FOOD & DRINK PROCESSING & PACKAGING
The Importance Of Sensor Triggering In Production And Process Automation Issue 09 2016
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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@fdpp.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.
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Features
Rockwell ME Adelphi Spelsberg RPC Adpak Fanuc Wiggle Nestle Paramount TCL Packaging
< 04 < 10 < 14 < 16 < 18 < 19 < 20 < 22 < 26 < 28 < 30
FDPP - www.fdpp.co.uk 3
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
Leading U.S. Pork Producer Optimizes Supply Chain Background From the popularity of baby-back ribs to the national obsession with bacon, Americans have an avid appetite for pork. The Maschhoffs -- the largest family-owned pork producer in the United States – helps satisfy that hunger from its headquarters in Carlyle, Illinois. In 2014, the company sold nearly $1 billion in pork -- enough to feed over 16 million average consumers annually. Like many major agricultural operations, The Maschhoffs started with a single family farm. For five generations, The Maschhoffs grew row crops and raised cattle. But brothers Ken and Dave Maschhoff returned to the farm home from college with bigger dreams. 4 FDPP - www.fdpp.co.uk
In 1991 they bought their parents’ share of the business and began expanding the operation. Today, The Maschhoffs’ pig operation employs about 1,500 employees. Contracting with production partners – about 550 family farmers across the Midwest – the company sells about 5 million live hogs annually. The buyers are packing plants and food producers such as Cargill, Hormel Foods and Farmland. The Maschhoffs provide pigs and feed to their production partners, and pay the farmers for the time, labor and space necessary to raise the hogs.
Challenge Running any large farming operation is a complex undertaking. That’s particularly true in modern pig raising, which entails a continuous logistics challenge: the need to move pigs to specialized farm sites at different stages of growth. Once small farmers commonly took on the entire farrow-to-finish operation – breeding sows, weaning piglets, growing feeder hogs and preparing them for market or “finishing.” But rising transportation and feed costs – along with the complexities of hog genetics and health risks – have forced many smaller farms to specialize and contract their services to large producers.
And so, a large operation like The
“We were having a hard time measuring
The company wanted to move to a
Maschhoffs must contend with a
all the impacts of our space decisions,”
distributed leadership model, with
continuous flow of pigs between
said Dugan, who oversees the transport
smaller geographic territories, to
different types of farms – from sow
of 700 to 800 trailer truckloads of live
give managers a better line of sight
(or breeding) facilities, to weaning,
pigs each week.
into the business’ leased assets and
feeding and finishing facilities.
The company’s logistical system
contracted farming operations.
“We have 73 different sow farms, and
consisted of Excel spreadsheets,
The problem? Without modeling and
when piglets grow to about 21 days
providing only a small window into
predictive technology, they couldn’t
old, we need to start looking for the
how many pigs were flowing through
reliably determine the optimal number
best space to house them,” explained
their system at any one time. Without
of divisions, or which facilities should
Morgan Dugan, director of supply chain
more precise analytical tools, they
be included in each region.
management and logistics for The
couldn’t project how much farm space
Maschhoffs.
they’d need in the next month, for instance, or compare the costs of their
“We could ask a flow planner to project our flow to sites for the next 52 weeks,
owned and leased facilities.
but that would require somebody three
can accommodate the sows and the
The Maschhoff’s analytical and
can’t really ‘war game’ different options
piglets. In six to 10 weeks, the young
predictive limitations became even
if you have to wait that long,”
pigs are moved to finishing facilities
more apparent when company
that can accommodate the larger size
leaders decided to reorganize the
animals.
business from a national to a regional
Weaning farms are specially equipped for young pigs, with pen sizes that
days to complete,” Dugan said. “And you
management structure.
FDPP - www.fdpp.co.uk 5
Solution The Maschhoffs analyzed different supply-chain modeling packages in tandem with a group of graduate business students from Washington University at St. Louis.
Other variables for the early models
“Going forward, we can use the Arena
included the costs of different
software to manage flow and capacity
facilities, known as yardage costs, as
more efficiently, and give us the
well as facility capacity and annual
flexibility we need to adapt to changing
feed costs. Feed costs were based on
site needs,” Dugan said.
projected demand according to the size and age of pigs, and the nearest
The project team created a real-world
feed mill.
model by taking digital “snapshot”
And because pigs from different
and ages of pigs and their locations,
sources can introduce new diseases,
inputting the data into tables. By
the project team also designed the
repopulating the system with current
“The Arena application provided total
models to identify and track the
data, The Maschhoffs can now run
flexibility that allowed us to model
movements of common groups from
the model forward to see occupancy
anything we needed,” Dugan said. “We
one location to another.
rates or various sites and flows – on
As part of a special project with the company, the students evaluated dozens of solutions. Arena®software was their No. 1 recommendation.
also felt we’d get a good return on our investment.”
In the midst of the build-out, The Maschhoffs issued a new challenge
of the operation’s existing number
a weekly basis, instead of annually, as in the past.
Arena’s flowchart modeling
to the implementation team: They
Now the operation can make timely
methodology made it easy to build a
moved the final implementation date
business decisions based on a real-
logistics process flow. Drag-and-drop
up by several months. The new target
world model that reflects all the
elements and structures simplify
date reflected the growing urgency
variability in their system, clearly
simulation building and visualization.
around the reorganization initiative
visualizing systemic effects of
The software also features built-
and the need for a modeled regional
changes.
in dynamic dashboards for model
analysis.
analysis. The Rockwell Automation team, who began immersing themselves in the daily operations of the business, spent weeks on-site at the Carlyle headquarters to understand The Maschhoffs’ operations and business parameters. To create the baseline models, the Rockwell Automation team sampled the flow of pigs through the system for several weeks, tracking them by
Results The Rockwell Automation team met the accelerated deadline. The result? Regional modeling and analysis pointed to four management regions, balancing efficiencies in flow, transportation and feed costs with the utilization of contracted sites. “It was exactly what we needed,” said Dugan. “The data allowed us to make timely recommendations on our new
The Maschhoffs’ leadership is confident in the decision-making behind their new regional structure. They also envision many opportunities to forecast future demands using Arena to drive better asset decisions. The results mentioned above are specific to The Maschhoffs’ use of Rockwell Automation products and services in conjunction with other products. Specific results may vary for other customers.
regions.”
Trademark Information:
status of the sow farms where pigs
After the first modeling phase was
Arena and Rockwell Automation are
are born, which affects the quantity of
complete, the team made additional
trademarks of Rockwell Automation,
pigs released into the system.
enhancements: loading live data and
Inc.
age. They also looked at the health
Arena’s simulations matched flow size to site size and type, maintained that weaning pigs, for example, weren’t sent to farms with large pens intended for finishing. 6 FDPP - www.fdpp.co.uk
transforming the strategic application into a powerful operational decision tool. WRITTEN BY Rockwell PHOTOGRAPHY BY Rockwell
GGR GGR Associates Ltd
Putting Reliability Back Into Equipment Performance
How do you ensure that your plant performs reliably? Many companies have invested heavily in recent years in new plant and equipment. Much of this equipment is running at higher speeds and is operating for longer periods than before, often 24/7. Yet, despite this investment in state-of-the-art equipment, plant efficiencies are not reaching target levels. To understand why plant performance is poor, one needs to look at the underlying causes. In many companies, most 'performance losses' are classed as downtime which, in turn, is equated with breakdowns. Breakdowns are seen as maintenance issues, i.e. an engineering problem. However, the reality is often very different. Most equipment in the food and drink industry will run virtually for ever if no product or packaging materials are put through it. The vast majority of losses centre around the machine/material interfaces, and there are many hundreds of these on a high speed packaging line. Most of these losses are likely to be caused by one or more of the following: •
Poor setting at changeovers or start-ups
•
Raw material or packaging material variations
•
Poor line control philosophy
•
Inappropriate cleaning
•
Incorrect operating procedures
•
Process control or process capability issues
•
Equipment design or specification issues.
Working closely with a number of household-name companies in the food and drink sector, GGR Associates have developed a very structured approach to address these problems. It includes elements of Reliability Centred Maintenance (RCM) from the US airlines, Total Productive Maintenance (TPM) from the Japanese car industry, FMECA and SMED (Quick Changeovers). The analysis is undertaken by a small team that knows the equipment well working under the guidance of a facilitator, and involves both operators and technicians as well as relevant specialists. The focus is on improving overall plant performance. Its application has led to dramatic improvements in performance levels in a wide range of companies, including many in the food and drink sector. For examples of successful projects, go to our website: www.ggrassociates.co.uk, or email us at: info@ggrassociates.co.uk. FDPP - www.fdpp.co.uk 7
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Micro-Epsilon With over 45 years experience and more than 15,000 customers worldwide, Micro-Epsilon understands the need for accurate, robust, intelligent sensors and measurement systems.
www.micro-epsilon.co.uk
The Importance Of Sensor Triggering In Production And Process Automation When measuring the position of moving targets in production and process automation environments, it is important to understand the different methods of sensor triggering, their impact on measurement cycle times and the benefits they can offer over continuous measurement, says Chris Jones, Managing Director at Micro-Epsilon UK. Triggering is a term often used in
on (initiated) every 5s for a duration
conditions: rising edge (positive edge),
sensing and measurement technology
of 1s. The measurements between
falling edge (negative edge), High level
and includes all the different methods
the target objects are of no interest
(H level) and Low level (L level).
of initiating a measurement or a
and so do not need to be evaluated.
controlled output of measurement
This type of sensor set up provides
Edge triggering
data.
savings in terms of the memory of the
After the triggering edge, provided
evaluation system.
by an initiator switch or PLC, the
Particularly in production and process automation environments, in order
It is important to understand the
to reduce the system load on any
different triggering methods available
downstream monitoring and control
and their relationship to sensor
units, a permanent measurement
measurement rate and cycle time,
output is often not the best approach.
particularly in fast-moving processes.
Instead, the sensor should wait for a signal from an external source that specifies the time for a measurement to take place, thus initiating the output of data. Triggering is therefore often initiated by an external signal. For example, consider a target object in a high speed production line, which passes a sensor every five seconds for a period of one second. If the sensor has a trigger function, the output of the sensor only needs to be switched 10 FDPP - www.fdpp.co.uk
Non-contact laser sensors are often installed in production and process automation environments to measure displacement, distance or position. These sensors can be triggered both via the ‘edge’ or the ‘level’ of the trigger signal. The following are implemented as trigger
analogue output is updated, or if a digital output has been selected, only a digital measurement is output via an RS422 interface (see Fig 1).
Level Triggering Level triggering, sometimes referred to as gating, causes the sensor to output measurements until the trigger condition is satisfied (see Fig 2).
As the processing occurs sequentially
In this example, only measurements
in time and parallel in space, the
for a particular range of positions are
next measurement is available at the
to be examined more closely. The
output after a further 400µs.
trigger signal (green) initiates the
The sensor time pattern therefore requires a chronological interval between two consecutive trigger signals of at least four cycles with
Trigger pulse values The trigger pulse duration ti must be at least one cycle period (= 1/ measuring rate). With a slower
measurement in the sensor. The time offset of the trigger signal and output signal of the sensor (blue) can be seen clearly on the oscilloscope.
edge triggering, or five cycles for level
The sensor needs this time for the
triggering. Thus a measurement is not
internal processing and output of the
output that was valid four cycles ago,
measurement results. Encoders are
but instead the measurement object
also suitable as trigger signal sources.
position is acquired exactly at the time
Rotary transducers can be found in
of the trigger.
all numerically controlled industrial systems.
measuring rate, the trigger pulse
As a result, a maximum trigger
duration must therefore also be
frequency of 625Hz occurs for a
The rotational speed or the closeness
extended (e.g. from ti = 400µs at a
measuring rate of 2.5 kHz. There
of the pulses from the encoder is a
measuring rate of 2.5 kHz, to ti =
remains a time uncertainty of a
direct measure of a linear change,
3.2ms at a measuring rate of 312.5
maximum of one cycle because the
e.g. of a conveyor belt. If an encoder,
Hz). The necessary level adaptation
sensor continues operating in its cycle
for example, supplies 1,000 pulses
to the LVDS specification (see Fig 3)
sequence and the trigger edge can be
per revolution and if the internal
of the sensor occurs via a controller
located within the first cycle, i.e. from
processing time of 1.6ms in the
that permits trigger levels from 2.4V
the start to the end of the first cycle.
sensor is taken into account, then the
to 24V.
The trigger input is interrogated within this period. The leads to a minimum length of the trigger pulse of at least one cycle.
encoder may revolve at a maximum of 0.625 revolutions per second (or 37.5rpm), so that the maximum trigger frequency for the measuring rate of 2.5kHz is not exceeded.
Application
Summary
A typical measurement application
Edge triggering supplies single
Time offset of trigger and output
with triggering is the bridging of gaps
signal
with single parts on a conveyor belt
The sensor subdivides the processing
(see Fig 5).
measurements on the output of a sensor and so replaces sampling operation. Also, the typical memory
and output of the measurements
overflow associated with continuous
into cycles. Assuming a maximum
measurement is also prevented,
measuring rate of 2.5kHz, 400µs is
which ensures an exact alignment
taken up with cycles for exposure,
between the measurement and the
reading in, computation and
time. If the sensor is combined with
controlling. A total period of approx.
a controller, taking into account the
1.6ms passes before the first
maximum trigger frequencies, an
measurement is available at the
economically practical measurement
output.
unit is produced for production and process automation applications. PHOTOGRAPHY BY Micro-Epsilon
NOTE WRITTEN BY Micro-Epsilon
FDPP - www.fdpp.co.uk 11
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Delphi Food Products Varied demands, one solution
WRITTEN BY Adelphi PHOTOGRAPHY BY Adelphi
Adelphi The Adelphi Group of Companies is comprised of four divisions, details of which can be found by clicking on the feature panels below.
www.adelphi.uk.com UK based Adelphi Packaging Machinery have successfully delivered a modifed fully-automatic lling and capping line for Delphi Food Products Ltd. The Challenge Delphi required a filling and capping solution for their varied range of high quality Greek products including
The Solution The machines supplied were modified specifically to meet Delphi Foods’ requirements. The filling machine is the versatile Adelphi Cerberus which is capable of filling various container shapes and sizes and with a few modifications was the obvious choice for Delphi Foods.
The capping machine uses the same modified, vacuum suction, decanting feed system as the filler and secures a push fit cap. Caps can be quickly changed for different product runs through the changeover of one small component on the capping head, making the Cer- berus very cost effective and efficient to run. The Benefits
Houmous, Taramasalata and Tzatziki,
A modified decanting feed system
which are lled into 170g, 283g and
for pots was put in place, featuring
Adelphi machines fill around 80% of
430g pots. The containers are heat-
a vacuum suction into a starwheel.
all of Delphi Foods products. “It is the
sealed before being capped, coded
The filling system had an increased
high level of after sales service from
using an inkjet coder, and finally
diameter inlet to the filling head, and
the ef cient, highly skilled support
gathered on a rotary collection table.
larger than standard pipework to the
staff, combined with the reliability and
nozzle. The nozzle was also increased
high build quality of the machines,
in size to allow for a higher filling
which made Adelphi the obvious
speed of the thick product. A simple
choice for Delphi Foods.” Tony Styllis
control panel allows the operator to
then added “Adelphi’s machines have
adjust the speed of the infeed table,
stood the test of time and the new
the starwheel and capping head.
machines have allowed us to double
When asked why Delphi Foods chose Adelphi as their preferred supplier, Managing Director Tony Styllis had this to say “Adelphi are our rst point of contact when we require any lling or capping machinery. They are experts in their eld and have always met our requirements with both speed and accuracy.” 14 FDPP - www.fdpp.co.uk
our production over the last year, allowing us to become a great deal more competitive.”
From entry level machines to full factory lines, we have food packaging solutions just for you
Commercial Salad Growers Box Clever With Spelsberg Spelsberg electrical enclosures
the design and build of reinforced
and 6,415kW of heat. State of the
have been used in a high tech
concrete bases, including free
art equipment is used throughout,
environmental control system for a
standing engine bases.
including electrical enclosures
commercial greenhouse operated by one of the largest salad growers in the
In another aspect of the project,
from Spelsberg made from high performance engineering plastic.
UK.
CambridgeHOK fitted all of the interconnecting pipework between
These replace the older style metal
Serving a market that is increasingly
the backup boiler plant and the Rolls
enclosures that were used previously
demanding and competitive, salad
Royce engines for high and low
and bring benefits such as more
growers need state of the art energy
temperature heat requirements and
stable internal temperatures, high
efficiency, lighting and climate control
management of carbon dioxide from
strength, reduce corrosion and â&#x20AC;&#x201C;
throughout their massive commercial
the flue gases. Related to this was
because they are visible to visitors â&#x20AC;&#x201C;
greenhouses. The electrical systems
the installing of two 5,600,000 litres
smart appearance.
are therefore huge, often linking
insulated hot water storage tanks to
multiple greenhouses via an
store the heat from the CHP engines
interconnected control system.
during the day, so that it can be
The electricity produced is fed into the local grid, while the extracted
utilised in the greenhouses overnight.
heat from the exhaust gases and the
manufacturer of commercial
The new Energy Centre Portal
heat the greenhouses. Further, after
greenhouses, has designed, installed
framed buildings that house all of
cleaning, the engine exhaust gases
and commissioned the infrastructure
the plant were designed and built
are injected into the greenhouses to
surrounding four 5.5MW Rolls Royce
by CambridgeHOK using composite
increase the ambient carbon dioxide
engines that are used in a combined
panels. CambridgeHOK also designed
content in order to promote plant
heat and power (CHP) plant for a
the electrical and control systems for
growth.
major grower on the Isle of Wight. The
the whole facility from 33kV at grid
project was centred on the need to
to LV and ELV circuits, utilising a Priva
modernise facilities, mainly to ensure
BMS control system to manage the
energy efficiency but also to improve
engines.
CambridgeHOK, the UK's leading
control and ensure the equipment and technology were state of the art so that safety and reliability were world-
The new energy centre is home
class.
to the latest
It involved the demolition of existing
represented
facilities and the building of two new
by four Rolls
CHP energy centres that serves the
Royce gensets
massive 27 Hectare (270,000 square
or gas engines,
metres or 67 Acres) of glasshouses.
each producing
It also included geo-technical surveys
5,605kW of
to establish ground conditions and
electrical power
16 FDPP - www.fdpp.co.uk
CHP technology,
engine cooling systems will be used to
CambridgeHOK selected Spelsberg to supply all the electrical enclosures and junction boxes required for the electrical and control systems.
Spelsberg Arla Foods is a global dairy company and co-operative owned by 12,700 dairy farmers with circa 2,700 of whom are British.
www.arlafoods.co.uk WRITTEN BY Spelsberg PHOTOGRAPHY BY Spelsberg
As well as the technical advantages,
The GTi enclosures are a popular
The fact that the Spelsberg enclosures
Spelsberg enclosures are easy to
choice for situations where
were a low cost solution compared
install and have good access for fitting
requirements for moisture protection
to a steel equivalent was therefore
the electrical components.
are especially high. They are made
much appreciated, while their ease
from high-grade polycarbonate, so
of assembly saved time on site and
represent a corrosion-free alternative
likewise added up to helping keep to
to steel boxes, and they are designed
the tight fitting-out schedule.”
Therefore, each enclosure can be populated, mounted and connected quickly, which on a large project involving many enclosures can added up to a significant saving in time and cost, the latter nicely complementing the units’ competitive purchase price. The production area is made up of 32 bays, in each of which the heating, ventilation, humidity, irrigation, lighting, solar shades, thermal shades and side screens are controlled. Every bay has its own local distribution board, made up of three Spelsberg enclosures mounted side by side below the raised beds or production tables so that they are easily accessible but out of the way of the growing plants. Most of the enclosures installed in the greenhouse are Spelsberg GTi and B Box models, both of which are made of high performance engineering plastic. These are smaller than the metal units used in the old, demolished facilities and were chosen partly because they could fit into the space available.
to be flexible and easily adapted to the requirements of the system in which they are used. Thanks to their modular design and open sides, they can be expanded or connected to adjacent GTis at any time without difficulty – and without the need for snapping away side walls. In fact they are always a favourite with installers, because they can be reconfigured at short notice if the system design changes during installation. The Spelsberg B Box design incorporates raised terminals, which makes installation quick and easy and also helps keep the wiring orderly and easily checked. It also has many other features that installers find attractive.
With energy being a major cost, CHP has become very attractive to the UK’s commercial growers who face pressure from the supermarkets to keep prices low and increasing competition from overseas growers who benefit from warmer climates and lower labour costs. Clare again: “Today’s commercial greenhouses use cutting edge technology throughout. Spelsberg enclosures are proving a popular choice with growers, who appreciate their ease of installation, long term reliability and tolerance of hot and humid operating conditions. “Space for you”
“In such projects, it’s easy for costs
Spelsberg’s company philosophy is
to quickly spiral upwards. However,
based around the idea of providing
if specification and delivery of
flexibility and freedom to its
components is well managed, then
customers. The space provided
it’s possible to generate a small cost
within each junction box; the large
saving per product, which quickly
distribution and warehousing space;
multiplies over the scale of the
and the freedom to customise almost
project.
any product, irrespective of quantity, all equates to “Space for you”. FDPP - www.fdpp.co.uk 17
RPC Promens RPC Promens delivers excellence in design and manufacturing in all the main plastics materials and processing technologies, including blow moulding and thermoforming, and we are the world’s leading specialist in rotational moulding.
www.rpc-promens.com
Bio Polymer ‘Mix’ Bottle Is A European First RPC Promens Consumer Nordics has developed a one litre milk bottle made entirely from a nonoil based bio polymer produced from sugar cane. Uniquely, an additional feature
where we always seek to choose a
“According to Euromonitor one of
that is now being developed and
solution with minimal impact on the
the top ten global trends in 2016 is
which is believed to be a first in
environment,” comments Armina
greener food,” explains senior sales
the European market, will see the
Nilsson, sustainability manager at
manager Jan Weier. “Certainly there
polymer mixed with a special mineral
Skånemejerier.
has been strong growth in organic
filler. This reduces the amount of polymer required for each bottle without impacting on its strength and performance, which will further enhance its positive environmental
“The new bottle from RPC Promens is ideal for our milk,” confirms Thore Bengtsson, the company’s strategic purchaser. “We have an excellent
food products in recent years and this has now led to more attention being paid to how they are packed. By using this new material, we can offer our customers a renewable and
profile.
working relationship with the
In its first commercial application, the
the tight deadlines for this project was
The 1 litre white blow moulded Modul
new Modul bottle has been selected
particularly beneficial.”
bottle is available with a choice of
by leading Swedish dairy company Skånemejerier for its range of nonhomogenised milk. “Sustainability is a vital consideration throughout all our operations including our packaging, 18 FDPP - www.fdpp.co.uk
company and their ability to handle
RPC Promens says that as consumers have taken a greater interest in the types of foods they are buying, their focus has started to switch to the packaging as well.
sustainable solution.”
closures and features a four-sided label applied by RPC Promens. WRITTEN BY RPC Promens PHOTOGRAPHY BY RPC Promens
Adpak Wraps Up Bart Ingredients Deal Bristol-based herb and spice
The machine will be used to wrap
Amanda Jenkins, Sales Office Manager
manufacturer, Bart Ingredients,
collations of spices ready for despatch
at Adpak added:
has continued with its program of
to the company’s retail customers.
investment in production capacity with the purchase of an automatic sleeve wrapping machine from Adpak Machinery Systems. Bart Ingredients was founded in 1963 and now sources and supplies herbs and spices to many leading major retailers. The machine purchased, an Adpak BP600 sleeve wrapper, is a high specification machine, providing space saving benefits as well as saving time and labour required to pack products.
“For food manufacturers like Bart
Commenting on the deal John
Ingredients, secure, well presented
Woodhouse from Bart Ingredients
product packaging is vital but must be
said:
achieved at a minimal cost.
“This is the third machine we’ve
“The reliable automated options we
bought from Adpak, who have really
offer provide quality packs at high
impressed us with their technical
throughput rates, whilst completely
knowledge and the quality of their
removing the need for manual
products.
collation or labour intensive end of
“This investment will enable us to ship more products faster by automating the packaging process – allowing
line packing. The payback from the machines is very quickly realised by our customers.”
us to keep up with ever increasing customer demand.”
WRITTEN BY Adpak
Adpak Adpak is the UK’s number one supplier of shrink wrapping machines, packaging systems and films to businesses large and small across a range of industries.
www.adpak.co.uk
FDPP - www.fdpp.co.uk 19
Fanuc Robots Collaborate With Each Other! PPMA Total Exhibition, NEC Birmingham, 27-29 September 2016, Stand C50
WRITTEN BY Abbey Labels PHOTOGRAPHY BY Abbey Labels
Abbey Labels FANUC City is situated at the foot of Mount Fuji, near Lake Yamanaka. Covering 1.5 million square metres, it is home to all FANUC’s unique production facilities.
www.fanuc.eu
At the PPMA Total Exhibition, on the
fencing, these cage-free robots can
Now, just as when a human intruder
FANUC stand (C50), FANUC is taking
work side by side with humans on
penetrates the safety system, the
robotic safety a further leap into the
shared or separate tasks.
robot in the cell will likewise react if
future. A collaborative robot, or cobot, designed for working safely with
In the conventional cell, which is
the collaborative robot gets too close.
completely open on two sides,
The game-changing human safe
FANUC’s Dual Check Safety (DCS)
CR-35iA robot has an impressive
containing a conventional robot.
technology is combined with a safety
35kg payload – higher than any other
scanner and safety camera. The robot
collaborative robot on the market,
Over the last couple of years, the first
will slow down to a safe speed as
opening up applications that have
generation of collaborative robot has
humans approach the cell, but will
previously been off-limits for both
been revolutionising the way in which
only stop when a hand moves into
traditional industrial robots and lighter
robots and humans work together.
the cell itself. This allows them to
duty collaborative robots. Key target
In contrast to traditional robots,
maximise productivity and not spend
areas include automation assembly
which cannot operate in an operator-
unnecessary time ramping back up to
lines, metalworking and packaging.
occupied workspace without safety
full production speed.
human colleagues, will be challenged to work alongside a caged cell
20 FDPP - www.fdpp.co.uk
Safe measurement, indication and control of rotational speed
Application-Report - Validation and Calibration of Welding Equipment
Task: The speeds of welding wires for manual welding systems, robot welding plants and longer conveyor lines need to be measured (WPQR = Welding Procedure Qualification Records).
Source: Cloos
It is also necessary to carry out validation and calibration tasks. This is because companies that work in accordance with the standards EN 1090/EN 50504/CE or ISO 9001/9002 have to have their welding equipment calibrated annually. A further task involves rapid and cost-effective troubleshooting.
Solution: The digital hand-held tachometer rotaro Tw (A5-1279) with the special adapter Tw was specially developed for the specific requirements when measuring speeds and lengths in the welding industry. The easy handling and measuring accuracy of the digital hand-held tachometer rotaro Tw, along with the option enabling the device to be recalibrated according to the required industrial standard, were the main reasons for the purchase decision according to the customer Cloos. The Tw adapter is plugged onto the digital hand-held tachometer rotaro, allowing it to measure welding wires with a diameter of 0.8 to 3 mm. Typical applications of the rotaro Tw involve calibration, maintenance and service tasks within the welding and wire industry.
In conjunction with the digital hand-held tachometer rotaro, the special adapter Tw complies with the requisite standards and can therefore be utilised as an additional measuring instrument in this field. It is used for measuring the wire feed speed mechanically and serves for determining and monitoring quality-relevant parameters for welding applications during production.
YouTube Tutorial
RHEINTACHO is a flexible, highly efficient partner- wherever speed must be measured, monitored or indicated. Innovation, the most modern production techniques and equipment, meticulous quality control along with a first-class workforce are the corner stones of our company. For the past 114 years, Rheintacho has used his extensive knowledge and experience to developed sensors, systems and customized solution to meet the customer’s requirements. RHEINTACHO Messtechnik GmbH · Waltershofener Str. 1 · D - 79111 Freiburg phone +49 761 4513 0 · fax +49 761 445 274 · www.rheintacho.de
Wiggle “moved” by CSL Conveyor Systems Ltd have recently completed a major installation supplying an extensive pack and sortation conveyor solution for global online retailer Wiggle Ltd. Operating as the UK’s #1 online Cycle, Run & Swim retailer along with being recently voted the Which? recommended #1 online outdoor & leisure shop. In 2015, due to the continuous
and sort them down 12 lanes into 4
growth of the business, they took the
dispatch zones for separate carriers
decision to relocate the Operation
and services. The system needed to
to a larger, consolidated Fulfilment
cope with up to 90 boxes per minute
Centre (320,000 sq. ft.) in the West
of varying sizes and weights, from
Midlands from the multiple small
very small parts and clothing up to
sites operated in Portsmouth.
large boxes of bicycle wheels!
After a rigorous tender process,
The conveyor system which was
CSL’s ability to provide a well demonstrated solution was key to meeting the brief and winning the contract. This included using the latest 3D CAD drawing software to help visualise the system as a life-like operational representation in the new building. The brief was to combine packed consignments from 3 pick/pack areas over 3 floors
22 FDPP - www.fdpp.co.uk
specially designed by CSL at over 900mm wide, was engineered in detail after taking into account all comments/ suggestions made by both management and operators at Wiggle together with fully recognising their requirements, considering the vast array of shapes and sizes of products whilst overcoming operational issues.
WRITTEN BY Conveyor Systems ltd PHOTOGRAPHY BY Conveyor Systems ltd
Conveyor Systems ltd To provide the optimum solution for materials handling requirements through the use of state-of-the-art 3D design, supply and integration of proven quality equipment to achieve the best return on investment.
www.conveyorsystemsltd.co.uk
The mezzanine consists of 2 upper
and weights causing damage to each
where a despatch operative removes
floors which along with the ground
other and potentially initiating jams
and places them onto a pallet or
floor form three independent pick/
along the system.
into a wheeled cage ready for carrier
pack zones and sortation areas which were designed specifically to avoid
The upper mezzanine floors use 2
collection.
powered Ambaflex spiral lowerators
CSL provided the full turnkey conveyor
(almost 100 units supplied by CSL
project including control, installation
Repairs.
throughout the UK to different
and commissioning of the wide range
customers), to safely and continuously
of packages.
Once an order is picked, packing
bring the boxes down where they are
operatives check the order then pack
then barcode scanned to determine,
into an array of outers ranging from
by way of state-of-the-art scanning
poly bags to large cardboard boxes
arrays on each line, which carrier
prior to applying carrier despatch
despatch lane they require.
Corrigan stated “As this was a new
When the packages reach the correct
the conveyor system prior to the
despatch lane they are diverted off at
mezzanine floor installation, but CSL
90 degrees using high speed switch
provided a detailed 3D drawing which
sorters. Depending on the source
included both the mezzanine and the
pick floor, they either decline down a
conveyors which brought clarity to
grip top belt to an ergonomic picking
this. The install process was smooth
height or transit on a horizontal
and the end results have allowed us to
roller conveyor to the discharge area
increase control, flexibility & volumes”
issues caused when one combined system is stopped for maintenance/
labels. The consignment is then placed on a section of zero line pressure (ZLP) accumulation roller conveyor which starts the transit to the sortation area on the ground floor. This type of conveyor is used widely on the system to ensure non-contact queuing due to the wide variety of sizes, shapes
Wiggle’s Programme Manager for the project and Head of Logistics & Operations Development, Dan facility it was difficult to visualise
FDPP - www.fdpp.co.uk 23
Aerolite™ - Europe’s Lightest Best Performing Bump Cap On The Market With Air Flow Technology
Paramount Packaging Takes A Fresh Approach With Latest Bespoke Flow-Wrapper
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. 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.
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
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.
flow-wrapper that has been adapted for reliable, high speed operation on the
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.
Ideal for salad and vegetable growers in particular, Paramount Packaging’s
More information is available from www.jsp.co.uk, or by calling +44 (0)1993 826050.
mobile field harvesting rigs widely used by fresh produce growers.
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
Process Sensors
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 24 FDPP - www.fdpp.co.uk
Provides on-line measurement solutions for food, drink, packaging and label manufacturers using NIR non-contact sensors to quantify oil, moisture and adhesive coat weight. ‘Live’ readings enable optimum efficiency through fine-tuning of process parameters such as fryer or oven residence time and temperature for fried or baked products, or applicator in the case of coatings resulting in
fewer stoppages, increased throughput, lower energy usage and consistent quality product. Sensors are configured per application; food-grade MCT 460 or high temperature MCT 466 SF for food manufacturers and MCT 460 or Guardian web profiling system for packaging and label manufacturers. Tel: 01536 408066 Web: www.processsensors.com
hfl
consulting Safety Safety Sustainability Sustainability Profitability Profitability
The problem-solving toolkit every plant manager needs. For For companies companies involved involved with with food food processing processing and and packaging, packaging, business business improvement improvement and and regulatory regulatory demands demands can can often often seem seem to to pull pull in in opposite opposite directions. directions. So So how how do do you you get get better better and and stay stay compliant? compliant? Long-term Long-term sustainable sustainable improvements improvements require require an an understanding understanding of of several several key key factors: factors: legislation, legislation, supply supply chain chain interactions, interactions, stakeholder stakeholder interests interests and and business business processes processes and and objectives. objectives. This This is is where where HFL HFL Consulting Consulting can can help. help. Having Having worked worked with with several several of of the the major major players players in in the the UK UK food food packaging packaging industry, industry, we we have have helped helped to to deliver deliver multi-million multi-million pound pound cost cost savings, savings, whilst whilst satisfying satisfying the the requirements requirements of of the the regulators regulators and and other other key key stakeholders. stakeholders. Find Find out out more more about about how how we we can can improve improve your your business business performance. performance. TT 0161 0161 304 304 5902 5902 EE info@hflconsulting.uk info@hflconsulting.uk W W hflconsulting.uk hflconsulting.uk
People Plant Process Productivity
Nestlé Waters UK agrees hydro power deal
WRITTEN BY Nestlé PHOTOGRAPHY BY Nestlé
always strive to make our products as sustainable as possible. "Bottled water is widely recognised as having the lowest environment footprint of all packaged beverages and this initiative brings us closer to zero environmental impact and sees bottled water production actually powered by water!” Jamie Needle, Development Manager at Derwent Hydroelectric Power, commented: “We are very pleased to have agreed to provide hydroelectric power to Nestlé Waters generated at our site in Belper on the river Derwent, and at
The Nestlé Waters UK bottling plant in
Today’s announcement is another
Buxton is now generating 30% of the
step forwards for Nestlé Waters
electricity it uses from water itself.
UK, whose factory in Buxton was
three years.
The site will be supporting its local
built with sustainability in mind and
"As a hydroelectric generator,
is already one of Europe’s most
sustainability is at the heart of our
innovative and efficient bottling
business model, which is why we
Ltd., a local hydroelectricity supplier.
facilities.
are delighted to be partnering with
The electricity generated at three
Charlie Roberts, Buxton Factory
Nestlé Waters to help their operations
community by sourcing electricity from Derwent Hydroelectric Power
two of our other sites, over the next
become as environmentally
of the facilities owned by the
Manager, said:
organisation, including the Belper
“Buxton is already one of the most
Mills site, will be purchased for use at
state-of-the-art factories for bottling
the Nestlé Waters factory in Buxton,
water in Europe. We frequently
making up approximately 30% of the
produce more than 2 million bottles
electricity used there and meaning
in a day of natural mineral and spring
renewable sources.
consumers can now enjoy bottled
water, giving people the chance to
www.nestle.co.uk
water, powered by water.
choose a healthy beverage, and we
26 FDPP - www.fdpp.co.uk
sustainable as possible.” Earlier this month Nestlé announced that of its grid-supplied electricity in the UK and Ireland now comes from
ABC-t Automated Bottle Closure Tester Out of specification capping machines can lead to lost production time and costly wastage due to incorrectly fitting closures. Mecmesin's ABC-t automatically measures the initial slip and bridge torque of ROPP closures to ensure that the capping process is operating correctly. •
Easy-to-use, with selectable pre-programmed tests
•
Closures reapplied to prevent spillage
•
Repeatable testing, ensures accurate, consistent results every time
•
Increase productivity, less production downtime
•
Early identification of capping head adjustment requirements
•
Eliminate the risk of repetitive strain injury
Contact us for more information: info@mecmesin.com and +44 (0) 1403 799979
Paramount Packaging Takes A Fresh Approach With Latest Bespoke Flow-Wrapper 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
This key technical enhancement
Paramount Packaging’s latest
Ltd (tel: 01252 815252; www.
allows the flow-wrapper to be easily
machine, which operates up to 120
paramount-packaging.co.uk) –
repositioned when the sides of the
packs per minute (ppm) with a low
exclusive distributor of Fuji Machinery
rig are folded up for transportation
maintenance box motion sealing
Company’s horizontal and vertical
between fields and even countries. It
system, boasts a convenient ‘plug and
form-fill-seal equipment in the UK
also boasts an integrated ink jet coder
play’ two-part infeed which allows it
and Ireland – has announced the
and labeller.
to be used with different types of rig
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
Specially developed for wet environments, the bespoke flowwrapper features an ultra-hygienic design to help prevent dust and dirt
and across a variety of applications. Offering fast changeover, the settings can also be stored on the front facing USB port and transferred to different machines for added flexibility.
produce growers.
accumulation, and offers easy access to the mechanical and electrical
Simon Martin, Sales Manager at
Ideal for salad and vegetable growers
components.
Paramount Packaging comments:
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.
It meets full wash down requirements and incorporates water drainage channels from the infeed.
“We have seen increasing demand for automated flow-wrappers that offer high speed yet accurate and reliable operation in harsh outdoor environments, and in all weather conditions. NOTE WRITTEN BY Paramount PHOTOGRAPHY BY Paramount
28 FDPP - www.fdpp.co.uk
However, a standard flow-wrapper
The USB port facilitates machine back
The innovative Fuji Vision System
requires careful handling and
up and allows product data to be
(FVS) is integrated in to the film
positioning meaning it might not
uploaded easily.
drive roller housing and helps ensure
offer the performance and efficiency benefits required by today’s salad and
Ideal for the overwrapping of irregular
product integrity by checking film tracking, image and joints, label
vegetable growers.
shaped, fragile or sticky products such
“As a result, we developed the rigid
Alpha VII back seal flow-wrappers
stainless steel frame with heavy duty
feature bottom film feeds for easy,
castors to allow the flow-wrapper to
positive transfer of product from the
Optional equipment such as film pre-
be moved around more easily, and to
infeed conveyor to the film tube.
creasing devices, labellers and hole
be taken on and off field harvesting rigs simply and quickly. It also provides a stable mounting for the labeller which on an inverted wrapper would normally be freestanding on
as fish, sausages or IV bags, Fuji’s
The range is capable of operating at speeds up to 250 ppm, with a maximum film width of 650mm and cut off length of 430mm, and capable
the floor underneath the infeed.”
of handling products measuring up
A 12” colour touch screen and multi
(height).
lingual operator interface can be customised using images, words and illustrations for simplicity and fast and accurate diagnostics, and enables easy operation by foreign workers.
to 200mm (width) and 100mm
Paramount’s Alpha VII series offer energy saving technology, improved production efficiencies and reduced operating costs.
application and print legibility, as well as barcode verification and optical character recognition (OCR).
cutters can be installed directly onto the wrapper. A non-contact fibre optic film run out switch makes threading film easier and also prevents marking.
Paramount Paramount Packaging’s objectives include the sale, service and ‘all encompassing’ support for Fuji’s range of Horizontal Form, Fill and Seal Wrappers.
www.paramount-packaging.co.uk FDPP - www.fdpp.co.uk 29
First printed, stand-up, ovenable pouch launched in Asda
WRITTEN BY TCL Packaging
PHOTOGRAPHY BY TCL Packaging
The first of its kind; a printed,
reduction in performance. The
which facilitates exceptionally strong
stand-up, ovenable pouch has
stand-up pouch format is particularly
seals, aided by high lamination bond
been developed by TCL Packaging
suitable for microwave ovens as it fits
strength. The pack also has good slip
in partnership with B&G Products.
easily inside and can be safely handled
properties for easy handling during
The pouch has been introduced this
when the contents are hot and poured
the packing process.
month on a new range of frozen,
out for serving.
fish-based cook-in-the-bag meals
Markus Jarvstrom, technical director
The product was developed and
comments: “This is a technically
Barraclough.
extensively tested by TCL Packaging’s
complex and innovative product that
technical team working closely with
we expect to transform how certain
The printed Doypack took 12
B&G who developed a new bag
foods are packed.
months to develop and is suitable for
conversion technique to create the
microwave and conventional oven
pouch. It has been fully certified by
cooking up to 200°C. The pouch can
Smithers Pira for food safety up to
also be stored as frozen.
220°C, 450°F Gas 7.
sauces, ready meals and soups
The Doypack is made from a PET
Production utilises the latest
glass packs. It reduces packaging and
structure to ensure rigidity and
ovenable inks and employs a new
waste and is recyclable at appropriate
stability during cooking with no
pouch-making conversion process
facilities”
in Asda, packed by Iceland Seafood
“This new product offers a real alternative for products such as currently sold in rigid plastic and
TCL Packaging is a UK based provider of printed flexible packaging films. Established in 1999, our production is certified to ISO 14001, ISO 9001 and BRC standards. TCL is a three times winner of EFTA print awards. www.tcl-packaging.com
30 FDPP - www.fdpp.co.uk
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
Creating industrial history since 1715 At John White & Son [JWS] we are proud to provide the best weighing solutions to our customers. Founded in 1715, JWS is a leading UK supplier of weighing solutions. Over the last 300 years, we have built a reputation for innovation and engineering experience. At JWS, our customers are our business. We provide you with unrivalled expertise in a range of weighing solutions. This is complemented by a dedicated after-care support team. Checkweighers Manual or dynamic models offering practical and affordable solutions developed as a result of a lifetime of experience in check-weighing. Our Cartomat is the preferred check-weigher in the food, packaging and bottling halls of all the major spirit producers in the UK. We provide weight indicators for a wide range of industries from factories to weighbridges. The indicators also have a wide range of applications from general weighing, check-weighing, to batch control.
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: enquiries@johnwhiteandson.com www.johnwhiteandson.com
32 FDPP - www.fdpp.co.uk
CALL US FOR A QUOTE 0133 782 7600 Better solutions, better results!
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
•
Touchscreen Displays
•
Food Grade Stainless Steel or colour finish of choice with
Nemacom Ltd.
branding.
Unit 6, Morgan’s Business Park, •
Fully IP65 sealed
•
Robust and reliable
•
Panel Mount Displays & Panel PCs
•
2~3 year warranty
•
Bespoke Service
Email: sales@nemacom.co.uk
•
UK Manufactured and Supported
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
The UK’s largest meeting place for advanced engineering professionals
Join us where the familiar and the collidecorridors to “Fantastic…I think thisunfamiliar“…the provide new opportunities supply is the best year across yet” the engineering and they are our chain. Dave Dave Withey, Withey, Graham Graham Mulholland, Mulholland, Senior Senior Project Project Engineer, Engineer, Research, Research,
“Fantastic…I think this is the best year yet” Dave Dave Withey, Withey, Senior Senior Project Project Engineer, Engineer, Research, Research, Jaguar Jaguar Land Land Rover Rover
Managing Managing Director, Director,
Advanced Engineering is the industry eventepm: where Jaguar Jaguar Land Land Rover Rover epm: technology technology group group high-technology manufacturing sectors converge under “…the been full all the time, one roof tocorridors meet andhave do business.
and they are our decision makers”
Graham Graham Mulholland, Mulholland, Managing Managing Director, Director, epm: epm: technology technology group group
“Fantastic show - lots of interest, not just from aerospace but from automotive and other sectors” Robert Robert Richards, Richards, BDM, BDM, Metrology Metrology Software Software Products Products
“Fantastic show - lots of interest, not just from aerospace but from automotive and other sectors” Robert Robert Richards, Richards, BDM, BDM, Metrology Metrology Software Software Products Products
“It w min spo got Mark Mark
“It was fantastic to meet with likeminded people - especially in motor sports and hybrid power…We’ve got some great leads to follow up” Mark Mark Harbord, Harbord, Sales Sales && Marketing Marketing Manager, Manager, LCL LCL Electronics Electronics
Contact us about exhibiting today gg +44 (0)20 8843 8800 or visit www.advancedengineeringuk.com
have been full all the time, r decision makers”
was fantastic to meet with likended people - especially in motor orts and hybrid power…We’ve t some great leads to follow up” Harbord, Harbord, Sales Sales && Marketing Marketing Manager, Manager, LCL LCL Electronics Electronics
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STEGO UK Ltd. | Unit 12, First Quarter Bus. Park | Blenheim Road, Epsom | Surrey KT19 9QN | www.stego.co.uk