< Previous18 Food & Drink Internationalwww.fdiforum.netBULK INGREDIENTSboth contaminated by other element onthe floor and leaking potentially harmfuldust particles which can lead to explosionsif the build-up is significant and theconditions create it.DustbustersMinimising dust contamination whenfilling and shifting millions of tonnes ofpowdered ingredients through a factory isa lasting challenge for many, but there areseveral innovative examples of newequipment that make this process easier.Spiroflow for example, has recentlydeveloped the T2 Angled Bulk BagDischarger, which provides an air-tightoperation that empties product with theminimum of residue and has angledframework, not horizontal flat surfaces,which reduces settlement and saves timeon cleaning.This kind of machine can tackleproducts as diverse as baby formula milk,sugar and flour to pharmaceutical powdersand granules. The machinery’sconstruction means fine dust is preventedfrom sticking to any part of thedischarger, resulting in improved hygiene.Bags of speedThe physical act of filling sacks at speedwith often granular and unwieldyingredients can be difficult. With dustflying everywhere and a flow rate simplyrelying on gravity, accuracy and weight isoften of the upmost importance.But, the release of a new bag filler fromPacepacker recently saw bagging speedsable to fill sacks up to 28% quicker. Withthe company’s FastPac, a sack placer,agricultural and contract packers nowhave something that will tackle nearlyevery medium from plastic to paper andplastic bags and sacks. Paul Wilkinson, Pacepacker’s BusinessDevelopment Manager, says, “As a resultof this modular construction, customerspay for the system they need and not forfeatures that will sit idle. “The enclosed construction meetscurrent safety requirements and a rejectsystem has been integrated to expel poorquality or badly-loaded sacks, withoutneed for manual intervention.”The new sack placer has been designedto meet the needs of all agricultural andbulk handling producers, workingseamlessly with the higher-spec multi-head weighers which are becoming acommon sight in many produce packingplants. Offering higher speeds at moreaccurate weights, sack systems need tomatch the pace of this increased output,Use of faster bagging machinesshould improve profits 17-19_Layout 1 21/11/2014 10:02 Page 2Food & Drink International 19www.fdiforum.netBULK INGREDIENTSwhich the FastPac system does effortlessly.Sack weights ranging from 2kg up to 50kgcan be accommodated.New tastesThe tastes of the world are changingand the use of powdered and granularingredients is booming. As more and moreconsumers demand quality and variety inequal measure, this has led to bulkingredients taking off in these areas too.EHL Ingredients, for example, hasspiced up the ingredients sector with thelaunch of a 20-strong range of new herband spice blends, rubs, marinades,coatings and seasonings.Grouped into six key categories, thenew ingredient blends include four drymarinades, six speciality blends, threetextured coaters, five everyday seasonings,a complete burger mix and a completesausage mix.Katherine Davis, new productdevelopment manager at EHL Ingredients,has been working on the new range sinceher appointment in July. Followingrigorous trials, tests and tastings, the newblends are now available to the foodindustry.The products offer a wide range ofapplications and can enhance the flavourof ready meals, soups and sauces, curries,pie and pasty fillings and meat dishes.Speciality blends are a versatile ingredientaddition to dry mix kits or for inclusion inburger and sausage formulations.Tasneem Backhouse, Sales andMarketing Director at EHL Ingredients,says, “This represents the largest everproduct launch from EHL and we areconfident the new blends will be popularamong our existing customer base and willalso appeal to new clients looking forinnovative, high quality spice blends fromaround the world.”Inspection and detectionWith such large amounts of ingredientsand foodstuffs being processed, it’s nosurprise to find that many innovationshave been developed to ensure that thereare as few foreign bodies andcontaminants within large scale storagesolutions as possible. For bulk solids in particular, VEGAhave been developing sensors that areproving to be the industry standard.Günter Kech, Managing Director atVEGA, says: “Radar technology is on asuccessful trajectory and we will ensurethat it stays there by even furthersimplifying it for level measurement ofbulk solids in future.” VEGA Grieshaber KG, launchedVEGAPULS 68, the first radar sensorspecifically tailored to applications in thebulk solids industry, on the market in2004. Compared to radar sensors forliquids, the bulk solids radar sensor iscapable of detecting and measuring signalsa thousand times smaller – signals thatwere previously masked by ‘noise’.The two-wire loop powered sensorshave since become the main alternative tomaintenance-intensive mechanical ‘plumbbob’ systems, or ultrasonic sensors, whichrequire a clear, dust-free view to theproduct. Thanks to simple applicationparameters, only a few settings are neededto fine-tune the radar sensor to themeasurement. The result is reliablereading, completely independent of dust,filling noise, strong air currents and hightemperatures, with no loss of echo issues.The potential for producers that usebulk ingredients seem endless, but whatsuccesses are built on in this area is notsimply ‘go big or go home’ but rather aconsidered approach. Using such largeamounts of ingredients and findingsuitable solutions to handle them is achallenge, but one that ultimately willcreate easier ways of working. As with most of the industry, an initialinvestment in equipment and suitablestorage facilities will prove to be worth itin the end. Keeping one eye on healthand safety and the other on profit marginsis always tough, but is perhaps the bestpath to take.PHOTOS: PACEPACKER17-19_Layout 1 21/11/2014 10:02 Page 320 Food & Drink Internationalwww.fdiforum.netEND OF YEAR SUCCESS STORIESAn emphasis onsustainability and theexploration of new marketshave been the keys tosuccess in 2014It would be wrong to say that 2014 sawthe effects of the financial crisis of recentyears totally eradicated, and with the newsthat Japan has returned to recession therecovery is clearly somewhat fragile. Yetthe news from the food and drink industrylooks encouraging with many companiesreporting hugely impressive growth overthe past twelve months.One way of tracing the success of theindustry is to review the attendances atthe various exhibitions and many of theseare reporting increased numbers in 2014.The Nordic Organic Food Fair in Malmoenjoyed a 13% increase in totalattendance, with the show itself doublingin size from its launch in 2013. Therewere also increased attendances at manyother shows in recent months includinglunch! and Packaging Innovations.There was also a 37% increase invisitors at drink technology India thisautumn – testament to how manypreviously under-developed nations areenjoying significant growth. The eventThe best of the bestwas sponsored by the professionalassociation Food Processing andPackaging Machinery in the GermanEngineering Federation, and its ManagingDirector Richard Clemens says, “Ourexpectations with respect to the numberof visitors and competence wereconsiderably exceeded. You sense a verypositive mood with correspondinginvestment projects.”Other territories also report impressivegrowth. The second Foodex Saudi eventtook place in November and this is amarket a growing number of businesses arelooking to target. Simon Blazeby, Head ofExhibitions at Reed Sunaidi, who mountedthe show, says, “The Saudi food sector isexpected to grow by 55.3% over the nextfew years, reaching $70 billion per annum.Being the largest consumer in the Gulf, theKingdom’s food and agriculturalcommodities account for 15%, or $17.5billion, of its imports, with agriculturalimports projected to grow by as much as76% by 2016.”This success in new markets doesn’tmean existing markets are losing out andmany companies are reporting newopportunities and successes during 2014.Those companies who have been able tomeet the increased demand amongconsumers for more natural flavours and amore efficient production process arereaping the rewards, with Kite Packaging,for example, introducing newenvironmentally friendly options for theircustomers such as the Air Shock, whichhave proven especially popular.Efficiency and sustainability haveprobably been the key topics for the foodand drink industry this year and over thenext few pages you’ll be able to see howmany companies across the world have metthe new challenges and enjoyed greatsuccess. They’re also well-placed to reacheven greater heights in 2015.Kite Packaging have introduced newenvironmentally friendly options for their customersin 2014 which have proven especially popular, suchas the Air ShockNew markets are opening up formanufacturers and distributors withshows such as Foodex Saudiillustrating particular success 20-21_Layout 1 21/11/2014 10:03 Page 1Food & Drink International 21www.fdiforum.netEND OF YEAR SUCCESS STORIESMaximum food safety, maximum production output, minimal costs:Klüber Lubrication helps you achieve all these goals more easily. Our high-performance NSF H1-lubricants are 0:6 JLY[PÄLKHUKOH]LHT\S[Ptude of approvals. They are available for all branches of the food-processing industry, for all components and tricky special cases everywhere in the world in the same high quality. Our experts will provide you with support to meet your individual requirements, from consulting to optimum lubrication management, ensuring more safety of production processes and OPNOLYWYVÄ[HIPSP[`Klüber Lubrication: 80 years of experience and professional services for your success.Klüber Lubrication Great Britain Ltd.sales@uk.kluber.com / www.klueber.comCertified speciality lubricants for the best possible taste.your global specialistKlüber assistseafood companyA leading seafood company, one of the largestsalmon smokers in Europe, has partnered withKlüber Lubrication to review its maintenanceoperations.The seafood company waskeen to continue pursuingtraditional smoker productionmethods combining themwith the best that foodinnovation has to offer tomaintain its reputation as aproducer of the best smokedsalmon in Europe. However,senior management wantedto update the wholeproduction system to ensurethey could continue to deliverthe best and most costeffective food possible in acommercially viable way.Klüber Lubrication werecommissioned to audit thelubrication process. The company had six lubrication suppliersdistracting them from their core business and wanted greater clarityand simplicity so that operatives knew which lubrication to use,when, where and how to reduce costs and maintenance downtime.A full lubrication audit by Klüber Lubrication highlighted thatthe installation of a comprehensive lubrication programme throughKlüberEfficiencySupport would deliver increased food safety.Additionally, this enabled the company to achieve greaterefficiencies boosting productivity while cutting waste.More importantly it helped increase maintenance intervals,achieve food safety compliance demanded by their customersincluding major retailers and significantly reduce costs oflubrication.By reducing the number of lubrication suppliers to one, theseafood company focuses in its core discipline of producing firstclass smoked seafood to retailers across Europe. It has a robustsafeguarded compliant system going forward backed up by technicaladvice and support. At the same time, Klüber Lubrication hasdelivered greater efficiencies reducing maintenance intervals andcosts, boosting productivity while safeguarding public health andinstalling an environmentally sustainable system.For further information, visit www.klueber.com20-21_Layout 1 21/11/2014 10:03 Page 222-23_Layout 1 21/11/2014 10:04 Page 1Food & Drink International 23www.fdiforum.netEND OF YEAR SUCCESS STORIESwarehouse storage to accommodate fivethousand pallets of packaging. Kite Online will report record turnoverfigures this year, and have set ambitioustargets for the year ahead to become thebiggest online retailer of stock packagingproducts. The site will improve usabilityeven more with new tools and guides tohelp all kinds of packaging buyers.Kite Packaging has been flying high forthirteen years – don’t expect it to let upanytime soon.For more information, visitwww.kitepackaging.co.uk.Kite Packaging plans to reachnew heights in 20152014 was a busy and impressive year for UK packaging distributor Kite Packaging, and plans for thecoming year aim to build on its current rate of growthKite announced the acquisition of twonew buildings as part of its growthstrategy during 2013 – which included a£1.5 million investment in the company’sNorthern operation and a £3.5 millioninvestment in Kite’s existing Midlandsoperation.The new space and predicted growth insales allowed for a completely new area ofthe business for Kite – S3, or SpecialistServices and Solutions, operates acrossthe entire group and were responsible forrolling out some exceptional automatedpacking solutions this year, includingthree new Kite-branded systems.The Kite Air Shock was launched inFebruary to Kite’s online customer base,as an environmentally-friendly, space-saving solution for fragile items. Theconsolidated range of inflatable packswere ideal for website customers,particularly those in the drinks marketlooking to pack fragile bottles and reducespend on materials. It provided not only acheaper alternative to polystyrene, butreduced customers damage rate from ashigh as 10% down to zero.This was followed by the Kite Wrap &Hold System, designed to provide a fastand efficient alternative to a variety ofvoid-filling and in-box solutions, bycreating a void out of space rather thanmaterial. Kite’s idea was to use stretchfilm to secure products to patentedcardboard wrap designs – these not onlyheld the product in place without usingadhesive but the intuitive designs alsoelevated the product so it was suspendedin the box, and therefore not effected bytransit damage and impact.Kite’s successful partnership withAudion Swissvac, demonstrated at thisyear’s PPMA Show, has been reflected inits website offering, and customers cannow choose from a variety of packagingmachines to suit their operation. Vacuumpacking machines are incrediblycompetitive in terms of pricing and areavailable with a choice of vacuumpouches in a variety of sizes. Themachinery range has seen a faceliftin terms of content as well, withKite’s web team working hardon accessible content, videosand images – a noticeableUSP of the Kite brand.2015 is set to beanother big year forthe Major Accountsbusiness, with arecent acquisitionof a brand new twoacre site in Swindon.Set to officially open inFebruary, once completedthe building will have enough22-23_Layout 1 21/11/2014 10:04 Page 224 Food & Drink Internationalwww.fdiforum.netDS SMITH consumers. Because ofthis, it was vitallyimportant the RRPwe developedsupported thecampaign andcommunicated themessage, andDS Smith madeeverything verysimple and straightforward.”Tony Foster, of DS Smithsays being involved in the relaunch was a great opportunity. “RRPis the last chance to reach the shopper during the crucial ‘momentof truth’ when they’re selecting their purchase on the shelf. Whenit’s well designed and consistent with the rest of the brand it’s ahugely effective part of the marketing mix.”DS Smith celebrates ten titles atEFIA Print AwardsDS Smith hasbeen recognised forits high qualitydesign andinnovation at theEuropeanFlexographicIndustry AssociationPrint Awards.A total of tenhonours were awarded to the corrugated packaging and supplycycle specialist, including Gold for work on the packaging forLyons Original Tea 600 and Silver for the printing for KitKatChunky and Mini D’Aim Eggs. The firm also scooped Silver for itspackaging on the Art of Hosting promotion for 12-year-old blendedScotch whisky Chivas Regal.Tony Foster says, “We work with our customers on designinnovation, creativity and on matching the graphic effect to thepack structure. The result is a sustainable pack that protects theproduct, maximises shelf space and crucially, encourages theshopper to buy.”DS Smith innovation keepsBrompton ahead of the packThe Brompton bike company turned to DS Smith when lookingfor new packaging. The challenge set for DS Smith was to raise thestandard of the corrugated packaging to reflect the quality of theproduct. The response was a one-piece solution that sets a newstandard for bike packaging. All elements of the bike are now securely located within thepack by creative use of an extended glue flange and precise flaparrangements. The internal base flaps fold to form a supportive yetcushioning structure which offers extra protection to vulnerableareas. The use of locking tabs has enabled Brompton to dispensewith tape that previously secured the pack, making the box moreaesthetically appealing and simpler to recycle. Tony Foster, UK sales and marketing director, says, “This is apack which really demonstrates how working so closely with thecustomer and truly understanding their needs, produces thehighest quality packaging. By using corrugated the packaging isentirely recyclable, and by taking our cue from the fold-up featureof the bike, we have produced a pack which is strong and protectsthe product in transit, as well as reflecting the quality of the bikeitself.”The pack has been recognised through the Starpack Awards,who have awarded their highest accolade, Gold.Branston Pickle teams up withDS Smith for relaunchBranston Pickle’s new owner Mizkan Euro Ltd has teamed upwith the packaging division of DS Smith to help breathe new lifeinto its ‘Bring out the Branston’ slogan. As part of a majorinvestment, Mizkan have kick started their promotional activitywith a new ‘two label’ design, where one Branston Pickle labelreads ‘Bring out’ and the other reads ‘Branston’.Jeena Patel, Packaging Category Buyer for Mizkan, says, “Thetwo label design has been created as a novel and fun way to engageExtensive innovationfrom DS SmithFor more informationon DS Smith, visitwww.dssmithpackaging.co.uk.24_Layout 1 21/11/2014 12:37 Page 1FACTORY AUTOMATIONCertainly, as far as employees areconcerned, the idea of automation almostalways seems to bring with it the fear ofextensive job losses, while there candoubtless be some disappointment amongmanagement when its introductionsometimes fail to achieve the long list ofsolutions they were hoping it would.As Roy Green of Harford Controlpoints out, “Those who haveimplemented automation projects realisehow difficult it can be to achievesuccessful outcomes and how easy it is tospend a small fortune on automation andstill not achieve desired objectives or, insome cases, any benefits at all.“However, when automation iseffectively implemented and the essentialbuy in from Chief Executive to factoryfloor is achieved, everyone benefits. Thecompany’s competitive edge is sustainedor even improved, market share is oftenincreased and, as a direct consequence,factory floor jobs are made more secure,thereby improving confidence and morale.“Clearly, especially in these highlycompetitive times, no company can affordto support labour intensive practices ifthere is a cost effective automation optionthat more comprehensively protectsmanufacturers from exposure to risk orreduces unit production cost. The dangeris that if such a cost effective option, orset of automation options, exist and areadopted by competing companies, thefuture of the whole company is put atrisk.“On the other hand, well thought outautomation has reduced exposure to riskand reduced operating costs in manysectors – so much so that many companiesin business today would not be inbusiness if they hadn’t invested wisely inautomation projects. Successful projects,however, must be judiciously thoughtthrough from the outset with clear ‘endgame’ objectives in mind.”Often it’s felt that automation can be apanacea for all the issue that may crop upon the production line, but it’s not simplya case of, for instance, whacking a cameraon a line and expecting productionstandards to immediately improve.Problem prevention or resolution throughonline vision systems is rarely that simpleand poorly executed automation is almostalways thanks to kneejerk reactions to aretailer’s demand or to some unexpectedfactory floor issues.Roy Green says, “One area where thisis becoming increasingly obvious is inpackaging line control. We havesuccessfully installed many online visionsystems for component matching whereno other technology was suitable. On theother hand, we have seen some visionsystems installed on lines quiteunnecessarily when a far less expensiveTheautomationanswerThe introduction of automation in the food and drink industry has beenthe cause of no little emotion and controversy over the years.28 Food & Drink Internationalwww.fdiforum.net28-32_Layout 1 24/11/2014 10:47 Page 1Food & Drink International 29FACTORY AUTOMATIONand easier to maintain 2D barcode labelverification system would have providedadequate protection from risk.“In our experience, things only gowrong in production environmentsbecause they can. When we talk about‘end to end’ thinking, we are obviouslykeeping the end in mind, but we are alsovery mindful of the start of the productionprocess. It’s often said that you can’t buildquality into a product if it isn’t designedin from the outset. We feel exactly thesame way about production and packingoperations. They only really work costeffectively when the thinking is pro-active- along the lines of what can go wronghere and how can we prevent it? This isRight First Time Quality in action. “No amount of online inspection,manual or automated, can produce a cost-effective quality product without wellthought out preventive measures andwork practices installed and instilledwithin the workplace ethos at everyopportunity. Left to chance, things will gowrong.“Through integrated automationtechniques, we set up whole productionlines which, apart from the obvious GMP,pro-actively minimises the risk of defectsand failure – but which set up wrongly inthe first instance can cause a whole batchfailure rather than the odd defect. This isthe opposite of the intended outcome, notbecause the automation project waswrong, but because of aspects such asinsufficient attention to detail ortraining.”One reason why companies introduceautomation is to deal with reject items,but as Roy Green says, “Automationadded to lines simply to knock off rejectsmay provide some degree of protectionbut at what cost? The best automatedreject devices are the ones that rarely needto reject anything. A huge pile of rejectsmight prove the automated reject device isdoing a good job but it also proves theproduction line has not been adequatelyset up or is not sufficiently capable ofproducing reliable, high quality product.“In the latter circumstances, we believethat root cause analysis, evaluation ofPHOTO: SHUTTERSTOCK.COM/VASILY SMIRNOVwww.fdiforum.net30 Á28-32_Layout 1 24/11/2014 10:47 Page 230 Food & Drink Internationalwww.fdiforum.netFACTORY AUTOMATIONworking practices and process capabilitymeasurement in order to set appropriatecontrol limits is far more important toensure successful outcomes, rather thanautomation itself. In such cases,automated rejection devices only serve toremind one how costly the problem iswhile providing some degree of protectionfor valued customers.”Companies that have introducedautomation with a clear idea of what theywish to achieve and a dedication topurchasing and installing the mostappropriate machinery have definitelybeen able to report impressive success.Companies such as Western MechanicalHandling have ensured the productionline is moving faster than ever and inrecent months they have taken advantageof developments by Intralox.Their new belt combines the hygieneand ease of cleaning of flat PU belts withlow maintenance benefits of positive drivemodular plastic belting. The belt can becustomised with flights for inclineapplications and are available as endlessbelts, or with a pinned joint where beltremoval for deep cleaning is required.WMH has delivered successful projectsacross the industry using IntraloxThermoDrive belts in a variety ofconfigurations from plain straight runningconveyors to flighted conveyors and swanneck elevators.WMH has also recently completed theinstallation of a new hand crimp pastyand pastry products assembly line forSamworth Brothers’ Ginsters factory. Theline will give the factory extra capacityand has been brought online specificallyfor small batch production runs of specialand development products. The newconveying includes a WMH productassembly and crimping conveyor and scrapremoval system and integrates a pastrycutter and guillotine from Rondo. Theline also features a manual tray-up stationto enable products to be loaded ontobaking trays for further processing.The beverage sector has specificrequirements with the production processto assist in product integrity, and DanRossek, product Marketing Manager atOmron, points out there are manybenefits of using vision systems for inlinedetection. “As a quality control measure,they can be utilised to inspect emptycontainers, before the actual fillingprocess, or for final exterior qualityinspections such as labels and booklets –or to detect the presence of straws, forexample. The final exterior inspection istherefore often integrated into a finalinspection station incorporating othertechnologies for a complete quality controlsolution.“Because of this flexibility, visionsystems are generally used for highervalue products, for example, verifyingserialised 2D codes on labels to fightcounterfeits. In a recent project, thisfeature enabled counterfeit bottles ofcheap wine labelled as expensive Italianwine to be successfully detected.“However, depending on the processand application, there are a number ofhurdles to overcome in terms oftechnology and cost, for example in high32 ÁPHOTO: SHUTTERSTOCK.COM/06PHOTO28-32_Layout 1 24/11/2014 10:47 Page 3Next >