< Previous20 Food & Drink Internationalwww.fdiforum.netSUSTAINABLE PACKAGINGIf there’s one overarching principlethat has united the global food andbeverage supply chain in recent years,then it’s the move to more sustainablepractices. This is true across numeroussectors, but it’s keenly felt when it comesto food and drink. Wastage at aproduction and manufacturing level is, ofcourse, still a resounding issue as far asboosting sustainability is concerned, but itis packaging where perhaps the biggestchanges need to be implemented. From a logistical standpoint, food anddrink generates plenty of packaging. It’snot simply a matter of packing productstogether and transporting them, as manyproducts have specific requirements,whether that’s a chilled environment, or agreater level of packaging material neededdue to a fragile nature. Then, of course,when it comes to the packaging of theproduct itself. Many fruit and vegetables,for example, are packaged with acardboard tray and wrapped in cellophaneor film. This is packaging on aninstitutionalized level, and with suchingrained attitudes and practices it cancertainly be challenging to overcome,inspire and indeed implement more eco-friendly solutions. As ever, difficultypresents opportunity. The mark of this shift is no morekeenly felt than with WRAP’s secondinterim report of Courtauld Commitment3. The report, which gathers data togetherfrom supermarkets who voluntarily signedup to the programme, reveals thatmanufacturing and retailers waste hasdramatically reduced when compared tothe baseline 2012 figure. Activity fromthese supermarkets has been the drivingforce in reducing the traditional groceryingredient, product and packaging wastein both the manufacturing and retailoperations. In terms of numbers, a further80,000 tonnes have been reduced sincethe 2012 base line. This demonstratesstrong progress towards the targetstanding at 3.2 per cent after the first twoyears, against the overall 3 per cent targetby 2015 for the agreement. These figures also show that efforts toreduce carbon dioxide emissionsassociated with packaging continue toexceed the target of maintaining a zero-increased level of CO2 emissions. Thelatest figures indicate a sustained positivereduction in carbon dioxide emissions of3.9 per cent. Progress remains well aheadof the packaging target, despite thebackdrop of growing sales which are up bymore than 5 per cent for thosesupermarket chains. This figure wasmotivated by changes in the mix ofpackaging materials and increases inrecycling rates which, when combined, hasresulted in the overall reduction of carbondioxide emissions – this despite packagingweight increasing by 0.7 per cent over thissame period. However, the increase wasfor single use transit packaging ratherthan household, which continued todecrease in weight. If the supermarket price wars proveanything, it’s that the constantcompetition between rival chains canprovide the impetus for positive change. Ifone chain is seen to be significantlyreducing not only its waste, but that of itssuppliers, then others are only likely tofollow. Identifying that changes topackaging are happening is certainly a wayto highlight the growth of sustainablepractices and to educate, but what exactlyis driving this change? As people move towards more healthylifestyles and continue to cut out sugaryfizzy drinks from their diets, the bottledwater sector has seen a tremendous rise insales. It’s advised that these bottles beused for single use purposes, while thisPackagingin motion With the increase in recycling and innovative productdesign, food and drink packaging is now more eco-friendlythan ever. 20-24_Layout 1 23/11/2015 11:26 Page 1Food & Drink International 21SUSTAINABLE PACKAGINGmay not often be the casewith many people, it doesindicate plenty of potentialwastage. Plastic bottles doenjoy the position of being oneof the most easily and mostwidely recycled kinds ofpackaging, and this continuousmotion of use, recycle andreuse has ushered in a kind ofpackaging and productionharmony. The latest data fromthe Beverage MarketingCorporation (BMC) has shownthat bottled water packaging isusing more recycled PET plastic,which is greatly reducing thesector’s environmental footprint.Between 2000 and 2014, theweight of an average half-litresingle-serve PET plastic bottle hasdecline 52 per cent. In terms ofvolume, this has result in a savingof 6.2 billion pounds of PET resin overthe last fourteen years. According to The National Associationfor PET Container Resources(NAPCOR), producing new productsfrom recycling PET uses around two-thirds less energy than what is typicallyrequired to make products from virginmaterials. Meeting zero waste to landfilltargets is a goal many businesses havepromised to meet by 2020 and beyond,and the humble water bottle is as good anindication as any that the industry is wellon its way. McDonald’s will always be somethingof a controversial topic when debating ordissecting the food and drink industry. Itsimultaneously represents many of theproblematic issues facing the industryand also many of the positive changes23 ÁPHOTO: SHUTTERSTOCK.COM/TZIDO SUNwww.fdiforum.netPHOTO: SHUTTERSTOCK.COM/IMAGE POINT FR20-24_Layout 1 23/11/2015 11:26 Page 2EUROPEAN SERIES91%of visitors met their objectives at the 2015 eventRegister today using code 1078for free entryMeet face-to-face withover 350 suppliers!24 & 25 February 2016NEC BirminghamThe future of branded and inspirational packaging CO-LOCATED WITHMEDIA PARTNERSINDUSTRY PARTNERSGOLD PARTNERSSILVER SPONSORSOFFICIAL MEDIA PARTNER www.easyfairs.com/PIUK www.easyfairs.com/EmpackUK www.easyfairs.com/Label&PrintUKRegister free today q qOrganised byGAZETTE20-24_Layout 1 23/11/2015 11:26 Page 3Food & Drink International 23www.fdiforum.netSUSTAINABLE PACKAGINGthat are happening. It’s hard to conceive of a city or townthat isn’t littered with some kind of McDonald’sparaphernalia; while this issue is down to the consumer, itdoes go some way to showing that the fast food chainproduces a vast amount of wastage. As a force for good,the company is taking a very proactive role when it comesto its packaging. As of October of this year, all centrally-sourced packaging that is distributed across the company’s38 European markets is chain-of-custody certified, meaningthat wood fibre used in its packaging comes from recycledsources of forests certified to one of two globally recognisedstandard for responsible forest management – ForestStewardship Council standard, or a Programme forEndorsement of Forest Certification national standard. Aswood fibre is used across its product range, from trayliners, straw wrappers, napkins, cartons, cup holders andmore, this is a significant step forward and one that islikely to inspire its competitors. Currently 50 per cent of itspackaging is made from recycled materials, and part of itsglobal vision is to source all of its packaging, alongside itsfood, sustainably. Although hardly exhaustive proof, the pledges from someof the world’s biggest food and drink companies andsupermarket chains actively looking to reduce theiremissions and wastage, has enabled food and beveragepackaging to become a very real sustainable industry. Add tothat the untold number of eco-friendly innovations beingapplied, and it’s safe to say that packaging is about muchmore than waste. PHOTO: AZRISURATMIN / SHUTTERSTOCK.COM20-24_Layout 1 23/11/2015 11:26 Page 4From South Africa with loveA 40 year oldsecret recipe, afamous chef and alink to a South Africandiamond family. Is this anew spy thriller? Well no,but it does lead to excellentBiltong.Here’s the link: the famousPartridge Restaurant was once thehome of the Cullinan Diamond familywho owned the Great Kimberley diamondmine. Willem Van de Ploeg, former head chefof said restaurant has shared the secret recipe with thecurrent owners of Chichester Biltong who own the Partridge restaurant building.The heritage of this recipe is almost as rich as the country from which itheralds. Now with the second largest biltong drying chamber in the UK, and notone but two Great Taste Awards, Chichester Biltong has certainly made a SouthAfrican mark on UK shores. Daniel Hill, digital marketing manager for the brand says: “Our biltong comesfrom a traditional South African recipe using only high quality British beef; we want more people to experience and enjoy this SA delicacy and the range offlavours we’ve paired with it.”The packaging needed to be rugged yet delicate with simple branding reflecting the history and colours of South Africa. National Flexible produced a kraftpaper laminate with registered window which does just that.National Flexible’s technical director Dave Daniels adds: “Biltong is one of my favourite snack foods, particularly as it provides an added protein boostwhen I am on the go. The paper window also allows the consumer to see how good the product looks too!” For further details on either the product, the packaging or what National Flexible can do for you, please contact James Walker Marketing Manager on01274 685566 or on James@nationalflexible.net, or take a look at our website www.nationalflexible.co.uk24 Food & Drink Internationalwww.fdiforum.netSUSTAINABLE PACKAGINGA PLA film for In Mould LabelsAt LabelExpo 2015, Taghleef Industries presented an injected container with an in-mould labelproduced with NATIVIA™ NTSS 40 µm. The highly transparent and glossy film offers a bio-basedand compostable - according to EU standard EN 13432 - solution for injected containers. This joint development project involved Taghleef Industries for the supply of the IML film,Grafiche Seven S.p.A. for the printing of the labels, and Elledi Plast S.r.l. for the injection mouldingof the PLA based container for cream cheese. The label was printed using reel fed offset and flexotechnology with 6 colors + varnish. NATIVIA™ NTSS superior stiffness and film flatness ensure print register stability during theprinting run, while film surface properties lead to suitable ink adhesion for IML application. Optimalstiffness is also crucial for efficient die cutting. A PLA based resin has been used for the injectionmoulding of the containers.To find out more visit www.ti-films.com or email staff@ti-films.com.Two Starpack GOLD winnersone innovative manufacturer- Holfeld Plastics - mastersin materials technologyStarpack 2015: H-PET absorbs 625 per cent moremoisture through reduced surface tension than PP in pre-packed products such as mushrooms and soft fruit.Starpack 2014 and Worldstar Winner: rPETeCO, alightweight, low carbon material for multi markets with ahighly tactile, non-plastic look and feelHydrozorb H-PET is a carefully blended combination ofr-PET and organic and inorganic insert fillers absorbingcondensation in pre-packed products such asmushrooms and soft fruit where shelf life is paramount.Improved weight to strong ratio for top loading moreresistant at lighter weights for over-wrapped productssuch a mushroomsrPETeCO is an innovative material for brandowners and retailers alike looking to add value intheir packaging and to enhance theirenvironmental credentials. The material has anon-plastic appearance is irresistibly tactile witha unique textured finish, blended with up to90 per cent post - consumer recyclate. For more information, visitwww.holfeldplastics.com or emailsales@holfeld-plastics.com.Laminate developed using MattNatureFlex™ filmA partnership between InnoviaFilms and Bio4Pack has resultedin a bio based laminate structurebeing developed usingrenewable and compostableNatureFlex™.BBII80 uses NatureFlex™ NKMatt film as the outer layer, givinga natural premium paperappearance. A metallisedNatureFlex™ film enhances themoisture barriers, making itsuitable for a wide range ofapplications such as cereal bars (used to wrap Sapana Delibars in this application) andcoffee (beans and ground). Patrick Gerritsen from Bio4Pack enthused, “We liked recommending and usingNatureFlex™ films in this application because they fit perfectly, not only with the ethos ofthe organic Sapana Delibars’ brand, but also because of the barrier properties they canbring to a laminate pack structure such as BBII80.”For further details visit www.innoviafilms.com 20-24_Layout 1 23/11/2015 11:26 Page 5FOR BUSINESSES THAT ARE SERIOUS ABOUT REDUCING THEIR CARBON FOOTPRINTWWW.RENEWABLESANDENVIRONMENT.COMYou can read Renewables &Environment on the go!Available on smartphones and tablets. Ideal forthose whospend time away fromtheir office25_Layout 1 23/11/2015 11:38 Page 1susceptible to ignition if certainconditions arise. In J.D.Neuhaus’s case, reducing thisrisk has meant operating withthe use of compressed air at 6bar pressure, with the additionof a spark protection optionavailable. Dust also presentsother health and safetyconcerns such as crosscontamination. One of themost assured means ofcurtailing these issues is toemploy a dust collector. Dustcollectors can be tailored to therequirements of any productionline, to allow and manufacturers keep health and safetyrisks to a minimum. Bulk materials also present a significant challenge formetal detection. Because these materials aren’t typicallypackaged until the end of the process - certainly wheresweets and snack foods are concerned and in metallicpackaging at that - it’s imperative that the product bechecked at every stage where metal contaminationcould potentially occur. As it stands, metal detectionusually forms a seamless part of the free-flowingproduction process, as metal detectors used in the snackfood sectors are gravity-fed, which means the productflows through a pipe directly through the metal detectorto ensure that no metal contaminates make it throughto the consumer. One of the most reliable, and indeed popular, meansof processing bulk goods is with a conveyer system.Using a conveyer system has many advantages overtraditional bulk handling practices and solutions, not26 Food & Drink Internationalwww.fdiforum.netBULK INGREDIENTS AND HANDLINGAs an amorphous term, ‘production line’ doesn’tfully sum up the variety of materials processed andtheir specific needs. As powders and other free-flowingmaterials, many bulk ingredients need to be handledand treated differently. Handling big bags of powderedor similar materials such as salt, flour, starches and soon puts an enormous amount of strain on equipmentacross the production line, which can eat intoproduction time and decrease efficiency. With their bigbag, air-operated hoists, J.D. Neuhaus have given theindustry a boost. Space is often at a premium as far as the productionline is concerned, doubly so when handling largevolumes of materials in one go. The fact that J.D.Neuhaus have manufactured their hoist to be of adesirable size in an environment where limitedheadroom conditions exist is very pragmatic. It’s able tooperate with either a single or twin bag load, as well asoffering safe, swift and accurate positioning. Boostingthese three aspects can greatly increase efficiency andthe amount of ingredients processed. The purposelydesigned hoists work by the connected twin overheadtrolleys connected with rigid spacer beams, and runningon an overhead support beam. Due to the nature of itsrequirements, the processing of bulk ingredients in thefood industry shares a common goal with constructionand engineering. Where one needs the accuracy, speedand safety of handling solutions such as J.D. Neuhausare offering, the other will surely benefit from thedevelopments. One of the biggest issues with handling powderedmaterials is tempering the inevitable dust. Thispresents a significant health and safety hazard, not justin terms of coming into contact with eyes and lungs,but also the risk of explosion. Although an explosion ismuch more likely where powdered chemicals arehandled, many powdered food based compounds can bePHOTO: PACEPACKER SERVICES28 ÁPRIORITISINGPRODUCTIVITY Handling materials in bulk can cause problems in efficiency, butthere’s plenty of new equipment and solutions helping to turnthat trend around. 26-28_Layout 1 23/11/2015 11:40 Page 1Food & Drink International 27www.fdiforum.netPHOTO: ALESSIA PIERDOMENICO / SHUTTERSTOCK.COMPacepacker launches FastPacline for high speed, versatilebulk bagging Customer demand for faster, more-versatile bulk bagginghas inspired Pacepacker Services to launch FastPac. Among the many benefits of the newly enhanced FastPacsack placer, is its ability to handle an unprecedented variety.This follows a growth in demand among European customersand UK exporters for using these materials to pack bags ofproduce in bags weighing 25kg and over. The added versatilityand speed makes the FastPac range ideal for bulk solidshandling, food packers and contract packers alike. Most conventional machines rely on suction cups to pick upand position sacks for filling. This method, however, limits theuse of porous bag material such as hessian and net.Pacepacker’s newly enhanced sack placer provides the optionof mechanical grippers, so it can handle porous materialsalongside paper and plastics. To ensure the pace of production is not compromised,Pacepacker has also begun to upgrade other aspects of theirbagging portfolio. For more information visit: www.pacepacker.com26-28_Layout 1 23/11/2015 11:41 Page 2Award Winning Automated Packing, Pick & Place and Palletising SolutionsTel: +44 (0)1371 811544 www.pacepacker.com28 Food & Drink Internationalwww.fdiforum.netBULK INGREDIENTS AND HANDLINGleast because of its dependability and safetransport of materials from one workstationto the next. Even more advantageous is itsability to cut down on unnecessary processesinvolved in material shifting, and likewisecurb the time needed in carrying materialsbetween two assembly points. As with allaspects of the production line, conveyersystems aren’t without their challenges. Inthis case, the technical problems which arisefrom continuous operations, as well as thehigh cost of maintenance, make it a solutionof two halves. Despite some of theshortcomings, the market is expected to enjoymoderate growth over the coming years,indicating a level of interest that willmaintain stability and possibly facilitatefuture growth. Driving the direction of thismarket is the needs and demands fromcustomers, such as faster and more versatilebulk bagging. In turn, this has inspiredPacepacker Services to launch a new high-speed bagging line. FastPac is just oneexample of an exciting marketplace, in thiscase it’s a sack placer that boosts the numberof bags packed per minute by up to 20 percent with a new top speed on 16-17 bags perminute. As dietary supplements and foodreplacement powders gain popularity andacceptance, the need for bulkhandling is only likely toaccelerate at the same pace. Ifthis market trend continueswith the same kind oftrajectory, then the need forproduction solutions whichtackle some of the biggestchallenges involved withhandling bulk materials will bemet, making some of the pricieroptions that much morefinancially viable to maintain.So too can it be said thatadvances in this area will leadto an even greater level ofefficiency and safety. PHOTO: PACEPACKER SERVICESBühler launches pioneering purpose-built equipmentfor hulling of all major pulse varieties The Bühler Group, a global leader in pulse processing solutions, has launched itsPULSROLL™ huller to support processors in their quest to produce innovative pulseproducts and tap into the burgeoning market for nutritious food alternatives in which pulsesplay a leading role. With its new fully CE and ATEX compliant PULSROLL™ huller, Bühler has introduced adedicated pulse hulling solution that removes the hull from multiple pulses, efficiently,hygienically and cost effectively allowing worldwide pulse processors to capitalise onthe compelling value-added opportunities emerging in this industry.This dynamic trend is set to expand yet further during 2016, which the UnitedNations has proclaimed as ‘International Year of Pulses’ and this places evengreater pressure on pulse processors to provide fully processed and added valuepulse products to meet market demand. With the introduction of the PULSROLL™, Bühler continues to build on its commitment to global pulseprocessors by providing them with technology dedicated to handling multiple pulses in the one machine.26-28_Layout 1 23/11/2015 11:41 Page 3Food & Drink International 29www.fdiforum.netFACTORY AUTOMATIONAutomation is one of the best ways tomake savings in a manufacturingenvironment. Repetitive, time-consumingtasks that were traditionally carried out byfactory operatives can now be completedquickly and efficiently by machines. Assuch, factory automation makes it mucheasier to meet large supply demands. Itmakes sound business sense to invest inthe latest automated solutions, especiallyfor businesses operating on a massivescale.When using automation for food anddrink products the safety and reliability ofthe latest technology means thatcompanies can make significant changesto the way their production line flows.Automation allows operatives to utilise agreater range of skills on the factory floor,and the additional capital generated byswitching to an automated system can bere-invested in other cost and time-savingtechnologies, and even in new productlines.The good news for companies is thatautomated solutions are becoming cheaperand more flexible by the day. From basicassembly machines to leak-test fixturesand laser profiling devices, the latestinnovations in automated technology arehelping businesses to reduce labouroverheads and prevent costly wastage.In the past, no matter how skilled theoperative, there was always potential forerror on the production line. Today, weare looking at the possibility of 100% errorand waste-free production, all thanks tofactory automation. Take, for example,the hydraulic leak-test fixture, a once-niche technology that is now commonlyAUTOMATINGthe processAutomation is a long term solution to a number of food and drinkproblems, so why are so many companies still not taking full advantage?30 ÁPHOTO: SHUTTERSTOCK.COM/VERESHCHAGIN DMITRY29-33_Layout 1 23/11/2015 11:43 Page 1Next >