Process, control and automation Warehousing optimisation www.fdiforum.netDECEMBER 2021 £3.50 STERLING A year of change A year of change INTERNATIONAL Food &DrinkFood &DrinkEnd of line packaging 01.qxp_Layout 1 22/11/2021 11:49 Page 1Packaging systems for the future of food gea.com/uk Contact us as fht.uk@gea.com Marination Preparation Processing Slicing Thermoforming Chilling/Freezing Bagging Reducing material, limiting wasteage • Thermoformers - PowerPak Range • Vertical filling & Packaging - SmartPacker Range • FoodTray •Thermoformers - PowerPak Range •Vertical filling & Packaging - SmartPacker Range •FoodTray – 80% plastic reduction :(67(51 0(&+$1,&$/ +$1'/,1* 8. /7' $XWRPDWLRQ &RQWURO 7HFKQRORJ\ D^/ W>^ 02.qxp_Layout 1 22/11/2021 11:49 Page 1Contents December 2021 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 & export12 In another year of COVID-19 and strain with its top export market, Australia has shown adaptability when it comes to exporting. End of year success stories16 It’s been a tough year, a turbulent year, but that hasn’t stopped businesses in the food and drink industry rising to the occasion. Process, control and automation22 From introducing collaborative robots to the factory floor, thereby helping to address labour shortages and mitigate challenges posed by social distancing and self- isolation, to reducing emissions during production with ever more innovative solutions, there’s a lot for food and drink manufacturers to consider. Traceability26 Traceability is considered to be an only legal and management requirement for any business and industry, but its importance, especially in the food and drink industry, has now reached the attention of consumers. 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) Journalist: Tess Egginton (t.egginton@blmgroup.co.uk) Eleonora Gallina (e.gallina@blmgroup.co.uk) Sales Director: Teri Cooper (t.cooper@blmgroup.co.uk) Sales: Vicky Hunt (v.hunt@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: ST OCK.ADOBE.COM/SVETLANA KOLP AKOV A • TOP: CARL TON FOREST 3PL • MIDDLE: SEALED AIR • BOTT OM: VEGA CONTROLS L TD End of line packaging 30 From case sealers and label applicators to pick and place machines, Food and Drink International explores the impact of automation on end of line packaging. Warehousing optimisation36 Removing the human element wherever possible may improve efficiency. But how viable is it to extend this philosophy to the entire warehouse? Recycling and waste management42 In the attempt to make the food and drink industry more sustainable, recycling and food waste present businesses and manufacturers with challenging obstacles. Events46 Your chance to keep abreast of forthcoming exhibitions and food fairs from around the world Classified 49 Food and Drink Diary 50 03.qxp_Layout 1 22/11/2021 11:57 Page 1Mars bars to be certified carbon neutral in UK, Ireland and Canada by January 2023 Mars has announced that all Mars bars sold in the UK, Ireland and Canada will be certified as carbon neutral by 2023. The company has already reduced its carbon footprint from direct operations in the UK by 67% since 2015. Mars is taking action to tackle deforestation, address land use and transform how it sources raw materials, which will result in a carbon footprint reduction of over 20% in the UK, Ireland and Canada by 2023. Mars said: “We will work with an independent auditor to certify the Mars bar as carbon neutral and will be adhering to the PAS 2060 standard for carbon neutrality, which provides radical transparency and is widely considered to be the leading standard of carbon neutral specification. “We’re proud that the Mars bar will be carbon neutral in the UK, Ireland and Canada by 2023, but we’re clear that the job isn’t done, and it is certainly not time to down tools.” 4 Food & Drink International www.fdiforum.net news Digitalisation – delivering for today’s FMCG brands and their contract supply network Market trends and consumer preferences are constantly changing and evolving, and suppliers of fast- moving consumer goods (FMCGs) are increasingly relying on their external manufacturing and co- packing partners to help bring products to market quickly and cost-effectively. However, many of these suppliers lack the ability to collaborate effectively, shackled by the limitations of manual and outdated systems that will not provide FMCG brands with the levels of support and innovation they need. Digitalisation provides a clear path through all this confusion. Cloud based platforms such as Nulogy, operate at brand, co-packer, and strategic levels. Multi-enterprise collaboration becomes a reality through their use and bridges the gap between brands and their external manufacturing and packaging networks. Real-time data is seamlessly shared, workflows streamlined, milestones and KPIs easily tracked with shared accountability between the FMCG and their supplier – all of which allow this ecosystem to bring consumer products to retail customers with increased speed, flexibility, and reliability. A collaborative solution is able to complement these pre-existing systems and seamlessly integrate with both internal systems and external suppliers, who can simply plug into the brand’s software. There are many benefits of this approach, from increased responsiveness and reduction in risk to optimisation of resources and improved sustainability. This is why Nulogy is leveraged by many of the world’s leading brands including L’Oréal, P&G, Mars, and Church & Dwight to both optimise and accelerate global supply chain performance. A multi-enterprise supply chain network – unified through digital transformation – can deliver both a raft of operational and financial benefits and, just as importantly, strengthen relations between FMCG brands and external suppliers. By sharing data and working together to fulfil orders, mutual trust is built. All sides can achieve their objectives, and this generates a ‘win-win’ situation in this critical part of the supply chain as it meets the demands of a constantly changing world. For more information visit www.nulogy.com Durham Box creates impactful SRP for snack brand start-up Leading packaging company, Durham Box, has created stand-out SRP for new kid’s cookie snack brand, Snackzilla. With design of the SRP by Kingdom & Sparrow, reflecting a character-led illustration style comic book design, Durham Box created three different digitally printed packs for chocolate, raspberry & syrup recipes. Durham Box were the first corrugated packaging manufacturer in the UK to offer single pass LED inkjet production for packaging, POS displays & corrugated board. In addition, they also supplied a flexo printed pack as a generic SRP. “We love the SRP’s and have had lots of lovely compliments on them,” said Marieke Syed, Snackzilla’s founder. “We used Durham Box following great recommendations from other food start-ups. Their customer service is amazing and they really went above and beyond to get packaging to us at short notice.” Durham Box’s Paul Barker, added: “This was an all-round lovely project to be involved in. Snackzilla is a great brand to work with and we look forward to further developing our association in the future.” For more information visit www.durhambox.co.uk First bottles produced at innocent’s carbon- neutral factory Manufacturing has started at innocent’s new carbon-neutral factory, with the first bottled drinks rolling off the production line at ‘the blender’ in the Port of Rotterdam. the blender is claimed to be the earth’s most sustainable healthy drinks factory and will produce up to 300 million litres in a year. The London-based drinks manufacturer worked in partnership with Kegworth-based food and drink project delivery specialist, Integrated Food Projects to develop the £200 million plant in the Port of Rotterdam’s new Food Hub. Andy Tebbutt, joint managing director at Integrated Food Projects, said: “Sustainability has been a focal point of the blender since day one of planning, and what has been achieved at the factory really does recalibrate the industry standard for what can be achieved in sustainability within the food and drink manufacturing sector.” Andy Joynson, chief blender at innocent, added: “We believe the blender is a shining example of what can be achieved, and as such we are committed to inspiring other businesses by sharing our knowledge and experience of building sustainable factories.” 04-11.qxp_Layout 1 22/11/2021 12:00 Page 1Enhanced security for your food production With ifm you can monitor and control your hygienic production processes in a precise and, thanks to IO-Link, even more comprehensive and convenient way: The new TCC tempera- ture sensor with integrated Calibration Check Technology continuously validates the measured value and protects the production process and product quality in equal measure. The LMT level switch works reliably even in highly viscous, sticky and foaming products . It approved (3A and EHEDG) sensor with G1/2”process connection and ceramic-capacitive CIP- cleaning and increase the availability of your system. ifm - close to you! An unbeatable team! ifm.com / ukifm.com / uk Go ifmonline Go ifmonline years W AR RANTY on ifm pro du ct s 04-11.qxp_Layout 1 22/11/2021 12:00 Page 2Axium process thrives under pressure Complex regulations and compliance requirements for high pressure pipework are driving demand for specialist services from hygienic fabricators, says Axium Process. The company reports that a growing number of manufacturers are turning to its team to help them modify, maintain and commission high pressure pipework. Sean Crowley, Technical Services Manager at Axium, explained: “During remedial work, we may find that existing processes don’t comply with current PER or hygienic engineering standards. These regulations cover a vast range of requirements, such as the compatibility of the materials used to prevent potential corrosion issues, weld procedures and qualifications, to name just a few. “This means that appropriate risk and technical assessments must be carried out to control, authorise and manage any proposed changes. As there are so many factors to consider, companies are now recognising the importance of partnering with specialist fabricators with the required expertise, qualifications and experience to ensure full compliance.” For more information visit www.axiumprocess.com 6 Food & Drink International www.fdiforum.net news Cake Décor switches to recyclable packaging for Ready to Roll Icing with National Flexible Cake Décor is the UK’s largest manufacturer of cake decorations. They were founded in 2006, owned by Orkla since April 2021 and have built a strong reputation for quality product and the highest customer service. They have a ‘right first time’ approach to NPD and have innovation at their very core, so when Waitrose wanted to change to printed film for their Ready to Roll Icing it was an easy discussion to have to suggest changing from a traditional laminate to one with post-consumer recyclate to beat the Plastic Tax being introduced in April next year. According to the Government website, the new tax is being introduced to “encourage the use of recycled rather than new plastic within plastic packaging. This will in turn stimulate increased levels of recycling and collection of plastic waste, diverting it away from landfill or incineration.” “Moving to a PCR film was made easy by working with National Flexible. It ran first time on our packing lines and both we and Waitrose are very happy with the result.” Robert Simpson Cake Decor For more information visit www.nationalflexible.co.uk 04-11.qxp_Layout 1 22/11/2021 12:00 Page 3Sealed Air’s innovative packaging film wins Resource Efficient Pack of the Year at UK Packaging Awards 2021 Sealed Air is celebrating a win in the UK Packaging Awards, held last November 12, with an innovative packaging film designed with the circular economy in mind. The global packaging company took home the award for Resource Efficient Pack of the Year with their CRYOVAC® Brand rBDF™ S10 Film, an ultra-thin food packaging film made using up to 30% food-grade Certified Circular Resins which is certified by the International Sustainability & Carbon Certification. At only 21 microns, CRYOVAC® Brand rBDF™ S10 Film is a third lighter than widely used HFFS packs and three times thinner than other thermoformable films. It was developed to be recycled back into food-grade packaging film via a process of advanced recycling called pyrolysis. Stephanie Poole, senior business development manager at Sealed Air, said: “This project supports Sealed Air’s pledge to design and advance our innovative packaging solutions to be 100% recyclable or reusable by 2025.” Kite introduce 100% recycled and recyclable alternative to polystyrene edge protectors The external edges, corners and sides of items are at high risk of damage if not properly protected before shipping. These outer most areas are the most susceptible to impact, making edge protectors essential packaging equipment for businesses sending out potentially fragile objects. Historically, polystyrene has been the only available cushioning product for sharp edges such as these, yet Kite Packaging has recently introduced a range of 100% recycled solid board alternatives that can also be recycled after use. Each product is made from compressed, recycled cardboard to create a highly dense and durable material. Hence, these edge protectors are as effective as they are sustainable by adding reliable reinforcement to vulnerable areas. Use the standard style for straight edges, the innovative yet simple locked corner design for pointed corners and the curved variety for rounded edges. Each style has unique features to adapt it to the varying properties of the object being packaged. Food & Drink International 7 www.fdiforum.net news 04-11.qxp_Layout 1 22/11/2021 12:00 Page 48 Food & Drink International www.fdiforum.net news Lindum launches new range of 30% recycled content pallet wrap Lindum Packaging has launched a new range of pallet wrap made with 30% recycled content and nano technology, creating a more environmentally friendly product with the added benefits of nano stretch film. The product has been developed to add more sustainable options to its existing range, as well as help companies avoid paying the new tax, that from April 2022 will charge UK businesses £200 for every tonne of plastic used not containing the minimum recycled material. Lindum’s in-house packaging technologist Rick Sellars said: “Unlike 100% virgin polymer films, the new range contains polythene resin material that has been recycled and then re- granulated. They meet the stringent OPRL definition of ‘recycled’ and are compatible with a circular economy model. “As the new tax gets closer, we expect to see a huge surge in demand for recycled content wrap so we are advising customers to take the necessary steps to switch to recycled content or minimise use of pallet wrap to reduce their liability.” Diageo to build $75 million carbon neutral distillery in China Diageo, the owner of Johnnie Walker and Singleton Scotch whiskies, has broken ground on the site of its first malt whisky distillery in China. Located in Eryuan County in Yunnan Province, the Diageo Eryuan Malt Whisky Distillery will produce Diageo’s first China-origin, single malt whisky. Sam Fischer, president of Diageo Asia Pacific and Global Travel, said: “Today we celebrate another significant step forward, and one which builds upon our local insights and combines those with Diageo’s global whisky expertise in order to delight the next generation of Chinese whisky consumers.” At more than 2,100 meters above sea level, the site of the 66,000 square meter distillery was carefully selected for its temperate climate, rich natural biodiversity, and access to natural spring water that is a source of the second largest highland lake, Erhai Lake, in Yunnan. Diageo’s ‘Society 2030: Spirit of Progress’ sustainability action plan will shape the design and development of the distillery to ensure it is a zero-waste site. Hearthside Foods to acquire baking division assets of Weston Foods Hearthside Food Solutions, the contract manufacturer, has signed a definitive agreement to acquire the assets of the cookies, crackers, cones and wafers division of Weston Foods, which includes six North American bakery facilities. This acquisition expands the Hearthside network to 43 production facilities in the US, Canada and Europe, bringing 1,100 full- time employees, additional production capacity, and an expanded base of premier food company customers. The Weston acquisition adds new capacity and an expanded ability to meet the needs of Hearthside’s customers. Chuck Metzger, Hearthside CEO, said: “The Weston acquisition is an ideal complement to our existing production network and business, bringing baking capacity, a roster of premier customers, expanded capabilities, and enhanced geographic coverage. We look forward to welcoming Weston’s 1,100 employees into the Hearthside family.” The transaction remains subject to regulatory approval and customary closing conditions. The parties anticipate the transaction to close before the end of the first quarter of 2022. Pilgrim’s UK connects lamb supply chain with Randall Parker Foods acquisition Pilgrim’s UK, the food and farming business, is showing its commitment to British farming with the acquisition of Randall Parker Foods (RPF). RPF’s two manufacturing facilities will form part of Pilgrim’s UK’s Dalehead Foods division. All 350 RPF employees, including its management teams, will remain in place under existing terms and conditions, with the business planning to invest further in the two sites. Andrew Cracknell, Chief Executive Officer at Pilgrim’s UK, said: “Randall Parker Foods has a strong reputation as a processor of quality lamb. [The acquisition] will bring our lamb operations closer together into a single integrated supply chain which will benefit team members and customers alike, securing jobs, investment and growth for a sustainable future.” Jim Gaffney, Managing Director of RPF said: “The future as part of Dalehead Foods looks both secure and exciting. I look forward to working with new colleagues and our customers to achieve our common goals.” ‘Peak Packaging Monday’ is Kite Packaging’s busiest day of the year Exactly one week before Cyber Monday, Kite Packaging have consistently seen more sales than any other day of the year. This trend has been dubbed ‘Peak Packaging Monday’ by Gavin Ashe, the Managing Partner of the employee share-owned company. This year, the day will land on 22nd November and restocking on Peak Packaging Monday will ensure that your company is best equipped to benefit from the prime marketing opportunities and times of massive growth potential. Kite Packaging supply a range of products specifically designed for rapid order fulfilment, headlined by their ecommerce boxes. Featuring a crash lock base, these boxes boast the fastest assembly time while offering an attractive presentation of the contents. Their ‘grab-and-pack’ boxes of shredded paper and shredded tissue have already proven especially popular this year due to their premium appearance, protective qualities and efficient packing time. Kite’s new gift packaging range supplies a selection of similarly peak appropriate products that combine the main considerations of ecommerce businesses this Christmas. © Shutterstock.com/ Andrew Ward 04-11.qxp_Layout 1 22/11/2021 12:00 Page 5PIONEERS OF SPACE For more information get in touch today W: teknomek.co.uk T: 01603 788 833 For every room, there’s a Teknomek solution. By getting the right advice and specifying the right furniture you can dramatically reduce your daily wash down time. Intelligent small changes really do make a big difference! •Stainless steel conveyor systems •Standalone units or fully integrated •Robotic and end of line equipment •Bespoke engineering capabilities •Turnkey and standalone solutions •Integration and project management •Service support and upgrades •Partnered with Lita Palletising Systems for over 30 years Kensal Handling Systems www.kensal.com | sales@kensal.com | tel: +44 (0) 1 582 425 777 Kensal Handling Systems Ltd, Kensal House, President Way, Luton, LU2 9NR 04-11.qxp_Layout 1 22/11/2021 12:00 Page 6Next >