< Previouson line 10 Food & Drink International www.fdiforum.net Arla expands mozzarella capacity Arla is investing € 80 million to more than double the production of mozzarella at its Branderup Dairy in Denmark to meet rising global demand. Arla’s mozzarella production in Denmark is concentrated on Branderup and Rødkærsbro Dairies. From here, cheeses are shipped worldwide to 100 countries on all continents. Arla will expand the milk weighing capacity, milk silo inventory, milk processing area, storage capacity and add a cheese production line to increase the annual production with 53 million kilos of mozzarella. The amount of extra cheese more than doubles the current mozzarella production, so that Branderup Dairy in the future will produce 91 million kilos of mozzarella per year. Arla will also create approximately 25 new jobs in the local market in connection with the increased capacity. The new investment is also an investment in more sustainable technology. The expansion begins next year and expected to be completed in the summer of 2021. Maple Leaf Foods goes carbon neutral Meat processor, Maple Leaf Foods, has claimed it has become the “first major food company in the world to be carbon neutral”. The company’s path to carbon neutrality is based on “aggressively reducing” emissions by meeting the golden standard of widely respected Science Based Targets. In doing so, the company said it has become one of three animal protein companies globally to set Science Based Targets approved by the international Science Based Target Initiative. As part of becoming carbon neutral, Maple Leaf Foods is also investing in environmental projects throughout Canada and the US to address its remaining carbon footprint, bringing it to zero. These projects support wind energy, recovering methane gas from landfills, composting and biomass programs to reduce methane emissions, and forest protection and re-forestry to conserve species and biodiversity. Cargill hub to help customers solve food formulation A newly opened Culinary Experience Hub in Belgium is allowing Cargill customers from across the EMEA region to solve food formulation challenges and co-create new The facility, based in Cargill’s R&D sit in Vilvoorde, features a bakery pilot plant, a regional frying centre and a culinary tasting area with capabilities for dairy, beverage, bakery, convenience foods and culinary applications. “Imagine you’re a Cargill customer trying to identify the best ingredients for consumers. You could hear about an ingredient’s specifications and functionality, and perhaps sample a prototype. Or you could come to Cargill in Vilvoorde to co-create and taste a freshly prepared plate of food products like the consumer would at home or in a restaurant,” says André van der Wulp, Cargill R&D leader in EMEA. “Cargill’s Vilvoorde Culinary Experience Hub houses a team of culinary experts and chefs that collaborate with customers to develop on-the-spot innovative solutions that specifically address the challenges and demands of consumers.” Nestlé & Corbion developing algae ingredients for plant-based products Nestlé has partnered with Dutch chemicals company Corbion to develop next-generation algae- based ingredients for plant-based products. The agreement will combine Corbion’s microalgae and fermentation capabilities with Nestlé’s expertise in the development of plant-based products. The aim is to establish a platform for the production and commercialisation of algae-based ingredients rich in protein and micronutrients. The research will work to further develop the functionality, taste, and nutritional profile for use in different types of products. Marc den Hartog, Executive Vice President Innovation Platforms at Corbion, added: “This new protein partnership with Nestlé has the potential to open important avenues for algae-based products into large global markets.” Kemin opens innovation centre in China Ingredient manufacturer, Kemin Industries, has opened a new Innovation and Technology Centre at its regional HQ in Zhuhai, China. The new CNY 100 million ($14.2m) 4,200 sqm facility will employ scientists to work in the industries Kemin serves, including human and animal nutrition and health, aquaculture, food technologies, pet food, specialty crop improvement and more. “This new laboratory will allow Kemin to harness the talent and creative thinking of Chinese scientists and the insights of our customers to develop the technologies they need,” said Dr. Chris Nelson, President and CEO of Kemin. “We must take the opportunity to tap into our local customer base to better understand their needs and the challenges they face. Opening a research and development centre here prepares us to better meet the growing demands of our industries in the region and increase our global impact.” © Shutterstock/Giuseppe Parisi © Shutterstock/pedrosala © Shutterstock/Chokniti Khongchum © Shutterstock/koya979 04-11.qxp_Layout 1 19/11/2019 11:27 Page 7English Tea Shop unveil new core range & gift collection English Tea Shop, a premium speciality tea company, has unveiled a new core range and gift collection in time for the Christmas period. The range contains organic and hand- picked flavour combinations that, the brand says, deliver a variety of “interesting and refreshing” blends. Included in the new launch is The Super Goodness Collection Gift Tin which boasts a variety of different flavour combinations, such as White Tea Matcha and Turmeric and Ginger & Lemongrass. The Ultimate Tea Collection, meanwhile, features six varieties and includes combinations such as Super Berries, Perfect Peppermint and Earl Gray. Also included is tea from the brand’s Core Range, Super Range and Wellness Range. English Tea Shop uses quality tea leaves and age-old practises to bring Brits tea from the heart of Sir Lanka, working with organic and Fairtrade farmers. Coca-Cola North America launches first new brand in ten years Coca-Cola is adding a new beverage to its North America portfolio with the forthcoming launch of a caffeinated sparkling water brand. The new AHA brand launches in March 2020 in eight fruity flavours, all of which have no calories as the company looks to meet changing consumer demands and tackle category The new sparkling water brand’s unexpected yet accessible flavour pairings, vibrant packaging and fresh marketing will meet evolving consumer demands and cut through a crowded category that continues to grow at double-digit rates. This is the first major brand launch in ten years for Coca-Cola North America following the 2006 launch of the Gold Peak tea brand. Extensive research and consumer insights informed the development process that brought AHA from concept to prototype in just over six months. on the shelf Motörhead launches trio of spirits in UK Motörhead, the veteran British hard rockers, is launching its spirits portfolio in the UK with a dark rum, vodka and single malt whisky. Aged for eight years in ex- bourbon barrels, the Premium Dark Rum originates from the Dominican Republic and is full-bodied with notes of chocolate, arrack and vanilla, with a spicy finish. Pure and clean yet still complex, the Motörhead Vödka is smooth enough to drink solo over ice, yet still bold enough to stand out in the crowd when combined with your favourite mixer. The Motörhead Single Malt Whisky is made in collaboration with Swedish whisky legends, Mackmyra, and their Master Blender, Angela D’Orazio. Matured in new American oak barrels for five years, the result is an easy to drink oaky and spicy whisky, with herbaceous aromas of tobacco and anise and character of citrus and almonds. Nestlé taps DC heroes for latest bottle launch Nestlé Pure Life has teamed up with Warner Bros. and DC to expand its portfolio with the launch of bottles boasting comic book characters Batman, Wonder Woman, Superman and Shazam. The new 330ml DC Collection are made from 100% recycled plastic (rPET) and are, in turn, entirely recyclable. Each bottle also comes with a superhero symbol on the side that, Nestle Pure Life said, encourages kids to finish drinking their water. Once done, they can shine a flashlight through the bottle, projecting the symbol on a wall. To ensure both the bottles and the sleeve labels are fully recyclable, Nestlé Waters North America is using new labels that are more compatible with the recycling process. Unlike some other sleeve-wrapped products, this new sleeve label technology does not require consumers to remove the label before recycling; consumers can simply place the cap back on the bottle when finished and discard in the recycling bin. Food & Drink International 11 www.fdiforum.net Chadwicks develops new lid for premium product range Market leading pre-cut lid and shrink sleeve manufacturer Chadwicks of Bury (part of the Clondalkin Group), has developed an aluminium lidding material to seal to glass. Developed in-house by Chadwicks, the decorative lids have been produced for a new premium yogurt range from Alston Dairy. Ken Dunlop, Sales Manager at Chadwicks said: “Typically, sealing pre-cut lids to glass presents many technical difficulties; however, when Alston Dairy approached us about developing a new type of material capable of sealing to glass jars we rose to the challenge. Alston also required a ‘crimped over’ lid to emphasise the premium nature of the range. “Working in partnership with our sister company Royal Vaassen in the Netherlands, we developed a material that provides an optimum sealing solution for glass, and teamed up with Seal-it-Systems to create the desired ‘crimping’ effect.” Emma Coupe, Development Director from Alston Dairy, said: “We are delighted with the finished product.” © Nestlé Waters North America 04-11.qxp_Layout 1 19/11/2019 11:27 Page 812 Food & Drink International www.fdiforum.net IMPORT AND EXPORT Rules to entry 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. Understanding what constitutes these risks and the guidance around their entry into the UK is prudent for importers dealing with counties outside of the European Union, as Food and Drink International explores. 12-15.qxp_Layout 1 19/11/2019 11:31 Page 1Food & Drink International 13 www.fdiforum.net IMPORT AND EXPORT © Shutterstock/Martin Charles Hatch Importers looking to bring food and drink products into the UK must currently comply with European law. Any products that don’t meet these standards will be barred entry. In order to avoid this outcome, importers are advised to be transparent and cooperate with current laws and that means goods need to be checked through designated points of entry (or DPE for short). Here documentary checks take place to assess the consignment, verifying what’s on paper is what’s in the container or truck. Physical checks may also need to be carried out before a consignment is allowed through. As the law stands, importers must notify DPEs at least one working day in advance of a consignment’s physical arrival. If an importer is attempting to bring foods into the country containing known contaminates, they must be brought through a DPE which is able to check produce. Far from a one-size-fits-all approach, DPEs all have their own specialities so while some deal solely with animal feed, others focus on produce, while there are some which are more specialised, dealing with dried fruits from specific geographic locations. Foods are considered to be high risk if they contain contaminates such as mycotoxins, aflatoxins, pesticides, salmonella and heavy metals. Mycotoxins are produced by fungus and the danger to human health comes when they are inhaled and solubilise in body fluids. Foods that are highest in mycotoxins – and are thusly checked in DPEs – include barley, wheat, rye, peanuts and hard cheeses, among others. Considering the UK imported £3.9 billion worth of cereals in 2017, the importance of these stringent regulations and thorough checks is obvious. Aflatoxins, on the other hand, is a mould acknowledged as a human carcinogen and most commonly found in peanuts and corn. The species of mould that combine to form this contaminate are found in soils where conditions are just right – this includes when decaying food, plants, hay and grains pile together to decompose in areas with high moisture and temperatures. For that reason, they’re most prevalent across Asia and Africa, meaning corn and peanuts imported from these areas often have to be checked. That’s not to say that every consignment needs to be sent to the lab as there are limits on the level of aflatoxins that can be imported into Europe. Consignments thought to exceed these levels, however, will be held while laboratory tests can be undertaken. 14 Á 12-15.qxp_Layout 1 19/11/2019 11:31 Page 214 Food & Drink International www.fdiforum.net IMPORT AND EXPORT The other prevalent contaminate is pesticides, residue from which can be found on fresh fruit and vegetables and pose a risk to human health. Foods most commonly contaminated include lettuce, spinach, strawberries, apples and blueberries. Of course, products thought to be contaminated with any of the above cannot be judged by eye alone and so lab checks are required. A small sample of the consignment is sent to the lab where it is tested for the suspected contaminate. The speed of results can depend on a number of factors including sample size – as larger or multiple consignments will need a larger sample – and what specifically is being tested for. A sample being analysed for the presence of aflatoxins alone will be much quicker than a sample being checked for multiple contaminates Further, testing for salmonella, takes longer as the bacteria needs to grow in a petri dish. To ensure that there are no chokeholds and tailbacks at ports and DPEs during these checks, consignments controlled at the border can be allowed to move inland pending the results of laboratory tests. But arrangements must be put in place to ensure any consignment remains under continuous control of authorities and, thus, cannot be tampered with pending lab checks. Until these results are known, a consignment is required to be stored at a UK External Temperature Storage Facility. The process outlined above and the laws and regulations that govern it will no longer be valid if the UK leaves the EU without a deal. In that eventuality, importing foods, livestock and animal feed into the UK will still be allowed to take place, and high risk foods will still be required to go through DPEs. But the process of notifying UK authorities of these imports will change. A no-deal scenario – still the default outcome if MPs can’t agree on the country’s course of action and no more extensions are granted – would mean that UK importers no longer have © Shutterstock/ Wipas Rojjanakard 12-15.qxp_Layout 1 19/11/2019 11:31 Page 3Food & Drink International 15 www.fdiforum.net IMPORT AND EXPORT access to the EU’s Trade Control and Expert System (TRACES). Instead, importers will be required to use a new UK system called the Import of Products, Animals, Food and Feed System (IPAFFS). Although importers can still use the TRACES system, IPAFFS can be registered for now, so it might be a good idea to hedge your bets. This outcome will also likely lead to an increase in the number of checks at UK borders. But perhaps most worryingly is that if the UK does leave next year without a deal there will be no implementation period. Better government knuckle down and work in everybody’s interests, including the importers that keep food and feed flowing into the country. Decline in employment, consumer confidence & global trade ahead A decline in employment, consumer confidence and international trade following Brexit is expected for the food industry, according to a report from industry experts. Global insights platform Atheneum and online statistics portal Statista have partnered to establish perceptions and outlooks for several industries globally, utilising the former’s network of over 500,000 industry experts. The food industry stood out globally against other industries, with experts particularly concerned about employment. Experts are particularly dissatisfied with their country’s current levels of international trade and over a third (39%) expect it to worsen over the next six months. Only 8% of respondents reported being ‘very satisfied’ with the state of international trade (less than one in 13 experts), and only 11% believe it will improve. Concerns and uncertainty around the value of the pound mean the UK could see a period of significantly reduced spending in the immediate aftermath of Brexit, as consumers wait to see the impact leaving the EU will have. Imported food should meet British standards, says majority of pubic The government should ensure that all imported food meets the same high animal welfare and environmental standards in place on British farms, new research reflecting the public has found. The research was carried out by ComRes on behalf of the British Guild of Agricultural Journalists (BGAJ). ComRes surveyed the public in September and found 84% support the view that imports should match British standards as Brexit threatens to open the door to imports from low cost producing, de-regulated markets across the globe. The study found that just 16% would buy food they know is produced to lower animal welfare standards if it was cheaper than food produced to a high standard. Professor of Food Policy at the University of London, Tim Lang, said: “The survey suggests the UK public almost certainly recognises the need for UK farming to tick lots of boxes. It’s got the message that farming is multi-functional. But have the politicians?” © Shutterstock/Africa Studio © Shutterstock/Aleksandar Malivuk 12-15.qxp_Layout 1 19/11/2019 11:31 Page 416 Food & Drink International www.fdiforum.net WAREHOUSING OPTIMISATION N ow more than ever, warehouse managers must invest in technology for transparent operations and to contribute to the consumer and retailer desire for traceability in the supply chain. In response, investment is being directed towards new and improved warehouse management systems (WMS), which are essential for maintaining accurate knowledge of inventory as well as in dealing with compliance regulations and changing supply chain requirements. Interest in WMSs has come as managers look to optimise capacity and boost efficiency of warehouses as well as reduce human error with a system that can program paths used in picking. WMSs have also proven to be beneficial in optimising warehouse layout - learning where goods should be stored for ultimate efficiency and to avoid unnecessary movement and travel The smart warehouse concept 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’. 16-19.qxp_Layout 1 19/11/2019 11:33 Page 1Food & Drink International 17 www.fdiforum.net WAREHOUSING OPTIMISATION times. Further, WMS programmes can organise how pallets are loaded and built based on factors such as expiration date, and direct product movement from entrance to departure. In conjunction with WMSs, barcode scanning and real time tracking tech are also sources of investment, and of prime importance is the Internet of Things (IoT). IoT allows a network of devices constantly communicating with one another to be created, which produce significant amounts of data on operations that can be acted upon. With IoT sensors and RFID tags around the warehouse and on goods, one is able to monitor the movement of products in and out of a warehouse. Constant real-time details on an item’s status and position are relayed with these sensors, allowing for improved visibility and stock accuracy, and they are capable of ordering stock when it is low. This tracking can also be utilised to discover patterns and demand trends, enabling warehouse users to be more proactive in regard to stock held in the future, and can help prevent incidents like overstocking. Linked to the supply chain, an IoT enabled warehouse allows companies to store and order what is needed. With companies placing precise product orders, food manufacturers can create only what is required, decreasing waste. Despite the potential benefits, connecting warehouse operations and equipment to the IoT has been prevented by concerns over security. Fortunately new technologies are in development to boost the safety of employing IoT sensors, for example Microchips that enable more efficient encryption. The usefulness of IoT in warehouses extends in enabling warehouse automation. Though the idea of fully automated warehouses is not yet feasible - with high costs, technology still developing and the need for a different type of workforce - many forms of automated and autonomous technology have entered the warehouse and are affecting warehouse design. Robot pickers, for instance, in an IoT enabled warehouse, can receive orders, locate items and communicate with smart shelves to find exactly where an item is and retrieve it efficiently. Meanwhile Automated Storage and Retrieval Systems (ASRS), such as cranes or shuttles navigating fixed tracks, can retrieve goods at heights potentially over 120ft safely and can automatically load pallets. Automated Guided Vehicles (AGVs) and Automated © Shutterstock/TRAIMAK 18 Á 16-19.qxp_Layout 1 19/11/2019 11:33 Page 218 Food & Drink International www.fdiforum.net WAREHOUSING OPTIMISATION Guided Carts (AGCs) transporting inventory can streamline replenishment, working in a variety of ways from following magnetic strips to using infrared and camera vision to manoeuvre semi-autonomously. Robot arms are another useful piece of automation technology, for de- palletising and palletising as well as picking and packing. Overall these robots enable quicker movement of goods and are able to process more items than humans. Shortening turnaround times, they also reduce human workload, redistributing efforts from time consuming repetitive tasks, and minimise chance of human injury and error. Drones are also flying into warehouses integrating automation for inventory and asset management as stock gets stored higher and higher to make full use of costly floor space. This rids the need to spend hours of labour using ladders and forklifts to reach barcodes for this task. Speeding up stock checking, scanner-carrying drones can read RFID tags. More advancements are needed, however, to allow for more drones to be used at once without colliding in tight spaces. Further instances of IoT technology making its way into the warehouse include wearables. Already well- established voice picking is being integrated with smart glasses that take advantage of Augmented Reality (AR). AR can be used to support picking by helping workers find picking points, indicating the best route to take and presenting a digital checklist of work orders. It has the potential to be used by pickers on foot and in for instance forklifts. AR can also help in sorting items on a pallet, indicating the best sorting order by fragility and weight to avoid damage and fully utilise pallet size, and help when loading trucks containing items of varying shapes to make full use of truck capacity. With smart glasses, workers can receive information while giving voice commands to scan barcodes or take photos. Connected to a WMS, real time object recognition and navigation assistance are also offered by this AR tech. Vision and voice picking wearables mean workers are not focusing on a screen, preventing accidents like trips, as they are more aware of their surroundings. Other wearables like smart gloves are being introduced too, with which one can scan barcodes, removing the need to use a clunky handheld scanner, allowing workers’ hands to be free. Wearables are developing rapidly, and the future could see exoskeletons wrapped around worker’s bodies to offer support, add to lifting capabilities, and reduce repetitive strain injuries. A further hot topic in warehousing and distribution is sustainability. Warehouse owners and users are looking to reduce energy consumption, waste and cut emissions. This is seeing © Shutterstock/August Phunitiphat 16-19.qxp_Layout 1 19/11/2019 11:33 Page 3Food & Drink International 19 www.fdiforum.net WAREHOUSING OPTIMISATION lighting replaced with highly efficient LED alternatives that reduce power usage, while smart warehouses are using monitors and energy management systems to regulate power usage to become more energy efficient. Further, as operating a high-tech warehouse uses a lot of power, owners are asking for solar panels to assist in offsetting utility cost. Electric vehicles are also being implemented, such as electric forklifts, eliminating the requirement for oil and gas by using lithium-ion batteries. Not only better for the environment, these are prime for the food industry as they can reduce contamination. Lithium-ion doesn’t have acid that could spill and has no fumes, which also makes them safer for staff. The batteries are also useful as they don’t require high levels of maintenance - with no cleaning, watering or equalising needed, which can reduce costs - and have impressive battery lives. © Shutterstock/panuwat phimpha Stertil FlexiEdge door supports 24/7 production of dairy products Stertil Dock Products has installed a FlexiEdge fast-action door to support round the clock operations for a global leader in the production of milk and dairy products. Measuring 2000mm wide x 3500mm high, the Stertil FlexiEdge fast-action door, type Power M2, was specified to provide ready access to a refrigerated area within the site’s butter loading dock. The new Stertil door replaced an existing solid sliding door that was heavy and difficult to open and close. By contrast, the new Stertil FlexiEdge door, which incorporates an insulated curtain, is lightweight, durable and easy to operate. Stertil’s FlexiEdge range comprises 16 models of many different types and styles including internal and external doors, all-weather doors, cleanroom and freezer/coldroom doors plus emergency exit doors incorporating breakthrough curtains. Standard models are available in widths up to 11 metres and heights of 5.5 metres whilst bespoke and special sizes may be specified. For more information, visit www.stertil-dockproducts.co.uk. 16-19.qxp_Layout 1 19/11/2019 11:33 Page 4Next >