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FOOD & DRINK PROCESSING & PACKAGING

Fortress Helps Nut Supplier Crack Metal Contaminant False Readings Festo and Siemens to focus on solutions for the packaging industry at PPMA Total 2016

Innovative Labelling Solution Wins Advanced Dynamics Greeting Card Contract Issue 10 2016

PLUS... Wrigley’s Confectionery Manufacturing Facility Expansion, Yorkville, Illinois, United States of America


AdhESivE ClEAnErS And rElEASE AgEntS Operator Operator Safe Safe Operator Operator Safety Safety is is paramount paramount to to our our company company and and all all products products in in our our range range are are operator operator safe safe when when used used as as per per label label instructions. instructions. Gard Gard Chemicals Chemicals is is registered registered to to OHSAS OHSAS 18001 18001 Health Health and and Safety Safety Management Management and and operates operates the the Global Global Harmonised Harmonised System System (GHS) (GHS) for for all all labelling labelling and and Safety Safety Data Data Sheets. Sheets. Environmentally Environmentally Friendly Friendly All All products products are are formulated formulated using using VOC VOC Free Free // Exempt Exempt substances substances wherever wherever possible possible and and mindful mindful of of current current legislation legislation trends trends these these formulations formulations are are under under constant constant review review to to ensure ensure we we remain remain the the No.1 No.1 Supplier Supplier of of Choice. Choice.

We We are are the the leading leading manufacturer manufacturer of of aa unique unique and and comprehensive comprehensive range range of of Adhesive Adhesive Cleaners Cleaners and and Release Release Agents. Agents. These These products products have have been been developed developed to to be be highly highly effective effective with with all all grades grades of of hot hot melt melt and and cold cold adhesives: adhesives: they they remove remove and and then then prevent prevent unwanted unwanted build-up build-up of of glue glue deposits deposits and and smears smears that that occur occur both both internally internally and and externally externally in in and and around around all all types types of of adhesive adhesive application/dispensing application/dispensing equipment, equipment, and and also also generally generally on on machinery machinery working working surfaces. surfaces. Gard Gard Adhesive Adhesive Cleaners Cleaners and and Release Release Agents Agents are are NSF NSF certified certified and and fully fully compatible compatible with with all all OEM OEM equipment. equipment. Our Our products products have have industry industry approvals approvals and and meet meet the the tough tough standards standards required required by by the the many many blue blue chip chip organisations organisations that that have have awarded awarded us us vendor vendor ratings ratings of of 100%, 100%, taking taking into into account account quality, quality, environmental environmental impact, impact, health health and and safety, safety, security security and and technical technical support. support. Gard Gard Adhesive Adhesive Cleaners Cleaners and and Release Release Agents Agents are are sold sold direct direct to to our our large large UK UK customer customer base; base; and and also also worldwide worldwide via via 2 FDPP - www.fdpp.co.uk

our our network network of of approved approved Distributor Distributor Partners, Partners, all all of of whom whom have have undergone undergone full full product, product, technical technical and and field field training training by by Gard Gard so so that that they they can can best best assist assist and and advise advise their their customers customers on on servicing servicing and and maintenance maintenance in in order order to to achieve achieve optimum optimum performance. performance. Food Food Safe Safe The The NSF NSF Registration Registration Mark Mark certifies certifies that that these these products products conform conform to to the the strict strict guidelines guidelines of of the the largest largest third third party party independent independent approval approval body body in in the the world world for for the the use use of of products products within within the the Food Food Industries. Industries. This This internationally internationally recognised recognised registration registration means means that that both both product product formulations formulations and and labelling labelling carry carry NSF NSF approvals approvals for for Food Food Industry Industry use. use.

We We operate operate within within the the Environmental Environmental Management Management Systems Systems under under which which we we are are ISO ISO 14001 14001 Registered Registered for for the the Manufacture Manufacture and and Supply Supply of of Maintenance Maintenance Chemicals. Chemicals. All All products products are are formulated formulated to to be be Environmentally/ Environmentally/ Eco Eco Friendly Friendly whenever whenever possible possible and and conform conform to to the the latest latest environmental environmental regulations. regulations. Gard Gard Chemicals Chemicals is is aa private private UK UK company, company, ISO ISO registered registered to to 9001/14001 9001/14001 Quality Quality and and Environmental Environmental Standards. Standards. The The company company was was first first established established in in 1977 1977 in in order order to to develop, develop, manufacture manufacture and and market market maintenance maintenance chemical chemical products products to to service service niche niche industrial industrial applications. applications. www.adhesivecleaners.com www.adhesivecleaners.com


Contents

The Team Editor Amanda Buckingham editor@fdpp.co.uk

Managing Editor Antony Holter editor@mhmagazine.co.uk

Creative Director Josh Holmes josh@mhmagazine.co.uk

Assistant Editor Justine Sanders justine@fdpp.co.uk

Sales Manager Louise Jamerson louise@fddp.co.uk Tel: 01227 392575

Digital Manager Jamie Bullock Jamie@mhmagazine.co.uk Tel: 01227 392571

Publishing Director Martin Holmes martin@fdpp.co.uk

Studio Designer James Sayer james@mhmagazine.co.uk

M H Media Global Ltd.

St Augustine’s Business Centre, 125 Canterbury Road, Westgate On Sea, Kent, CT8 8NL

Tel 01843 830249 l Fax: 08721 152240

www.fdpp.co.uk

All web addresses are inter-active, simply click the web address of your choice to view the company website. There is also a useful tool bar where you can search for a specific product, or simply view the index on page 3 and then type in the page number of the section that you wish to view. Please mention FDPP when responding to items in this issue.

Every effort is made to ensure the accuracy and reliability of material published in Food & Drink Process & Packaging however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers. No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

Features

Wrigleys < 04 Burket < 20 Mitsubishi < 26 RPC < 38 Russell finex < 40 Festo < 46 Industrial Vision < 50 Fortress Tech < 54 Advanced Dynamics < 58 FDPP - www.fdpp.co.uk 3


Wrigley's Confectionery Manufacturing Facility Expansion, Yorkville, Illinois, United States of America Mars subsidiary Wm Wrigley Jr. Company opened a new 145,000ft² Skittles production line at its existing confectionery manufacturing facility in Yorkville, Illinois. Its new manufacturing line will

The Illinois department of commerce

Contractors involved with the

enhance the company's capacity

and economic opportunity (DCEO)

expansion

to meet an increasing demand for

awarded $250,000 for construction

Wrigley awarded a contract to HR

Skittles, a popular rainbow-coloured

and $37,500 to aid in job training.

Green, an engineering and technical

sweets brand.

Through the economic development

consulting company based in the US.

"This expansion has created 75 new

for a growing economy programme,

Under the contract, HR Green

permanent manufacturing associates

DCEO granted Wrigley $2m in tax

provided a range of services including

and hundreds of construction jobs."

benefits.

plotting, landscape architecture, and

Skittles are produced at the Yorkville

This expansion has created 75 new

factory and distributed across the

permanent manufacturing associates

US, South America, Central America,

and hundreds of construction jobs,

US-based design-build company Gray

Mexico, Canada, and the Caribbean.

supporting economic development in

Construction was contracted to build

Yorkville and Illinois.

the new production line.

Wrigley's Yorkville factory expansion

onsite final civil engineering for the Yorkville plant expansion in May 2014.

details

Skittles production process

Wrigley announced its plans to add

Skittles are bite-sized, fruit-flavoured,

a new Skittles production line to the

chewy sweets, which are offered in

existing facility in Yorkville in May

flavours such as wild berry, tropical,

2014. Construction began in June

original, and sweet and sour.

2014 with an investment of $50m. NOTE WRITTEN BY Wrigley PHOTOGRAPHY BY Wrigley

4 FDPP - www.fdpp.co.uk


The new line will produce Skittles in

Details of Wrigley's existing plant in

three levels. In the first phase, the raw

Yorkville

ingredients are mixed in a kitchen and then dried. They are then formed into Skittles-shaped pieces. These are then coated with hard coloured shell using an enrobing machine. A layer of shine is then added with the letter S on it. A variety of Skittles' flavours are then put together in each package.

Marketing commentary on Wrigley Established in Chicago in 1891,

Wrigley's existing Yorkville

Wrigley manufactures and distributes

manufacturing factory is a one-

a range of products including sweets,

storey building covering 215,000ft². It

jellies, chocolate, gums, lollipops, and

opened in 1995.

mints. Its global footprint spans 40

With a workforce of approximately 300 people, this facility produces

countries and its products are sold in more than 180 countries.

Wrigley's brands such as Life Savers

The company currently operates

non-chocolate sweets, mints,

21 manufacturing facilities in 14

doublemint gums, and Juicy Fruit

countries. Wrigley's brands in the US

gums.

market include 5 Gum, Altoids mints, Doublemint, Big Red, Hubba Bubba, Eclipse, Big Red, Extra, Creme Savers, Juicy Fruit, Freedent, Orbit, Starburst, Winterfresh, and Spearmint. Over the past seven years, Wrigley has invested approximately $200m for the expansion of its operations in Illinois. Wrigley was acquired by confectionery producer Mars for $23bn. In addition to Yorkville Skittles facility, Mars operates a Skittles production line at its candy-making plant located in Waco, Texas.

Wrigley With operations in approximately 50 countries and distribution in more than 180 countries, Wrigleyâ&#x20AC;&#x2122;s brands bring smiles to faces around the globe.

www.wrigley.com/uk FDPP - www.fdpp.co.uk 5


Is Food Safety Critical To Your Process? managers often continue with old paper recorders. Happily, new options are becoming available. The Eurotherm nanodacâ&#x201E;˘ recorder/controller offers four channels of precision analogue batch recording, easily meeting the requirements of regulators for accuracy and repeatability, and data logging requirements of 21 CFR 11. For more demanding applications,

Food Safety is subject to

Paper records, such as the Eurotherm

unprecedented scrutiny from

392 circular chart recorder have

governments and regulatory bodies

served the industry well for many

globally. The reason is simple:

years, but the mechanical nature

According to a recent study by the

of the printing mechanism can

World Health Organisation food

compromise reliability and accuracy.

borne diseases affect 1 in 10 of the

It is also easy to lose or damage

population globally, accounting for

paper, and HACCP requires that

420,000 deaths annually. Of these,

original records are maintained on-

over 125,000 are infants or babies

site for several years - copies are not

A hybrid such as nanodac also has

aged 5 years or below.

permitted. .

high quality PID control, including

Apart from the dangers to public

Other regulated industries such as

health, the cost of a major product

pharmaceuticals and aerospace

recall can run into millions of pounds,

switched to graphical video recorders

even billions, and the reputational

long ago: Data is automatically

damage is incalculable. Organisations

forwarded to supervisory systems for

could be subject to criminal liability

reporting and recording, and solid-

including prison sentences and

state electronics are intrinsically more

substantial fines, let alone the cost of

reliable in a production environment.

lost production. Understandable then, that food safety is a primary concern of plant managers. The question is, with ever-increasing scrutiny, are existing methods of record keeping for HACCP control points sufficient? The US Food Safety Modernization Act is leading the way towards digitisation of record keeping, with increased attention on the performance of subsuppliers in eradicating hazards. 6 FDPP - www.fdpp.co.uk

the Versadac recorder provides a back of panel solution with almost unlimited capacity. Both allow alarm and discrete input logging, communications with other devices, results available in the data record, electronic signatures and batch data recording.

advanced cascade with unique auto tune. Such units can control a retort or autoclave, including VSD, and record the results. The standard 96x96mm panel size will retrofit in place of an older PID controller. A high quality TFT display assures a perfect operator interface for interaction and alarm visualisation.

HACCP regulations mandate that electronic records are not subject

NOTE WRITTEN BY Eurotherm

to falsification, and have electronic

PHOTOGRAPHY BY Eurotherm

signatures, but many low cost data loggers do not provide this security level. The â&#x20AC;&#x153;gold standardâ&#x20AC;? for data recorders in the food and beverage industry is US FDA 21 CFR 11, but chart recorders meeting this standard can be expensive, so plant

Eurotherm

As part of the Schneider Electric business, Eurotherm is a leading global supplier of Industrial Automation and process control, measurement and data management solutions and services

www.eurotherm.co.uk


Always be ready for your audit

21CFR11 enabled nanodacâ&#x201E;˘ recorder / controller

Straightforward compliance management

Extremely cost eďŹ&#x20AC;ective multi-channel batch recording for critical control points, plus precision process control

Eurotherm Online Services - ďŹ nd records when you need them with instant access to historical and current compliance status

eurotherm.co.uk/foodsafety


Fluoropolymers in the Food & Drink Industry From Design Engineers and Production/

Protective FEP sleeves and films allow for

Maintenance Managers through to

maximum performance and efficiency of

Quality Assurance Technicians, sourcing

UV Disinfection lamps. We produce FEP

high performance materials is critical.

heat shrink sleeves to cover standard UV

Fluoropolymers exhibit unique properties,

bulbs to protect food from potential lamp

setting them apart from the more ‘general

breakage. Some food production lines

purpose’ plastics and easily meet strict

employ ‘in line’ UV treatment conveyor

regulatory requirements within the

zones where sheets of FEP are used to

industry. Natural fluoropolymers are

shield multi-lamp units. Our FLONFILMTM

virgin materials, containing no additives

500 FEP film is available in thicknesses

Monitoring and Analysis Instrumentation

or other foreign ingredients and some key

from 12 to 500μm with a standard width

characteristics include:

of 1220mm.

Whether it’s an in-house Quality

No leachables or extractables

Inherently stable at high

samples or a 3rd party testing laboratory involved in contract analysis, sourcing an effective fluid handling solution that

temperatures •

meets strict technical criteria whilst

Virtually 100% inert to almost all

producing highly accurate results within

substances •

tight operational budgets can be a

Smooth, non-stick surfaces (self-

challenge.

cleaning) •

Low gas diffusion/permeation

Effective UV transmission

FDA 21 CFR 177.1550 compliant

Beverage Dispensing

present a challenge to most polymeric

leaching or contamination risk, such

materials: intermittent high temperatures

FDA conforming consumables are

over a long period of time coupled with the

usually required during maintenance of

requirement for a biologically harmless,

monitoring and analysis instrumentation.

inert tubing product. Polyflon PTFE, FEP

Polyflon’s range of inert, high purity tubing

and PFA tubing represent a tried and

in coils or ‘cut-to-length’, meet all industry

tested, regulatory compliant solution.

requirements cost-effectively whilst

our tubing is greatly reduced due to

Disinfection

very smooth internal surfaces, leaving

range of PVDF and PFA connectors, valves, flowmeters and manifolds used extensively in Ozone Generation equipment and Chlorine dosing water treatment plant. Polyflon PTFE, FEP, PFA and PVDF tubing and PTFE convoluted tubing are available to suit all types of fitting.

8 FDPP - www.fdpp.co.uk

and PVDF /PFA compression fittings and valves are the solution. With no

Food & Drink Preparation, Preservation,

Polyflon offer a comprehensive

Polyflon PTFE, FEP and PFA tubing

Hot beverage dispensing machines

Build-up of internal residue within

Unaffected by Ozone and Chlorine,

Assurance Team testing production line

the taste and aroma of the beverage unaffected, ensuring consistent quality. Our Pharmed®BPT and Norprene® peristaltic pump tube assemblies combine high performance, low maintenance and FDA conformance. To enable efficient re-

retaining high-performance throughout continued testing. They’re also resistant to repeated cleaning cycles with aggressive fluids; making them sustainable and cost effective. For more information, contact our technical sales team on 01785 859 054 or email info@polyflon.co.uk

conditioning/maintenance of dispensing machines, we offer cut-to-length tubing to customer specification for easy fitting. TygonTM, Norprene® and Pharmed® are Saint-Gobain Performance Plastics Registered Trademarks


High-Performance Plastics For Food & Drink Processing PTFE, PFA, FEP Tubing

FEP Film

PFA & PVDF Valves & Fittings

Pump Tube Assemblies

®

Tygon S3

Pharmed BPT

TM

Disinfect | Dispense | Analyse

www.polyflon.co.uk info@polyflon.co.uk

01785 859 054

Stay Up-To-Date Subscribe To Polyflon News http://bit.do/PolyflonNewsletter ®

®

Tygon, Norprene and Pharmed are Saint-Gobain Performance Plastics Registered Trademarks TM

FDPP - www.fdpp.co.uk 9


FOODLUBE® Win-Win: Optimised Performance Balanced With Safety to customers through its ISO 21469:2006 certification too. Like NSF H1, this certification is globally recognised and important for BRC audits as it provides highly credible, independent assurance that products are formulated, manufactured and supplied hygienically and safely. As part of the ISO 21469 certification process, lubricant manufacturers provide risk assessments for lubricant use, conduct factory audits, help customers develop and police

Today’s advanced lubricant

It is vital, therefore, that safety

formulations are driving ever more

risks are identified and addressed

impressive benefits, with food-

right along the production line,

grade lubricant range FOODLUBE®

which includes putting lubrication

giving food and drink processors

formulation and application

the opportunity to balance high

techniques under scrutiny. The use

For processors, sourcing NSF H1

machinery performance and uptime

of NSF H1 registered lubricants, like

lubricants from an ISO 21469:2006

with independently verified safety

those in the FOODLUBE range from

certified manufacturer represents

assurances.

ROCOL®, is key. NSF H1 products

the belt-and-braces approach to

provide independent, authoritative

reducing lubricant contamination

assurance that their formulations

risk – the importance of which cannot

meet hygiene requirements for

be understated in today’s climate. It

incidental food, cosmetics or animal

also means FOODLUBE products fit

feed contact.

extremely well with HACCP programs

In the two decades that FOODLUBE has been a leading lubrication solution in the processing industry in the UK and internationally, the appetite for food-grade products

effective quality assurance procedures and monitor product composition through on-going sampling and retesting.

as part of a comprehensive food

has rightly grown stronger as more

Being NSF H1 registered means the

manufacturers put brand protection at

product ensures compliance with

the top of their priority list.

the latest safety standards, and is

With the high performance capabilities

guaranteed to be manufactured

of today’s food-grade lubricants, such

only from FDA-listed ingredients

as those in the FOODLUBE range,

free from animal derived materials,

processors have at their disposal

nut oils, soya, dairy and genetically

solutions for all applications across

modified (GM) ingredients. The

their plant which minimise production

FOODLUBE range is also free from

downtime. Safe formulation comes

mineral hydrocarbons. ROCOL

without compromising performance.

Key to this is avoiding product recalls. Recalling a product on safety grounds is of course a costly exercise in the short term, but longer term such an incident can be detrimental to the brand, reducing consumer trust and resulting in financial losses.

provides an additional, more comprehensive safety assurance

10 FDPP - www.fdpp.co.uk

safety management approach.


ROCOL® ROCOL is part of ITW, a multi-national US owned, Fortune 150 company. We develop, manufacture and market technically advanced industrial lubricants and line marking systems to industries worldwide.

www.rocol.com

By using the finest food-grade

deliver tangible improvements to

It starts with a survey that includes

base oils, including synthetics,

processors that improve the bottom

lubricant, frequency and application

renewable oils and silicones, as well

line.

methods for each asset, which

as treatment with the most effective anti-oxidants and additives to address specific applications, the complex

The other strand includes examining new ways to help processors safely

is compatible with TPM and lean manufacturing techniques.

apply FOODLUBE products – the

From this, performance measures are

packaging options for food-grade

set to monitor and report every single

accommodated.

lubricants and how risk can be

application and any training needs are

engineered out of the packaging itself.

identified - all backed with technical

ROCOL ensures this balance of safety

ROCOL’s introduction of DETEX®

support and lubrication consultancy.

and performance as part of its dual

metal detectable caps and actuators

innovation strategy. This combines

on all grease cartridges and aerosols

proactive identification of new

illustrates this.

lubrication management programme

These help maintenance engineers in

operational efficiency, with full audit

food processing environments reduce

compliance regarding lubrication

application risks.

the risk of plastic contamination,

and the bottom line benefits of

representing a vital step in

rationalised lubricant usage.

The development of FOODLUBE XT

maintaining operational safety at a

Chain Fluid illustrates the first strand.

consistently high level – even more

The product was developed to help

so when part of a comprehensive

bakeries and other industrial chain

lubrication management programme,

operators minimise the problem of

such as ROCOLcare®.

needs of the processing industry,

ROCOLcare assesses every dimension

with how lubricants are supplied,

of the production area, from

stored and applied, helps us assure

application frequency and techniques

processors that we can protect their

to signage and training.

brands ever more effectively.

demands of today’s food, drink and clean industries can be comfortably

formulations to overcome current and emerging production challenges, with practical solutions to minimise

messy black deposits building up in high-temperature applications, whilst keeping maintenance products NSF H1 food-grade. Customer feedback demonstrated that products like this

The result of implementing a is an agreed roadmap to increased

This combination of formulating and manufacturing a wide range of foodgrade solutions to meet the complex backed by practical assistance

FDPP - www.fdpp.co.uk 11


Masosine Certatm : The Cleanest Pump You Will Ever Need Unlike traditional pumps

Significant benefits over less efficient

with rotors that cut

pumps

through the fluid, Certa’s sinusoidal rotor gently carries fluid through the pump to dramatically reduce shear while cutting power consumption by up to 50%

Group has been designed to set a new benchmark in clean pumping for all food and beverage industry applications. Certa TM is latest innovation from MasoSine, the creators of Sine® pump Technology. Its launch sets even higher pumping standards in food processing. Offering EHEDG (Type EL Class I) and 3A certification as standard, Certa is extremely easy to clean for minimal maintenance and downtime. Furthermore, this advanced new innovation in food pump technology not only delivers high suction

circumferential piston pumps, for example, which are difficult to clean in their standard configuration. Indeed, for CIP, users will find they have to

FDA and EC1935 compliant

to modifications by drilling the rotor

the world over understand

from Watson-Marlow Fluid Technology

a far better proposition than

with high viscosity fluids.

Food and beverage plants

The new MasoSine CertaTM pump

CertaTM Sine® pumps offer

subject circumferential piston pumps hub which ends up in a performance loss.

that equipment can play

Certa can also offer significant

a key role in reducing the

benefits over less-efficient lobe

risk of contamination and

pumps, as well as twin-screw pumps,

maintaining high quality

which exhibit high internal slip due

levels.

to bigger internal clearances and

With this in mind, all contact

therefore offer less gentle handling.

parts on the CertaTM sine

Importantly, different applications

pump are FDA and EC1935 compliant.

– resulting in changes to viscosity, temperature, and flow rate - can

Performance and reliability Of course, the food-contact compliant Certa Sine® pump also offers all of the typical advantages and high performance levels delivered by proven MasoSine sinusoidal technology. Gentle pumping with virtually no pulsation, superior viscous handling, simplicity, reliability, energy efficiency, interchangeable parts and low cost of ownership all help food and beverage plants compete in a highly competitive marketplace.

be easily deployed with one pump setup. This mean there is no need for modifications such as bigger clearances for high temperature applications. Along with certified innovation for food industry applications, the new CertaTM Sine® pump series will provide an ideal solution for F&B, cosmetic or at any facility that requires the highest cleaning standards. NOTE WRITTEN BY Watson Marlow PHOTOGRAPHY BY Watson Marlow

Watson Marlow Watson-Marlow Fluid Technology Group

capability to handle viscous products,

(WMFTG) is the world leader in niche

it offers significant advantages over

peristaltic and sinusoidal pumps and

alternative technologies. 12 FDPP - www.fdpp.co.uk

associated fluid path technologies.

www.wmftg.com


W E

N

by Masosine

The cleanest

pump you will ever need

by MasoSine

High suction capability to handle viscous fluids EHEDG Type EL - Class 1 Up to 50% less power than other pump types, especially with viscous applications Low shear and zero pulsation Self-draining and easy to clean

wmftg.com/certa-uk 01326 370362

FDPP - www.fdpp.co.uk 13


AGC Map-Pak Analysers leading the way in Modified Atmosphere Packaging Quality Control One of the main concerns for food

The Map-Pak range can also be used

and measure the headspace gas.

processing companies around the

to test and check the gas mixtures

This is achieved by puncturing the

world is to reduce costs whilst

at source from gas cylinders or

packaging with the needle from the

maintaining their high quality control

other sources using the innovative

Map-Pak analyser which will then

standards.

and low cost Map-Pak Calibration

draw a sample and analyse the gas

Interface. There are varying company

components in the pack.

AGC Instruments is an advocate of handheld analysers for Modified Atmosphere Packaging (MAP) to achieve the most efficient and cost effective quality assurance. When using MAP, there are two main issues which are the packaging seal integrity and accurate gas mixtures. If the seal integrity is sufficient, the gas mixture should be accurate. Therefore, AGC Instruments developed the Map-Pak range of gas analysers for the food industry to validate these two interlinked requirements for successful MAP quality control. 14 FDPP - www.fdpp.co.uk

policies and audit requirements but typically the quality assurance team in a food manufacturing facility will remove a package at regular intervals

The Map-Pak Gas Analysers were developed to satisfy three key provisions: speed, accuracy and verification.


1. Speed - Fast and easy to use for all operators

3. Verification - In-depth results reporting for food safety audits

Once the Map-Pak needle is inserted

Software is also available for all

in the packaging, the user only has

Map-Pak analysers at no additional

to press one button to obtain sample

cost and allows the results saved

measurements within seconds. The

in the unit to be easily downloaded

unit can operate for seven hours on

to a computer for record-keeping.

one charge or alternatively it can be

Furthermore, an optional compact

operated whilst running off the Mains

printer for printing the results on

AC power.

labels and receipt-size paper is

2. Accuracy â&#x20AC;&#x201C; Modern sensor technology Using the latest and award-winning sensors, the Map-Pak range employs both electrochemical and nondispersive infrared sensors (NDIR). These sophisticated measurement systems combined allow fast and accurate readings.

required level which can be preprogrammed by the operatives. AGC Instruments are currently seeking distributors for the Map-Pak range. To become a distributor please visit www.agc-instruments.com or contact us directly on sales@agc-instruments.com

available. These two add-ons will enable swift verification for the quality control process in Modified Atmosphere Packaging. The printed and saved results show the Operator and Product titles along with a PASS/FAIL message if a gas level is exceeded or is below the FDPP - www.fdpp.co.uk 15


Advances in Technology Provide New Ventilation Solutions extra cooling capacity for redundancy the fans run at slow speed which further reduces costs. Master and Slave PLC arrangements also provide a resilient solution to cooling. Temperature and Humidity Compliant Warehouse Cooling Many locations can maintain compliant conditions by using only ‘free cooling’ (fresh air). Multiple EC fans can be connected directly to Everyone is aware that simple

In warm weather a refrigeration based

simple temperature controllers giving

ventilation can provide a perfectly

cooling system is often used to reduce

the simplest of automated solutions.

satisfactory solution to cooling many

internal temperatures. This is both

industrial and commercial premises in

expensive to install and to operate. In

the food and drink industry. However

many applications the refrigeration

recent advances in fan technology,

element can now be replaced by direct

controls and evaporative cooling have

evaporative cooling, where the hot air

now taken this principle to a new level

is passed over simple wetted filters

of performance.

and the air is cooled by evaporation.

Electrically Commutated Fans

Programmable Controllers

At the heart of any ventilation system

A new generation of low cost

sophisticated air handling system

is the fan. For both room temperature

Programmable Logic Controllers

that can compare with any air cooling

management and efficiency, fan

(PLC’s) are now available which

refrigeration system at a fraction of

speed control is essential. This is also

provide a simple method to

the energy cost and provide a high

demanded by local regulations and

manage ventilation systems. The

level of control of the environment.

European Energy Directives.

controller typically takes inputs from

Traditional fans have induction motors typically controlled using variable frequency inverters or voltage control. This approach has now been replaced with Electronically Commutated (EC) fans which have significant advantages over the traditional AC fans. Direct Evaporative Cooling

stringent conditions have to be met or when heating and cooling systems need to be integrated. In conclusion – Ventilation coupled with evaporative cooling and modern controls can provide industrial and commercial premises with a

temperature, relative humidity and carbon dioxide sensors and produces control signals to operate fans, dampers and control valves using internal logic. Computer Room Cooling All IT equipment in server rooms and data centres requires cooling. A ventilation system supplemented

For many buildings ventilation can

with direct evaporative cooling can

service all of the cooling needs for

reduce the cooling energy bill by

over 90% of the time.

over 95%. Because there is normally

16 FDPP - www.fdpp.co.uk

PLC’s can be used where more

NOTE WRITTEN BY EcoCooling PHOTOGRAPHY BY EcoCooling

EcoCooling For more information and case studies please contact EcoCooling on the details below: Contact Details: Sales@ecocooling.org www.ecocooling.org Twitter: @ecocoooling1 Tel: 01284810586

www.ecocooling.org


Save 90% On Cooling Costs With EcoCooling Energy Efficient Cooling Ventilation and Evaporative Cooling Use outside air most of the year in the UK | Energy efficient natural cooling for the warmer days | No refrigerants | 3500 installations worldwide | UK based

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Proven Savings Energy savings calculator available | Relevant case studies and testimonials | Clients include Premier Foods, Butchers Pet Foods, Subway, Marks and Spencers, Cott Beverages, Diageo, Shire Foods and Nestle

FDPP - www.fdpp.co.uk 17

EcoCooling Ltd, IP28 6RE | 01284 810586 | sales@ecocooling.org | T@EcoCooling1 | ecocooling.org


IMPORTANT INFORMATION FOR

The 'Easy' Way to specify Variable Speed Drives for Food and Beverage Applications By Kevin Brown, Managing Director Quantum Controls Ltd Finding the correct VSD or motor controller can be a fairly daunting task as there are many variables with each F & B application and system. However, below are some helpful tips and suggestions to help you select the right drive. Hopefully, the mystery becomes less complex as you understand what your specific industry application needs are. The Application Before you get too far into the process of looking at VSDs, it is a good idea to gather the basic motor and system information that will help you in selecting the proper VSD. Most of this information can be found on your motor nameplate such as: •

Kilo Watt Power

Full Load Amps (FLA)

Voltage

RPM

Service Factor

It is also helpful to know if the motor is inverter duty rated

Special Enclosure Needs

Kilo Watt (kW) Although it is important to size the VSD with the FLC of the motor(s) being controlled, knowing the kilowatt of the load is a great way to search for drives that may fit your application to be further narrowed down by other variables. Full Load Current (FLC) Using the FLC rather than horsepower ratings is the proper way to size a VSD. You will want to compare the motor with the amp ratings of each VSD you are considering.

18 FDPP - www.fdpp.co.uk

Voltage It is crucial to match the voltage of the VSD and motor to your available voltage on site. In addition, if continuous operation is a must, then the following should be specified: •

+/- 10% voltage fluctuation

+/- 3% frequency variation

Type of Load (Constant Torque or Variable Torque) Does your variable frequency drive application require a variable torque or constant torque drive? In the Food and Beverage sector the majority of applications will be centrifugal pumps and fans. Speed Range Generally speaking, a motor should not be run at any less than 20% of its specified maximum speed allowed. If it is run at a speed less than this without auxiliary motor cooling, the motor will overheat. Auxiliary motor cooling should be used if the motor must be operated at slow speeds. Control Method With 2-wire control, only one switch is used to run the variable frequency drive. With 3-wire control, two switches are used to run the drive. One switch is needed to stop, and another to start the variable frequency drive. Speed Reference Alternatives •

Speed Potentiometer

Digital Programming / Display Unit

Analog Signal Follower

Selector switch speed selection

Serial Communications

Special Enclosure Needs An important aspect of selecting the right VSD for your F & B application deals with the environment surrounding the drive, with area wash down being common place special attention should be paid to the IP Rating of the drive enclosure. Inverter Duty Rated Motors Motors all use wire that has been designed to handle the high voltages that can occur due to a drive usage. Some additional recommended features of inverter rated motors include grounding rings, isolated bearings and special cooling features (such as a separate fan to cool the motor at low speeds, typically on a constant torque application). Food and Beverage Custom VSD Builds At this time you may also consider other options and VSD accessories such as: •

Disconnect or Circuit Breaker

HOA (Hand/Off/Auto Switch)

Pilot Lights

Bypass

Line Reactor

Harmonic Mitigation

Door Mounted Interface

dv/dt filter

Final Recommendations This an abbreviated guide for the full version please visit the resource section of www.quantum-controls.co.uk to download for free. If you have any questions about your application or in sizing a new VSD call and talk to one of our application specialists before purchasing or send your enquiry to sales@quantum-controls.co.uk 01661 835566


Emerging Food Preservation Technology Requires Precision Control Our ability to preserve food has a long history - with more recent developments being directed by the desire to maintain nutritional value in addition to the original taste and texture of the food. Research in this field within the UK

current directly through the product

processes which require the use of

is helping to develop new techniques

to be heated and it is the electrical

automated control valves that are

that can be applied on an industrial

resistance of the product which

integrated with the main production

scale and one company at the

causes the increase in temperature.

control system and designed to

forefront of this field is Campden BRI. Based in Gloucestershire, Campden BRI conducts research and development work for the food and drinks industry worldwide which involves not only fine tuning new technologies but also up-scaling them

Since the whole product is acting as the conductor, the energy is released throughout the product rather than at its surface, making it extremely efficient; in fact, modern production facilities claim up to 95% efficiency for

for commercial production.

this process. In addition, this method

This work is supported by

shock to the product compared to

collaborative partners such as BĂźrkert

traditional methods, which improves

Fluid Control Systems, who offer

the retention of taste and colour

expert advice on the physical process

within the food. From a control

components and control apparatus.

perspective, accurate temperature

Mr Mark Lilley, Field Segment

measurement is essential as well as

Manager, Hygienic - Food and

precise flow control of the product to

Beverage, looks at the up and coming

ensure a continuous and consistent

technologies for food preservation

production rate. Use of a PT100

and the control infrastructure that

temperature sensor combined with

may be required to deliver a reliable

a controller such as the BĂźrkert Type

and efficient process.

8619 multiCELL can be used not

Ohmic Heating Application of ohmic heating within industrial processes is now well advanced, especially in the food, pharmaceutical and biotechnology sectors, where the efficiencies have already been proven. The process involves applying an electrical 20 FDPP - www.fdpp.co.uk

of heating greatly reduces the thermal

only to control the process but also to record process data as part of the quality control regime. Flow control of the food product can be achieved to a high level of precision thanks to a range of intelligent control valves supported by process controllers. These can also be used to manage Clean-In-Place (CIP)

withstand the high temperatures and aggressive cleaning media. High Pressure Processing (HPP) In essence HPP is a cold pasteurization technique using cold water at extremely high pressure, around 3000 to 7,000 bar, to kill vegetative bacteria by damaging the cell membrane of the organism and proteins within the organism. This can maintain the original flavour and consistency of the food and provides an extended shelf life without the use of heating or preservatives, which makes HPP well suited for preserving the 'fresh' characteristics of a food. The control of the process requires a number of valves and controllers to supply the cold water and to evacuate the vessel after each batch has been processed. However, for such a high pressure application, some of these will be specialist pieces of equipment, while the remainder can be specified to suit both the application and to allow integration into the control infrastructure of the processing plant.


NOTE WRITTEN BY Burket PHOTOGRAPHY BY Burket

Pulsed Light Processing Work is ongoing to develop this technology within the food industry. Pulsed light processing can offer a significant extension to shelf life for products which would normally have a very short shelf life and are susceptible to mould growth, such as

Over 100 applications are now in use

As food preservation technology

industrially – mainly for packaging

advances so the process control

decontamination. Much greater

infrastructure needs to keep pace and

inactivation can be achieved on

continue to deliver improvements in

smooth surfaces such as packaging.

hygiene and efficiency.

Pulsed Electric Fields

Furthermore the increases in the

This technology can be applied to

baked goods.

liquid products which are pumped

Using a surface treatment can deliver

mildly elevated temperatures and

a modest reduction in microbial

then cooled rapidly. The process

numbers which is sufficient to offer

kills bacteria, yeasts and moulds

considerable improvements in shelf

while retaining the freshness, taste,

life.

vitamins and colour of the food

through a pulsed electric field at

product. Precise control improves efficiency Clearly, the control of the temperature, pressure and flow of the product needs to be carefully maintained in order to offer a

amount of information available from local devices can improve the feedback for control loops and provide better information for increasingly sophisticated plant visualisation, management and reporting software. As the research and development of new food processing techniques continues, so Bürkert maintains its own development of fluid control systems, offering its expertise to promote an integrated approach that will ensure compatibility with existing production facilities.

consistent, high quality, final product for the consumer. Bürkert has provided a range of control and monitoring systems which are specifically designed to meet this

Burket Bürkert Fluid Control Systems is one of

specification and also ensure that

the leading manufacturers of control and

the necessary standards in process

measuring systems for fluids and gases.

data collection are met.

www.burkert.co.uk

FDPP - www.fdpp.co.uk 21


Brewery Bottling Machine Biofilm Control On-line monitoring to detect biofilm formation on a bottling machine reduces the risk of product contamination and increases filling capacity of the bottling machine The Situation In the brewing and beverage industry, the potential build-up of biofilm on air-exposed surfaces of bottling units creates a high risk of product contamination. Wet surfaces, splashing product and air-borne micro-organisms promote biofilm build-up where product-spoiling or pathogenic micro-organisms can develop. Aerosols and splashes resulting from the high speed motion of bottles that are filled but still open, can transfer biofilm from the surfaces

of the filling machine to the product.

Several probes were installed at

This risk is routinely managed

different locations on the bottling

by employing excessive cleaning

machine (Figure 1) providing a

measures and in many cases biocide

continuous, on-line signal that

overdosing on a time-based schedule.

corresponded to the actual biofilm

Condition based cleaning (CBC) as a cost reducing alternative to time based cleaning

formation rate on the surfaces and level of contamination risk. The signal was used to initiate a cleaning regime when the biofilm level reached

CBC was implemented in a brewery

a pre-defined limit replacing the

using ONVIDAâ&#x20AC;&#x2122;s onvi-CONTROL

rinsing at regular intervals. In this way

monitoring devices for on-line

unnecessary time-based cleaning

measurement of biofilm formation on

measures were avoided and the filler

a bottling machine.

surfaces were cleaned only when necessary.

Figure 1 onvi-CONTROL probe in the area of filler out-feed

Figure 2 shows the signal from two probes and the pre-defined critical control level of biofilm attachment (red line). When this level was reached by one probe, automatic rinsing of the surfaces was initiated as indicated by the red arrows. An additional foam cleaning procedure was initiated at fixed time intervals or when product change occurred (green arrows). Routine microbiological tests in parallel showed the hygiene level was kept within the defined specification.

22 FDPP - www.fdpp.co.uk


Sensor1

100

Sensor2

Schwallung bzw. Schaumreinigung 2087,5

2087

CCL

75

Biofilm %

2086,5

50

2086

2085,5

25

Sensor 1

2085

Sensor 2 0

2084,5

Di, 5.09 00:00

Di, 5.09 02:00

Di, 5.09 04:00

Di, 5.09 06:00

Di, 5.09 08:00

Di, 5.09 10:00

Di, 5.09 12:00

Di, 5.09 14:00

Di, 5.09 16:00

Di, 5.09 18:00

Di, 5.09 20:00

Di, 5.09 22:00

Mi, 6.09 00:00

Figure 2: Automatic biofilm control on a bottling machine

Return on Investment Compared with time-based cleaning, the real-time detection and subsequent control of biofilm formation led to a reduction of rinsing events on the bottling machine (Figure 2) while maintaining the required plant hygiene level. Cost for

Number of cleaning events

water and chemicals were reduced and bottling capacity was increased by 9.7 million bottles over 6 months.

1000 800 600 400 200 0

Time-based cleaning

Condition-based cleaning

Figure 3: Reduction of the number of cleaning events by CBC over 6 months

NOTE WRITTEN BY ONVIDA GmbH PHOTOGRAPHY BY ONVIDA GmbH

FDPP - www.fdpp.co.uk 23


Warehouse Automating

66 MACHINERY UPDATE JULY/AUGUST 2016 www.machineryupdate.co.uk

Machinery Update reports on how an Italian and British partnership will bring

benefits to a majorAutomation, UK food manufacturer’s centralised warehouse Feature: robotics and vision

Pictured here is a previous installation involving robotics technology supplied by PHS UK which has provided operator-free operation at the end of the line

Italian manufacturer Trascar and its robotic palletising system which is established by Trascar and PHS, a Pictured here is a previous installation involving robotics technology supplied by PHS UK which has provided operator-free operation at the end of the line UK agent Phoenix Handling Solutions connected to a series of conveyors company used to designing complete

Warehouse automating (PHS) has secured a multi-million euro order from a British food company

and flow diverters.

solutions for the UK market. "We

have already gained many blue chip

for an automated case handling and

CENTRALISED PALLETISING AREA

palletising system that puts robotics

The line will handle packs from

explains sales director at PHS Andrew

at its heart.

production to the new area assigned

Lawless.

references over a long period of time,"

for on automated palletising.and 0845 265 7570 partnership will Machinery Update reports howcentralised an Italian British This British producer of an historic When complete, the pallets will be bring to a major UK food manufacturer’s centralised warehouse brand benefits has selected Modena-based automatically stretchwrapped via

I

Trascar as a technology partner for talian manufacturer Trascar and theUK installation of its first automated its agent Phoenix Handling Solutions (PHS) has secured palletising system at its plant.a The multi-million euro order from multi-million euro order will be a British food company for an installed by handling the end ofand the palletising year. automated case system that puts robotics at its heart. This British of an historic This new producer order consolidates thebrand has selected Modena-based Trascar as a presence of both Trascar inof technology partner forPHS theand installation its first system at its theautomated UK, where palletising in little more than two plant. The multi-million euro order will years of doing business together, be installed by the end of the year. they have already acquiredthe several This new order consolidates presence of both PHS and Trascar orders for complex systems ofin ever the UK, where in little more than two increasing value. The new order will years of doing business together, they involve the planning, have already acquired several orders for the design, the assembly and testing of an articulated 24 FDPP - www.fdpp.co.uk

Tosa 125 systems series high speed ring complex of ever increasing value. which will be fully automatic without any operator intervention necessary. The new order will involve the planning, wrapping machines, labelled and then The system is currently at the planning the design, the assembly and testing of transferred intorobotic a new palletising warehouse.system phase, but will manage simultaneously an articulated up to eight pallet building positions, which is connected to a series Automatic shuttles will completely for a wide variety of case dimensions of conveyors and flow diverters. automate the pallet handling and stacking patterns at a high output. This important order was obtained CENTRALISED PALLETISING AREA aspect, which will be fully automatic thanks to the business partnership The line will handle packs from without anyto operator established by Trascar and PHS, a production the newintervention area assigned company used to designing complete for automated centralised palletising. necessary. Phoenix Handling Solutions solutions for the UK market. When complete, the pallets will be The system is currently at the via “We have already automatically stretchwrapped We continue to grow evengained during many tough blue chip references over a long period of Tosa 125 series high speed ring wrapping planning phase, but will manage economical times as we are fortunate time,” explains sales director at PHS machines, labelled and then transferred simultaneously up to eight pallet enoughLawless. to have very good support Andrew into a new warehouse. T 0845 265 7570 Automatic shuttles completely building positions, for awill wide from our European suppliers, with new W www.phs-uk.com automate the pallet handling variety of case dimensions andaspect, products being developed to stay one

stacking patterns at a high output.

step ahead, whilst being mindful of costs

This important order was obtained

and our enviroment.

thanks to the business partnership

www.phs-uk.com


Phoenix Handling Solutions Ltd Who are we? we are a (UK) supplier of palletisers, wrapping machines & automation systems. We are able to offer stand alone machines or complete â&#x20AC;&#x2DC;Turnkeyâ&#x20AC;&#x2122; solutions if required, incorporating the following. Robotic/Layer Palletisers/De Palletisers, Pallet Wrapping machines, Case Packing/Shrink Wrapping of products, Pallet Shrink, Pallet Stretch Hooding Machines etc. We have the expertise to pull together complete lines, using our wealth of knowledge gained over 50 years, having many references which can be viewed.

PHS are proud to announce that we

transfers them to a Tosa top sheet

have been successful in winning a

applicator and auto stretch wrapping

large contract within the soft drinks

machine.

sector. We received an enquiry to convey cased products from 4 production lines to a centralised palletising area, all conveyors being of stainless steel manufacture.

sold 6 print and apply Logopak case labelers and a Logopak pallet labeling machine. PHS have supplied the complete line A-Z with project management from the UK working

for most major soft drinks producers,

hand in hand with our principle

basically a bag in box. Cases are

suppliers Trascar and Tosa Italy.

with empty and full pallets being fed automatically in and out. Once the pallets are complete the shuttle car

PHOTOGRAPHY BY Phoenix Handling ltd

As part of the turnkey supply, PHS

The customer produces concentrate

conveyed to a Fanuc 410i robotic cell

WRITTEN BY Phoenix Handling ltd

For more information about Trascar or Tosa please refer to our web site www.phs-uk.com or e mail to info@phs-uk.com for sales.

FDPP - www.fdpp.co.uk 25


Leading UK Food Group Chooses Mitsubishi Forklifts Addo Food Group “Happy As Larry” With Complete Mitsubishi Package One of the UK’s leading food

ingredients including eggs, meat,

Operators say the intuitive handling’s

companies, the Addo Food Group,

seasoning and packaging from a lorry

precision and predictability – even

says investment in new Mitsubishi

parked on the road and transfer them

in the tightest corners and aisles –

GRENDiA ES forklifts is helping feed

75 yards to the loading bay.

gives them more trust in their control

their ravenous production lines and maximise production of over 256 million of the nation’s best-loved pork pies, sausage rolls, pasties and Scotch

“Outside space is very restricted; there’s very little room to move and we have very tight corners. Added to

of the vehicle, and this added driver confidence pays off with faster, more assured manoeuvring leading to increased productivity.

eggs.

that, the loading bay itself is also on an incline, so for us manoeuvrability

Mr Cook continues: “Because there’s

Faced with an ageing fleet, the Dorset

and stability of the trucks are

not a lot of space around here, the

Foods division – where hundreds of

paramount.”

trucks have to be robust and stand

thousands of the UK’s Scotch eggs are baked and fried – sought out a very specific type of forklift truck to deal with their conditions on site. Trevor Cook, Supply Chain Manager at Addo Food Group, explained: “The forklifts each have to unload up to a ton of 26 FDPP - www.fdpp.co.uk

To keep productivity levels high and the perishable ingredients on the move, the Addo Food Group opted for the LPG-powered Mitsubishi GRENDiA ES FG15N Series forklift for its compact design and fully hydrostatic steering.

up to knocks, and with Mitsubishi we knew we were getting a truck with a reputation for reliability and non-stop performance, whatever the conditions.”


NOTE WRITTEN BY Mitsubishi Forklift PHOTOGRAPHY BY Mitsubishi Forklift

In order to deliver that level of

Mr Cook added: “Competitive pricing

“Because my role extends beyond

dependability, Mitsubishi have built

was one of the most important

purchasing and goods inwards

in strength from the ground up,

factors, and Grant at Andover Fork

to include despatch and logistics,

with features like the rugged rear

Truck Services came up with a very

deadlines turnaround times are

axle assembly with metal bush

attractive package. But at the same

all-important to me. Knowing that

mounts (instead of more fragile

time, we needed really rapid service

Andover have got my back is a great

rubber mounts favoured by some

response times.

plus for me.”

“A simple but important example is

To find out more about the award-

Also as standard is the GRENDiA’s

the replacement of indicator lights

winning Mitsubishi Forklift Trucks

Belly Seal, a must-have for the dirty,

or bulbs. Because space outdoors

range and Andover Fork Truck

all-weather outdoor environment

is restricted they can easily get

Services, call the

of Dorset Foods’ loading areas. This

damaged… but we need them working

Greenline 0845 371 3048 or contact

unique under-truck protection – and

when we’re unloading from a wagon

info@red-diamond.co.uk.

sealed wheel arches – prevents the

truck on a public road.

competitors) as standard.

cyclonic effect, which draws dirt and dust into the engine and recirculates it into the working environment. With the Mitsubishi design, dust and dirt is kept off their incoming ingredients, as well as dramatically prolonging the engine life.

“It’s a real health and safety issue, and time is a big factor. But whenever we have an issue the Mitsubishi service team are out like a flash, so the drivers and I are happy as Larry.

Mitsubishi Forklift Our local Mitsubishi Forklift Trucks dealers have been hand-picked to bring you the forklift trucks that will best meet your needs and the support you need to ensure your trucks stay in constant productive action.

www.mitsubishi-forklift.co.uk.

FDPP - www.fdpp.co.uk 27


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“Hands up” if you worry that 1 in 6 touch screens carry E.Coli! …”but touch screens are used everywhere!!??”… …”I must come into contact with one at least a dozen times a week!”… In these days of increasing health

Protection Plus+ is an excellent form of

Every measure should be taken to reduce

awareness, more and more people

infection control in food environments,

risk in public places and in the workplace.

are showing concerns with regard to

hospitals and medical practices. The

multi- use screens, whether it be in a

films can be used on touch screen

supermarket, shop or bank. Most people

EPOS systems in restaurants, bars,

consider touch screens as a vehicle for

supermarkets and stores: places where

spreading germs therefore confronting

food is sold and produced, reducing the

this issue can only be a positive approach

risk of contamination.

S.M.T.L.), Bridgend. Proven to kill a

Increased use of touch-screens as

recognised as being a serious public

Clear Diamond is a UK based manufacturer

reception kiosks, check-ins and control

health hazard, such as E-coli, MRSA and

of high grade Anti- Bacterial polyester

panels where large numbers of people are

Pneumoniae.

protection films for all makes and sizes of

using the screens on a daily basis, requires

screen and touch screen devices.

that the screens are protected from

to satisfy their anxieties.

Specifically developed to provide high performance all-round screen protection for touch screen and LCD displays, Clear Diamond high performance anti-bacterial protection films have a proprietary hard coating that kills 99.9% of bacteria and pathogens. The hard coat incorporates pure metal Nano - technology which prevents bio-film colonization of the surface. The surface treatment will kill pathogens such as MRSA, E-coli and other virulent bacteria, greatly reducing the risk of crosscontamination. In recent years the risk of pandemics has increased greatly with different strains of Influenza and viruses such as Sars and the Corona virus. As a means of exogenous pathogen control, the films are ideal for prevention of HAI (Hospital Acquired Infection). Strains of bacteria are becoming more and more resistant to anti-biotics’ which is a serious public health issue.

30 FDPP - www.fdpp.co.uk

damage and the users are protected from infectious agents.

The Clear Diamond protection films pass BS EN ISO 22196:2011 tested at the National Health Service Laboratory ( Surgical Materials Test Laboratory wide range of harmful bacteria that are

www.clear-diamond.com


The Utility Forum are a well-established energy consultancy under the leadership of founder and Managing Director Chris Holdsworth and based at the historic Marsh Mill in Lancashire Proud to be 100% privately owned. We work for you, not our shareholders To discuss any energy-related matter, contact Chris Holdsworth

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New Closure Testing Microsite Launched By Mecmesin

Mecmesin, a leading British designer

may require torque or tension/

and creativity in design is continually

of force and torque testing equipment,

compression testing to meet

expanding the vast array of closures

has launched a new vertical solution

legislative or functional requirements.

and containers which need to be

microsite for manufacturers and end

tested for quality performance.

users of packaging closures.

Accurate and repeatable test measurement often needs custom

Due to the differing shapes and sizes

ClosureTesting.com focuses on the

fixturing, and the site showcases

involved it can often be difficult to

specific requirements for the quality

grips and fixtures designed for unique

select the best type of test equipment

testing of all types of closure and

customer samples—in addition to a

and holding fixtures to measure the

guides the visitor to the product best

wide range of standard accessories—

strength of closures – Mecmesin’s

suited to the closure material and test

alongside case studies and success

new microsite, backed up by the

type combination selected.

stories.

illustrative presentation video, clearly

Mecmesin has supplied test solutions

Responsive web design is

to customers in all consumer

implemented for the optimum user

packaging industries; medical/

experience that is equally accessible

pharmaceutical, cosmetics and

across mobile, tablet and desktop

personal care, drinks, food/dairy

browsing devices. Video media also

and household/industrial and the

features extensively; performing

microsite provides quick access to this

international closure test standards,

wealth of experience.

product overviews and best practice

The content covers applications

for ensuring accurate test data.

shows the best testing solutions and guides potential users to the most cost-effective equipment to meet their needs.”

Mecmesin Mecmesin is an established market leader in the design and manufacture of closure testing solutions, from simple, manual

for screw caps, tamper evident,

Mecmesin’s Sales Director and

ROPP and child-resistant closures,

Mecmesin GmbH Managing Director

automated closure testing systems.

plus stoppers and dispensers that

David Wilde comments: “Innovation

www.closuretesting.com

closure testers through to complex

FDPP - www.fdpp.co.uk 33


HygienicOptical Optical Immersion Immersion Probe Hygienic Probe

3A Certified Probe Enables CIP and SIP For Optical Analysis

3A Certified Probe Enables CIP and SIP For Optical Analysis

World Leading Carbon Dioxide CO2 Sensors made in Scotland For Dairy Products Drinks Food and Pharmaceuticals

For Dairy Products Drinks Food and Pharmaceuticals

No oror cavities, all all sanitary fittings, completely Nosharp sharpcorners corners cavities, sanitary fittings, completely smooth, electro-polished surfaces. smooth, electro-polished surfaces. Design, construction and manufacturing processes all annually Design,toconstruction manufacturing processes verified 3A standardsand by independent third party. all annually

verified to 3A standards by independent third party.

For more information contact Hellma UK Ltd For more information contact Hellma UK Ltd Email: sales.uk@hellma.com Phone: +44(0) 1702 335266

Email: sales.uk@hellma.com Phone: +44 (0) 1702 335266

Scotland is well known for producing delicious foodstuffs, but did you know that the production and well-being is assisted by the monitoring of CO2 levels? Insignia Technologies Ltd and Gas Sensing Solutions Ltd (GSS), based near Glasgow, produce World leading CO2 sensors. GSS manufacture unique solid state, low power and fast

response Non-Dispersive Infrared sensors used in food production facilities. Insignia Technologies utilise intelligent plastics and pigments to produce simple, cost effective CO2 activated, colour-changing labels for food packaging. For more information please visit: www.gassensing.co.uk www.insigniatechnologies.com

EXPERIENCE COUNTS! With over 150 years combined experience in gas and air handling Northey Technologies and MILâ&#x20AC;&#x2122;S Vacuum can provide a solution to your Food & Drink Processing and Packaging needs. Bottling Conveying Cooling De-Gassing Distillation Drying Egg Transfer Evisceration Filling

Let Our Experience work for you

34 FDPP - www.fdpp.co.uk

Freeze Drying Milk Transfer Mixing M.A.P. Oxygen Sealing Thermoforming Tumbling Vacuum Packing

Sales@Northey.net www.northey.net Tel. 01202 667832


Bell Hungry For New Business Bell Packaging are delighted to announce that we are now able to supply Jetran® packaging suitable for presenting food.Traditionally Jetran® has been used for non-food items and the only opportunity for food and confectionery producers to use this unique packaging is for pre-wrapped items. Commenting on this announcement Director Peter Lennie stated “For many years Bell have worked in the non-food sector and established a network of agents and distributors. Our plant in Luton operates the world’s largest production of clear tubing and with over 300 standard sizes we have excess capacity and are looking for new markets. “When we introduced the new flat top design of end cap in 2015 more than half the enquiries we received were from food companies. Having consulted with them alongside our High Street customers it is clear that

fdpp Uddeholm advert.indd 2

07/09/2016 17:31

Jetran® is wanted in the food sector.” Jetran® packaging has been used by many of the world’s leading confectionery brands for gift sets. Another area of interest is drink and liquor – traditionally these products are presented in glass bottles – but why hide them in a board box? The new presentation can transform a simple bottle into a gift and have a secondary function as a storage tube when the bottle has been consumed. The packaging provides excellent visibility for the decorated bottles that are housed inside and has maximum impact when on display in store. For more information and samples on this product development please contact Bell Packaging on 01582 459292 or visit our website at www.bellpackaging.com

FDPP - www.fdpp.co.uk 35


The long history of PCM in dosing and filling for the food industries

To dose accurately the most varied food

DosysTM pumps are designed to handle

ingredients and to fill containers of any

liquid, semi-solid and viscous products.

kind to ever higher rates are skills that

The dosing volume can be easily adjusted

PCM has been excelling in for more than

by simply increasing or decreasing the

80 years. Our machines are used by food

piston movement.

PCM Filling Pumps And Systems With PCM filling solutions it is possible to fill, layer and inject a wide range of products using the same system.

manufacturing companies around the

All PCM filling systems are designed to

world.

provide maximum volumetric flexibility. In other words, not only can you fill

The applications are numerous. We have

containers of all shapes and sizes, but you

identified no less than fifty food products,

can also vary the filling volume from one

among which we find milk, yoghurt, fruit,

cycle to the next.

sauces, cheeses, vegetables, chocolate, caramel or oils. PCM systems have been

DosysTM pumps enable an unrivaled

Versatility extends to its compatibility

installed in more than 70 countries to more

level of control and cleanability (CIP/

with a multitude of filling ingredients,

than 400 different companies, among

SIP) with no dismantling or the need for

from liquid flavourings to viscous jams,

which we find the most prestigious and

complicated bypass systems.

from sticky toffee to semi-solid sauces. Finally, PCM filling systems integrate easily

demanding ones in terms of productivity PCM Dosymixâ&#x201E;˘ Inline Dynamic Mixer

and quality. The PCM dosing and filling systems, by integrating transfer, dosing, mixing and filling functions, have managed to bring to their users the dosing accuracy, speed of execution, respect of the ingredients and compliance with hygienic standards required by processes increasingly

The choice of dynamic mixer is recommended for applications with fragile and sensitive ingredients containing solids or fibers. As it mixes products through progressive contact rather than shearing, the Dosymixâ&#x201E;˘ is particularly suitable for use with fragile products such as fruit.

demanding and requiring flexibility and

Its low mixing volume also means that

adaptability.

itâ&#x20AC;&#x2122;s ideal for the addition of time-sensitive

Never waste a drop with the Dosys

products, and although this industrial food

metering pump

mixer is powerful, its low volume operation

TM

Besides giving a very accurate on-demand dosing of the ingredients, the DosysTM pumps can meter the ingredients with precision, thanks to the servo-driven piston and a patented flow-control valve.

36 FDPP - www.fdpp.co.uk

reduces product loss both during the process and at the end of a production cycle.

with any production line and packaging equipment, thanks to their modular design.


No compromise on : Food safety & hygiene / Operational flexibility / Accuracy-repeatability / Productivity 2 Dosing

3 Mixing

1 Transfer HyCareâ&#x201E;¢

May 2016

4 Filling

CHOOSE PCM FOOD SYSTEMS FOR :

Baked goods

Fruits & vegetables

Personal care

Sugar & Starches

Beverages Meat, fish & animal food

Dairy

Convenience food

Follow us : www.pcm.eu


Enhanced Choice With New Size Pe Food Container RPC Sæplast is introducing a third size

container can be personalised with

construction that lasts up to seven

into one of its top-selling PE reusable

company logos and can incorporate

times longer than single wall versions,

plastic container ranges for food

tracking options such as a barcode,

while offering easier and safer

processing.

QR code or RFID technology.

handling for users.

The new 750 litre container sits

The RPC Sæplast PE range is

The one-piece container is easy to

between the existing 630 and

produced in 100% food grade

clean and maintain. The solid inner

875 litre sizes to offer customers

polyethylene and is particularly

core prevents absorption of liquid,

additional choice and flexibility in

suitable for supply chain handling

and the avoidance of easily broken

food transportation and storage. It is

in the meat and animal by-products

joints and hard to clean crevasses

available in a variety of colours, with

industries. Its one-piece, seamless

eliminates the danger of harmful

or without a drain plug, and can also

triple wall design and closed cell

bacterial growth for maximum

be specified with a lid. In addition, the

core offers a rugged and reliable

hygiene.

WRITTEN BY Saeplast

Saeplast SÆPLAST is a world leader in the design and production of doublewalled, insulated tubs and three-layer, specially strengthened PE tubs and palettes for use in manufacture of food products and in the recycling industry.

www.europe.saeplast.com

38 FDPP - www.fdpp.co.uk


Safe measurement, indication and control of rotational speed

Application-Report - Quality control: Printing machines

Task: On an 8-colour flexographic printing press, there is a web inspection system whereby several individual frames are automatically sent to a monitor every second over the entire width of the material using a mobile camera. Since these are only snapshots, the operator has to check the print quality randomly, in addition to manually, while the machine is running (max. 400m/min).

Source: Clondalkin Flexible Packaging

Examination criteria:  A „positive“ typeface will often be printed in a differently coloured, recessed „negative“ typeface. The two images have to be superimposed precisely, so that the base material, such as white paper, does not show through on the edges of the font.  The typeface may not fray at the edges  There may not be any printing lapses (the printed image appears „porous“).

Solution: Using the RT STROBE 10000 LED stationary stroboscope, the complete web width can be illuminated effortlessly. As a result, quality control is performed much more quickly and effectively.

The extremely high light intensity of the RT STROBE 10000 LED is guaranteed by 480 high-power LEDs. Thanks to a homogeneous illumination area of up to 100 cm, excellent results can even be achieved under less than favourable lighting conditions.

Printing errors which only occur at the edges of the material web can be recognised immediately at a glance. Without effort, a person can sometimes even „take a quick look at it in passing“. The brightness can be adjusted to the material/printing image so that reflections can be prevented.

RT RT STROBE STROBE 10000 10000 LED LED

User User panel panel

RHEINTACHO RHEINTACHO isis aa flexible, flexible, highly highly efficient efficient partnerpartner- wherever wherever speed speed must must be be measured, measured, monitored monitored or or indicated. indicated. Innovation, Innovation, the the most most modern modern production production techniques techniques and and equipment, equipment, meticulous meticulous quality quality control control along along with with aa first-class first-class workforce workforce are are the the corner corner stones stones of of our our company. company. For For the the past past 114 114 years, years, Rheintacho Rheintacho has has used used his his extensive extensive knowledge knowledge and and experience experience to to developed developed sensors, sensors, systems systems and and customized customized solution solution to to meet meet the the customer’s customer’s requirements. requirements. RHEINTACHO RHEINTACHO Messtechnik Messtechnik GmbH GmbH ·· Waltershofener Waltershofener Str. Str. 11 ·· DD -- 79111 79111 Freiburg Freiburg phone phone +49 +49 761 761 4513 4513 00 ·· fax fax +49 +49 761 761 445 445 274 274 ·· www.rheintacho.de www.rheintacho.de


Separating Seeds At Eco Treasures One of the main production activities of Eco Treasures is the ecological extraction of essential oils from residual vegetable feedstock and fine fruit seeds. In order to meet high quality

With the Russell Eco SeparatorÂŽ

standards, and ensure the best

installed in place of the previous

production efficiency, the Belgium

sieving system, Eco Treasures was

based company turned to Russell

able to separate dust from the fine

Finex, the leading supplier of high

seeds enabling them to send the

quality separation equipment, for

seeds through the press dust free.

an innovative processing solution.

The results were very positive.

Russell Finex Eco separator at Eco

Not only did the Russell Finex

Treasures The extraction of seed oil

machine eliminate the dust from

from residual frozen pulp begins by

the seeds, it also saved them

enjoyed 80 steady years of successful

separating the seeds from the juice

time by reducing the amount

growth to become an international group

pulp. In order to separate the seeds,

of labour that went into their

the frozen pulp is first melted and

previous production process. These

employing over 200 direct employees

then dried. The issue the company

two factors contributed to the

was facing was that there was too

reduction in manufacturing costs

much dust from the dried juice pulp

for Eco Treasures, an increase in

attached to the seeds after the

productivity, as well as a better

drying process, which resulted in a

product for their customers.

lower quality of extracted oil.

40 FDPP - www.fdpp.co.uk

{

WRITTEN BY Russell Finex Ltd PHOTOGRAPHY BY Russell Finex Ltd

Russell Finex Ltd Established in 1934, Russell Finex have

with annual sales exceeding ÂŁ25 million ($40m).

www.russellfinex.com


Bauer Gear Motor www.bauergears.com

Boston Gear www.bostongear.com

Warner Electric www.warnerelectric.com

WE'RE COMMITED TO THE

FOOD & BEVERAGE MARKET The industry-leading global brands of Altra Industrial Motion provide precision engineered power transmission components to meet the most demanding washdown requirements for all types of food processing and beverage applications. Altra offers a full range of drivetrain solutions including clutches & brakes, speed reducers, air motors, gear motors, overload clutches, torque-limiting devices, belted and synchronous drives, capping headsets and precision bearings.

www.AltraMotion.com


Paramount Packaging Takes A Fresh Approach With Latest Bespoke Flow-Wrapper

Aerolite™ - Europe’s Lightest Best Performing Bump Cap On The Market With Air Flow Technology

The HardCap™ AeroLite™ from JSP is the latest addition to the PPE specialist’s range of bump caps designed for work environments where there is a risk of impact between the head and stationary objects. New back seal flow-wrapper customised for reliable, high speed operation on mobile field harvesting rigs widely used by salad and vegetable growers Paramount Packaging Systems Ltd – exclusive distributor of Fuji Machinery Company’s horizontal and vertical form-fill-seal equipment in the UK and Ireland – has announced the launch of an Alpha VII FW3710BS/B back seal flow-wrapper that has been adapted for reliable, high speed operation on the mobile field harvesting rigs widely used by fresh produce growers. Ideal for salad and vegetable growers in particular, Paramount Packaging’s flexible new flow-wrapper is mounted on a robust stainless steel support frame to ensure stability and rigidity when sitting on the harvesting rig. tel: 01252 815252

www.paramount-packaging.co.uk

Creating industrial history since 1715

The new bump cap, designed by JSP’s in-house Research & Development team, features a full high-density polyethylene (HDPE) shell, so the wearer is protected not only from impact to the front and top of the head but also from scrapes to the side of the head. This significant increase in protection has not been gained at the expense of comfort: the HardCap™ AeroLite™ is extremely lightweight and comfortable to wear. In fact, at under 135g, the cap weighs about the same as a typical standard-sized smartphone – and it’s just as cool and stylish. To significantly reduce heat build-up the sleek textile cover has large open weaved panels to facilitate the transfer of cool air and mitigate the build-up of heat and discomfort – particularly if the cap is being worn over long periods. The HardCap™ AeroLite™ is available in black or blue, with either a 50mm or 25mm peak. The longer peak provides more shade in outdoor or brightly-lit environments, while the shorter version allows for better vision when looking upward. More information is available from www.jsp.co.uk, or by calling +44 (0)1993 826050.

Checkweighers

At John White & Son (JWS) we are proud

Manual or dynamic models offering practical and affordable solutions

to provide the best weighing solutions

developed as a result of a lifetime of experience in check-weighing.

to our customers.

Our Cartomat is the preferred check-weigher in the Food, Packaging

Founded in 1715, JWS is a leading UK

and Bottling halls of all the major spirit producers in the UK.

supplier of weighing solutions. Over the last 300 years, we have built a

We provide weight indicators for a wide range of industries from

reputation for innovation and engineering excellence.

factories to weighbridges.

At JWS, our customers are our business. We provide you with

The indicators also have a wide range of applications from general

unrivalled expertise in a range of weighing solutions. This is

weighing, check-weighing, to batch control.

complemented by a dedicated after-care support team.

John White & Son (Weighing Machines) Ltd 6 Back Dykes - Auchtermuchty – Fife - KY14 7DW

Tel: +44(0)1337 827600 Fax: +44(0)1337 827444 E-mail: enquires@johnwhiteandson.com www.johnwhiteandson.com

42 FDPP - www.fdpp.co.uk

CALL US FOR A QUOTE 0133 782 7600 Better solutions, better results!


WRITTEN BY Power Control PHOTOGRAPHY BY Power Control

‘Power Hungry’ Industry Must have Contingency Plans for Power Cuts It is no secret that the UK’s energy

Unlike the other food production

A UPS however, would ensure that

supplies are under threat. We have

related subjects that surround Brexit

there was no break in power and

already seen the surplus in capacity

such as rising ingredient costs,

protect the machine from cutting out,

diminish by a staggering 10% in the

new manufacturing legislations

delivering a continuous power supply

last five years*.

and barriers to trade, developing

until full mains power can be restored.

These narrower margins mean higher risks of outages, spikes and surges, which are a growing concern for all

contingency plans to tackle the dwindling power supplies is an area where food manufacturers can take

“A carefully mapped out power protection strategy and a small

control.

investment into a UPS solution could

already losing £thousands in lost

Mr Trolley summarised: “The

simple: Take control, be prepared and

revenue due to power disturbances.

food industry has been grossly

do not get caught out!”

UK businesses. These are individually

Jumping on the Brexit discussion band wagon, one of Britain’s leading energy lawyers stated back in February that a British exit from the EU could raise the risk of blackouts**. Now it seems

unaware of the large power drain on manufacturing equipment and many have overlooked the desperate need for improved emergency power systems.

there is just a lot of speculation and

Whilst, the basics have been applied,

scaremongering without any clear

manufacturers must understand that

messages about the future of the

the risks to power supply are greater

country’s electricity supply.

than ever before and consequently

That being said, it would be safe to assume that as the population and therefore the power grid, supplies

manufacturing sector recognises

will continue to put businesses in

the importance of these emergency

perilous positions.

power contingency plans. We believe

continues to be the country’s largest

to find out about our other products and services please visit www.pcl-ups.com, call 0800 136993 or email info@pcl-ups.com

strategies. “PCL hopes that this £multi-billion

is worth over £81.8bn*** and it

For all other company information or

must enforce more resilient protection

becomes more reliant on technology

The UK food production industry

go a very long way and our message is

they should be an integral part of every manufacturer’s efficiency strategy.

manufacturing sector. It is also one

“It would be no use having a

of the most ‘power hungry’ and

production line capable of filling over

therefore has the most to lose in the

50 ready meal trays per minute,

event of a power failure.

if it were to fail due to a power disturbance. The losses caused from the downtime would be catastrophic. FDPP - www.fdpp.co.uk 43


Polyurea technology - The toughest and most durable protective coating for the food manufacturing industry The latest Polyurea protective coating creates a high-strength, waterproof, flexible, seamless membrane. It provides a durable surface that can withstand repeated power washing and is resistant to many chemicals. Fast cure time allows return to service within hours. • Protect surfaces in food processing plants and facilities • Durable interior lining for food and beverage storage tanks • Non-slip surface for floors, walkways and loading areas. Polyurea technology has a far longer service life than many traditional coatings. It can be applied at a range of temperatures. It has higher elongation, greater flexibility and wont crack or peel like traditional coatings. It contains no VOCs, solvents. CSC Services are a specialist contractor providing high performance cleaning, repairs and specialist coatings. A range of resin flooring products are also available. Visit www.csc-services.co.uk

Ty-Rap® Detactable fastening solutions Designed to perform in food & beverage Absolutely.

Ty-Rap ® detectable cable ties help mitigate contamination risks in the food & beverage sector. The Ty-Rap ® detectable cable ties from ABB incorporate a unique compound (patent pending) that can be detected by X-Ray equipment, metal detectors and visual inspection equipment. By specifying the Ty-Rap ® detectable cable ties and accessories of ABB for your plant you help reducing the risk of product contamination. new.abb.com/food-beverage Tel. +44 (0) 333 999 9900 Fax. +44 (0) 333 999 9901 E-mail: lv.enquiries @ gb.abb.com

44 FDPP - www.fdpp.co.uk


Festo and Siemens to focus on solutions for the packaging industry at PPMA Total 2016 System is strongly positioned to address Industry 4.0 requirements and applications. Its exceptionally flexible electromechanical design enables adaptable, reconfigurable and economic production, even for mixed requirements and small batch sizes. Its OPC-UA interface enables open integration into Industry 4.0 environments. Visitors to the stand will also see examples of how Festo is implementing this key industrial M2M communication protocol for At this year’s PPMA Total Show, Festo,

complex product diversity and high

the leading supplier of automation

levels of mass customisation. Its

equipment, will be showcasing

freely definable and configurable

exciting new developments and

linear transport rail can be easily

solutions for the processing and

integrated into existing intralogistics

packaging industry on its stand

systems, with precise synchronisation

B70 in Hall 5. For the first time

and seamless infeed and outfeed of

in the UK, in collaboration with

transport carriers.

Siemens, Festo will demonstrate the Multi-Carrier-System, a new linear motor track system which delivers a flexible and modular transport solution for industrial automation. The collaboration brings together the extensive controls expertise of Siemens with Festo’s linear motor and mechanical guidance technology. Festo will also highlight some of its latest new products and demonstrate solutions for Industry 4.0. The Multi-Carrier-System addresses the acute need for flexibility in modern manufacturing and production environments driven by increasingly 46 FDPP - www.fdpp.co.uk

The movement of carriers within the system can be rapidly and easily adapted to deal with different

interoperability into its other field level controllers, alongside open interfacing to other industrial control and communications standards, including PROFINET and IO-Link. For more information on advanced handling systems for processing and packaging and to meet Festo’s industrial automation experts, please visit stand B70, hall 5 at PPMA Total 2016.

formats, sizes and types of product – down to batch sizes of one. Applications could include cosmetics packaging with its huge number of product variants, food and beverage processing with quick seasonal changes or industrial manufacturing

Festo Festo is a leading international supplier of automation technology with a turnover in 2015 of around €2.64

of customised one-off products

billion.

ordered via online configurators.

www.festo.com

Incorporating decentralised sensors and intelligence within its workpiece carriers and drives, the Multi-Carrier-

WRITTEN BY Festo PHOTOGRAPHY BY Festo


Test your food packaging at SATRA • Assessing suitability for food contact applications • Determining overall migration to the requirements in Regulation (EU) No 10/2011 • Migration into aqueous and fatty food simulants • Specific migration of extracted metals • REACH restricted substance testing

For more information on overall migration testing see

www.satra.co.uk/fddp

SATRA Technology Centre, Wyndham Way, Telford Way, Kettering, Northamptonshire, NN16 8SD, United Kingdom Tel: +44 (0)1536 410000 Fax: +44 (0)1536 410626 email: chemistry@satra.com www.satra.co.uk


BRC Accredited Tempering & Blast Freeze In addition to it's BRC accredited storage & distribution operation, IBL is proud to announce the continued development of its blast and tempering facilities in line with the BRC Accreditation system. IBL now operates 2 continuous flow tempering lines that significantly increases its tempering capacity into 2016. Both lines are supported with equalisation and rapid air facilities to ensure consistent end temperatures are continually achieved.

Contact Ian Desmonde on 0151 549 7414 E: iand@intbl.co.uk | www.intbl.co.uk

Introduction to MC Integ Ltd Specialists in Liquid Storage Integ have been involved with liquid storage for over 35 years, in all that time we have supplied a huge range of Tanks/Vessels to Store Various Liquids, Integâ&#x20AC;&#x2122;s vast experience is at your disposal, so please contact us to discuss your storage needs. Below is a simple list of the type of products/services we can supply:Carbon Steel/Stainless Steel Storage Tanks- (Rectangular/Cylindrical)-Shop and Site Constructed Dairy/Brewery Tanks Oil Tanks (Welded)-Shop and Site built Pressure Vessels- PD5500/EN13445/ASME VIII Thermal Stores/Chilled Buffer Vessels Water Tanks/Vessels Design/Drawings of Tanks/Vessels Post Engineering Design/Drawing service. Interconnecting Walkways/Platforms between Tanks/Vessels. Installation Service available on all our Tanks/Vessels. Demolition Services Industries Served:Petrochemical Oil & Gas Power Stations Breweries Solvents Pharmaceutical/Cosmetics Food Industry Chemicals Paper Mills Oil Terminals Dairy Sewage Nuclear Recycling Plants Water Industry Waste Industry Please take a look at our Website for a general understanding on the type of Tanks/Vessels and Projects we have been involved with at www.mc-integ.co.uk | 01359 270610 | keith@mc-integ.co.uk

48 FDPP - www.fdpp.co.uk


THE NEW FILTER FAN PLUS

EXPELS MORE AIR FROM AN ENCLOSURE.

STEGO ‘the protector of electronics’ have developed a new filter fan series. This series has a more effective airflow and significantly increases air volume, thanks to its unique air-flap outlet technology, and only one filter mat. But there is more …

TAKE A LOOK AT ALL PRODUCT HIGHLIGHTS:

WWW.FILTERFAN-PLUS.COM

STEGO UK Ltd. | Unit 12, First Quarter Bus. Park | Blenheim Road, Epsom | Surrey KT19 9QN | www.stego.co.uk


Rockwell Automation Rockwell Automation, the world’s largest company dedicated to industrial automation and information, makes its customers more productive and the world more sustainable.

www.rockwellautomation.com

Ivs Brings Vision To Universal ‘Cobots’ Oxfordshire-based Industrial Vision

inspection, guidance, identification,

ease of deployment within factory

Systems (IVS) is now integrating

measurement, tracking and counting -

automation. These will marry

its machine vision technology with

in many diverse sectors.

perfectly with the UR robots provided

the latest collaborative robots, also known as ‘cobots’, from Universal

“This new generation of affordable,

by R.A. Rodriguez.

lightweight robots is unlocking new

“We use Rodriguez as they are a

markets and applications as they work

qualified, knowledgeable supplier

side by side with human workers,”

that offers a good background in

says Earl Yardley, director at IVS.

robotics automation with the UR

“The result is increased total factor

robots,” says Mr Yardley. “Working

productivity and the elimination of

together on projects means we can

the need for costly precision fixtures,

leverage their substantial knowledge

robot.

thus allowing different parts to be

on flexible automation, coupled with

processed and inspected without

our extensive expertise on automated

Founded in 2000, IVS has grown to

changing tools.”

machine vision solutions. As a result,

Robots. IVS is pitching the visionenabled UR3, UR5 and UR10 models, which are supplied in the UK by R.A. Rodriguez (U.K.) Limited, at customer applications such as inspecting complex components, as well as providing positioning feedback to the

become a major supplier of machine vision and artificial intelligence solutions to industry. The company’s vision systems are used all over the world in automated production processes for quality control, 50 FDPP - www.fdpp.co.uk

The latest generation vision systems from IVS are based on high resolution digital camera technology combined with sub-pixel accuracy vision software for unparalleled

we can approach projects with a team philosophy utilising a large engineering resource between the two companies.”


Among numerous target applications

IVS will offer vision-enabled versions

of 150N but can be set to stop if it

at IVS customers, the vision enabled

of UR3, UR5, and UR10 model

encounters a force as low as 50N, if

UR-series ‘cobots’ will assist human

robots from Universal Robots. The

required.

workers with inspection processes.

UR3, in particular, is expected to

IVS believes that, in the future,

prove popular. This smaller table-

inspection benches will include space

top robot can be used to provide

for an operator and a robot to work

camera inspection on multiple sides

in partnership as part of the quality

of complex parts and components,

control process.

allowing precision automated

Mr Yardley says that working with

inspection.

‘cobots’ has the added advantage

The compact UR3 weighs only 11kg,

of working safely and effectively in

but has a payload of 3kg, ±360°

workspaces occupied by humans:

rotation on all wrist joints and infinite

“Collaborative robots are designed so

rotation on the end joint. Importantly,

that the robot and human can work

the UR3 is built with the same proven

together without barriers. By offering

collaborative technology as the larger

ready-to-run inspection solutions

UR5 and UR10 robot arms. All three

utilising robots and vision in tandem,

robots feature the identical safety

we are opening a new era for real-

system and ±0.1mm repeatability.

time machine vision inspection.”

The UR3 has a default force sensing

IVS is a member of the British Standards Institute, CE Marking Association and the Processing & Packaging Machinery Association. In addition, the company is an accredited member of the SafeContractor® scheme. For more information on IVS visit: www.industrialvision.co.uk

FDPP - www.fdpp.co.uk 51


HBM High Precision Digital Load Cell For Demanding Applications! HBM â&#x20AC;&#x201C; a market leader in the field of

for-trade applications per OIML R60 up

HBM software PanelX, which combines

test and measurement â&#x20AC;&#x201C; is pleased to

to 3,000 divisions, which in turn ensures

support for the configuration process

announce the new FIT5A Digital Load

accuracy, reliability and overall safety in

with an intuitive user interface, a wide

Cell, specifically designed to meet the

any heavy-duty production facility.

range of parameters for adjustments and

needs of demanding applications where speed and accuracy are key.

batching processes can be conveniently Housed in a welded casing and

set.

hermetically encapsulated, the robust Suitable for use in a wide range of

FIT5A load cell is available with an IP

For more information, please contact

production environments with harsh

rating of up to IP69K, making it suitable

HBM on +44 (0) 208 515 6000 or visit

ambient conditions, which require

to a wide range of demanding process

www.hbm.com

dynamic weighing, filling and metering;

applications with

for example in the food production and

sensors based on strain

process industries; the robust FIT5A load

gauge technology.

cell offers manufacturers high precision and processing speed.

In addition to the standard model, the

Based on the very latest HBM strain

FIT5A is also available

gauge technology, the innovative new

in various extended

load cell features integrated overload

versions. Through the

protection and the suitability for legal-

use of professional

Driving innovation. Achieving flexibility. Improving simplicity. Ultrasonic Sensor UMB800

 Ultracompact all stainless steel ultrasonic sensor (1.4404/316L)  EHEDG and ECOLAB certification: specifically designed for use in food

contact zones (hygienic design)  Resistant against aggressive chemicals and detergents  Maximum flexibility for integration into existing equipment and machinery

www.pepperl-fuchs.com/umb800

52 FDPP - www.fdpp.co.uk


Mastering challenges. Opening communication channels. Redefining flexibility. R100 and R101 Series The New Generation.  State-of-the-art

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NOTE WRITTEN BY Fortress Technology PHOTOGRAPHY BY Fortress Technology

Fortress Helps Nut Supplier Crack Metal Contaminant False Readings Replacing its existing metal detectors with five Fortress Technology’s Stealth Vertex systems has yielded a 40% improvement in sensitivity and eliminated the issue of false rejects for a leading UK nut and dried fruit processing and packing company. From its BRC (British Retail

“We were getting a lot of false

“It didn’t represent value for money to

Consortium) Grade A-accredited

rejects on the one machine, so we

replace the multihead weighers and

factory the company supplies

had to replace that, but it was also

packaging machines that continue to

processed nuts and fruit & seed mixes

a commercial imperative for us to

work well for us. What we needed was

to major blue chip manufacturers,

upgrade to a higher specification of

to get more productivity out of them

retailers and food service operators.

detection equipment,” explains an

by retrofitting them with reliable in-

These are marketed under their own

engineering manager at the company.

line metal detection units,” continues

brand as well as customers’ private

“We operate to the highest BRC

the engineering manager. “The small,

labels and include everything from

standard and wanted to further

compact Vertex head fitted beautifully

snack pots to individual and sharing

enhance our market position by

within the available envelope, and we

pouches and bagged peanuts popular

investing in the capability to reliably

liked the fact that Fortress offered full

with the pub trade.

detect the tiniest metallic particles.”

installation and integration with our

In 2015, the independently-owned

Having purchased metal detection

business decided to upgrade its

equipment from several different

The ultra-slim Vertex from Fortress

metal detectors on five packing lines.

suppliers over the years, the company

detects metal contaminants in

Weighing and filling bags of peanuts

saw this as an opportunity to

free-falling product prior to final

and treenuts ranging from between

rationalise its sourcing approach. It

packaging. The sensitive unit uses

50g and 1kg, one of the company’s

turned to Fortress, whose technology

digital signal processing technology

older detectors was generating

had previously proved reliable. The

to ensure detection of the smallest

false rejects, resulting in frequent

mini Vertex units could also be

ferrous, non-ferrous and stainless

downtime. Similarly, the other units

fully integrated with their existing

steel contaminants. Complying with

were not as efficient or as sensitive

multihead weighers and vertical

stringent HACCP regulations, the

as they needed to be to underpin

baggers.

built-in data collection software with

existing kit.”

the snack producer’s market-leading

USB data transfer establishes the

reputation for safety and quality.

Vertex as an effective critical control point.

54 FDPP - www.fdpp.co.uk


Product waste free falls to zero Screening a variety of nuts immediately prior to bagging at speeds of 80 packs per minute, the new detectors have eliminated false rejects altogether.

four times a day on most lines. Our

customers with even greater

previous metal detectors required

confidence, as the engineering

manual set-up. With the new Fortress

manager concludes: “The benefits

units it’s a simple case of selecting

of switching to one supplier that can

a new product recipe via the control

offer compatible kit are multiple.

panel.”

As well as solving the issue of

What’s more, detection sensitivity has

Installation of the five Vertex

products being wasted as a result

almost doubled; the Vertex systems

detectors took place in autumn 2015

of false rejects, having access to

are capable of detecting ferrous and

over two days. To minimise disruption

common spare parts, ongoing support

non-ferrous particles as small as

to production, the units were installed

and minimal training equates to a

1.0mm and stainless steel particles

individually so the other four lines

better total cost of ownership and

down to 1.5mm, compared with

could continue to run as normal.

faster return on investment.”

2.5mm previously.

The value the detectors have

Fortress Technology

The new detectors have also reduced

brought to the fruit and nut

product changeovers to less than a

processing and packing company

beginnings in 1996 believing that through

minute as the engineering manager

has been two-fold. In addition to

superior product design and engineering

rationalizes the benefit of having

improving the line performance

equipment that’s easy to use and set

having the latest inspection

up: “We change products three or

technology on-site fills its

Fortress Technology began its humble

the production of higher quality equipment with better sensitivities could be achieved.

www.fortresstechnology.com FDPP - www.fdpp.co.uk 55


Displays & Panel PCs for the Food & Drink Processing Industry Nemacom are a specialist UK manufacturer of rugged, fully IP65 sealed Touchscreen Displays and Panel PCs for the Food & Drink Processing Industry. We produce a wide range of displays in Stainless Steel that are suitable for the most challenging environments including wash-down and outdoor use. We also offer a bespoke service to ensure your specific needs are met.

Touchscreen Panel PCs

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branding.

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2~3 year warranty

Bespoke Service

Email: sales@nemacom.co.uk

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Web: www.nemacom.co.uk

25 years in business

Betty’s Lane, Norton Canes, Staffordshire WS11 9UU. UK. Tel: +44 (0)1543 495020 Fax: +44 (0)1543 495021


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Innovative Labelling Solution Wins Advanced Dynamics Greeting Card Contract abelling badged, wrapped greeting

BasicFeeder with extended outfeed

is the UK distributor for renowned

cards can be particularly challenging,

and ingeniously-placed transport

global machine manufacturers such

which is why Gemma International,

belts that dispensed the cards onto

as Pack Leader, Köra-Packmat and

the UK’s leading supplier of greeting

the transport conveyor of Pack Leader

Eurokett, as well as supplying cutting

cards, gift packaging and party

ELF-20 desk-top labellers.

edge sheet counters made by B.Matic.

Guides and sensor location were

The company is on a mission to

altered for the flat products and

provide customers with invaluable

the feeder and labeller were then

automatic solutions to improve their

mounted onto an aluminium frame

production efficiency, quality and

with sliders that allowed exact

costs. As well as greeting cards and

positioning of the feeder relative to

gift wrap, its specialist wrapping,

the labelling conveyor, both sideways

labelling and feeding solutions are

to help products get to market quickly.

and lengthways. In fact the system

also in industries such as food,

was so successful Gemma then

drinks, pharmaceuticals, cosmetics,

Gemma chose to replace repetitive

approached Advanced Dynamics with

toiletries, printing and other related

manual price point labelling of

a second order to additionally label

sectors. Exceptionally accurate and

wrapped greeting cards, including

Hanger Packs of gift wrap and tags as

robust, fully-automated systems from

products with badges attached to

well as cards. Gemma’s DC & Logistics

Advanced Dynamics are suitable for

them, at its Andover facility with an

Manager, Adrian Stait, said: “After

a variety of goods and can accurately

automated process which would save

seeing a demonstration of the ELF

label the full range of package

time, reduce costs and significantly

equipment at Advanced Dynamics’

configurations to suit individual

boost output, particularly at peak

facility I was confident that it met our

budgets, operating conditions and

periods such as Christmas. The

needs.

product characteristics.

ranges, turned to Advanced Dynamics Ltd for a cost-effective automated labelling system. Advanced Dynamics is a specialist in automated labelling processes that can save companies money by ensuring labels are applied accurately, so as not to compromise the presentation quality, and at speed

challenge for Advanced Dynamics was to design a bespoke labelling system for Gemma that was versatile enough to label both badged and flat cards. After trialling sample cards supplied by Gemma, Advanced Dynamics built an innovative labelling system from equipment that exactly matched the customer’s requirements. It could cope with all card sizes, badged and

The machines have allowed us to bring all of our labelling ‘in-house’ and therefore make significant cost savings. I would recommend Advanced Dynamics to anyone looking to automate the application of labels.” With a combined experience of over 120 years in the labelling and packaging field, Advanced Dynamics

flat, as well as applying all the various

Our company, Advanced Dynamics Ltd,

label types and positions required on the cards. To meet the specification Advanced Dynamics incorporated a specially-adapted Köra-Packmat 58 FDPP - www.fdpp.co.uk

Advanced Dynamics Ltd was established in 2005 following the

NOTE WRITTEN BY Advanced Dynamics Ltd PHOTOGRAPHY BY Advanced Dynamics Ltd

merger of WLT Ltd and Crusader Europe Ltd.

www.advanceddynamics.co.uk


hfl

consulting Safety Sustainability Profitability

The problem-solving toolkit every plant manager needs. For companies involved with food processing and packaging, business improvement and regulatory demands can often seem to pull in opposite directions. So how do you get better and stay compliant? Long-term sustainable improvements require an understanding of several key factors: legislation, supply chain interactions, stakeholder interests and business processes and objectives. This is where HFL Consulting can help. Having worked with several of the major players in the UK food packaging industry, we have helped to deliver multi-million pound cost savings, whilst satisfying the requirements of the regulators and other key stakeholders. Find out more about how we can improve your business performance. T 0161 304 5902 E info@hflconsulting.uk W hflconsulting.uk

People Plant Process Productivity


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FDPP - Issue 10 2016  
FDPP - Issue 10 2016