End of year success End of line packaging INTERNATIONAL FoodDrink FoodDrink www.fdiforum.net DECEMBER 2019 £3.50 STERLING Warehousing optimisation Star quality Star quality 01.qxp_Layout 1 19/11/2019 11:18 Page 1Total Business Solutions for the Food Industry From concept and development through to final component production we provide our global food processing and packaging industry customers with cutting edge, high performance, solutions. For instance, take our new ZP3P Series Vacuum Pads. Good for film packaging applications when the shape of the workpiece changes whilst being lifted. Silicone rubber compliant with the FDA (USA Food and Drug Administration) 21CFR§177.2600 elution test is used. Blue colored pad Reduced leakage Reduction of wrinkles made on thin workpieces (film, vinyl, etc.) during adsorption 2CFHQTſ lm packaging application Flat type pad/ Flat type pad with ribs Wrinkle prevention with the stopper in the centre of the vacuum pad RoHS Vacuum Pads Series ZP3P Developing Solutions for the Food Processing and Packaging Industry SMC - more than just pneumatics Follow us on www.smc.uk For more information contact: 01908 563888 or check-out our website. 02.qxp_Layout 1 19/11/2019 11:18 Page 1Contents December 2019 This magazine is now fully recyclable. By recycling magazines, you can help reduce waste and add to the 5.5 million tonnes of paper already recycled by the UK paper industry each year. Before you recycle your magazine, please ensure you remove all plastic wrapping, free gifts and samples. FoodandDrinkInternational @fdiforumwww.fdiforum.net company/fdiforum News 4 • General news • On line - production news • On the shelf - new products and initiatives Import and export12 A litany of laws and regulations exist to govern the import of food, livestock and animal feed to safeguard public health and environmental welfare, doubly true of foods considered to be high risk. Warehousing optimisation16 The rise of e-commerce and high levels of demand have majorly impacted the construction and design of warehouses, seeing them made larger and pushing them to become high tech automated centres for materials handling – so-called ‘smart warehouses’. End of year success stories20 Food & Drink International wraps up 2019 and invites businesses to share their own success stories for the year. Traceability 24 All steps in the supply chain – from farm to fork – are under increasing pressure to boost traceability from regulators, retailers and consumers. Process, control and automation 31 Integrating automation into the production chain provides a myriad of benefits, improving efficiency, accuracy and cost savings, and yet many food businesses are still reluctant to fully embrace automation. Group Editor: Steve Fisher (s.fisher@blmgroup.co.uk) Editor: Michael Fisher (m.fisher@blmgroup.co.uk) Editor’s PA: Angela Sharman (a.sharman@blmgroup.co.uk) Journalists: Stuart Pearcey (s.pearcey@blmgroup.co.uk) Dominic Cuthbert (d.cuthbert@blmgroup.co.uk) Tess Egginton (t.egginton@blmgroup.co.uk) Sales Director: Teri Cooper (t.cooper@blmgroup.co.uk) Sales Manager: Sam Trott (s.trott@blmgroup.co.uk) Sales: Vicky Hunt (v.hunt@blmgroup.co.uk) Ruth Feather (r.feather@blmgroup.co.uk) Tel: +44 (0) 1472 310302 Accounts & Subscriptions: John Downes (j.downes@blmgroup.co.uk) Design & Production: Gary Jorgensen, Mark Casson (studio@blmgroup.co.uk) Editorial: Tel: +44 (0) 1472 310305, Email: fdi@blmgroup.co.uk Part of the Business Link Magazine Group: Armstrong House, Armstrong Street, Grimsby, N E Lincs DN31 2QE England All rights reserved. No part of this publication may be reproduced, transmitted, photocopied, recorded or otherwise without express permission of the copyright holder, for which application should be addressed first to the publisher. While every reasonable care is taken, neither the publisher nor its participating agents accept liability for loss or damage to prints, colour transparencies, negatives or other material of whatever nature submitted to this publication. The views expressed in this publication are not necessarily the views of those held by the publisher. MAIN: SHUTTERSTOCK/AGFOTO • TOP: SHUTTERSTOCK/PANUWAT PHIMPHA • MIDDLE: SHUTTERSTOCK/KYRYLO GLIVIN • BOTTOM: SHUTTERSTOCK/DAVIZRO PHOTOGRAPHY Beverages36 Consumer demand has shifted to healthier, functional beverages, pushing companies to expand past existing product lines to produce something innovative. End of line packaging40 Investing in end of line packaging not only offers efficiency and process optimisation benefits for food and beverage producers, but also environmental gains. Recycling and waste management44 Companies in the food and drink industry are being held to higher standards than ever before regarding the amount of waste they produce and its effect on the environment. PLD Paris 202049 PLD - Packaging for Premium & Luxury Drinks, the new drinks packaging focus, is co-located with ADF&PCD Paris 2020: the world’s largest dedicated event for the aerosol, dispensing, perfume and cosmetic packaging markets. Events 50 Your chance to keep abreast of forthcoming exhibitions and food fairs from around the world Classified 53 Food & Drink Diary 54 03.qxp_Layout 1 19/11/2019 11:19 Page 1Rigid Containers attains hygiene accreditations for direct contact food packaging Rigid Containers, part of the VPK Packaging Group and a leading supplier of sustainable corrugated packaging, has attained its first BRC Global Standards Higher Hygiene and The American Institute of Baking (AIB) certification. The accreditations were earned by the company’s Wellington site, allowing Rigid to further build on its packaging solutions to the food and drink sector and now supply direct contact packaging to manufacturers. Over half a million pounds was invested by the business in readying the Wellington site for both the BRC and AIB audits, with improvements made to the building, equipment upgrades and enhanced training for staff. The BRC Global Standard for Food Safety is developed by food industry experts from retailers, manufacturers and food service organisations to ensure it is rigorous and detailed. It provides a framework to manage product safety, integrity, legality and quality, and the operational controls for these criteria in the food manufacturing, processing and packing industry. 4 Food & Drink International www.fdiforum.net Endress+Hauser achieves UKAS accreditation Endress+Hauser’s wet flow calibration rig, based at the company’s UK headquarters in Manchester, has been awarded UKAS accreditation. UKAS ensures that companies meet the requirements of ISO 17025, the international standard for testing and calibration laboratories. The rigorous auditing process tests the quality and method of the calibration as well as the competency of technicians carrying out the work, the process of creating and storing documentation and the traceability of reference standards. “It’s a trust issue,” explained Mohsin Patel, Internal Repair and Calibration Team Leader. “Because we’re UKAS accredited, customers can trust us and know that we provide a quality service. It means they can rely on the accuracy of their flowmeters, which is vital for quality-critical applications in the life sciences, oil & gas and food & beverage sectors.” Endress+Hauser said it aims to become the number one calibration provider in the UK. news Heineken swaps plastic rings for cardboard topper on multi-pack cans Heineken UK is removing plastic rings and shrink wrapping from its beer and cider multi- pack cans as part of a £22 million investment. The move will see the brewer remove 517 tonnes of plastic annually from the supply chain. In place of the plastic rings, Heineken is switching to a topper made from sustainably- sourced cardboard. According to the brewer, this new topper is 100% recyclable, compostable and is robust and easy to grip. The new topper will be rolled out across Heineken, Foster’s and Kronenbourg 1664 multi- pack cans and made available in UK retailers from April 2020. This will be followed by all Heineken brands in multi-pack cans – including Strongbow, Bulmer’s and John Smith’s – by the end of 2021. The £22 million investment will be split between the brewer’s Manchester, Tadcaster and Hereford sites, with the technology piloted at the Manchester brewery before the end of the year. “Now, after years in development and huge investment, we’re extremely pleased to announce our recyclable and compostable topper innovation, a significant milestone in our journey to eliminate all single-use plastic,” said Cindy Tervoort, UK Marketing Director, Heineken. WorldFish commits $1m for aquatic foods research Nonprofit WorldFish has committed $1 million to fund new research into aquatic foods for planetary health and human wellbeing with an emphasis on Africa. The commitment for 2020 aims to support the development of a new, multi- year global research programme on fish and future aquatic foods. It will also establish a ‘Fish for Africa Innovation Hub’ to help accelerate national and regional efforts to meet Sustainable Development Goals by 2030. According to the Malaysian headquartered nonprofit, these aims will be accomplished through “cutting-edge market and policy innovations informed by scientific evidence on affordable, safe and sustainably fish and aquatic foods”. This latest commitment follows the nonprofit’s pledge in 2017 of $57.8 million to generate scientific research and innovations. © Shutterstock/Alexander Raths © Heineken UK 04-11.qxp_Layout 1 19/11/2019 11:27 Page 1newsFood & Drink International 5 www.fdiforum.net Admiral Taverns acquires pub portfolio from Marston’s Community pub group, Admiral Taverns, is acquiring a portfolio of 137 pubs across England and Wales from brewery, pub and hotel operator Marston’s for £45.9 million. Over the last year, Admiral has accelerated its growth strategy to expand its estate of community pubs. In October, it acquired 150 pubs from Star Pubs & Bars. This latest deal adds yet more pubs to its expanding portfolio as the group continues its strategy pf acquiring, integrating and developing sustainable tenanted pub businesses. To support the integration of the pubs in the portfolio which currently operate under retail-agreements, the group has formed a partnership with experienced managed- operator Helen Standing. This partnership will facilitate the smooth transition of these pubs to the Admiral platform whilst the Group evaluates the longer-term opportunities for these sites. Ornua opens €30m cheese production facility in Spain Ornua, Ireland’s biggest exporter of dairy products, has officially opened a €30 million cheese production facility in Ávila, Spain. The new facility replaces a former Ornua cheese manufacturing site which was destroyed in a fire two years ago. The mozzarella and pizza cheese facility enhances Ornua’s pizza cheese making capacity and capability. Currently, it supplies enough cheese for over 100 million pizzas each year. The reopening of the Ávila facility also marked the creation of Ornua Ingredients Europe which brings Ornua’s Spanish and UK Ingredients businesses together. The new division, which provides cheese and dairy powder ingredients, supplies over 75,000- tonnes of added value ingredients to food manufacturing, QSR and pizza customers. The Ávila site features a R&D Centre of Excellence with a pilot plant and innovation kitchen dedicated to developing the next generation of pizza cheese and cheese ingredients for the $130 billion global pizza market. Industrial handling solutions from Simmatic Automation Specialists Simmatic Automation Specialists has been providing industrial handling solutions for over 20 years. Using extensive expertise, the company has evolved to produce in-house end of arm tooling and vacuum handling solutions. Simmatic has a clear vision of the futures requirement to automate process solutions. Representing likeminded innovative forward- thinking companies Vmeca and Airwork, ensures it can keep offering the very latest in technological developments that best suit the customer’s needs. The firm invite you to challenge it with your difficult to handle pouches, sachets and boxes and it will give you the most optimised and reliable solution for your process, send them to the company and detail the process and it will get video supported offer to you. Recently, Simmatic was challenged to handle sausage rolls and pasties at two per second and developed an in-house EOAT which gave a totally reliable solution despite the difficulty of delicate pastry. For more information, visit www.simmatic.co.uk. Delta 3000 transforms the sandwich run and Tiffin Tiffin Sandwiches’ search for an ultra-hygienic flow wrapper has ended at ILAPAK’s Delta 3000 flow wrapper. So impressed is the independently- owned sandwich producer with the Delta 3000’s performance that it has named this model its flow wrapper of choice and invested in three of these machines since 2016. Tiffin produces over 20 million sandwich items annually, supplying schools, hospitals and other outlets via a nationwide distribution network. It first invested in ILAPAK’s entry-level Smart flow wrappers to automate its packaging operation. In 2016, when Tiffin was looking to purchase a more advanced flow wrapper that would deliver both hygiene assurance and efficiency gains, it turned to ILAPAK. ILAPAK had just launched its new Delta series of modular flow wrappers, and the mid-range Delta 3000, with its high speed hermetic sealing capabilities and hygienic build, looked to be ideal for Tiffin’s requirements. “I was really pleased with what I saw; efficiency, mechanically, electrically and hygiene-wise it was perfect,” recalls Michael Tomes, Engineering and Facilities Manager Hygienic design is a major consideration for Tiffin, as the sandwiches are made in a high care area and the machines need to be cleaned thoroughly and regularly when switching between fillings for food safety and allergen labelling reasons. The roller configuration on the Delta 3000 was another tick in the box, as Tiffin could see that the additional roller would result in more reliable sealing. “The Delta 3000 uses three rollers for making the fin seal, rather than two as is the case with most entry level flow wrappers. This makes for extremely consistent sealing performance,” explains Chris Gee, Sales Manager at ILAPAK UK. For more information, visit www.ilapak.co.uk. © Shutterstock/View Apart 04-11.qxp_Layout 1 05/12/2019 12:52 Page 26 Food & Drink International www.fdiforum.net news Multiple awards for The Label Makers’ complex and distinctive rum label A complicated illustration for rum brand, Diablesse, has been faithfully interpreted through embellishment and print by leading label manufacturers, The Label Makers. The result is a standout pack that has won both the ‘Label of the Year’ at the recent UK Packaging Awards and the ‘Special Effects in Labels and Packaging’ category in the Digital Printer Awards 2019. The rum is produced by independent Manchester distillers, Farman & Son, and comprises two expressions - Diablesse Caribbean Rum and Diablesse Clementine Spiced Rum. The label, designed by Leeds- based creative agency, Made by Analogue, tells the story of the ‘Diablesse’, a temptress from Caribbean folklore. “The Label Makers did a wonderful job in bringing the label from design to life and, from my initial vision, they completely fulfilled what I hoped could be achieved,” said founder, Cleo Farman. David Webster, Managing Director of The Label Makers, added: “We are delighted with how the label has been received to-date.” Kemin centralises supply chain with latest innovation Kemin, a global ingredient manufacturer that strives to sustainably transform the quality of life with its products and services globally, has centralised the supply chain for BactoCEASE® NV, its clean-label, vinegar-based food safety solution, by establishing production in Europe. This expansion provides a more sustainable supply of the product with reduced delivery time, increased production speed and more flexibility for customers ordering Kemin ingredients in the EMEA region. Earlier this year, Kemin Food Technologies – EMEA region, launched BactoCEASE® NV OR Liquid and NaturCEASE™ Dry, two new clean-label solutions that help meet customer demand for food safety in the protein market. BactoCEASE® NV OR Liquid is an organic ingredient that extends the shelf life of meat, poultry and fish by controlling the growth of spoilage bacteria without negatively impacting the finished product’s texture or flavour. NaturCEASE™ Dry is an all-in-one ingredient consisting of buffered vinegar and plant extracts to preserve meat colour, flavour and freshness. China’s pork market will need five years to rebalance, says Rabobank China’s disease-hit pork market will not stabilise until 2025 due to the time needed to rebuild its decimated herd inventory, according to a new report from Rabobank. Analysts from the bank say that China’s pig herd will take over five years to recover from the damage wreaked by African swine fever (ASF). China’s pig herd has already contracted from over 430 million animals in August 2018, when the first case of ASF in the country was reported, to now stand at under 200 million pigs. The focus next year and in 2021 will be on small-scale restocking and large-scale importing before hog production increases in the years to 2025, when the market should rebalance and prices stabilise, says Rabobank. However, even then the total herd is unlikely to return to the 2018 peak, analysts predict. The report, ‘China’s Recovery from African Swine Fever, Rebuilding, Relocating and Restructuring’, says that China will be unable to import enough pork to make up for the production shortfall in the coming years, causing high global prices and prompting consumers to change habits. Rabobank predicts China’s population will consume more chilled, frozen and processed meat – rather than the preferred fresh warm pork – while poultry consumption will rise to make up some 30% of the market by 2025. As a result of ASF, China’s pork market will be changed forever, with pork’s share of the market declining from the recent 63% to 53%, the bank’s analysts forecast. Bulletin lunched to help reduce listeria contamination in dairy The International Dairy Federation (IDF) has published a new bulletin outlining how steps in the production process can minimise listeria contamination in dairy products. The bulletin summarises risk areas and measures that should be taken in the food production process to minimise the risk of L. monocytogenes contamination in dairy products. “Effective management and hazard analysis within the dairy processing environment can minimise the likelihood of contamination with L. monocytogenes, therefore giving better food safety assurance,” said François Bourdichon, main author of the publication and present Chair of the IDF Standing Committee on Microbiological Hygiene “This bulletin provides details on additional measures that must be taken to avoid contamination and ensure the safety of dairy products which are so essential for a healthy diet.” © Shutterstock/felipe caparros © Shutterstock/shellygraphy 04-11.qxp_Layout 1 19/11/2019 11:27 Page 3news To advertise your services on the news pages contact us on 01472 310302 Food & Drink International 7 www.fdiforum.net Endo Sport launches UK’s first CBD-infused sports drink The UK’s first CBD- Infused Sports drink, designed to be used by both athletes and non- athletes during workouts, was launched at the International Drinks Exhibition in November. With interest in CBD oil growing at an unprecedented rate, Endo Sport taps into the fitness market and offer gym- goers an alternative to their current sports drink. With 10mg of CBD per 500ml bottle, Endo Sport can be taken as a pre- or post-workout drink. When taken before a workout, it delivers a boost of energy and increased focus to help get the customer through their gruelling session. After a workout, the anti- inflammatory properties of CBD get to work to help reduce post- exercise muscle soreness and speed up recovery. As well as delivering the benefits of CBD, Endo Sport will also help? consumers by replacing electrolytes lost through physical exercise and providing enhanced hydration?. Endo Sport will come in two flavours, Orange and Berry & Tropical. From simple to complex With the launch of its new low-cost high specification VEGABAR pressure switch/sensor and VEGAPOINT level switches, VEGA can help customers in even more areas in the food and beverage production processes. The new level and pressure devices have a universal adapter system of process fittings that provide the flexibility needed to keep installation and spares inventory costs low. A unique ultra-bright, eye- catching, 360° illuminated status display ring ensures visibility, safety and process reliability. Its status colours can be custom-selected easily seen from any direction – even in bright daylight. Some of the new pressure switch/sensors feature displays and keypads with dual easy-read text and VDMA menu, ensuring the right set up every time. Another prominent feature of the instruments is their communication capabilities. They feature Bluetooth wireless, which offers another option for safe remote and easy set up or function check of devices without the need for a PC, cables or connectors. THE SPOTLIGHT IS ON YOU #fruitlog2020 =ub|Ѵo]bvঞ1-ĺ1ol HIGHLIGHTS 2020 New: Hall 27 featuring leading global players Spotlight on sustainability across all events Your local contact: l-m7Š=ub|m;|ĺ1ol 04-11.qxp_Layout 1 19/11/2019 11:27 Page 48 Food & Drink International www.fdiforum.net news Stylish new carton highlights SIG’s core USP – flexibility SIG continues to innovate and address consumers’ ever-changing needs with the launch of its unique combistyle carton pack. Featuring a distinctively shaped corner to ensure on-shelf differentiation, combistyle offers instant consumer appeal, added functionality and more convenience. combistyle brings a fresh and distinctive look – a stylish corner panel provides a comfortable and safe grip, while allowing brand owners to effectively communicate key messages with eye-catching designs. Customers will benefit from the low investment needed to upgrade to combistyle on existing CFA810 and CF812 filling machines, which also can fill combiblocMidi and combifitMidi, the original packs for these lines. This offers manufacturers the best shape flexibility for different product types and the ability to adapt to changing market demands, as three carton formats can be filled on a single line. Upgrading will not only maintain efficiency on the original line, but also help to bring new and exciting beverages to market in a faster time period. For more information, visit www.sig.biz. Newly developed pork cuts unlock more profit for producers The Agriculture and Horticulture Development Board (AHDB) has developed several new pork cuts that, it says, unlocks profit from a third of the carcase. Should industry adopt the new methods profits may increase significantly, the AHDB says, creating new uses from what is known as the forequarter, commonly used for lower value offerings like chops and sausage meat. Cuts such as the Derby rib, a chuck eye joint, a Presa steak, pork Henry and Boston butt have been created, drawing innovation from global butchery methods and cooking research. Dick van Leeuwen, AHDB’s Business Development Manager and Master Butcher, created the new guide to help futureproof the industry. “Consumer demands and eating habits are continually changing therefore there is a constant need for new cuts and product development,” he said. “By using seam butchery – which preserves individual muscles within the pork forequarter, utilising the bone structure and upgrading individual muscles into modern, consumer friendly cuts for the retail and foodservice sectors, represents significant profit opportunities for a variety of businesses working with pork.” Within the new range are cuts suitable for a variety of cooking methods like, ready meals, sous vide – a partial cook method to reduce consumer cooking time and increase shelf life – BBQ, roasting, pot-roasting, grilling and frying. The thirty-five new cuts are detailed in the board’s ‘Profit from the Pork Forequarter’ guide. Specially engineered Hyster lift trucks refresh operations at Heineken Six new Hyster electric lift trucks which feature special engineering to meet the demands of brewery operations have been provided to the Heineken Ireland site in Cork. Heineken Ireland’s site in Cork employs 458 people and ships 2 million kegs per year to pubs, hotels, restaurants, supermarkets and wholesalers. As such, the brewery’s yard operations are intense, loading and unloading on average 20 lorries each day. “Empty kegs arrive every day and have to be unloaded and placed on a conveyor to take them to the production area,” explains Matt Hardy, Industry Manager for Hyster Europe. “At the same time, full kegs are collected and stacked in the storage area ready for despatch.” To help overcome these challenges, the Hyster Special Truck Engineering Team developed a raised operator compartment for the six new Hyster J3.5XN lift trucks which improves all-round and upwards visibility. The new lift trucks also feature a specialised Kaup Keg clamp attachment. © Shutterstock/rtem Mastercard and Envisible fostering food supply chain traceability Mastercard is combining its blockchain solution with supply-chain visibility specialist, Envisible, to foster traceability in the food supply chain. Envisible’s Wholechain traceability system will be powered by Mastercard’s blockchain- based Provenance Solution and used by US food cooperative Topco Associates to help its member-owners’ supermarkets trace and highlight the origin of seafood. Beginning with Food City, Topco is working with its member grocery chains to pilot the use of the technology to provide better line of sight into ethical sourcing and environmental compliance of the seafood selection sold at their stores. The first of several species to be tracked will be salmon, cod and shrimp. Dan Glei, Executive Vice President of Merchandising and Marketing at Food City, said: “Using Envisible Wholechain, powered by Mastercard, our grocers will be able to stock shelves with confidence and also be able to pinpoint issues in the food chain during any unfortunate events such as recalls.” © Shutterstock/Zapp2Photo 04-11.qxp_Layout 1 19/11/2019 11:27 Page 5news Food & Drink International 9 www.fdiforum.net Vion to transform beef facility into dedicated plant-based site Vion, the Dutch pork and beef producer, is making good on its promise to introduce meat alternatives by opening a dedicated plant- based site. Earlier this year, CEO Ronald Lotgerink announced the company’s intent to introduce meat alternatives to meet consumer demand. Now, the company has earmarked its Leeuwarden site as the home for its future plant-based facility. Built in 2007, the site currently operates as a beef facility. Vion said the site can be “easily adjusted” to become suitable for plant-based production and can be scaled up to add more production lines, freezing capabilities and larger storage capacity. Mr Lotgerink said: “The capacity for livestock processing in the Netherlands has grown significantly in the past two years, and has proven to be more than sufficient to meet the demand. “Given the knowledge we gained from our investment a few years ago, we are now making the strategic choice to invest in a dedicated plant-based site in Leeuwarden.” Where’s there’s a mill, there’s a way Babcock Wanson has supplied flour millers Whitworth Bros. with two TPC Thermal Fluid Heaters for its flour heat treatment process at its Barlby Road, Selby site. A new customer for Babcock Wanson, Whitworth Bros. had been using another manufacturer’s thermal fluid heater, but it suffered a failure of the heating coils and the incumbent company was unable to supply a swift solution. Babcock Wanson’s Thermal Fluid Heating System rental service proved an invaluable solution. Two ‘plug and play’ TPC 400B Thermal Fluid Heater were delivered to site and set up by Babcock Wanson’s experienced commissioning engineers. From here, Babcock Wanson TPC 600B and TPC 1000B thermal fluid heaters were ordered by Whitworth Bros. These are now in situ and are being used to pre-heat filtered air, which is then used as part of the heat treatment process of flour which changes the baking properties for suitability in different food products, such as sauces, batters etc. 04-11.qxp_Layout 1 19/11/2019 11:27 Page 6Next >