turnkey solutions from feasibility studies, designand implementation of vision systems through to documentation,training and support. The Cognex Gold Partner System Integrator(PSI) Programme aims to provide customers with superior servicestandards, as both Cognex and Bytronic are 100% committed toresponding efficiently to queries, with both teams dedicated tosatisfying customer needs throughout the life of a project.John Dunlop, Bytronic’s Technical Director, says, “The award ofGold PSI status for Bytronic is a real testament to our on-goingpartnership with Cognex. We are now part of a prestigious groupof worldwide integrators that have a deep understanding of theproducts and a capability to design, build and deliver visionsolutions of the highest standard.”Tel: 01564 793174www.bytronic.com38-41:Layout 1 15/11/13 11:00 Page 442 Food & Drink Internationalwww.fdiforum.netINVALUABLE ADVICE FROM INDUSTRY SPECIALISTSMEET THE EXPERTAbbey Logistics Group Ltd is a Greener European Logistics Provider operating liquid tanks,powder tanks (silos) and palletised trailers (ambient & temperature controlled) throughout the UK andEurope.For more information on Abbey Logistics Group’sservices, call 0151 955 6515orvisit www.abbeylogisticsgroup.comon the road to a greener future42-43:Layout 1 15/11/13 10:49 Page 1Food & Drink International 43www.fdiforum.netAbbey Logistics Groupprovide greener innovative logistics solutionsAbbey Logistics Group operate liquid tanks, powder tanks and palletised trailers - ambient and temperature controlled - throughoutthe UK and Europe, and have won huge acclaim thanks to their commitment to high standards and energy efficiency. Operating over 230 trucks and 320 tanks and trailers across eleven bases, they are the leading names in food movement in the UK.They can provide bespoke solutions to meet all requirements – palletised products, liquids or powders, in any combination. Emphasisingtheir high standards, Abbey’s operations are accredited to global standards ISO9001, ISO14001 & OHSAS18001. One of Abbey’s major advantages is its innovative and efficient Twin Cargo Trailer, unique to the UK. It is capable of carrying 25tonnes of liquid in the bottom half of the trailer and returning with 26 pallets on the top half of the trailer – or vice versa.In addition to their core transport services, Abbey Logistics Group offer a silo/tanker evacuation service, a bagging/de-bagging servicefor powder products (rip & tip) and 10,000 sq m warehousing space in Merseyside.For more information call +44 (0) 151 955 6515 or visit www.abbeylogisticsgroup.comCompact bag-tipping station by Tetra PakDust-free manual bag tipping stationHighlights:• Dust-free • Easy cleaning • Vibrating sifter integrated • High standard of hygiene • Compact design • ATEX-compliantApplication:Tetra Pak’s compact manual bag-tipping station is specifically designed to manually dump any kind of powder received in bags. Theunit is suitable for bag sizes up to 25 kg. The specific design combined with an integrated sifter allows an end product free of foreignbodies (control sifting). In addition an optional integrated filtration system ensures a full sanitary process. The upper tilting part of theequipment facilitates easy cleaning of the vibrating sifter.Thanks to the high sanitary design, the compact manual bag tipping station is particularly suitable for the food, dairy, pharmaceuticaland chemical industries.Options include:• Integrated filtration system • Stainless steel 316 • Different sieve aperture diameters to meet different product requirements• Magnetic rod to prevent ferrous metal from entering the processFor more information, call +33 (0)241 632626 or visit www.guerinsystems.comRevolutionising food testingTwistDx is proud to expand its DNA Food Testing and Identification range with the release of TwistFlow®Red Snapper andTwirlaTMinstrument. TwistFlow®Red Snapper is a species authentication kit developed to solve the issue of mislabelled fish beingsold in place of the valuable Red Snapper fish. TwistFlow®Red Snapper is due for release 29th November 2013 and will be thecompany’s first, revolutionary, species authentication kit. TwirlaTMis a portable mixing incubator that prepares RPA reactions for end-point measurement. The TwirlaTMis small, lightweight, and has multiple power options and thus the perfect solution for field-use RPA. TwirlaTM is due for release 29th November2013.In response to the horse-meat scandal earlier in the year, TwistDx is also releasing two further species authentication kits early 2014for the detection of horse and pork DNA. Every kit utilises Recombinase Polymerase Amplification technology, a breakthrough alternative to PCR. RPA benefits from ultra-fast detection, single molecule sensitivity, little or no hardware requirements and simple to use, stable lyophilised reagents.Find out more at www.twistdx.co.uk42-43:Layout 1 15/11/13 10:49 Page 244 Food & Drink Internationalwww.fdiforum.netBULK INGREDIENTSWhen buying ingredients, it makesperfect sense to buy in bulk. After all,with long shelf lives, ease of storage andinnovations in handling equipment there’snever been a better time to make theswitch to large amounts of rawingredients. However, there are challenges that cropup. Thankfully there have been advanceson virtually every level of the industry tomake dealing with heavy, unwieldyvolumes of produce that much easier.Recent trends have included receivingbulk ingredients direct in pre-mixed formfrom the supplier in specially-adaptedpackaging, making it easier to transferfrom pallet to product. This not onlybrings down the cost per kilo, but alsomakes the process that much moreefficient.Dust control is also an issue that hasbeen tackled in an innovative way. Use ofdirectly-feeding storage like silos orreservoirs is being routinely used over theold methods of storing in bags orcontainers on shelves. Bags are often kepton factory floors, being bothcontaminated by other element on thefloor and leaking potentially harmful dustparticles which can lead to explosions ifthe build-up is significant and theconditions create it.Weighing in Weighing is something that can have ahuge impact on operations. Being caughtout by inaccurate amounts of product cannot only harm your overall packagedproduct’s weight, but also recipes ifinaccurate amounts are used. For example, Costco recently upgradedits scales to a checkweigher to achievemore accurate weighing for its bakery andconfectionery ingredients.Costco installed six ZQ375-30kg unitsat each of its newest warehouses atLeicester, Southampton and Farnboroughand one larger, floor standing 90kgcapacity ZQ375 for bulk weighing in thebutchery departments. The equipmenthad to meet stringent hygiene standardsand precisely weigh a wide range ofingredients, from custard to food dye, toensure a high quality final product.Wayne Parsons, Regional BakeryManager for Costco, says, “At Costco wetake a lot of pride in the fact that wefreshly bake a lot of our products in thebakeries at our warehouses. To do this,it’s important that the scales we use areconsistently accurate, convenient to use,and have an easy to read indicator. Thisallows us to deliver a high-quality endproduct.“One of the most important features ofthis scale for us is that it is a lot easier toThe bulkof itOffering ingredients in bulk is not only a great way to market costsavings to customers, but is also an effective way of storingvoluminous production. But how do companies manage their bulkingredient needs?44-46:Layout 1 15/11/13 11:05 Page 1Food & Drink International 45www.fdiforum.netclean than the previous model. Hygieneis obviously very important to us as wethoroughly clean the scales throughoutthe day.“Another particularly useful feature ofthe ZQ375 Checkweigher is that it iscapable of five gram divisions and a capacityof 30kg, whereas the old scales we used wereonly capable of divisions by ten grams. When weare dealing with ingredients such as food dye, thisfeature is particularly useful as it allows a much greaterlevel of accuracy when dealing with smaller quantities.”This division highlights the fact that sometimes using small amountsof high-volume bulk storage is sometimes needed. Accuracy thereforetakes an even bigger emphasis than before.New bulk tastesSelling ingredients in bulk is nothing new, but perhaps what weconsider buying in such volumes changes more than we think. Onearea which has grown recently is the specialist ingredient market, morePHOTO: SHUTTERSTOCK.COM/BGTON46 PHOTO: SHUTTERSTOCK.COMMAREKULIASZA demand for different seeds thanksto a more health-conscious publichas led to bulk sales increasing byunprecedented levels.The nature of bulk ingredientschanges as consumer tastes do,we’ve seen Mexican chili grow inprecedence to a point wheredemand is such it needs to bedelivered in bulk.Use ofdirectly-feedingstorage like silos orreservoirs is being routinelyused over the old methodsof storing in bags orcontainers onshelves44-46:Layout 1 15/11/13 11:05 Page 246 Food & Drink Internationalwww.fdiforum.netBULK INGREDIENTSesoteric ingredients have begun to be soldas bulk as consumer tastes have changed.For example, EHL Ingredients hasrecently seen a boost for its Mexicanchillies. Within the last twelve months, red andgreen jalapeño, habanero and ancho – aswell as blends of Fajita seasoning, Cajunseasoning, Blackened Cajun seasoning,have all shown a 20% increase in sales,compared with this time last year. According to research, Mexican is thefastest growing cuisine in the UK,showing 10% growth year on year .Additionally, Mexican food on-the-go isalso experiencing a surge in popularity,particularly among quick service, casualdining and takeaway burrito outletsoffering fast, affordable and filling foods.Mexican burrito outlets are amongHorizons Ones To Watch as furthergrowth is expected during the second halfof this year and beyond. Tasneem Backhouse, sales director atEHL Ingredients, says, “Mexican foodcontinues to be popular in the UK withinthe restaurant and casual dining sectors,in takeaway, in retail ready meals and kitsas well as in at-home cooking.” Similar stories have emerged recently,including bulk sales of seeds such assesame, poppy and linseed increasing in asimilar way as healthier diets arepromoted. This kind of phenomenonoften occurs when retail products provepopular and bulk ingredient suppliers startPHOTO: SHUTTERSTOCK.COM/KEANTIANStorage has moved onimmeasurably from sacking orsimple bagging, you are morelikely to encounter permanentsilos, reservoirs or containers.The waywe deal with bulkingredients is nolonger as animmovable commoditythat we lean on whenwe need itto experience a trickle-down effect to thefoodservice and catering industries.The way we deal with bulk ingredientsis no longer as an immovable commoditythat we lean on when we need it. It nowseems that despite their nature, bulkingredients is actually a fast-moving sectorof the industry.44-46:Layout 1 15/11/13 11:05 Page 3Food & Drink International 47www.fdiforum.netBAKERY & CONFECTIONERY48 Ulrick & Short suppliesbakery manufacturersacross the world with cleanlabel non-GM ingredients,such as its range of Delytefunctional fat replacersTechnologymeets traditionBakery and confectioneryproducts often build theirsuccess on the traditionalapproach – but that doesn’tmean the sector is slow toincorporate new ideasThe bakery and confectionery sector isgoing through some interesting times.Many of the products in the sector areparticularly indulgent and the good newsin this regard is that the worst of therecession appears to be over andconsumers are looking to purchase moreluxury products. Yet this rise also goeshand in hand with increased interest inhealthier and more natural products –leading to many manufacturers looking tochange their recipes.Certainly the bakery market shows nosign of slowing its growth – in the UK itwas worth £11 billion in 2012, and that’sdespite challenges from wet weather andan increase in grain prices due tocontinental droughts. Yet changes inconsumer lifestyle can be seen from thefact that, at the same time, the free fromsector is marching on, grabbing a £238million slice of the market last year thanksto increasing demand for these productsas a lifestyle choice.It’s no surprise that many in theindustry therefore see a breakthrough infood technology over the next few yearsthat will enable in-store bakeries inparticular to meet the burgeoning demandfor high quality products made fromnaturally gluten-free, non-GM ingredients.Adrian Short of ingredient specialistUlrick & Short points out, “Thousands ofpeople are selecting gluten free, dairy freeor other free from products, not always bynecessity but often as a way of reducingconsumption of certain food groups andover-processed products in particular.“Manufacturing onsite is oftenlogistically impossible without the risk ofcross-contamination, and it’s therefore theresponsibility of knowledgeablemanufacturers and ingredient suppliers toinvest heavily in research and developmentin order to create great products that justhappen to be gluten free. The in-storebakery benefits from frozen or part-bakedbreads or confectionery that can betruthfully displayed as ‘finished in storetoday’ or ‘baked by us for you’ – and, ofcourse, a label boasting only natural,healthy ingredients.”Clean label ingredient specialists haverisen to the challenge, developing naturallygluten-free, non-GM starches, flours,proteins & fibres based on a range of crops– and maximising advanced R&Dtechniques to deliver new functionalities forboth food manufacturers and consumers.One example of this could be seen atthe recent International Baking IndustryExposition, where Roquette demonstratedits microalgae-based lipid ingredient forwhich it has obtained GRAS designation.They showcased this in a variety of bakeryapplications, including brownies, crackers,and muffins. In each application, the useof microalgae has enabled Roquette tosignificantly reduce the total calories andfat – while maintaining all the positivesensory attributes consumers have cometo expect from these products.47-49:Layout 1 15/11/13 12:24 Page 148 Food & Drink Internationalwww.fdiforum.netBAKERY & CONFECTIONERYThe changes in consumer tastes haveseen a host of new products joining thefamiliar staples on retailers’ shelves. Thisyear’s IBIE joined forces with the TortillaIndustry Association to provide greateraccess to new suppliers, new ideas andnetworking opportunities for a product thatcontinues to increase its mainstream appeal.The ethnic flatbread was once consideredpurely a Hispanic speciality product but isnow firmly entrenched in an increasinglydiverse diet. Indeed, at $11 billion per year,tortilla sales in the USA have surpassedother ethnic and specialty bread items,including bagels, croissants and muffinsThis has meant manufacturers lookingat new production methods, with AshlandSpecialty Ingredients promoting theirAqualon and Blanose cellulose gums,which are used in masa flour mixes toimprove water absorption and retention intortilla dough, both cooked and uncooked.Julie Masker, nutrition scientist atAshland Specialty Ingredients, says, “Theincrease in water absorption creates atortilla with improved texture andBelow: Taura Natural Ingredients has teamed up with VIP4VIP inthe Netherlands, to ramp up distribution of its URC GourmetSeries fruit pieces for the bakery sectorRight: The egg-glazed hot dog roll developed by Butt Foods isbaked individually rather than batch baked, which means there’sno join mark, and each roll is quick frozen to retain freshnessThe newtechnology hasallowed for bakery andconfectionery productsto be produced farfaster than has everbeen the caseextended shelf life, which are criticaladvantages in a high-speed productionenvironment.”These recent additions to the marketare hugely welcome, but part of theattraction of many bakery products comesfrom their traditional methods – followingrecipes and production processes thathave been passed on through generations.However some of these aren’t quite assustainable as they used to be due tochanges in regulations and a supply chainthat has speeded up quite substantially.The challenge, therefore, is to incorporatenew methods that include all the samequality as before but with increasedconvenience and safety.One example of a traditional recipebeing produced more effectively comes viaFranz Haas and their high-capacity waferbook builder. Due to the demand forefficient high-output wafer ovens, Haashave continuously enlarged baking platesizes and increased the number of bakingplates in their ovens over several years tohelp increase the production of theperennially popular wafer fingers. Haas’ wafer baking ovens havecontinually improved to the extent thatthey can now deliver up to eighty or evenmore wafer sheets per minute in formatsof up to 350 x 730 mm, depending on theparameters of the baking time or recipe.This is hugely impressive, but the oven isjust part of the overall wafer productionline. To make smooth large-scaleproduction possible, therefore, it’s alsonecessary to provide suitable downstreamequipment that can cope with the highoven output.FHW Franz Haas Waffelmaschinenhave developed a fully automatic high-capacity wafer sheet sandwiching devicefor building wafer books, which meets thevarious challenges posed by the highproduction speeds. The new systemcomprises a cream spreading machine, abase sandwich former and a stacking andpressing device, known as a book builder.At the beginning of wafer book building,a conveyor feeds a base sandwichconsisting of an uncreamed top sheet anda creamed wafer sheet from the basesandwich former to the book builder. Thepick-up plate of the book builder, whichcan move both horizontally and vertically,lifts the base sandwich by vacuum. Afterthat, a creamed wafer sheet is fed to thebook builder, the pick-up plate puts thebase sandwich onto the wafer sheet andlifts the wafer book which has now threewafer and two cream layers. This process47-49:Layout 1 15/11/13 12:24 Page 2Food & Drink International 49www.fdiforum.netBAKERY & CONFECTIONERYInnovativeand tasty - new crispy Veggie Chipsby Franz HaasConvenience FoodIf you had to decide between“healthy” and tasty, whatwould you choose? Mostconsumers would say:“Why do I have to chooseand why has somethingto be either tasty orhealthy?” and theyare completelyright. Franz Haas Convenience Food have asked themselves the samequestion and found the perfect answer: Tasty is healthy! And healthy is tasty!Veggie Chips are 100% natural, they combine different flavorslike tomato-basil, carrot-curry or the pumpkin-ginger. Being glutenfree and low in fat they are the ideal fun product for target groupslike kids or teenagers. In combination with dips they bring anenjoyable snack for parties or night outs and they can go as arefreshing side dish to any drink or cocktail. The low fat productionmakes them also interesting in the fitness and beauty food sector asthey are low in calories and consumers do not have to abdicatetaste and enjoyment. Franz Haas’ innovative and vitamin conserving productionmethod guarantees various fresh and savory combinations, and anaverage shelf life of six months. If you are interested in the newVeggie Chips by Franz Haas Convenience Food,contact reinhart.adam@haas.com for your individualpresentation or sample box of Veggie Chips.is repeated until a wafer book in the desired configuration iscompleted. Finally, the wafer book is conveyed to a wafer bookcooler before it is cut into wafer fingers by a cutting machine.The benefit for manufacturers comes from the very highcapacities that can be met thanks to the continuous workflowwithout intermediate stopping of the wafer sheets. Convenience isalso improved as the wafer sheets can’t be broken during theprocess as their entire surface lies on the conveyor belt or is heldby the vacuum plate during the whole process. The wafer sheetsare exactly aligned to each other and height-calibrated in one step.In addition the machinery is much easier to clean and maintain.The new technology has allowed for bakery and confectioneryproducts to be produced far faster than has ever been the case, withimprovements in traceability, security and efficiency, and incorporatenew, healthier ingredients. As far as consumers are concerned,however, the products maintain the same taste that have always beenthe case – creating a perfect mix of innovation and tradition.FHW Franz Haas Waffelmaschinenhave developed a fully automatic high-capacity wafer sheet sandwichingdevice for building wafer books47-49:Layout 1 15/11/13 12:24 Page 3Next >