FOOD & DRINK PROCESSING & PACKAGING Issue 36 2021
Ishida celebrates exhibition return with latest automation solutions
ICE Vector establishes Clearmark’s foray into pallet labelling
NON-INVASIVE up to 6 logs STERILIZATION Juices & wines, or honey & creams keeping its properties unchanged with our Pulsed Electrical Fields (PEF) simple to operate two-stage multi-paramater system. For piloting & small production to sterilize most common bacteria. It has an option for the PEF assisted juice extraction from vegetative cells or can combine any of two processes above. It has the industry broadest set of variable pulse parameters to fit all major processes: 5-500Hz rep. rate, 2.5-50µs positive rectangular pulses at 5-50kV/cm el. fields, 2-3kW, a timer, scope controls of pulse shapes. + HELP TO REACH YOUR STERILIZATION GOALS.
Practical Intense Pulsed (UV) Light
R&D system to sterilize up to 6 logs samples of foods and packaging from common and UV resistant bacteria, spores and fungi by using its optimal for each case pulse parameters covering most of applications: Pulse rates 1-4Hz, a timer, pulse energies 250J and 500J, 1-2 kW, one or two IPL flash lamps with the highest pulse intensities for R&D PL systems. THIS SYSTEM ALLOWS TO FIND STERILIZATION PARAMETERS for our customized Tunnels with Intense Pulsed Light.
info@wek-tec.de
www.wek-tec.de
Contents
The Team Editor Amanda Buckingham editor@fdpp.co.uk
Digital Sales Manager Jessica Bennett T: 01227 392571
Business Manager Josh Holmes josh@mhmagazine.co.uk
Digital Manager Jamie Bullock jamie@fdpp.co.uk Tel: 01227 392571
Publishing Director Martin Holmes martin@fdpp.co.uk
Studio Designer Richard Bland richard@mhmagazine.co.uk
M H Media Global Ltd.
Office 15, Second Floor, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, CT13 9FD
Tel 01304 806039
www.fdpp.co.uk All web addresses are interactive, 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. Please mention FDPP when responding to items in this issue.
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Features SIG
< 04
CSB-SYSTEM
< 18
DELTA ELECTRONICS
< 26
ISHIDA
< 28
GEA
< 40
SEEPEX
< 46
CLEARMARK
< 50
EMMI
< 58
EU AUTOMATION
< 64
BRILLOPAK
< 66
GREENCORE
< 70
HABASIT
< 80
METTLER-TOLEDO
< 82
PROSEAL
< 86
PPMA 2021
< 88
ADVANCED ENGINEERING
< 90
FDPP - www.fdpp.co.uk 3
State-of-the-art facility demonstrates SIG’s engineering excellence and sustainability leadership SIG’s second state-of-the-art production
shared resources in both production and
carton packaging. The expansion of
plant for aseptic carton packaging in
operations. The new facility is also close
our production network will enable us
China is now up and running. Despite
to SIG’s Asia Pacific Tech Center, with
to further strengthen our position in
challenges posed by the pandemic, the
industry-leading innovation capabilities
the growing Chinese market. It also
large-scale project has been successfully
that bring a flow of new concepts and
means we can respond more quickly to
implemented, once again demonstrating
solutions to SIG customers. Having the
the needs of our customers to provide
SIG’s ongoing commitment to
Tech Centre nearby ensures SIG can
holistic solutions to the food and
engineering excellence and sustainability
keep pace with, and anticipate, new
beverage industry.”
leadership.
trends.
The new plant is located close to SIG’s
Samuel Sigrist, CEO of SIG: “The Asia
in China, SIG is committed to serving
existing production facility at the Suzhou
Pacific region continues to be one of
the Chinese market by providing
Industrial Park (SIP), which allows for
the major growth engines for aseptic
high-quality products and services
4 FDPP - www.fdpp.co.uk
By building a second production plant
Our close partnership with the two largest Chinese dairies, and other food and beverage companies, will continue to grow and develop.”
with the two largest Chinese dairies,
The new plant’s best-in-class
and other food and beverage
environmental, safety and operation
companies, will continue to grow and
performance has already been
develop.”
recognised with a prestigious
By 2024, the new plant will cover an area of 120,000 square metres and is expected to have an annual production
to customers across the Asia Pacific
capacity of 8 billion carton packs. It
region. The entire production process in
has been designed and built to have
the new plant is managed intelligently,
the lowest possible carbon emissions,
which significantly improves operational
with an artistic combination of classical
and production efficiency. The smart
Chinese garden and modern elements.
manufacturing system covers extrusion,
Photovoltaic panels on the roofs can
printing, creasing, cutting and sealing.
provide 1.5 million kWh of solar energy and collected rainwater is also reused
Samuel Sigrist continues: “SIG has
after treatment to save around 28,000
built up a strong customer base across
tonnes of tap water per annum. In
the Asia Pacific region, providing
addition to energy-saving lighting
outstanding innovation capability and
devices, special lighting systems
end-to-end solutions for differentiated
are installed to significantly reduce
products, smarter factories and
electricity consumption.
international industry certification: LEED (Leadership in Energy and Environmental Design) gold certification for building design and construction. LEED is a green building certification programme created by the U.S. Green Building Council which is used worldwide. SIG’s new packaging plant was the first plant in China’s aseptic packaging industry to be built in strict accordance with the LEED gold certification standard. Watch our video For insights into trends that drive the food and beverage industry and inspire us to innovate, visit our SIGnals blog: https://www.sig.biz/signals/en
connected packs. Our close partnership
FDPP - www.fdpp.co.uk 5
Spray lubrication for baked goods production: plant manufacturer Sugden invests in technotrans solution Technotrans SE is further expanding its activities in the food industry. Sugden Ltd, one of the leading manufacturers of production lines for bakery products, is investing in the high-precision spray lubrication system spray.xact food. The first technotrans units will be used as mobile versions in the British plant manufacturer’s pancake and Multi-Plant Lines. Thanks to the low-mist, compressed-air-free application of release agent, Sugden users save resources, improve their product quality and prevent unwanted oil residues in the production environment. The technotrans system is to be installed in other Sugden plants in the future, including those for Vanderpol Waffle production. “Our goal was to completely eliminate the use of compressed air when applying release agents to our heated plate systems. In this way, we offer our customers even more process reliability and control. With the help of the technotrans solution, we have succeeded in doing just that. In addition, product quality increases and line operators save resources,” says George
difficult. On the other hand, conventional,
George Jackson also praises the
compressed air-driven solutions often
partnership with technotrans: “The
produce aerosols that can be inhaled by
cooperation was fantastic. The teams
employees without the use of extraction
in Germany and here in the UK have
equipment and can accumulate in the
been extremely helpful in running
production environment. With the help
product trials and giving us valuable
of spray.xact food from technotrans,
information back to help us in design
Sugden prevents these problems. The
and application.” Due to the Covid 19
temperature-controlled valves ensure
constraints, most of the coordination
optimum viscosity of the release agent
from project planning to go-live
to be applied, which ensures a precise
took place virtually. Despite these
spray pattern. There is no need for an
limitations, Jackson says the project
extraction system, as spray.xact food
proceeded in a focused and efficient
spray lubrication does not produce any
manner. “The exchange with the
unwanted mist.
technotrans team and the successful implementation of our requirements
Jackson, Sales Manager at Sugden. The
OPTIMALLY ADAPTED TO THE
quickly convinced us, so the decision
company develops and manufactures
BAKING PROCESS
was really easy for us.”
customized industrial baking systems - for
Stuart Packer, New Business Development
English muffins, crumpets and pancakes,
Manager at technotrans, also emphasizes
among others. In these systems, products
the flexibility and adaptability of the
are cooked directly on a hot plate to which
system. “With spray.xact food, customers
a release agent is applied. When looking
are able to adjust all relevant parameters
for a new and, above all, easy-to-integrate
from speed to spray quantity according
spray lubrication solution, the company
to their needs. Each spray valve can be
opted for a system from technotrans after
individually programmed in the process.”
only a few test runs.
technotrans transfers this flexibility to the
The challenge in this baking process is,
a mobile version was developed that is
on the one hand, that the release agent is
mounted on a trolley system and can be
viscous, which makes precise application
moved freely.
6 FDPP - www.fdpp.co.uk
design of the unit. For the Sugdens project,
Sugden would like to continue the collaboration in the future. The manufacturer plans to integrate the spray.xact food system on further pancake and Multi-Plant Lines, as well as well as on the Vanderpol Waffle Lines the company is currently designing and manufacturing. For more information see: www.technotrans.de
Precise lubrication for the food industry WITHOUT COMPRESSED AIR ENERGY AND RESOURCE EFFICIENCY – highly efficient spraying system with low aerosol mist, precise and economical media application – ability to spray high viscosity liquids, e. g. oils, emulsions, water, media containing sugar and starch, liquid egg – uniform application of liquids on end products, moulds, sheets and any conveyor system – designed for high speed production processes
power to transform
lower material input
higher product quality
individual customized setup
Industrial Reliability & Safety in 3 Steps By Michael Riccio, CRL, CAT-1 IRT
instead of going through the time and
When the new equipment arrives from
Global Marketing Manager, IRISS Inc.
cost of expanding their workforce, they
the manufacturer with these monitors
can apply condition-based reliability
built-in, customized parameters can
technologies to maximize their available
be set for the specific operating and
The critical importance of electrical power to every aspect of our world cannot be exaggerated. It must be generated and distributed effectively to end-users, and any disruption in that process means loss of operations, money, and in extreme
workforce skills and availability. These Reliability Technologies can be specified with the specification engineer and Original Equipment Manufacturer at the
cases, life. Therefore, the reliability of
initial design/build stage or retrofitted
electrical power creation and distribution
into existing equipment through a simple
must be continually safeguarded and
and inexpensive process.
improved. This does not happen by chance or through reactionary-maintenance
MONITOR
tasks, and it must be focused on from the
With the use of a monitoring system on
early design stages and continue through the life of the assets tasked with these functions.
transformers and throughout substation electrical equipment, asset conditions can be continually collected, trended, and
environmental conditions the asset is exposed to that keep it within a “safe zone” to maximize functional reliability. When the asset condition data exceeds the custom parameters, alarms can notify electrical technicians of a possible issue that may require inspection. Keeping human interaction with equipment to only instances where confirmation inspections of potential faults are deemed necessary minimizes workers’ risk and eliminates the humanerror threat to asset functionality.
assessed. Monitors feed data through a
INSPECT
gateway to software and apps, allowing
Once the wireless monitoring system
the concerns at hand by maximizing
the information to be continuously
notifies technicians of a possible issue
the value of workforce time and skill.
accessed from workstations and mobile
with a transformer or other piece of
Scalability is no longer an issue when,
devices.
electrical equipment, the use of pre-
Adopting a “Monitor, Inspect, & Manage” approach is a proactive way to avoid
8 FDPP - www.fdpp.co.uk
Adopting a “Monitor, Inspect, & Manage” approach is a proactive way to avoid the concerns at hand by maximizing the value of workforce time and skill. installed inspection windows on the asset allows a safe, efficient method of inspecting and assessing any possible issue during an energized condition. Once solely designed for thermographic inspections using infrared cameras, advancements in manufacturing have led to the inclusion of ports that allow for ultrasound and partial discharge technologies to be incorporated into the inspection. Visual, infrared, and ultrasound inspections can be done simultaneously by a single employee. Additionally, this design protects inspectors from arc flash/electrocution risk, removes the need for bulky and expensive PPE, and allows the inspection to be accomplished more efficiently. Not only does this represent a significant process improvement driven by original design, but it also falls in line with the most recent NFPA 70E updates and continues to protect critical assets from human interaction/mistakes that may cause failure.
MANAGE The data collected during inspection can be stored through intelligent asset management tags attached to the
pre-installed inspection windows. From
“Monitor, Inspect, Manage,” the use of
the asset location, information can be
technology allows single individuals to
transmitted into a dashboard system
accomplish inspection tasks with minimal
accessible from workstations and mobile
training. Specialized skill sets of electrical-
devices.
focused staff can be used for actual
Customizable routes can be established
necessary maintenance/repair activities.
before, and condition reports generated
CONCLUSIONS
after data analysis to further increase
From the inception of equipment design
efficiency. These designed aspects allow managers to assess operations and decide how best to increase Mean Time Between Failure (MTBF).
PROPER TRAINING One major issue facing the industrial world is a coming wave of retirements from the workforce, with fewer new
and manufacture, all possible measures to ensure asset reliability should be specified and implemented. These measures should prove themselves to be learnable, repeatable, and continued throughout any workforce changes to cement the successful practices into the very culture of the role requirements.
workers entering the industry than the
Transformers and other critical electrical
pending need created by this exodus. As
power assets being monitored remotely
the electrical industry expands worldwide,
cut down on technicians’ routine tasks
creating the need for a larger workforce,
focused on engineering and electrical
the problem is multiplied. The only way
operations by providing around-the-clock
to succeed is to capitalize on reliability
coverage. When an alarm notification is
technologies designed into the system that
received, correctly designed and installed
allows the industry to do more with less.
inspection windows allow an individual
While Designing for Safety & Reliability from the equipment-side should drive the overall process toward continuous improvements, the proper tools are only as useful as the hands wielding them. Hardware and software designed/ specified by the engineer and constructed by the OEM are ineffective if the people responsible for their oversight are not adequately trained.
technician to easily do visual, infrared, and ultrasound, and partial discharge assessments of the energized equipment. The data collected on the asset can then be stored, trended, and analyzed through the management software. This process increases the Mean Time Between Failure (MTBF) by allowing for planned shutdown and maintenance only when it is necessary. www.iriss.com
Shifting to an engineered reliability system for the electrical maintenance team means training new and veteran staff alike. With
FDPP - www.fdpp.co.uk 9
Experience global know-how locally: New products from Minebea Intec at PPMA this September After most of last year’s trade fairs were cancelled due to COVID, Minebea Intec has broadly positioned itself for this year’s upcoming events: The leading provider of weighing and inspection solutions presents new products and powerful software tools that increase the efficiency and output of production plants. The first UK trade fair to take place for the industry since the pandemic will be PPMA this September.
NEW LABELLING SOLUTIONS PORTFOLIO: FOUR FUNCTIONS IN ONE DEVICE
equipped them with a new load cell.
evaluating the collected data from the
PPMA is taking place 28-30 September
The inspection solutions have received
checkweighing of finished products as
MID approval for belt speeds of up to
well as other measured values from
3 metres per second. This means that
the overall process, reacting with
up to 600 products per minute can be
suitable measures and thus increasing
accurately and reliably weighed. With
the efficiency of his production.
in the heart of the Midlands at the NEC, where a range of exhibitors will present products related to packaging and processing. In the exhibition halls in Birmingham, the two new price labelling solutions WPL-S and WPL-A from Minebea Intec will be on show for the
the new load cells, the minimum weight has also been lowered: products of just 5 grams can be weighed accurately and
first time.
reliably.
With the manual price labelling system WPL-S and the automatic variant
SPC@ENTERPRISE SOFTWARE: FOR ADDED EFFICIENCY
WPL-A, Minebea Intec is opening up
In addition to the optimal weighing
a new portfolio for applications in the weighing and labelling of products. Both labelling solutions offer the ideal complete package for customers in the food industry: weighing, price labelling, labelling and product traceability in just one device. However, it is not only new products that will be presented at the show - some of the manufacturer’s products have received a major upgrade.
ACCURATE HIGH-SPEED WEIGHING
solution, Minebea Intec also offers the right software to optimise efficiency and production capacities: Among other things, SPC@Enterprise, a software package for statistical process control and average weight control, will be presented at the trade fair. SPC@Enterprise is currently available in version 4.0 and includes all the necessary options for prepacked goods
In production, maximum output with high
and statistical process control, such as
quality is one of the top priorities: high-
the collection of random samples as
speed weighing is therefore currently an
well as automatic checks throughout
exciting topic in the industry. Minebea
the entire process. By networking a
Intec has given its checkweighers with
wide range of devices and systems,
EMFC technology a turbo upgrade and
the user has the option of statistically
10 FDPP - www.fdpp.co.uk
DIGITAL OFFER: FREE OF CHARGE AND AVAILABLE AROUND THE CLOCK In addition to physical trade fairs, the new Minebea Intec digital contact options remain. Interested parties will find a wide selection of free offers on the website. Minebea Intec offers two options for consultation and research on weighing and inspection solutions: interested parties can either book an appointment in the Virtual Showroom, where experts provide advise and answer questions. Alternatively, there are several online calculators to choose from which can be used to calculate the return on investment, for example. The webinars are the perfect compliment: in just 45 minutes, participants gain an insight into various issues relating to weighing and inspection solutions. Missed webinars can also be viewed afterwards at the participants convenience. www.minebea-intec.com
Automatic in name, automatic in nature...
See us at Weigh Price Labeller WPL-S
Automatic Weigh Price Labeller WPL-A
PPMA
0 Stand C8
Increase your product quality, food safety and efficiency!
The Minebea Intec weigh price labelling family is growing. We brought you the WPL-S and now we’re excited to bring you the WPL-A, increasing product quality, food safety and efficiency, automatically!
Minebea Intec UK Limited 2760 Kings Court, Birmingham Business Park Birmingham B37 7YE Phone +44 . 121.779.3131 | Email cs.uk@minebea-intec.com
www.minebea-intec.com
PhoenixTM solution to HACCP Cook & Chill CCP Validation As part of any Food processors HACCP
process. The data logger making the
At the heart of the thru-process
program, validation of cook and chill
physical temperature measurement,
monitoring system is the PhoenixTM
processes is a critical and significant
with multiple thermocouples, travels
data logger. The PhoenixTM NT data
task, taking time, effort, and resources.
safely with the product through the
logger range has been designed
process. Protection from process PhoenixTM have developed a thru-
conditions such as heat, steam,
process temperature monitoring
water, and oil is provided by a suitably
technology specifically for this task,
designed thermal barrier. The thermal
designed to meet the challenges of the
barrier provides robust protection to
food processing market. Ideal for the
the data logger to prevent damage
validation process for any new cook
but also ensure that it maintains a safe
regime, new product, or annual process
operating temperature to give accurate
certification. Whether performing an
temperature readings. Monitoring of
oven survey “oven mapping to identify
continuous conveyorised linear and
cold spots” or validating the cook under
spiral ovens and semi-continuous
production conditions, the thru-process
or rotational batch cooks is feasible
profiling solution gives you the accuracy,
where the use of external recorders
efficiency, and reliability you need to
with trailing thermocouples is tedious,
satisfy your HACCP demands.
completely impractical, and possibly unsafe . Employing the thru-process
specifically for the challenges of monitoring food processing applications with an IP67 case design protecting from moisture. Type K or Type T data logger options allow accurate measurement of both cook and chill processes (Type T measurement range -200 °C to 400 °C). Data logger and thermocouple correction factors can be applied to the recorded data logger data to maximise measurement accuracy. PhoenixTM offer a range of thermal barriers to suit the process type, duration, and temperatures. Even if a standard
As its name suggests, thru-process
principal, process monitoring can be
thermal barrier cannot meet the
profiling is the method by which product
performed under true production
process requirements, PhoenixTM can
and or process temperature is monitored
conditions without compromising line
often custom design a unique solution
throughout the complete cook / chill
productivity .
to suit.
12 FDPP - www.fdpp.co.uk
Monitoring core temperatures of food
The PhoenixTM Thermal View Food
products can be a challenge and getting
Software provides a comprehensive
it right or wrong can have a significant
suite of analysis tools to convert
influence on the data collected and
the raw profile temperature data
therefore any decisions or conclusions
into useful process information. The
made. PhoenixTM offer a range of
analysis tools include the ability to calculate Fo/Pu values for the process
different designs of thermocouple to suit
against target micro-organisms.
different product types and sizes. The
For a typical chicken cook process
needle thermocouples ensure you can
the lethality parameters for Listeria
measure the true core/cold spot of the
Monocytogenes (Tref 70 °C, Dt 16.2
product accurately and repeatably. Fitted with standard miniature thermocouple sockets, the data logger is also compatible with other generic commercially available thermocouple designs. Employing the thru-process temperature monitoring principle provides the food technologist with a complete temperature profile of the cook process from start to finish. This information is like the Cook
Employing the thruprocess temperature monitoring principle provides the food technologist with a complete temperature profile of the cook process from start to finish.
DNA giving full details of the product
s and Z value 7.5 °C) can be input to automatically and accurately calculate for each monitoring point the number of decimal reductions of the pathogen achieved during cook to meet CCP limits. The information gathered, further to process validation, can be used to allow informed process problem solving and optimisation to maximise product quality, yield, process productivity and
and or process temperature which is
From the profile graph you can see
invaluable to allowing validation of the
instantaneously the variation in product
Cook CCP. From a temperature profile it
temperature at any point in the process
is possible to accurately quantify product
either at different locations on the
safety (pasteurisation) knowing both the
product (whole chicken) or different
temperature, and time at temperature, of
product positions within the cooker,
Further Information
the product.
cooking rack or across a mesh belt.
www.phoenixtm.com
efficiency. Contact PhoenixTM to help Find, Fix and Forget your Food Cook Problems!
FDPP - www.fdpp.co.uk 13
Smart Solutions from AutoCoding Systems AutoCoding Systems was acquired by JBT Corporation in February of this year and now not only enjoys the support of a major US company, but also has the opportunity to work jointly on packaging line applications with their sister company, Proseal. As a global provider of automation solutions to factory production and packaging areas, AutoCoding Systems has developed a suite of modular software products to facilitate processes such as device integration, data collection and integrity, packaging verification, code deployment and code inspection. Food and beverage suppliers are under increasing pressure to meet increased production schedules whilst maintaining
Checking the presence, legibility and location of printed codes is often challenging, particularly at high speeds.
of physical paper records that must be retained and subsequently stored. AutoCoding Systems’ latest innovation in automatic print inspection is 4Sight. Checking the presence, legibility and location of printed codes is often
the highest standards in product quality
Over the years, AutoCoding Systems has
and safety. This can be achieved with
expanded functionality with the addition
increased automation, removing the
of value-add modules offering greater
The 4Sight software resides on the SICK
human element of the packaging line
scope for the collection of data. For
camera, communicating directly with
set-up thereby reducing the risk of
example, the Paperless Quality module
the printing equipment. It works with
errors.
automates both in-line and off-line
all brands of printers and understands
routine quality checks. The AutoCoding
the intended message for printing. The
The core AutoCoding product deploys
challenging, particularly at high speeds.
line terminal can be configured to
solution can be set to differing levels of
secure set-up and message data to
individual requirements creating various
inspection from print presence to full OCR
packaging line devices, including coders,
methods for capturing data which can
and users can configure acceptable print
barcode scanners and inspection
then be used for reporting purposes. QA
tolerances depending on the application,
equipment, irrespective of brand. By
checks can be mandated at the beginning,
thereby reducing the number of nuisance
automating these time-consuming
during and end of a production run with
stops.
processes, downtime during job set-up
details of all checks consolidated into
and changeovers is greatly reduced and
the AutoCoding audit log. This not only
the risk of coding and packaging errors
creates an unbroken audit trail of QA
minimised.
checks, but also results in a reduction
Other modules include Inspection Reporting to monitor the performance of, and collect data from, multiple checkweighers, metal detectors and x-ray equipment whilst the Line Performance Reporting module captures real-time manufacturing data which can then be visualised in customisable reports to display accurate packaging line / device / product performance data. www.autocodingsystems.com www.proseal.com | www.jbtc.com
14 FDPP - www.fdpp.co.uk
Cognex machine vision and barcode reading solutions are used for:
Label & code quality verification
Defect detection
Package seal inspection
Anti-counterfeiting
Missing item detection
Explore the latest technology to boost your line. Contact us at +44 121 296 5163
Short Cuts Cost Lives Manufacturing, construction, and engineering are a big part of our economy But those workers also face a greater likelihood of serious work injuries than other workers. IN 2019/20 the HSE reported that 111 workers were killed in workplace accidents and 69,206 non-fatal injuries were reported by employers. Machinery accidents cost employees billions every year and on average employees who are injured usually have to take weeks off work or may never return.
WOULD YOU TAKE THAT CHANCE? Lockout Tagout is an essential tool in the control of hazardous energy, in a wide range of industry sectors to prevent accidents. What are hazardous energy sources? Hazardous energy sources include electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other sources in machines and
equipment is being cleaned, maintained, and inspected. As well as for company shutdowns, turnarounds, power outages and more. What is the difference between lock out and tag out?
used to control?
• Ensure Lockout equipment is suitable for the intended task. • Develop a written programme, with that MUST be followed.
release. Tagout means to place a tag
• Any new machines must have a
on a switch or other shut off device
written programme/procedure
that warns not to start that piece of
developed against it.
WHAT ARE THE 10 STEPS OF LOCK OUT TAG OUT?
Which form of energy is lock out tag out
any stored/residual energies.
on a device that prevents energy
The unexpected start-up or release of
proximity to the machine.
• Allow time & apply actions to relieve
process & procedures with all details
equipment.
for any employee/operative in close
either personally or departmentally.
Lock out means to place a lock
equipment.
stored energy is immensely dangerous
• Clearly identify padlocks and tags
Lock out tag out can easily be implemented by following this simple 10 step process, 1. Prepare
• All new & existing staff are to be trained and made aware of LOTOTO, it’s dangers and how to implement safely. According to the standard operating procedure (ongoing activity). • The only person to remove a lock is the one who applied it. • Implement and review the Lockout Tagout process and procedures
Lock out tag out is a hazardous energy
2. Notify
annually. Update and improve where
control system used to ensure
3. Turnoff
required.
that machines and equipment
4. Isolate
are totally isolated from
5. Lock/s Application
all energy sources. Locks are used to secure switches and valves in the OFF or
Recognising the importance of a lock out
• You must Try-Out every time. Confirming the success of the isolation before proceeding with the task.
SAFE position.
tag out system is the first step towards
Lock out tag out is still the best-known
process. It is not the whole solution, but
It goes without saying that industrial
practice for this protection and should
it can clearly contribute, below are our
equipment can be dangerous, that’s why
be utilized any time the machine or
simple lockout/tagout tips to follow
safety measures, process, products,
16 FDPP - www.fdpp.co.uk
implementing an effective safety
STAY ALERT AND DON’T GET HURT!
Machinery accidents cost employees billions every year and on average employees who are injured usually have to take weeks off work or may never return. and personal protective equipment are used when using them. But machinery can also present hazards when it is not in operation and that’s why lockout/tagout is governed by strict regulations UK wide, such as
should be conducted each time a task
ongoing updates, competency checks
occurs with potential risk. The machine/
and refresher courses conducted.
task specific written energy control procedures will ensure every task has the risk assessed before any action commences. Potentially a one-off task outside of the norm can arise, meaning any works on said task should have a risk assessment conducted by a qualified & authorized representative to control this project. A newly written energy control program should be completed in case of a future re-occurrence.
CONCLUSION Lockout Tagout is not an optional activity! The responsibility to govern this within establishments begins at the top. To instill the culture, behavior, and awareness to a high standard throughout. Major industries are adopting the LOTOTO process due to the awareness and associated real-life risks. It is now being
LOCKOUT TAGOUT SAFETY CHECKS
recognised as best practice for safety
• HASAW 1974
Audits and visual inspections should
manufacturing, food processing plants
• Electricity at work Regs 1989
be regularly carried out by a competent person, following the specific guidance
and more. Sectors such as renewable
• PUWER Regs 1998 – Reg 19 for isolation from Sources of Energy • Quarry Regs 1999 • OSHA 1910.147 – Control of Hazardous Energy - osha.gov The purpose of these regulations is to prevent injury and fatality. Contact with moving machinery and isolation (including stored energy) is still in the fatal 6, identified high consequence hazards. Employers must develop, implement, and enforce an energy control program in line with regulations. As well and providing the correct Lockout Tagout equipment to fulfill the procedures in place.
outlined through regulations and company process/procedures. At least annually, a full audit and site survey should be completed to ensure that all equipment is of high quality, in good working order & in the
management in quarries, oil & gas, heavy
energy, waste and large retail companies are beginning to apply company-wide procedures utilising LOTOTO to ensure employee and operative safety with a structured and controlled procedural method.
required volumes to complete tasks.
We’ve got a lot of work to do to lockout
Additionally, the audit should cover
machines better and control hazardous
and fulfill any newly updated/improved regulations. It’s also worth noting, any new piece of machinery on site which will require isolation and its energy controlled. Should have a standalone machine specific energy control program written against it (working closely with the
energy more effectively. Lockout/tagout is not the whole solution it should be combined with effective lockout training. At Spectrum Industrial we can help by conducting a lockout/tagout survey to help you identify what you need, you can download our eBook to find out what is involved in a lockout/tagout survey.
RISK ASSESSMENT
manufactures guidelines on its energy
Lockout Tagout is a process designed to
out to all affected employees. All new
reduce/eliminate risk, when performing
employees should be trained to the
Remember, “Short cuts, may cut a lift
high risk tasks. A risk assessment
level of every operative on site with
short!”.
sources and moving parts) and trained
Or click here to contact us.
FDPP - www.fdpp.co.uk 17
ERP solution adds value to ham production IT solutions from CSB-System have brought digitalisation to ‘a new level’ at the Spanish ham factories of international Swiss food company Bell Food Group. The production facilities in the Spanish ham regions of Extremadura and Castile-La Mancha have been brought to an entirely new efficiency level over the past few months. Until recently, redundant work steps and incomplete information were substantial cost drivers. One of the most important
All information and data are available in a single system across the entire process so that stocktaking is accomplished with a mouse-click.
requirements of the Bell Food Group was therefore to change from a paperbased data capture execution to a digital information flow in areas such as the processing of recipes, purchase orders, and traceability. For example, at its factory south-west of Madrid, which has a production capacity
with a mouse-click – just like checking
processes by means of technology – an
of 5,000 tons of raw ham including the
revenues.”
achievement that was only possible, as
popular “Jamon Ibérico”, up to one million hams can be hanging in the warehouses for drying and aging; and with different breeds of pigs processed in different
“The quick availability of information in the ERP enables us to act much quicker,” confirms Peter Ettrich, who is responsible
Friedli emphasises, because the IT team and the consultants at Bell Spain devoted a lot of time to it. “We have intensively investigated the steps in production, the
types of ham and having different curing
for the CSB applications at 19 Bell
and aging times depending on the quality
factories all over Europe and was the
and the designated certification, the
overall project manager for the project in
data from the various steps of the
implementation of traditional methods
Spain. In labelling, Bell Food Group has
production cycle,” he says.
on a large scale and in an industrial
also seen rapid progress thanks to the
environment can be challenging.
reduction of errors. The installation of a
Friedli believes that the company’s IT
ham grading system has advanced the
consultants need to be proficient in two
integration of software and hardware.
worlds – both IT itself and also food
“In the past, the facility did not really have an exact, comprehensive overview
type of reports required by the company, and the best ways for generating useful
processing. “We are all in the same boat,”
of the production process,” explains
In addition, ERP has generated added
he points out. “It is therefore important
Sven Friedli, Bell Food Group’s Chief
value by optimising order picking, with
to have a common understanding of the
Information Officer. “For stocktaking, for
digital information replacing paper forms.
processes in food production. A mere
example, it took weeks to count all hams.
The use of hand-held devices not only
IT specialist without extensive industry
Now, we have introduced an integrated
accelerates processes, but also reduces
supply chain solution that tracks the
expertise could do little to get us forward.
errors and, consequently, necessary
entire process, from the purchasing of
The CSB project team has brought the
rework.
digitalisation at our ham factories to a
the pigs up to the sale of the ham. All
new level.”
information and data are available in a
Overall, the project has been a huge
single system across the entire process
success and helped Bell Spain to
Email: info@csb-system.com
so that stocktaking is accomplished
overcome problems in the production
www.csb.com
18 FDPP - www.fdpp.co.uk
Innovative imaging technology easily detects seal contamination, even through printed films Contamination in the seal of rigid packages causes important issues for food producers as it may lead to leakage and consequently reduced shelf life, health issues and even expensive recalls with potential brand damage. As such automatic detection of contaminated seals is important for both food safety and production automation. Engilico™, specialist in in-line seal inspection for flexible packaging, now introduces its newly developed seal inspection solution for
Hyperspectral imaging provides higher contrast and allows to detect different substances, even through printed film.
plastic or cardboard rigid trays, pots
The new HyperScope™ solution is
sealing issues may induce extra costs
and thermoforms sealed with plastic
based on hyperspectral imaging (HSI).
due to line stoppage, manual re-
film.
This technology enables to obtain
packaging or machine cleaning. For
images with much higher contrast
inspection of flexible packages such as
than traditional vision systems
pouches, flow wraps and VFFS bags,
and can even detect contamination
Engilico already marketed SealScope™,
through printed films. Typical
an in-line, 100% seal inspection sensor-
applications are the in-line
based solution for flexible packaging
inspection of trays with meat,
such as pouches, flow-packs and
cheese, fruits, ready meals,
bags. But many – and often the same
snacks, etc.
- food manufacturers use also rigid
One of the main concerns in the packaging industry is to avoid leaking of open packages. Defective packages have a vast impact on outgoing product quality and productivity, as
trays, pots and other thermoformed packaging, and they have a similar need for seal inspection of these packaging types. This why Engilico developed HyperScope™, an innovative system based on hyperspectral imaging, to detect contamination in seals of thermoformed packages.
SEEING MORE WITH HYPERSPECTRAL IMAGING Product in seal often causes issues for standard vision systems, as there might be not enough contrast between the plastic film and the contamination. To increase contrast, traditional vision systems use opposite lightning, but this is not possible when using cardboard trays or backing materials, that are very popular as an ecological alternative to
20 FDPP - www.fdpp.co.uk
Product in seal often causes issues for standard vision systems, as there might be not enough contrast between the plastic film and the contamination replace plastic materials. And in case of printed packaging, often used in more luxury packaging, the contamination can
Visual image: When product and film have similar colors (yellow-on-yellow),
Hyperspectral image: The higher contrast clearly reveals contamination
also not be seen by a traditional camera.
contamination in the seal is not visible
(red) in the seal (green)
An alternative is X-ray inspection, but this technology is expensive and is only efficient in case the material density is sufficiently different to reveal the distinctive materials, which is not the case for contamination of organic materials such as meat, cheese and vegetables. A solution to overcome these challenges is hyperspectral imaging. A traditional vision camera provides a single image with spectral information from the three
The hyperspectral 3D spectral image map is built from hundreds of images in different wavelength bands. Every pixel is analyzed individually and differences in materials or composition can be detected, even through printed film. A contaminated seal has as a different spectral profile than a clean seal.
primary colors (RGB). Hyperspectral camera technology results in hundreds
as the camera, HyperScope is suited for
package is inspected and the system
of images, each with information of a
cardboard trays or paper-based backing
issues a signal to an ejector to reject
specific wavelength range, including
material sealed with plastic film.
packages with seal issues. The “core”
infrared wavelengths. For the detection of contamination in the seal, the relevant wavelengths are merely situated in the (near)-infrared region. As different materials react uniquely to infrared light, they can be reliably detected based on their specific transmission, reflection and absorption properties. Since hyperspectral imaging delivers the spectrum for each pixel in the image, it provides information about the chemical composition
IN-LINE, 100% INSPECTION HyperScope™ is directly integrated in the food production line, checking up to 160 packages per minute. Every
of the HyperScope™ system is situated in the software controller that instantly processes the hyperspectral image to recognize the package regardless of its orientation, and to analyse the seal quality. All information is displayed on an operator-friendly touch screen to provide feedback on every package. All production related data, such as product type, number of good/ bad packages, date, time is saved to monitor the production quality.
of the measured
In general, in-line seal inspection
sealing area. Because
enables customers to realize better
infrared light
packaging quality, higher packaging
penetrates the top film,
productivity, end-of-line automation
hyperspectral imaging
and reduction of manual inspection.
allows to distinguish with high contrast undesired materials such as meat, fat, oil from the plastic film, even if the top film is printed. Also because the products are illuminated from the same side
www.engilico.com info@engilico.com Renaat Van Cauter Marketing director Renaat.vancauter@engilico.com
FDPP - www.fdpp.co.uk 21
GAME-CHANGING NEW CAT® ELECTRICS CHALLENGE DIESEL FORKLIFTS Impact Handling, the leading premium material handling specialist and sole UK distributor of Cat® Lift Trucks, announces details of a game-changing new range of electric lift trucks, that deliver the lowest total cost of ownership yet seen within their class. Designed Designed and and built built in in Europe, Europe, the the allallnew new Cat Cat 4.0 4.0 to to 5.5 5.5 tonne tonne counterbalance counterbalance machines machines off offer er aa remarkable remarkable set set of of capabilities capabilities that that achieve achieve new new benchmarks benchmarks in in electric electric lift lift truck truck performance, performance, while while at at the the same same time time being being more more energy-effi energy-efficient cient –– and and quieter quieter by by far far –– than than any any of of their their peers. peers. Each Each of of the the six six models models in in the the EP40-55(C)N(H) EP40-55(C)N(H) range range is is designed designed to to maximise maximise every every possible possible electric electric advantage, advantage, matching matching their their counterpart counterpart diesel diesel machines machines in in terms terms of of power power and and flflexibility, exibility, while while emitting emitting zero zero pollution pollution during during operation. operation.
The The trucks trucks are are also also well well protected protected against against the the elements, elements, with with major major components components such such as as the the traction traction motors motors and and controllers controllers achieving achieving IP54 IP54 and and IP65 IP65 ratings ratings respectively. respectively. Peter Peter Woodhouse, Woodhouse, Business Business Development Development Manager Manager at at Impact Impact Handling Handling comments: comments: “The new range really does present the most powerful case yet for moving from diesel to electric power. For many applications, its elevated performance and ability to operate seamlessly both out doors and in, even in heavy weather conditions, will be hard to ignore.”
Lithium-ion Lithium-ion isis available available throughout throughout the the range, range, which which adopts adopts clever clever battery battery management management technology, technology, simplifi simplified ed opportunity opportunity charging, charging, and and quick-connect quick-connect access access points. points. Lead-acid Lead-acid optioned optioned machines machines benefi benefitt from from automatic automatic ventilation, ventilation, and and aa convenient convenient battery battery inspection inspection hatch hatch for for fast fast checking checking and and water water top-ups. top-ups. Additionally, Additionally, an an easy easy access access battery battery compartment compartment enables enables quick quick on-truck on-truck servicing servicing and and sideways sideways exchange. exchange.
® ®
FAST AND AGILE
The The trucks’ trucks’ exceptional exceptional agility agility gives gives drivers drivers the the feeling feeling of of driving driving aa much much smaller smaller machine, machine, with with dynamic dynamic aids, aids, including including OmniTurn all-wheel all-wheel steering, steering, providing providing better better grip, grip, smoother smoother turns turns and and unbeatable unbeatable manoeuvrability. manoeuvrability. AA 100°+ 100°+ rear rear turning turning axle, axle, allowing allowing instant instant side side turns turns without without the the need need for for initial initial backward backward movement. movement.
Cat Responsive Drive System (RDS) adapts adapts performance performance characteristics characteristics rapidly rapidly in in reaction reaction to to driver driver behaviour behaviour and and ensures ensures all all movements, movements, stops stops and and starts starts are are smooth. smooth. Intelligent Intelligent curve curve control control maximises maximises cornering cornering safety safety by by smoothly smoothly adjusting adjusting truck truck speed speed and and minimising minimising side side forces. forces. AA PowerBurst feature feature adds adds extra extra acceleration acceleration or or climbing climbing torque torque when when needed, needed, while while electric electric diff differential erential locking locking helps helps in in slippery slippery conditions. conditions.
Onboard Onboard hydraulic hydraulic technologies, technologies, including including SmoothFlow,, make make materials materials handling handling even even smoother, smoother, faster, faster, safer safer and and more more precise precise by by optimising optimising mast mast and and fork fork movements movements according according to to load load weights weights and and lift lift heights. heights.
QUIET AND COMFORTABLE
Driver Driver welfare welfare has has been been aa key key consideration consideration throughout throughout the the development development of of the the new new range, range, ensuring ensuring an an ergonomic ergonomic environment environment and and generous generous levels levels of of equipment. equipment. Built Built for for demanding demanding indoor indoor and and outdoor outdoor applications, applications, the the trucks trucks can can be be equipped equipped with with panel panel cabin cabin options options and and additional additional comforts comforts like like air air conditioning, conditioning, directable directable ventilation ventilation and and heating heating –– bringing bringing electric electric benefi benefits ts to to any any industry industry sector sector or or environment. environment.
Onboard Onboard low-noise low-noise technology, technology, including including market-leading market-leading SilentRun+ SilentRun+ hydraulic hydraulic pumps pumps and and quiet quiet drive drive units, units, combines combines with with aa spacious, spacious, uncluttered, uncluttered, vibrationvibrationfree, free, flfloating oating operator operator compartment compartment to to keep keep drivers drivers comfortable comfortable and and stress-free. stress-free. Both Both enclosed enclosed and and open open cabins cabins give give exceptionally exceptionally clear clear all all round round views views with with no no need need to to lean. lean.
© ©2021 2021MLE MLEB.V. B.V.(registration (registrationno. no.33274459). 33274459).All Allrights rightsreserved. reserved.CAT, CAT,CATERPILLAR, CATERPILLAR,LET’S LET’SDO DOTHE THEWORK, WORK,their theirrespective respectivelogos, logos,“Caterpillar “CaterpillarYellow”, Yellow”,the the“Power “PowerEdge” Edge” and andCat Cat“Modern “ModernHex” Hex”trade tradedress dressas aswell wellas ascorporate corporateand andproduct productidentity identityused usedherein, herein,are aretrademarks trademarksofofCaterpillar Caterpillarand andmay maynot notbe beused usedwithout withoutpermission. permission.
The The new new range range is is another another example example of of Impact’s Impact’s ongoing ongoing commitment commitment to to providing providing its its customers customers with with the the widest widest choice choice of of premium premium handling handling equipment equipment in in the the UK, UK, while while delivering delivering exceptional exceptional value value and and the the lowest lowest possible possible total total cost cost of of ownership. ownership.
0800 169 9789 www.impact-handling.com
CLEANING & M AINTENANCE
Sponsored Sponsored by by Total Total Clean Clean
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Our Mission Our Mission
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To To achieve achieve and and To To achieve adhere achieve adhere and and adhere adhere to to all all statutory, statutory, to to all all selfselfstatutory, statutory, selfselfregulatory regulatory and and regulatory regulatory and and environmental environmental environmental environmental requirements requirements requirements requirements
Total Clean Total is aClean family-run is a family-run cleaning business cleaning with business over with 30 years’ over 30 experience years’ experience in in deliveringdelivering expert contract a huge to range of commercial clients. clients. expertservices contractto services a huge range of commercial We We focus focus on on We We delivering delivering focus focus on onthe the delivering delivering highest highest the standards the standards highest highestfor for standards standards all all our our clients clients for for all all--our our both both clients clients in in cleaning cleaning -- both both their their in in cleaning cleaning work work their their work work premises premises and and in in our our customer customer service service every every day. day.we To To employ do do this, this, the we we employ employ the the most mostand dedicated dedicated and and premises premises and and in in our our customer customer service service every every day. day. To To do do this, this, we employ the most most dedicated dedicated and efficient efficient people, and andall give give them all all the the training training they need need in in order order to to do do the best best job job possible. possible. efficient efficient people, people, and andpeople, give give them them all the thethem training training they they need need in inthey order order to to do do the the best best job jobthe possible. possible. Our Ouralso clients clients can can also rely on us us to to be be at at the the forefront of ofin innovation innovation in in the the cleaning cleaning industry, as as we we Our Our clients clients can can also rely rely on onalso us us to torely be be on at at the the forefront forefront of offorefront innovation innovation in the the cleaning cleaning industry, industry, as as industry, we we implement implement the the latest latest technology technology wherever wherever we we can. can. implement implement the the latest latest technology technology wherever wherever we we can. can. We Wehave believe believe we we have one one of ofranges the the widest widest ranges ranges of of accreditations accreditations and and certifications certifications of of any any cleaning cleaning We We believe believe we we have one one of ofhave the the widest widest ranges of of accreditations accreditations and and certifications certifications of of any any cleaning cleaning company, all of of which which oblige us usto tostrict adhere adhere to to strict strict codes codes of of conduct. conduct. company, company, all allcompany, of of which whichall oblige oblige us us to tooblige adhere adhere toto strict codes codes of of conduct. conduct.
Total Total Clean Clean profile profile TFM TFMTotal 042019.indd Total 042019.indd Clean Clean profile profile 22 TFM TFM 042019.indd 042019.indd 22
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24 FDPP - www.fdpp.co.uk
Tomorrow’s Tomorrow’s FM FM Yearbook Yearbook 2021/22 2021/22
Our Values Our Values Responsibility Responsibility
Improvement Improvement
Excellence Excellence
Creating Creating effective effective customercustomer partnerships partnerships Consistently ConsistentlyConsistently Consistently delivering delivering delivering delivering Carbon Carbon zero zeroCarbon Carbon certified certified zero zero certified certified Meeting Meeting individual individual Meeting Meeting client client individual individual client client excellent excellent service service expectations expectationsexpectations expectations excellent excellent service service Own Own brand brand Own Own brand brand Highly Highly trained trained & & DBS DBS environmentally environmentally friendly friendly Attracting best best Attracting Attracting operaopera- best best operaoperaHighly Highly trained trained & & DBS DBS environmentally environmentally friendly friendlyAttracting checked checked staff staff products products products products tives tives available available tives tives available available checked checked staff staff High High quality, quality,High High quality, quality, Business Business management management Business Business management management Continuous Continuous improvement improvement Continuous Continuous improvement improvement environmentally environmentally friendly friendly systems environmentally environmentally friendly friendlysystems systems systems products products Embracing Embracing new new Embracing Embracing new new products products Reporting Reporting and and Reporting Reporting and and technology technology technology technology Fully Fully accredited accredited company management managementmanagement management information information information information Fully Fullycompany accredited accredited company company Quality Quality audit auditQuality Quality app app audit audit app app
Trust TotalTrust Clean Total to deliver Clean to andeliver excellent an service excellent service •• ••
•• ••
Our Our family family •• values values Our Our family family and and unceasing unceasing values values and andattention attention unceasing unceasing to toattention attention detail detail means means to to detail detail you you can can means means be be sure you sure you can can we we will be will be sure sure meet meet we we your your will will meet meet your your requirements requirements requirements requirements every every time time we we every every clean. clean. time time we we clean. clean. We’re We’re expert expert •• We’re We’re in in all allexpert expert types types of of in in all cleaning, all cleaning, types types of of across across cleaning, cleaning, aa broad broad across across range range aa broad broad of of business business range range of types, of types, business business including including types, types, offices, offices, including including offices, offices, car car showrooms, showrooms, car car showrooms, showrooms, retail retail and and hospitality hospitality retail retail and andpremises premises hospitality hospitality and and premises premises schools. schools.and and We Weschools. schools. also also offer offer We We CQC CQC also alsostandard standard offer offer CQC CQC standard standard cleaning cleaning in in all all cleaning cleaning types types of of in in all medical all medical types typesfacility facility of of medical medical and and have facility have facility an anand and excellent excellent have have an an understanding understanding excellent excellent understanding understanding of of the the rigorous rigorous of of the the rigorous rigorous standards standards necessary. necessary. standards standards necessary. necessary. We We have have••experience experience We We have have in experience in experience multi-site multi-sitein in cleaning cleaning multi-site multi-site across across cleaning cleaning London London across across and andLondon London around aroundand and the the UK, around UK, around delivering delivering the the UK, UK,the the delivering delivering the same same outstanding outstanding same same outstanding outstanding service service everywhere. everywhere. service service everywhere. everywhere. We We also also •offer •offer We We aa also range also range offer offer of of expert expert aa range range complementary complementary of of expert expert complementary complementary services, services, including including services, services, window window including including cleaning, cleaning, window window carpet carpet cleaning, carpet and and upholstery upholstery and andcleaning, cleaning, upholstery upholstery deep deep cleaning, cleaning, cleans cleansdeep deep and and end end cleans cleans of of tenancy tenancy and and end endcleans, cleans, of of tenancy tenancy builders builders cleans, cleans, cleans, cleans, builders builders janitorial janitorial cleans, cleans, janitorial janitorial supplies supplies and and supplies supplies waste waste management. management. and and waste waste management. management.
Give us a Give call to usfind a call outtomore find out about more theabout Total Clean the Total service, Cleanand service, get a and week’s get a week’s cleaning free*. cleaning free*. T: 0207 935 T: 0207 5088 935 5088 E: enquiries@totalclean.co.uk E: enquiries@totalclean.co.uk www.totalclean.co.uk www.totalclean.co.uk *The *The cost cost of of one one*The *The week’s week’s cost cost cleaning cleaning of of one one week’s week’s will will be be cleaning deducted cleaning deductedwill will from from be beyour your deducted deducted first first general general from from your your cleaning cleaning first first general general invoice invoicecleaning cleaning -- please please invoice quote invoice quote TFM2020 TFM2020 -- please please quote quote when whenTFM2020 TFM2020 contacting contacting when when contacting contacting us us to to claim claim your yourus us discount. discount. to to claim claim your your discount. discount.
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FDPP - www.fdpp.co.uk 25
Controlling the Bake of the Perfect Loaf Bread. Just thinking of the word pushes
With one heater above the conveyor and
your olfactory senses to imagine yeast-
the other below, each needs to be set to
based delights at the counter of your
a different temperature. Spare outputs
favorite bakery. But baking the perfect
from the Delta Temperature Controllers
loaf, and in large enough quantities,
were available and linked to relays for
demands furnaces that accurately
audible and visible alarm signals. These
control the process from beginning to
signals were also replicated in the DOP-
end. This was precisely the task faced by
107WV HMI.
Mechatronics Ltd., a system integrator and official distributor of Delta Motion,
Closely coupled with the quality of the
Drive, Control, and Robotics products
bake is the speed control of the conveyor
based in Bulgaria.
belt. The MS300 VFD is linked to an the conveyor was implemented using an
inductive proximity sensor that is easy to
The requirements for the bread furnace
MS300 Series inverter. This AC motor
clean and remains accurate in the dusty
machine defined four temperature zones.
variable frequency drive (VFD) also
baking environment. Installed closed to
The first zone is especially powerful to
supported the RS-485 Modbus interface
compensate for the cooled conveyor belt
the gears, the built-in programmable
and is ideal for open-loop control of IM
and the relatively cool loaf entering the
and PM motors.
logic controller (PLC) of the MS300 is
oven. At this step, steam is also injected into the furnace to give it that freshlybaked sheen. It is followed by three temperature-controllable baking zones that are carefully controlled for baking the optimal loaf. The conveyor belt of this traveling oven design must also be held at the correct speed throughout the
Of course, the quality of the bake is ultimately defined by the furnace. Special attention was given to selecting the optimal control approach for the seven heating elements used. After careful deliberation, the DTC1000 Temperature Controller was selected as the main
process. Rounding off the specifications
controller, with DTC2000 controllers used
was a human-machine interface (HMI)
in parallel for the remaining six heaters.
to configure the baking process, deliver
These are also connected to the Modbus.
temperature status of each zone, and
The selection of established, reliable
output any error status information.
components, along with the careful programming, were critical in delivering
For the HMI, the team selected the
a low-maintenance design that could be
Advanced HMI DOP-107WV from the
operated 24/7.
DOP-100 Series. This touch-based control panel features a 16:9 7» color TFT
To provide optimal temperature
screen with a modern-looking, narrow
regulation, the auto-tuning function of
frame. Its multilingual support meant it
the DTC1000/2000 was used. The inputs
was well-suited for the target market,
are acquired from third-party PT100
while user-friendly editing software
temperature sensors while control of the
ensured that the final user interface was
heating elements is implemented with
easy to navigate. With several RS-485
solid-state relays. Auto-tuning uses a
capable COM ports, it integrated perfectly
training process to configure the closed-
with the other components selected for
loop PID controller once the sensors
the furnace. Considering the operating
and heaters are installed in this 250
environment, the flat, wipeable surface
kW furnace. Further complicating the
of the DOP-107WV proved the ideal
implementation is the dual heating and
choice for a dusty bakery. Control for
sensing of the last three baking zones.
26 FDPP - www.fdpp.co.uk
configured to monitor and calculate the conveyor speed. This is continuously compared it to the setpoint defined in the HMI. Thus, the end-customer only needs to set the desired baking time, the required temperature, and then press run to start baking. The Mechatronics Ltd. team benefited from the broad range of industrial automation solutions in the Delta portfolio. Integration of the VFD, HMI, and Temperature Controller was simplified thanks to the out-of-the-box interoperability and connectivity of the components selected. Most people would assume that baking bread is very simple. On the contrary, the bread furnace project has highlighted the skill required of both bakers and engineers to create a machine that delivers the perfect loaf. The auto-tuning function of the DTC1000/2000 played a large part in ensuring that bakers can deliver a quality product every batch, by providing excellent temperature control,» said Victor Ogedegbe, Field Application Engineer at Delta. www.delta-emea.com
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YouTube
Ishida celebrates exhibition return with latest automation solutions The benefits of automation solutions,
been designed to meet private label
of the product for fast and accurate
which have been so invaluable during
manufacturing requirements.
weighing. Precision Pulse Width
the coronavirus pandemic, and which will continue to support companies in fast-moving and increasingly competitive markets, will be the key
At the same time, in line with the ongoing move to smart factories, the machines can also be part of a fully
Modulation (PWM) ensures that product is fed to the hopper in a controlled manner to optimise weight combinations, while Ishida’s patented
theme of the Ishida Europe stand (D40)
integrated and centrally controlled
at the PPMA Show as the company
packing line, designed and installed by
looks forward to welcoming back
Ishida and supported by its advanced
efficiency and close to zero giveaway.
customers for face-to-face visits.
Sentinel monitoring software. The
The weigher offers impressive speeds
Ishida Sentinel Reporting Pack, which
of up to 400 weighments per minute.
high-speed filtering and Anti-Floor Vibration (AFV) ensure optimum
Ishida will be displaying latest models
is included on all Ishida models free
from its market-leading multihead
of charge for life, provides instant
Best-in-class foreign body detection
weigher, checkweigher and X-ray
visibility of live machine performance
and quality control for a wide range
inspection system ranges. All three
from anywhere in the world.
of packaged and unpackaged food
offer individual benefits – the 28
products is provided by Ishida’s IX-
head CCW-RV multihead weigher
The Ishida CCW-RV-228WB multihead
GN-4044 X-ray inspection system,
has been specifically designed for
weigher incorporates custom-
offering maximum consumer
sugared confectionery; the IX-GN X-ray
designed parts which can deal with
reassurance and brand protection. The
provides a versatile mid-range quality
the particular challenges of sticky
IX-GN can reliably detect contaminants
control and inspection solution; and
sugar-coated confectionery to deliver
including steel, aluminium, tin, glass,
the DACS-G-F015 checkweigher has
smooth and consistent movement
stones, dense rubber and plastic,
28 FDPP - www.fdpp.co.uk
Ishida has now introduced a new service offering for its X-ray range, which delivers a guaranteed Total Cost of Ownership (TCO) of less than 3% per annum over a fiveyear period. metal detection and reject devices, including mechanical, electrical and software features that surpass the inspection and failsafe assurance requirements of private label goods for UK retailers. The machine on display also features Ishida’s proven IDCS (Ishida Data Capture System), a powerful software that captures and manages data from every pack that passes over the checkweigher. This provides in-depth real time performance monitoring that helps to identify opportunities for performance improvement and bones and shells for unrivalled food
system for greater sensitivity to
safety. In addition, Ishida’s advanced
specific foreign bodies. The machine
Genetic Algorithm (GA) technology
can also carry out several other quality
enables operators to optimise the
control functions such as counting components, weight estimation, missing, broken or deformed items, and
enhancement throughout the line to deliver increased Overall Equipment Effectives (OEE). In addition, both the IX-GN and DACSG-F incorporate Ishida’s Retailer Reject Confirmation (RRC) software that
product voids.
checks and confirms that any out-
Ishida has now introduced a new
been successfully removed from the
of-specification product or pack has
service offering for its X-ray range, which delivers a guaranteed Total Cost of Ownership (TCO) of less than 3% per annum over a five-year period. In the checkweigher range, the DACS-F015 Advanced-Line model uses Ishida’s Force Restoration weight cell to deliver precision weighing accuracy for high-speed production lines. Manufactured in the UK, this model is a full combination system which includes
production and packing line, to meet individual UK retailer quality standards and codes of practice. “We are delighted to be back at the PPMA Show and the NEC after such a long-enforced absence,” commented Ryan Jones of Ishida Europe. “As a business, we have continued to work successfully throughout the pandemic using the benefits of remote technology, but the ‘personal touch’ is also an important part of the Ishida experience, so we are delighted to be able to interact face-to-face with our customers and prospects once again. www.ishidaeurope.com
FDPP - www.fdpp.co.uk 29
HMI Solution for Food Processing In the food processing industry, the daily cleaning of automation equipment and process equipment is extremely important to ensure food safety. Therefore, the human machine interface (HMI) for food production facilities must be able to withstand high-pressure and high-temperature washing and be cleaned with acidic cleaners to facilitate daily scrubbing and water washing. A suitable HMI solution for food production facilities should have: • The IP69K rating ensures the highest degree of protection in food processing environments where sanitation and cleanliness are required. • The use of stainless steel materials has high anti-corrosion efficiency. • The surface should be easy to clean, featuring a seamless flat design that
30 FDPP - www.fdpp.co.uk
The human machine interface (HMI) for food production facilities must be able to withstand high-pressure and high-temperature washing and be cleaned with acidic cleaners to facilitate daily scrubbing and water washing.
manufacturing processes. In addition to computing performance, HMI systems used in the food industry has many factors to consider, such as whether it can withstand intensive spraying and repeated high-pressure cleaning.
OUR SOLUTIONS The GOT815W-511 and GOT812W-511 are powered by the Intel® Core™ i57300U processor. The high-reliability touch panel PCs offer a choice of either
prevents the buildup of any dirt on the bezels.
one 2.5” SSD HDD or one 2.5” SATA HDD for storage. For flexible communication, both panel PCs have one full-size and
• Waterproof connectors allow complete
one half-size PCI Express Mini Card slots
protection during the cleaning process.
for Wi-Fi/3G kit. Moreover, they support
Human Machine Interface (HMI) allows direct data flow collection and
the VESA mount and are compatible with Windows® 10 and Windows® 10 IoT.
communication between machines and
Axiomtek UK Ltd.
facilities, as well as real-time monitoring
T: 01612093680
and control of operating processes,
E: info@axiomtek.co.uk
to create fast and collaborative
W: http://www.axiomtek.co.uk/
EAO Series 82 Pushbuttons Enhanced protection. Fast mounting IP67 front and rear sealed 316L Stainless steel Pushbuttons with integrated M12 connector. Burgess Hill June 2021 – EAO, the expert partner for innovative, intuitive and reliable Human Machine Interfaces (HMIs), has extended the robust and attractive Series 82 switches series with an overmoulded option and M12 connector. The new 22mm mounted version in food grade stainless steel offers fast mounting as well as complete front and rear IP67 protection. It is common to expose actuators and indicators to extremely harsh operating conditions. For example in the food & beverage industry, where alkaline cleaning agents and corrosion severely affect HMIs. Typical applications • Food and beverage production machinery • Factory automation • Conveyors and packing machinery • Maintenance and repair operations The overmoulded version is the Series
82-6657 and is capable of meeting these strict requirements offering reliable enhanced protection. These attractively designed illuminated pushbuttons feature a housing made from SUS 316L stainless steel and a Tritan light guide resistant to many cleaning agents. These design features provide protection against wear and ensure consistent clarity of both the dot and the ring illumination. Advantages of the overmoulded version • Complete IP67 protection for illuminated pushbuttons • Tritan light guide resistant to cleaning agents • Housing made of SUS 316L stainless steel • High resistance to vibration and impact • M12 connector for fast and resilient mounting • 24VDC illuminated versions available with red, green, white or blue LEDs
The switches utilise a robust M12 connector. This connection method saves customers time when it comes to mounting as well as enabling a highly resilient HMI connection. The rear of the device is also IP67-compliant thanks to the overmoulding of the switch and connector, ensuring that the HMI has complete and reliable protection. The overmoulded version also offers very high resistance to vibrations and impact. Contact EAO Ltd on 01444 236000 or email sales.euk@eao.com to discuss your project Read more on www.eao.com/82
Precision Motion Control. Reliable, repeatable, precise. High torque hybrid stepper motors.
. Motor frame sizes from 14 mm to 106 mm . Step angles from 0.72 to 1.8 degrees . 2, 3 and 5 phase motors, unipolar or bipolar windings . Factory fitted encoders and closed loop stepper motors . Wide range of AC and DC microstepping drivers . Customisation of motor shafts, connectors and cables Call Jason on 01444 236000 to discuss your motion control project. EAO Ltd | Phone: 01444 236000 | E-mail: sales.euk@eao.com | www.eao.com/sanmotion
EAO_AD_Sanyo_Denki_190x130mm.indd 1
11.05.2018 08:55:32 31 FDPP - www.fdpp.co.uk
A modern relocation company designed for the manufacturing sector JTS Relocations Ltd was formed by Timon and Jenny Thorncroft, bringing together over 65 years of experience within the UK removal industry. Specialising in Commercial and Industrial Removals, they are totally focused on delivering service levels that are second to none, whilst remaining faithful to their key guiding principles – a quality service, Health & Safety and care for the environment. You can be assured that you are in safe hands with JTS.
efficiencies or moving an entire plant set-up to a new factory location, they will carry out the task effectively and to your schedule. Factory and warehouse removals Whether you are looking to move one machine, an entire factory full of equipment or an entire storage
INDUSTRIAL RELOCATION A SPECIALITY
warehouse JTS are experts in
Unlike most commercial removers that
equipment, ensuring that the vehicle is
transporting heavy machinery and
Manufacturing plants JTS undertake turnkey projects and make the whole process of plant relocations as easy
loaded correctly and safely to eliminate
and fast as possible for you and your
are also highly experienced in carrying
any risk of damage in transit. Because
business. They understand that the
out industrial, plant and manufacturing
every project is different they provide
process needs to run smoothly and
moves. Whether it’s installing a
bespoke solutions based on your
safely without affecting your company’s
replacement unit into a line to increase
requirements.
operations or customer base.
focus solely on office relocations JTS
32 FDPP - www.fdpp.co.uk
Unlike most commercial removers that focus solely on office relocations JTS are also highly experienced in carrying out industrial, plant and manufacturing moves. As well as transportation they can provide engineers to dismantle and install plant and machinery equipment to provide a completely rounded service. Sensitive items and heavy machinery Experienced in working within hygienic and sensitive environments JTS combine their experience and knowledge with state of the art technology and equipment to secure, remove, transport and re-house items safely and without fuss. Whether it’s delicate equipment or extreme heavy loads they are adept at extracting and reinstalling items within
Members of the British Association of
to us at the time and, with the cost
Removers and the Commercial Moving
of buying, maintaining and upgrading
Group (CMG)
vehicles to adhere to increasing
FLEET-FREE AND ECO-FRIENDLY In 2018 government figures stated that the majority of Britain’s greenhouse gas output (an estimated 33 per cent of carbon dioxide (CO2) emissions) came
regulations we made the decision to go fleet-free.” “The nature of commercial removals is such that our crews might be required to work anywhere in the UK and, though
tight confines.
from the transport sector.
the electric and hybrid options are
A COMMITMENT TO QUALITY
Everyone within the sector is responsible
supply chain issues. By hiring vehicles
for reducing their emission, and great
nearer the job site we reduce our carbon
strides have been taken in the design
footprint and, contribute to the client’s
and build of vehicles including making
local economy. Vehicles are driven
them more efficient, less polluting and,
economically so they use as little fuel as
improving their aerodynamics, whilst
possible. It’s a win-win as far as we’re
improved driving skills to help reduce
concerned.”
Clients can have complete confidence and peace of mind when choosing JTS. Health and safety All members of staff are fully trained in manual handling, safe working at heights, identifying risks and hazards, emergency first aid and undertaking secondary risk assessments. Health & Safety consultants ensure that all requirements are met for every job providing Method Statements, Risk Assessments and Instruction Sheets. ISO standards and award-winning JTS hold the following standards and have twice won the prestigious Commercial Mover of the Year award: - ISO 14001 Environmental Management System - ISO 9001 Quality Management System - ISO 45001 Occupational Health and Safety Management System - BS 8522 The Commercial Moving Standard
emissions. JTS Relocations have gone a step further,
improving there are still logistical and
IT’S ONLY LOGICAL CARBONLOGIC
owning no removal vehicles at all. Dedicated to minimising the company’s carbon dioxide emissions and reducing their carbon footprint, rather than owning removal vans they source reliable low-emission transport as close
As well as reducing their own carbon
to each job as possible so crews don’t
footprint JTS offer inclusion to their
need to travel long distances in large
clients. They can calculate the most
vehicles from a single depot. Instead
efficient method of carrying out any
where feasible they use public transport
project, calculate the actual emissions
or a shared minibus to reach jobs, thus
and offer a baseline scheme to offset
reducing emissions and traffic.
the CO2 free of charge. Through Carbon
JTS Director Jenny Thorncroft explains “When we formed the company in
Footprint Ltd the client can be provided with a certificate on completion.
2008, we chose to operate in a far more
www.jtsrelocations.com
sustainable and eco-friendly way. There
info@jtsrelocations.com
were no electric HGV options available
0800 849 1501
FDPP - www.fdpp.co.uk 33
New Food Grade Tank Cleaning Site for Manchester LPW Group – the national vehicle cleaning specialists – have opened a brand new tank cleaning site in central Manchester. Conveniently situated next to major motorway links, the LPW Tankwash site introduces a new and accessible facility for the city and surrounding networks. Equipped with the latest technology and equipment, the site provides a specialist cleaning and sanitisation service for road tankers, tank containers, and all other intermodal equipment. The complete pressurised tank washes can thoroughly clean a vast range of food substances including: edible oils; sugars; chocolate; flour; juices, and dairy products. As a dedicated food grade tankwash, no chemical cleaning takes place on the site, meaning the possibility of cross-contamination is significantly reduced. At every location, the LPW Tankwash team are highly skilled and experienced operatives. This enables a fast
From speaking and listening to our existing customers across the UK, it became apparent that an accessible location in Manchester was needed.
turnaround time – saving invaluable
accessible, convenient, and professional service for drivers.” LPW Tankwash forms a part of the wider LPW Group, who specialise in commercial vehicle and building cleaning. With over 45 years of industry experience, LPW Group are the UK’s market-leader in national cleaning
time in transit - without any
site locations, including Purfleet and
compromise on quality and service.
Avonmouth.
The seals necessary to comply with
answer to this need, and will provide an
services. Their impressive client base spans
Gary Moon, Managing Director of LPW
from independent fleet operators to
also provided by the team.
Tankwash, says: “We are delighted to
major blue chip organisations. The
open our brand new Manchester tank
group now comprises a portfolio of
Tankwash site services include:
cleaning facility. From initial planning
eight brands, including: LPW Tankwash,
to building developments, we have
LPW Truckwash, Mobile Fleetwash,
committed these last few months to
LPW Fleetcare, LPW Fleetsales, Carlyle
create a state-of-the-art site to suit
Limited, Wilson Contract Services, and
our customers’ requirements in Central
Pureclean Car Care.
stringent food safety regulations are
• Food grade tank washing • IBC cleaning • Steam heating • Sanitisation • Air filtered blow drying
Manchester and the surrounding areas.
For queries about the new Manchester
• Hose and flex cleaning
“From speaking and listening to our
Tankwash site, or any further enquiries,
• ISO 9001\2015 certified washes
existing customers across the UK, it
contact LPW group directly on 01708
became apparent that an accessible
463 400 or email
This Manchester Tankwash site adds
location in Manchester was needed.
enquiries@lpweurope.com
to LPW’s existing network of national
The latest LPW Tankwash site is in
www.lpweurope.com
34 FDPP - www.fdpp.co.uk
Food Grade Tankwash Stations Across the UK
LPW LPW Tankwash Tankwash Green Green Lane, Lane, Eccles, Eccles, Manchester, Manchester, M30 M30 0YD 0YD
LPW LPW Tankwash Tankwash Avonmouth Avonmouth Docks, Docks, BS11 BS11 9YD 9YD
• No chemical cleaning on sites • Quick & efficient service
LPW LPW Tankwash Tankwash Juliette Juliette Way, Way, Purfleet, Purfleet, RM15 RM15 4YD 4YD
• Electronic wash certification provided • Fully compliant & licensed to discharge • All washes ISO 9001\2015 certified
lpweurope.com/tankwash
01708 463 400
enquiries@lpweurope.com
Safetech continues to expand Safetech have had another successful year as the premier manufacturer and installer of automatic personnel protection systems. “We thought that with the complications of Brexit and the pandemic, we wouldn’t be able to continue our business growth“, says Managing Director Robert Smith, “but the company has continued to expand and we’re delighted our new Guardian Ultra product is proving so popular. We’ve recently taken orders from Norway, Sweden, France, Canada, Mexico and the USA”.
The new Guardian aerial frame Safetech’s latest system features extensive upgrades and improvements. A PL-d was achieved and validated by an independent test house. Sophisticated monitoring and diagnostics give immediate feedback to the operator.
Guardian Ultra control panel
The aerial frame mounted above the conveyor has been completely re-designed using glass-reinforced plastic. This new structure is lighter, stronger and can be configured to bridge any size of equipment. The versatile design allows material to pass without obstruction.
Although Guardian Ultra is a highly improved and refined system, the basic principle behind Safetech products has always been the same – to prevent injuries automatically and reliably. Guardian is suitable for protecting personnel in a wide range of processes, including refuse recycling, paper, board, plastic and metal handling, and many manufacturing and engineering functions. Tel: +44 (0) 191 521 4316 Email: info@safetechsystems.com Website: www.safetechsystems.com
Supplier of high quality plastic, aluminium and glass packaging solutions to Global pharmaceutical, cosmetics, and food sectors
WWW.CJK.CO.UK | 01663 750222 | SALES@CJK.CO.UK 36 FDPP - www.fdpp.co.uk
Hygienic Flow Equipment Specialists ITS are process flow equipment experts, with a multitude of top equipment brands available and over 100 years combined experience in the food and beverage, brewery, dairy, pharmaceutical and personal care industries. From Hygienic Valves, High Performance Pumps, Pigging Systems or Tank and Mixing Equipment, through to Automation Systems, Installation Materials, Heating and Cooling Products or Spares, ITS and our in-house experts can technically support you with large systems projects, one off product purchases, and even maintenance or repair services. ITS was formed in 2002 from a core of Alfa Laval people, to take over the distribution of Alfa Laval Flow Equipment. Now a partner distributor to other top industry brands, including, Bornemann and Mouvex, Worcester, Norbro, Pipetite, Liag and Daniatech, we distribute stocked items with a fast, next day service at competitive prices, all with an unmatched customer ethos. As a family owned business, we live by our core values and hope to reflect these in the service provided to our customers.
Our mission: "Operating within a safe and transparent culture of respect and innovation, we are dedicated to positively conduct ourselves with high ethical standards and integrity. We will continue to invest in and develop our staff, reliable product ranges and services provided, to ensure the high standards expected within the markets we trade are upheld or exceeded. As the complete solutions supplier of choice, we value all stakeholders of the business and build strong relationships to reinforce our unrivalled reputation and future growth." - Peter Jeans, Company Founder
Contact Industrial Trading Solutions Ltd Tel: 01675 465191 Email: Sales@industrialtradingsolutions.com Website: www.industrialtradingsolutions.com
Distributing Solutions
Processing Excellence
Keep your daily operation running smoothly by securing and monitoring your valuable keys and equipment whilst keeping them easily accessible. Ensuring keys and tools are kept secure & readily available can be a tricky balance to maintain, however this is achievable with our key & asset management systems. Shadow Boards can be upgraded by adding our Single Unit’s (T1) to them subsequently increasing the organisation and security of your valuable machine tools. Contractor and employee safety when maintaining factory machinery is vital to all food processing companies, with our Lock Out, Tag Out (LOTO) system we can ensure that you will know who is working on which machine at a glance. For the food processing industry, we offer Metal Detectable Access & Retention Pegs which identify any mislaid pegs when processing the food and are easy to detect and withdraw. Whilst keeping keys & assets secure our products also increase accountability by making sure that you can see who has which key or asset at any time simply by just glancing at the system.
“The system has led to a reduction in reordering replacement tools and the tools are always in the correct place and available for the next person to use.”
“No longer have to go hunting around the plant for missing equipment.”
Sales@Keytracker.co.uk
GEA doubles flow rates of the GEA Hilge CONTRA multistage centrifugal pump range With the introduction of a third size in
and O-ring sets are required to be kept
the GEA Hilge CONTRA range, GEA is
in stock.”
expanding the performance spectrum of 100 cubic meters per hour. The new
MITIGATING THE RISK OF CONTAMINATION
GEA Hilge CONTRA III meets the general
In both the food and pharmaceutical
requirements of the dairy, beverage and
industries, the requirements for
food industries. It is particularly well
purity and reproducible quality of
suited for demanding pharmaceutical
raw materials, active ingredients and
applications in which sterile, no-cast
end products are particularly high. In
materials in CIP- and SIP-capable
pharma applications, the water typically
specialized pumps are a critical factor in
transferred by pumps is of WFI (water
the manufacture of life science products.
for injection), PW (purified water) and
of its centrifugal pumps to a flow rate
FLOW RATES DOUBLED
AP (aqua purificata) quality. Other media to be transferred are infusion solutions,
The GEA Hilge CONTRA III multistage
suspensions, nutrient solutions,
centrifugal pump in the CONTRA range
alcoholic solutions, vaccines or blood
is designed according to the Hygienic
plasma. The plant components installed
Design guidelines and has a decades-
directly in the production area must not
long track record in sterile applications
contaminate circulating media (high-
thanks to its electropolished surfaces,
purity water) or products (cell cultures,
high-quality sealing materials and
solutions from the fermenter) – neither
versatile designs. “Centrifugal pumps
by the penetration of undesirable
are, so to speak, the workhorses of
substances from outside, nor by the
the process engineering industry. They
materials used.
are the most widely used pumps in the design ensures the necessary hygienic,
PROCESS-RELIABLE, FAIL-SAFE, EASY TO CLEAN
reproducible production,” explains Martin
GEA has designed the CONTRA pump
Zickler, Product Manager for hygienic
range to meet the highest process
pharmaceutical industry because their
centrifugal pumps at GEA. By introducing the new size with increased drive power, GEA has doubled the maximum flow rate to 100 cubic meters per hour compared to the previously available range. “Our target for the GEA Hilge pump range is to cover as large performance spectrum as possible with just a few sizes,” says Zickler. “This reduces spare parts inventory costs for plant operators. The greater the number of individual pump sizes in a process line, the wider the range of mechanical seals
40 FDPP - www.fdpp.co.uk
Our target for the GEA Hilge pump range is to cover as large performance spectrum as possible with just a few sizes reliability, material and failure safety requirements. “When CIP cycles are not perfectly carried out, production downtime costs increase. This is why we design plant components such as our GEA Hilge CONTRA III to be both hygienic and easy to maintain so as to improve plant availability,” says Zickler. This not only contributes to product safety, but also to gentle product handling and plant efficiency. CIP and sanitizing cycle times can be reduced, which in turn saves water and cleaning agents as well as the energy required to heat the cleaning media. Servicefriendly patented Adapta design of the CONTRA III allows the pump to remain
FREQUENCY CONVERTER FOR VERSATILITY Increasing the versatility of the GEA Hilge CONTRA III, frequency converters are also an integral part of the hygienic in the pipeline in the event of a motor
milled components instead of castings
change. The system does not need
for media-contacting parts. Zickler:
to be revalidated for pharmaceutical
“Because they are prone to cavitation,
applications, thus minimizing
cast parts are particularly undesirable
maintenance requirements.
in the pharmaceutical industry. Their
TOTAL DRAINAGE THROUGH ECCENTRIC DISCHARGE PORT AND INCLINED SURFACES
reduced cleanability makes reproducible, easy-to-clean production difficult.” However, both aspects were important parameters for GEA in the development
Criteria for the cleanability of pumps are
of the pump. All materials have therefore
primarily the absence of dead spaces
been carefully selected for their use in
and a cavitation-free design of all media
hygienic processes. The casings are made
contacting parts. This applies, among
of deep-drawn rolled or forged steel
other things, to the installation space of
of grade 316L (1.4404 or 1.4435). The
the mechanical seal and the arrangement
non-porous and cavitation-free surface
and dimensioning of the drainage
enables different sterilization standards
system, which is essential to avoid any
with surface roughness from Ra ≤ 0.8 µm
contamination. The fluid can already
to Ra ≤ 0.4 µm.
drain off completely with a surface CONTRA pumps are installed vertically,
VERSATILE CUSTOMIZATION OPTIONS
this can be achieved even without the
The entire CONTRA range is
need for a drain valve.
characterized by a wide range of
inclination angle of 3°. If GEA Hilge
NO-CAST COMPONENTS ARE EASY TO CLEAN
concept. Pharmaceutical companies that also operate their plants under partial load and on weekends particularly benefit from speed control, as the water distribution system must be kept in motion continuously in order to prevent contamination, regardless of the actual operating phase. Frequency converters have a significantly lower heat effect on the pumped media compared to throttled centrifugal pumps. Less cooling is required as a result and energy costs are reduced. The sensitive media is protected from thermal damage. More information can be found online at gea.com.
configuration options, allowing plant operators to use the pumps in a variety of applications. Whether installed
Material selection plays an equally
horizontally or vertically, the GEA Hilge
important role for quality and safety
CONTRA III achieves a very high efficiency
in process control. Manufacturers
thanks to the precise operating point
therefore prefer high-quality stainless
design and various impeller geometries.
steels, which ensures hygiene, corrosion
For pumps that are to be used in
resistance and a long service life.
explosive atmospheres, the CONTRA
In order to facilitate cleanability in
is available in the Adapta variant. This
hygienically sensitive applications,
design has EC conformity approval
GEA relies on forged, deep-drawn and
according to ATEX Directive 2014/34/E.
FDPP - www.fdpp.co.uk 41
Ergonomic handling solutions The Covid pandemic has brought new challenges to industries all over the world. Due to the dramatically increasing number of online orders and growth of e-commerce, and the pressures associated with staff health and safety, goods must now be picked and packaged more safely and efficiently than ever before. No matter which industry you work in, our range of ergonomic handling solutions can improve productivity levels and health & safety at the same time.
TAWI’s Mobile Order Picker (MOP)
rotate reels with ease, and grip them
Turn two person lifts to one person lifts
allows one person to do the job of two
from either the core or the outside to
by allowing the operator to lift upto
while protecting them from injuries
250kg at just the push of the button.
reduce damage to your goods. Our lifting
caused by lifting heavy objects. The
Our vacuum lifters remove 100% of the
trolleys are perfect for lifting reels of
MOP is compatible with any forklift or
weight of the goods from the operator
film and packaging and are available in
pallet jack, making it a highly versatile
stainless steel, making them suitable for
piece of equipment. With its adjustable
the food and beverage industry.
allowing them to move quickly and with precision. Other solutions such as trolleys, and chain and wire hoists solve a multitude of manual handling issues; the versatile range of equipment on offer allows you to lift nearly anything
tower height, operators can reach into pallet racks and other low headroom
Make sure to look out for TAWI at The
spaces giving them the ability to access
PPMA Show to see a demonstration of
otherwise hard to reach areas.
our equipment, or to have a chat with one of the technical team! – 28th-30th
with TAWI. We offer both stationary and
Our trolleys are built with a modular
mobile solutions, customisable solutions,
design, so parts and attachments are
and also stainless steel and ATEX rated
interchangeable, making them highly
www.tawi.com
solutions.
adaptable to your needs. Lift, tilt, and
eh.info@piab.com
42 FDPP - www.fdpp.co.uk
September (Stand number C34)
Brewery has no regrets following rebellious move from steam to thermal In 2015, with business improving but
“The move from steam to thermal
enabled them to process research
original process equipment reaching end-
was a leap of faith on our part, but the
and development batches and has
of-life, Rebellion Beer Company bucked
warnings received from other breweries
been especially useful throughout
the trend and, with impartial advice from
have been proven to be incorrect!”
the pandemic when, at the beginning,
heat transfer specialist Fulton, replaced
says Rebellion Beer Company’s Mark
throughput was decimated because
its ageing steam boiler for a thermal
Gloyens. “Product quality has improved
pubs were forced to close. However, as
fluid system. Now, six years on, we
because we now have more control over
lockdowns came and went, Rebellion
approached Rebellion’s Mark Gloyens to
temperature for the wort boiling process
successfully pivoted its business and
update us on how brewery life has coped
than ever before. We’re getting a very
started selling direct to the consumer
with the switch.
good quality boil that is controllable and
via a home delivery service, which meant
we have achieved everything we wanted
throughput very quickly returned to pre-
from the move from steam to thermal
pandemic levels, currently two to three
fluid”.
batches per day, with each boil lasting up
Anyone running a brewery will tell you just how critical the boil phase of the brewing process is; and when Rebellion
to 90 minutes.
set out on its journey from steam to
Thanks to the control and flexibility that
thermal, they were warned that they’d
the thermal system affords Rebellion,
“The beauty of the thermal fluid
never succeed in getting that clean
the brewery has had the ability to
installation is its flexibility and ability to
flavour achieved from a steam-driven
achieve various size batches as and
very easily adapt our changing brewing
rolling boil.
when required. Until recently, this has
strategies.” says Mark.
44 FDPP - www.fdpp.co.uk
“Historically we would have been doing
savings made compared to maintaining
Fulton, he simply tells them to come and
two brews per day to achieve maximum
the old steam system – and despite the
take a look because it speaks for itself.
output, but because of its flexibility, we
thermal fluid installation being a more
“It’s just a neat, compact installation
are now able to shut the thermal fluid
expensive capital outlay initially – has
that’s relatively maintenance free and
heater down for a day per week to deep
certainly contributed significantly to
extremely flexible!”.
clean the brewhouse and increase output
the return on investment, with the
to three brews per day for the remainder
investment now fully paid for.
of the week. Something that would have been very difficult to achieve with steam.”
Expanding on the flexibilities of the
Beyond the control and flexibility, there
announced that Rebellion is about to tap
are many other factors that have had
into the existing brewhouse line to create
a positive impact on Rebellion Beer
a small-batch development brewery
Company, as Mark explains: “A steam
and yeast propagation plant on the site.
boiler is essentially a pressure vessel
“It’s been such an easy expansion to
and regulations state that pressurised
achieve. We’ve just been able to tap into
systems must undergo an annual
the existing thermal fluid line and use
insurance inspection. This inspection
the system for another duty without
would often take the steam boiler offline
impacting on everything else.” says Mark.
and mean our brewing processes were down for a day or more, with disruption from the downtime potentially being felt for several days after. Additionally, with even the best water treatment programme in place, steam at pressure can be very corrosive, leading to problems with steam traps, flanges and pipework, which we always seemed to be maintaining and was always therefore another potential for process downtime.
The beauty of the thermal fluid installation is its flexibility and ability to very easily adapt our changing brewing strategies
thermal fluid system, Mark has also
The new development line is capable of brewing five hectolitre (500 litre) batches and will enable development or commercial batches – such as strong beers or one-off batches that may not appeal to the wider consumer – to be processed without having to invest in a
And when asked about his advice to anyone considering a new brewhouse or complete overhaul of existing plant; and perhaps sitting on the fence when it comes to considering steam versus thermal? “You obviously need to consult the experts as we did when we approached Fulton over six years ago. They were completely unbiased because they manufacture both steam and thermal fluid solutions.”. says Mark. “But for Rebellion Beer Company, a thermal fluid solution was a no brainer. It’s more cost-effective, more reliable, relatively maintenance free and a much neater, more compact system that still provides the quality of heating needed for brewing. It’s just a better way of doing it!” For further information on its range of
full 4,000 litre brew.
steam- and thermal-based heat transfer
Summarising, Mark Gloyens says that
brewhouses, visit www.fulton.co.uk,
whenever he’s asked if Rebellion is happy
email sales@fulton.co.uk or call the
with the thermal fluid installation from
office on +44 (0)117 972 3322.
solutions for brewing processes and
“With thermal being more of a closed loop system, we’ve not experienced the same issues with leaking gaskets, flanges, etc., making the whole installation not only look but also feel so much more reliable than steam!”. In putting a figure on the annual cost savings of maintaining a steam system – including servicing, water treatment, chemical dosing, etc. – compared to thermal fluid, Mark Gloyens estimates that the thermal fluid system is much lower and could be at least half that of the previous steam boiler installation. And six years on, Mark estimates that the
FDPP - www.fdpp.co.uk 45
Hard-to-handle fruit, veg & poultry waste proves easy pickings for SEEPEX BTM pumps A sophisticated chopping, pumping and
HYGIENIC WASTE REMOVAL
waste removal solution from progressive
The benefits to food manufacturers
cavity (PC) pump specialist SEEPEX
of switching from conventional waste
UK is making light work of previously
removal methods to an enclosed,
challenging by-products from whole
automated solution like the BTM are
chickens, potatoes and cabbages to
three-fold. Firstly, it is more hygienic.
peelings and fruit stones. The BTM range
Transferring waste products through
is not only cutting food producers costs, it’s also improving their standards of hygiene and health & safety. Waste is an unavoidable part of the production process at fruit, vegetable and poultry processing facilities. Whether in the form of trimmings, wash residue and by-products, or as a result of off-specification batches, overproduction or expired goods, it must be handled within strict sanitary guidelines and quickly removed from production areas. Not only does this free capacity so that primary processing operations can continue, but waste and by-products can also create an additional revenue stream as animal feed or compost, or to generate renewable energy. This makes their efficient removal and swift onward transfer even more important to
a closed pipe system eliminates, production area. It is not uncommon
for example, the need for dedicated
to find conveyor belts, compressed air
cleaning of tote bins prior to re-entering
systems, vacuums, water flumes, and
high-care areas which prevents
manual handling via waste containers
potential cross contamination.
such as tote bins being used even at large food production factories. These
IMPROVED HEALTH & SAFETY
methods can be inefficient, unsanitary
Secondly, it is safer. Manual handling
and expensive.
or conveying systems often result in
AUTOMATED, ALL-IN-ONE ALTERNATIVE
onto the floor, presenting an immediate
Fortunately, there are sophisticated,
who are in danger of slipping on it.
hygienic and cost-effective alternatives on the market. Seepex BTM pump range is one such option. The patented chopping and pumping solution, featuring an enclosed pipework system, is already being used in waste handling applications at many fruit, vegetable
manufacturers’ bottom lines.
and poultry processing factories
However, some waste products
Thanks to an integrated cutting unit
are notoriously difficult to handle.
that reduces particle size, the BTM
Large, highly viscous or non-flowable
effectively chops and pumps in a single
foodstuffs can prove particularly
operation, reducing the solids volume
challenging: for example, whole
by up to 60%. This creates a pumpable
chickens; chicken frames, heads, feet
consistency, without requiring the
and necks; whole cabbages or potatoes;
addition of water, enabling whole
and fruit stones, seeds and peels
vegetables and even entire birds such
from vegetables and fruit. As a result,
as DOA or off-specification chickens to
some operators still rely on traditional
be hygienically and efficiently removed
methods to remove them from the
off-site.
throughout the UK and Europe.
waste product falling or being dropped health and safety risk to operatives, Furthermore, this fully automated solution requires only one staff member to load product into the hopper. This leads to improved health and safety on the factory floor due to a reduction in traffic and hazards in high-risk areas – fewer forklift trucks, fewer operatives and fewer tote bins.
COST-SAVING SOLUTION Finally, the BTM pump range is more efficient, generating significant cost savings. By chopping, pumping and transferring all-in-one as the BTM is able to create a pumpable consistency without requiring any additional water, resulting in savings from water usage. This has the additional benefit of reducing the volume of waste by up to 60%, making it easier to transport and thereby cutting transport costs. The operating and energy costs of the BTM are considerably lower than vacuum or compressed air systems, generating
SEEPEX BTM pumps chop and pump in a single operation
46 FDPP - www.fdpp.co.uk
savings there.
Thanks to an integrated cutting unit that reduces particle size, the BTM effectively chops and pumps in a single operation
SEEPEX bespoke waste pumping solutions
And by removing a manual element from the process and automating it, food producers are saving on labour costs, too, freeing employees for more lucrative, primary production roles. Where high care production areas are chilled, removing waste via a simple pipeline rather than manually through doorways, will also assist in reducing energy costs as well as minimising potential contamination from external sources.
BESPOKE OPTIONS FOR MOST CHALLENGING WASTE STREAMS
a large pitch that enables the product to
fitted with Smart Conveying Technology
be conveyed into the cutting elements to
(SCT); an innovation from Seepex that
ensure continuous pumping.
enables rapid dismantling and cleaning,
Horizontal and vertical grinders can
Where more challenging by-products
also be integrated, as can stone and
need to be transported, customised
knife traps to prevent pump damage,
solutions are available. ‘Bridging’ can
while dewatering devices can help to
be an issue with certain wastes, so the
reduce waste volume even further.
BTM pump range includes augers with
Finally, all BTM pump systems can be
increasing pump stator life by up to 200% and reducing maintenance time by up to 85%. Pumps fitted with SCT are also suitable for Clean-Out-of-Place (COP) or CIP. www.seepex.com
HANDLING FOOD WASTE? NOT ROCKET SCIENCE WITH SEEPEX PUMPS. SEEPEX open hopper BTM progressive cavity pumps with a feed auger and macerating knives chop and pump food waste in a single operation. Products such as whole fruit and vegetables, peelings and fruit stones; poultry (DOA, heads, feet, necks) and even ready meal packaging are hygienically removed through enclosed pipework from high care to low risk areas. y Hygienic waste removal from high care to low risk areas y Elimination of manual handling, cross-contamination and cleaning y Reduced waste volume resulting in lower transport costs
CONVEYING CAPACITY Up to 130 m 3/h PRESSURE Up to 24 bar
y Low energy requirements compared to blown or vacuum systems y Produces ideal feedstock for biogas and pet food production, and animal feed y Handles a variety of challenging food waste
SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com
FDPP - www.fdpp.co.uk 47
Essentials for your production line The instrumentation below measures
• Emptying of containers
for highly accurate flow rate and
and controls the pressure, flow and
• Transfer within tank plants
volumetric measurement of fluids and
level of liquids and gases within the production line. We aim to help you save money and reduce waste on your production line using this range of selected products.
JUNG PROCESS SYSTEMS – HYGHSPIN TWIN-SCREW PUMPS - NEW Jung Process Systems - OEM’s first ever pump supplier, have been specialists in hygienic twin-screw pumps since 2009. The new Hyghspin twin-screw pumps are described in three words as hygienic, gentle and economic and we are proud to announce Jung Process Systems as an addition to our pressure and flow product range! The main advantage of the Jung Hyghspin twin-screw series is that it enables efficient, hygienic and optimally adapted transport and production processes. Hyghspin twin-screw pumps can be
• Transfer within production processes (supply, pressure boosting, discharge) • Metering and filling As well as pumps, we can supply and advise on several process management products which will help optimise your production line.
and pharmaceutical industries. It has a measuring range of 0.1...10 m/s and operating pressure is 0.1.
REFRACTOMETER: IRM-11 BY ANDERSON-NEGELE The refractometer is an Inline measurement of the concentration of liquids with refractive index scales
INDUCTIVE CONDUCTIVITY SENSOR BY ANDERSON NEGELE
such as °Brix, Plato or customer-
INDUCTIVE CONDUCTIVITY METER ILM-4
CAPACITIVE LIMIT SWITCH BY ANDERSON NEGELE
With the ILM -4, it is possible to
NCS-11
directly measure the concentration of a medium that can effectively improve the CIP cleaning process and be economically advantageous. Suitable for product quality monitoring too. MAGNETIC-INDUCTIVE FLOW METER BY ANDERSON NEGELE
suited to a wide range of applications,
The FMI magnetic inductive flow meter
including:
from Anderson-Negele is designed
48 FDPP - www.fdpp.co.uk
pastes for customers from the food-
specific. So, it is possible to measure dissolved particles in liquids.
The capacitive limit switch limits detection of media with low or no water content like syrup, fruit concentrates, alcohols and oils with a dielectric constant εr (Dk) ≥ 2. With a measuring range of Dk ≥ 20 and an operating pressure maximum of 10 bar.
TURBIDITY SENSORS: ITM-51, ITM51-R BY ANDERSON-NEGELE Anderson-Negeles’ front-flush turbidity sensor is for low to high turbidities, with an IO-Link for media with a turbidity of 200… 300.000. We can offer sensors with different measuring methods for almost any application.
L3 PRESSURE AND LEVEL TRANSMITTER BY ANDERSONNEGELE Anderson-Negeles’ L3 pressure and level transmitter has been designed to measure process pressure or hydrostatic level in hygienic process applications.
VEOX INNOVATIVE MIX PROOF VALVE
available from DN 25 to DN 150.
MIXPROOF VEOX with IO LINK BY DEFINOX
valves.
for food, brewery, cosmetic processes. The valve is fitted with two valve seats, each with a “floating” PFA seal in a
The main applications of a pigging valve are for the pigging system.
DEFINOX PIGGING SYSTEMS:
particular slot that makes the valve extremely easy to clean.
Pigging systems are ideally suited for processes with high viscosity and fast
When the valve opens, the “floating”
hardening media, e.g. yoghurt, dressing,
PFA seal allows cleaning also in the
cheese, chocolate, toothpaste, etc.
track behind the PFA seal.
See a brief overview of our
The Mixproof valve is also available as
recommended products below
a tank outlet valve which isolates the
seat ensures that the flow can be
of butterfly valves from Definox are
same design principle as Definox’ other
requirements and is the ideal solution
Typically, you would see butterfly
cosmetics. The DPX & DPAX range
process technology and based on the
the strongest process technology
tank from the rest of the process.
dairy production, food, chemical and
guidelines for the high standards of
The VEOX Mixproof valve meets
HYGIENIC BUTTERFLY VALVES BY DEFINOX - DPX AND DPAX valves like this used for brewing,
been developed according to hygienic
and visit https://www.oem.co.uk/ resources/blog/essentials-for-yourproduction-line for the full article,
The shape of the body and the valve
which explains why each instrument would be useful in your production
maintained with the same functions as floating gaskets.
line.
PIGGING VALVES AND SYSTEMS BY DEFINOX
Alternatively contact our pressure &
DEFINOX PIGGING VALVE: The pigging valve and system has
HYGIENIC PRESSURE, FLOW AND LEVEL PRODUCTS
flow department, where our product specialists are waiting to help you with your enquiry: pressureandflow@oem. co.uk or call us on 0116 284 9900
We represent process management solutions from Anderson-Negele and Definox, both leaders in their respective markets. We can supply and advise on: • Hygienic pressure gauges & sensors • Turbidity sensors, hygienic valves & pigging systems • Check, sampling & mix proof valves • Conductivity sensors • Hygienic flow sensors & flow switches • Hygienic level sensors & switches
pressureandflow@oem.co.uk +44 (0) 0116 284 9900 www.oem.co.uk
FDPP - www.fdpp.co.uk 49
ICE Vector establishes Clearmark’s foray into pallet labelling Digital coding innovator Clearmark is celebrating its 20th anniversary by making its foray into the logistics labelling space with the launch of the innovative ICE Vector Pallet Labelling System. The ICE Vector brings to the marketplace a new high performance, low maintenance tertiary option that is exceptionally easy to integrate with line and warehouse management systems. ICE Vector completes Clearmark’s coding portfolio, enabling customers to benefit from joined-up coding solutions across their primary, secondary and tertiary operations paving the way for the factory of the future. Unique engineering differentiators makes the ICE Vector a high performance system including: climate controlled cabin to ensure consistent print quality; robust long-reach cartesian-style arm guarantees GS1 specification label placement on all pallet configurations; a dual operator interface for continual working during ribbon/label reel changes; intelligent I/O system to seamlessly communicate with today’s highly automated warehouses. “We have been paving the way for entering the tertiary marketplace ever since we moved into secondary coding with our now flagship product, the ICE Vulcan, in 2014. Having spent the intervening years building our expertise in print & apply and honing our technology, we have developed a tertiary offering that is unmatched by anything else available on the market today” says Clearmark’s Technical Managing Director, Chris Simpson. The launch of ICE Vector is timely,
Clearmark is celebrating its 20th anniversary by making its foray into the logistics labelling space with the launch of the innovative ICE Vector Pallet Labelling System warehouses call for smarter, faster, self-
specifications for SSCC pallet labelling
reliant systems to meet demand.
or three sides for customer specific applications.
The ICE Vector Pallet Labelling System promises to deliver an attractive ROI for any high-throughput operation looking to automate its pallet labelling process, from food, beverage and pharmaceutical factories, to supply chain and logistics operations. Powerful, reliable performance and seamless integration with factory warehouse management systems (WMS) are the bedrock of the ICE Vector advantage. The ICE Vector is powered by the ICE Vulcan print
The ICE Vector is designed as a robust, fully enclosed system, thanks to a pneumatic guard protecting the print engine from dust and environmental conditions. Optimum conditions within the enclosure are maintained via a thermostatically controlled heater (as standard) with the doors only opening at the point when the ICE Vector is ready to label. With a label arm reach of 650mm
with warehouses accelerating their
engine – the fastest in its class. With
investment in intelligent automation,
a compact footprint of just 1125mm x
mitigating supply chain issues
875mm and operational speeds of up to
system, label placement is accurate
(exacerbated by Brexit and the
100 pallets an hour, it can perform up to
and repeatable on a wide range of
pandemic). As more products flow
four label applications per pallet, with
pallet configurations. This ICE Vector
through supply chains at speed,
two adjacent sides to conform to GS1
is capable of printing at up to three
50 FDPP - www.fdpp.co.uk
out of the enclosure via a sturdy 2 axis cartesian guided motion control
With warehouses becoming more sophisticated, system communications are having to follow suit. The ICE Vector
times faster than rival print engines and
Clearmark now has a coding solution for all
in an extensive range of onboard data-
three packaging types: primary, secondary
protocols, including both Zebra and SATO.
and tertiary. Primary coding applications
The machine features two CLARiTY™
are served by the ICE Zodiac Hawk family
touchscreen interfaces. Label and ribbon
and the ICE Viper Plus, while the ICE Viper
changes can be executed efficiently
Plus, ICE Vulcan, ICE Torus and Zebra
thanks to the internal interface and
systems address secondary coding.
to machine settings and performance
“We found that customers wanted to
information of the ICE Vector’s interface
buy their pallet labeller from the same
with the line PLC. Additionally, the
company that supplied their case labeller
screen can also be viewed remotely
and thermal transfer overprinter – mainly
using a networked PC and standard web
for commonality of parts and operation
browser. As well as helping to mitigate
familiarity. It has long been our goal to
coding errors and meeting retail and
offer coding solutions for all of these
regulatory traceability requirements, this
applications, but we had to be sure
automated data management of SSCC
we could match the performance that
codes approach can enhance Overall
Clearmark is known for in primary and
Equipment Effectiveness (OEE).
secondary coding applications. With the
thanks to Intelligent Motion™ technology, which enables precise automatic
The Government’s recently announced
control of the labels and ribbon feed,
capital allowance incentive for
this translates to the removal of 80%
investments in new machinery and
of wear parts compared to traditional
plant is providing further impetus for
pallet labelers. The result is an incredibly low maintenance solution with the lowest cost of ownership and gives greater reliability of equipment, without traditional service intervals.
With the introduction of the ICE Vector,
is simple to integrate with a WMS system
the external interface gives full access
The ICE Vector is designed as a robust, fully enclosed system, thanks to a pneumatic guard protecting the print engine from dust and environmental conditions.
allowing the financial case to stack up.
automation. Between now and March
ICE Vector, we believe we have achieved exactly that,” explains Chris. For more information about the Vector, visit www.clearmark.uk/vector
2023, British manufacturers investing
UTM: https://www.clearmark.uk/
in qualifying plant and machinery
products/labellers-lpa-uk/vector-
assets will be able to benefit from
pallet-labeller?utm_source=PR&utm_
130% corporate tax relief (usually 18%)1
medium=Digital
With a label arm reach of 650mm out of the enclosure via a sturdy 2 axis cartesian guided motion control system, label placement is accurate and repeatable on a wide range of pallet configurations.
FDPP - www.fdpp.co.uk 51
How Product Inspection Facilitates the Flexibility and Product Safety that Co-packers Need to Deliver Contract packagers have a highly
The growth in e-commerce has directly
Choosing the right product inspection
demanding role in the food supply chain,
affected packaging formats and supply
technology will help them provide the
needing to be both flexible and capable.
chain models, and contract packers have
flexibility and product safety standards
Product inspection technology can help
had to respond to that.
they need. It can help co-packers to
them meet these needs, writes Niall McRory, Global Key Account Manager,
Another area where contract packers
address other challenges too.
have needed to show flexibility and
For example, according to 2020 report,
Division.
the ability to quickly respond is in
Contract Packaging and Manufacturing
compliance with increasing legislation
Packaging Operations, Trends &
So many of the trends that shape today’s
around the world aimed at improving
Challenges, by the Association for
food manufacturing industry demand
levels of product safety. Compliance with
Packaging & Processing Technologies,
a flexible approach to packaging. For
standards demand not just a flexible
further key challenges are in the areas
contract packers this calls for huge
mind set, but equipment which can
of labour and counterfeiting. With the
flexibility in everything they do – from
efficiently handle frequent changeovers
former, a shortage of skilled labour,
their culture to the equipment they
between different legislative needs, as
and the rising costs of employment in
invest in, including the product inspection
well as capture the information required
general, represent a significant issue to
technology they deploy.
to guarantee provenance.
overcome for packers.
Mettler-Toledo Product Inspection
52 FDPP - www.fdpp.co.uk
The growth in e-commerce has directly affected packaging formats and supply chain models. In light of all these challenges, many contract packagers are reassessing the role of their product inspection technology, looking to find efficient flexibility from within this critical area of their packaging lines. The solutions are present in a number of different ways: and the level of compliance with
Product changeovers – Contract
emerging product safety legislation.
packers need to switch between jobs more frequently. Every minute lost in
For more information:
downtime during a changeover is a
E: niall.mcrory@mt.com
cost, but modern product inspection
Mettler-Toledo Product Inspection
systems are noted for their ease of
www.mt.com/pi-pr
transition between job types, often via tool-less processes that can be set
Mettler-Toledo is proud to be a
in motion with the press of a button.
member of the European Co-
Hundreds of product set-ups and their
Packers Association (ECPA). The
parameters can be pre-programmed
company fully understand the
and stored with data automatically
key role that co-packers have in
accessible in the event of a product
the supply chain and, as such, is
safety audit or recall. Indeed, similar
developing educational content
product set-ups can be clustered,
including webinars. The expert
avoiding the need for any changeovers,
advice is positioned to help co-
thereby maximising line availability.
packers improve product safety,
Ease of machine use and learning
production to test has a negative effect
through software – The latest product
on Overall Equipment Effectiveness
inspection systems have the ability
(OEE). Some modern metal detection
to analyse the composition of a pack,
systems can continuously monitor the
automatically select the best hardware
detection performance and provide an
and software settings and create an
early warning should sensitivity drift.
optimised product menu for that job.
This self-monitoring means the testing
This auto set-up routine combined
frequency can be reduced, in turn
with a well-designed touchscreen
increasing the line availability.
user interface, which naturally guides users step-by-step through all operations, increases speed of setup/ adjustment, decreases the amount of training required and also reduces the
Faster production line speeds – Every manufacturer wants to produce quickly. As such, product inspection manufacturers have responded by
frequency of possible operator errors.
creating product inspection machines
Reduced testing frequency – Foreign
throughputs in excess of 800ppm,
body inspection equipment such as
depending upon application. These can
metal detection systems, need to be
now keep pace with systems such as
regularly manually checked to ensure
quick labelling applicators. Such speed
that the detection levels are being
increases have been achieved without
achieved. However, regularly stopping
compromising the quality of inspection
which can inspect and reject at
protect their brand, comply with legislation, reduce product recalls and prepare for digitalisation.
As part of its Product Inspection Open House (6th and 7th October), Mettler-Toledo will present a free online seminar entitled How Product Inspection Innovations Improve Food Safety and Automate Quality Processes for Co-Packers on the 6th October at 8am and 2pm (BST). To register www.mt.com/ pi-copackers. For more information about the Open House visit: www.mt.com/pi-open-house-2021
FDPP - www.fdpp.co.uk 53
Where quality control is essential Throughout the Food and Beveridge, Pharmaceutical and Medical industries robust cleaning procedures are implemented, microbial growth must be eliminated to ensure food production is not stalled by contamination. Pharmaceutical and medical facilities regularly quality assess their products for any indication that the products are not sterile. These increased cleaning procedures mean that a standard electrical enclosure isn’t enough. The Tempa hygiene range is specifically designed to handle frequent and extreme cleaning practices. The roof of the enclosure is angled to prevent the accumulation of water droplets, water from the cleaning process contain microbes which can accumulate and result in contamination of food or pharmaceutical products. The sloped roof design ensures that water droplets do not have a platform to accumulate. Additionally, the gasket that is incorporated into all of the hygiene range is not the standard polyurethane, instead a silicon gasket is employed. The molecular geometry of the silicon gasket means that it is more robust in high temperatures and extreme pH, the Tempa gasket can maintains integrity up to 200 degrees, thus allowing for heat-based cleaning procedures and accommodate virtually all cleaning
Pharmaceutical and medical facilities regularly quality assess their products for any indication that the products are not sterile. These increased cleaning procedures mean that a standard electrical enclosure isn’t enough.
products. The increased durability and high compressibility of the silicon gasket is a contributing factor to the hygiene ranges IP66 rating and as well as the passing of the 69K test, which is characterised as high temperature (steam) protection class. This rating is essential in allowing pressurised cleaning of the panels, which is a routine part of the most cleaning processes in the sterile production facilities.
stainless steel, ensuring that the IP66
water, lack of accumulation sites and
rating is justified and that the enclosure
negates the need for additional cleaning
maintains its integrity under extreme
practices by the end user.
pressures. The hygiene range offers several specific design aspects, including internal door hinges to reduce external surface area for possible microbial accumulation sites, cylindrical wall fasteners to prevent water accumulation opportunities and a unique lock design
Within this range the enclosure, locks,
which has been specifically designed
hinges, and wall fasteners are all
for this new range, to allow for flow of
54 FDPP - www.fdpp.co.uk
The Temp hygiene range has been designed with one goal in mind, to provide our end user with a durable, robust and effective enclosure, that can withstand any cleaning processes they can throw at it. To provide our end users with a product that they can trust in an industry where quality control is essential. www.tempapano.com
Lanemark brings heating benefits to small brewery application A new gas process heating system from Lanemark Combustion Engineering is now fully operational in London at a leading micro-brewery, Villages Brewery, with particular gains noted in terms of operational efficiency. “We have installed and commissioned a liquid heating TX 25E burner package on a brewing kettle supplied by Bespoke Brewing Solutions, with whom we liaised closely throughout the project,” says Lanemark’s Process Burner Sales Manager, Adrian Cadman. “This provides a capacity of 30 hl – or 18 UK barrels – and is now central to Villages Brewery’s production.” The burner is installed on the external wall of the circular vessel, firing through the structure into a submerged 2½” nb. stainless steel tubular heat exchanger which takes the form of a helical coil located at the base of the tank in order to deliver the optimum blend of maximum heat transfer and minimum intrusion into the available space. Benefitting from Lanemark’s own TxCalc specification software, efficiencies in excess of 80% are readily achieved. This is further enhanced by low exhaust temperatures of typically 180°C, which is markedly lower than alternative systems where up to 300°C, reducing efficiency to just 50%, can be noted.
Archie Village, Director at Deptford-based Villages Brewery – which distributes to a wide range of pubs and bottle shops throughout the capital – highlights the role played by the new installation. “The overall aim of the project has been to facilitate an increase in production output while building on the high quality that is at the heart of our reputation – and the Lanemark system is already delivering in both respects,” he says. info@lanemark.com www.lanemark.com
LANEMARK BREW VESSEL HEATING
At the heart of your brewery planning...from day one • Low operating costs • 80%+ efficient • Helical coil heat exchanger occupies minimal space • Accurate temperature and rolling boil control • Natural gas and propane
Tel: +44 (0)24 7635 2000 Email: sales@lanemark.com 5146 Lanemark SIBA HPL Ad SDAW.indd 2
COMBUSTION ENGINEERING
FDPP - www.fdpp.co.uk 55 05/02/2020 13:43
The New SRP Cobot by Phoenix Handling Solutions The new SRP Cobot from PHS is an
scanning system to the front. Should
• 6 bar air pressure
extremely compact, versatile and fully
a person be detected by the radar, we
• Lease purchase, hire purchase, lease
automatic, low-cost modular robot
automatically slow down the Robot into
only or outright purchase options
palletizing system, based on a Hanwha
Cobot mode, ie it runs at a lower speed
available
HCR-12 industrial collaborative robot.
for safety reasons.
Designed for easy, low-capacity palletizing on a very small footprint. The system is available in two versions. Given the vast experience of PHS in end of line automation, Cobots were a natural progression for our business for existing and new customers alike.
Should your business be considering Advantages
a low cost palletizing solution, then
• Low investment, fast ROI
please contact Phoenix Handling
• Standardized system - fast delivery
Solutions Limited:
and installation • Very compact footprint, easy to relocate by pallet trolley or forklift • Collaborative industrial robot -
They are simple to install and do not
safety fencing and safety radar
require masses of conveyors to feed
scanner included – CE certified
them. Hence they can be easily placed at
• Easy product change-over
the end of a production line picking and
• Can handle Euro 1200 x 800 or
placing product 24/7 if required.
Chep style 1200 x 1000mm pallets x 2 positions
Safety plays a huge part of the PHS
• Optional layer sheet inserter
solution, as we provide a fully guarded
• Up to 6 cycles per minute, either
cell to follow the strict guidelines for CE
single or multi picking according to
T: 0845 265 7570
marking Cobots, with safety guarding
gripper type and dimensions
E: admin@phs-uk.com.
at each side of the machine and a radar
12 FDPP - www.fdpp.co.uk 56
• Single phase power supply
www.phs-uk.com
Emmi, Borealis and Greiner Packaging partner up to create first chemically recycled polypropylene ready to drink iced coffee cups Emmi CAFFÈ LATTE, one of the leading
business models, and pioneer materials
ready to drink iced coffee brands in
partnerships.”
Europe, has started to incorporate
“Borealis looks forward to a world
chemically recycled polypropylene into
without plastic waste,” says Trevor
its packaging. The cups are produced by
Davis, Head of Marketing, Consumer
Greiner Packaging and the chemically
Products at Borealis. “The chemically
recycled material comes from Borealis,
recycled polypropylene used in this new
one of the world’s leading providers
Emmi CAFFÈ LATTE cup is manufactured
of advanced and circular polyolefin solutions based in Vienna, Austria.
with Borealis Borcycle™ C portfolio of
Emmi, Switzerland’s largest milk
solutions, giving polyolefin-based, post-
processor is committed to climate protection and the circular economy. The dairy company has the stated goal to make all of its packaging 100% recyclable and is committed to various measures to promote circularity such as packaging that contains at least 30% recyclate by 2027. Focusing on recyclable packaging and the use of recycled materials, Emmi is taking a first step with its successful Emmi CAFFÈ LATTE brand.
transformational chemical recycling
It takes joint efforts by food and packaging manufacturers to reduce waste and make measurable progress in the circular economy, polypropylene is currently still in its infancy, where Greiner Packaging and Borealis are leading the way. Only limited quantities of chemically recycled polypropylene are currently available,
MATERIAL SCARCITY AND ENVIRONMENTAL POLICY
and Emmi is one of only a few food
From September 2021, Emmi’s
plastic through its early commitment
successful brand of chilled coffee drinks,
and long-standing collaboration with the
Emmi CAFFÈ LATTE, will use at least
development companies.
manufacturers to have secured a share of the chemically recycled polypropylene
100 tonnes of plastic based on the recycled material each year. Chemical
“It takes joint efforts by food and
recycling renews plastic back to plastic
packaging manufacturers to reduce
creating recycled materials with a level
waste and make measurable progress
of purity equivalent to fossil-fuel based
in the circular economy,” says Bendicht
PP and hence, fit for protective, food-
Zaugg, who is responsible for
safe and other demanding applications.
Sustainable Packaging at Emmi.
In this way, Emmi is utilizing difficult to recycle feedstock preventing plastic waste that would be likely landfilled or incinerated. In the future, depending on the availability of suitable material, the amount of recycled plastic in Emmi CAFFÈ LATTE packaging is to be further
“We have had a long and rewarding partnership with both Emmi and Borealis,” says Greiner Packaging Key Account Manager Vincenzo Crescenza. “This achievement is in line with our stated goal to work towards achieving
consumer waste another life. It offers all-round benefits enabling the transition to a circular polyolefin industry whilst creating virgin quality plastic products. By staying true to our EverMinds™ ambition of accelerating action on circularity, together with our valuable partners along the whole value chain such as Emmi and Greiner Packaging, we are reinventing for a more sustainable living.” The chemically recycled material used for Emmi CAFFÈ LATTE cup consists entirely and solely of ISCC (International Sustainability & Carbon Certification) material, on a mass balance basis. Mass balance is a methodology that makes it possible to track the amount and sustainability characteristics of circular and/or bio-based content in the value chain and through each step of the process. This provides transparency ultimately also to the consumers, enabling them to know that the product they are buying is based on this renewable material.
PACKAGING FACTS: • Technology: Injection molding • Decoration: Sleeve • Material: 30% Borcycle™ C chemically recycled PP
increased.
a circular economy. Our strategy
www.greiner-gpi.com
is to develop innovative products,
www.group.emmi.com/che/en
The new technology to recover the
develop new service partnerships and
www.borealisgroup.com
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PRECISION ENGINEERING 3D ADDITIVE MANUFACTURING REVERSE ENGINEERING TOOLMAKING
Conformal cooling in mould tools is reducing both quality errors and cooling time Conventional mould tool making has limitations, meaning the moulds are being designed larger and larger so they can take more impressions to increase numbers of components and keep up with demand. As a result, the moulding machines are being supplied as large operational units taking up significant factory space and requiring high energy for operation. Laser sintering has been demonstrated to be a more effective manufacturing process for mould tool making. However, there remain barriers to its application for mould tooling in the plastic caps and closures industry due to concerns around the mould cooling technology and the need to provide enduring wear resistance. The current cooling channels are straight drilled and cause lengthy and uneven cooling, which often results in the formation of hot spots and high scrap rates.
Agemaspark seeks to overcome these barriers by developing a highly efficient advanced manufacturing process for the production of laser sintered mould tools with a novel ceramic
AGEMASPARK.COM
In December 2020, we purchased an EOS 290 which is already demonstrating examples of how we can produce conformal cool in Maraging Steel with a hardness of 54 Rc, and if required, apply a ceramic coat to give increased tool life and a friction free release (pictured below right).
20% reduction in cycle time
Conformal cooling works by creating a suitable cooling channel at a well-defined distance from the cavity—which is impossible using a conventional drilled cooling mechanism—thereby reaching areas where it is difficult to do so using conventional methods. The temperature sensors embedded on each cavity will enable effective control of the cooling.
Agemaspark Ltd Units 1 & 2, Croft Court, Sandall Carr Road Kirk Sandall Industrial Estate, Doncaster South Yorkshire, DN3 1QL United Kingdom Tel: +44 (0)1302 882666 Email: admin@agemaspark.com
coating. The mould tools will make use of the breakthrough process utilising conformal cooling channels embedded with temperature control sensors enabling localised temperature control. This will overcome inherent deficiencies in the current plastic caps and closures mould tooling technology (pictured below left).
Results show that it is possible to reduce cycle times by up to 20% and at the same time increase the continued quality of the moulding.
The environmental advantage from using this method is to increase the impression on the same envelope or reduce the size of the tools and therefore the size of the mould press, reducing energy consumption. The cooling water requirements reduced from tens of thousands of litres used in any 24 hours to just 10-20 litres because the heat transfer is just local to the moulding and is contained in a closed loop system (pictured below centre). Agemaspark has also used this approach on existing tooling by removing the tops and re-sintering with conformal cooling channels replacing the moulding area.
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PSR Plastics When it comes to the unique demand of the food and beverage industry, PSR Plastics steps up to the plate with industry knowledge, expertise and bespoke manufacturing. Based in Melton Mowbray, PSR is a familyowned business who have earned their reputation as a reliable name in the manufacturing of engineering plastic components. For over 30 years PSR has been delivering enhanced performance, improved safety and an extended lifetime to food and beverage processing and packaging machinery. With an extensive material selection, contemporary machine shop and highly skilled team, PSR’s innovative solutions enable businesses to reduce downtime, run efficient operations and keep commitments to their customers. ADVANCED ENGINEERING PLASTICS
• Improved chemical resistance under
With a modern CNC machine shop
harsh cleaning/sanitising chemicals
home to advanced routing, milling,
• Noise reduction from metal-on-metal wear • FDA approval
High-performance plastics have quickly
QUALITY PRECISION COMPONENTS
become the first choice for components
Catering to businesses of all sizes, from
in an industry where more traditional
large-scale producers to independent
materials once dominated. Engineering
manufacturers, CNC technology can
plastics are now used extensively in
create custom components quickly,
metal replacement applications as not
efficiently and with the highest degree of
only do they surpass key properties but
accuracy.
they are also easier and more costefficient to manufacture. • PSR’s material grades offer an abundance of benefits to food and beverage industry applications, including: • Minimal wear, even at higher loads and line speed for reduced maintenance • Enhanced performance in extreme low and high temperatures
turning and cutting machinery, PSR is well-equipped to create the highest quality precision components used in industrial preparation, packing and distribution machinery. Not only do PSR cater for bespoke components but, as suppliers of Rexnord Marbett and Movex, PSR can provide access to specialist conveyor parts. Example components include wear pads and strips, pulleys, sheaves, gaskets and bushings, to name a few. QUALITY SERVICE & SUPPORT Understanding that time scales can be critically important in the food and beverage industry, PSR offers a priority service to expedite orders for customers on a strict deadline, ensuring all operations continue to run smoothly. Though over the years the technology, material selection and employees have seen continuous investment, what has remained the same at PSR, however, is their commitment to quality and unparalleled customer service. For more information: www.psrplastics.com
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Engineered For
Endurance
Panduit Launches New Generation FlexFusion™ Cabinets Panduit has launched its new FlexFusion™ cabinets which can be custom configured to meet the specific needs of any ITE environment. The requirements of data centres are constantly evolving, it is therefore essential to have rack solutions capable of offering maximum scalability. With the growth of edge data centres and colocation sites, these arrays must not only be flexible in their design, but also be configured for specific environmental and equipment needs that push the limits for maximum cooling and cooling efficiency. For more information visit: https://pages.panduit.com/FlexFusion.html
Lubron FoodSafe Universal foodsafe lubricant with ptfe Lubron Foodsafe from Eco-Point Laboratories is a high-performance foodsafe universal lubricant containing penetrants, corrosion inhibitors, water displacing agents and ptfe. The remarkable lubrication properties of ptfe combined with our unique manufacturing process means that Lubron Foodsafe will penetrate, protect and lubricate in areas where other products fail. NSF White Book registration 159120, category H1. ptfe solid lubricant provides a dry film boundary layer to the bearing surface, greatly reducing start-up friction and enhancing slow speed lubrication. Eco-Point Laboratories utilise the smallest possible ptfe particles, along with optimised morphology, to maximise solid lubricant performance and durability. If it moves – Lubron Foodsafe. • Available in bulk and aerosol • Strong penetrating action • Leaves ptfe film to provide long lasting lubrication • Penetrates and frees rusted nuts, bolts, screws etc • Excellent corrosion protection • Stops internal corrosion in wire ropes etc
• ptfe reduces “sticktion” on machinery start-up • Belt and chain conveyers • Bearings, chains, runners • Wire ropes • Sliding doors, slideways • All types of machinery • Removes moisture
Get in contact for more information. T: +44(0)14 9479 2803 E: info@ecopoint.co.uk W: www.ecopoint.co.uk
Internal and external rolling doors and shutters to improve and protect your productivity both safely and securely. Design | Install | Maintain
■High-speed doors - improve workflow efficiency ■ Fire doors - ensure staff safety ■ Shutters - security and asset protection ■ Custom doors - designed your
way
Get a free consultation, contact us on +44 (0) 191 214 0404 info@hartdoors.com
www.hartdoors.com FDPP - www.fdpp.co.uk 61
Analyse a PROFIBUS network and diagnose faults in less than 2 minutes using AI Did you know that it takes 2 to 4 years
communicates with Procentec’s Atlas
to master an industrial protocol, like
solution, and then securely sends only
PROFIBUS or PROFINET fully? Gaining,
this file rather than the complete network
updating, and sharing that knowledge
information to Procentec’s SNAP server.
is a big challenge in this dynamic finding, analysing an industrial network
A COST-EFFECTIVE WAY TO MAINTAIN UPTIMES
can take a technician...
Focusing on preventative scheduling
environment. In the process of fault-
maintenance or accelerating the time
- several days without a diagnostic
it takes to troubleshoot can result in
solution
significant savings. SNAP can be had for
- multiple hours with a mobile diagnostic
about a quarter of what it costs to employ
tool
a full-time field technician for a year,
- up to 45 minutes with a permanent
so the prevention of just one downtime
monitoring system
session means that, for many operations, the tool pays for itself in next to no time.
With the SNAP Kit, you will be able to slash that time to 2 minutes or less;
YOUR NETWORK PARTNER
a true time saver that directly guides engineers to the best repair path!
Procentec is the global leader in
SNAP: IDENTIFYING THE CAUSE OF YOUR NETWORK’S ISSUES IN SECONDS
for the industrial automation market.
diagnostic and monitoring solutions It develops and manufactures network components and products for PROFIBUS, PROFINET, EtherNet/IP and EtherCAT.
SNAP stands for Synthetic Neurologic Analytic Processor. This unique, self-learning feature digitalises the knowledge associated with determining physical layer faults [i.e. oscilloscope measurements] and message layer analysis [i.e. hexadecimal messages] and delivers it in a single automated monitoring service via Procentec’s ComBricks and Atlas solutions. The analysis is written using simple language
and images, removing the need to interpret complicated oscilloscope images and messages yourself. ComBricks creates a base level of understanding of your network communication. Then, when the designed thresholds are reached, it creates a trigger file of either the physical or message layer information,
Some of its products are the most recognised solutions on the market today. It is also a certified PROFIBUS and PROFINET Competence and Training Centre. The Procentec Academy has certified over 4,000 engineers to implement and maintain their PROFINET and PROFIBUS networks to the highest standards available. In addition, experienced consultants assist on projects around the world, advising on architecture, engineering, training and commissioning. For more information and personal advice, please contact Sean Ogborne (UK Sales Manager) via sogborne@ procentec.com or +44 (0) 753 430 7696. www.procentec.com
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Monitor your Industrial networks 24/7 and reduce costly downtime! How do you keep your plant running 24/7, maximize productivity and reduce network failure? Factories lose between 5% - 20% in productivity due to unplanned downtime, where just 1 minute of downtime can cost thousands of pounds.
Atlas2 Plus
ComBricks
Procentec, the leading diagnostic solutions provider for industrial automation with over 20 years of experience, enables you to fully take control over your plant with innovative solutions for permanent monitoring.
→ Remote monitoring of your PROFIBUS installation accessible via web-browser.
→ Remote monitoring for PROFINET, EtherNet/IP, EtherCAT and PROFIBUS.
→ Customizable modular system for PA and fiber optic repeaters.
→ Dynamic graphical and hierachical displays of a network’s topology.
→ The only product with an integrated oscilloscope.
→ Scoring mechanism and traffic light alert system for simple insight → NEW: Self-learning machine with predictive fault-finding capabilities. → NEW: Optional LED display on the device itself for a quick overview.
Visit Visit procentec.com procentec.com for for more more information information and and our our newest newest automation automation solutions. solutions.
Your network partner.
T: T: E: E:
+44(0) +44(0) 753 753 4307 4307 696 696 sogborne@procentec.com sogborne@procentec.com
What is the future of packaging automation? While we all know that it is what is on
Similarly, customers can get ‘best before’
the inside that counts, we have to admit
warnings, real time offers, or they can track
that the exterior plays a significant role as
the journey of their products across the entire
well. Packaging is of utmost importance
supply chain using the data stored digitally.
in today’s commercial world, leading manufacturers to find the best solutions
FLEXIBLE MOTION CONTROL
to respond to customers’ needs. The latest
Packaging does not only have to be
Industry 4.0 technologies allow producers
interactive, it also has to keep up with
to move a step further in digitalising their production and making customers feel more connected. Here, Neil Bellinger, head of EMEA at automation parts supplier EU Automation, discusses three main innovations in packaging automation that will help manufacturers stay competitive and optimise their production.
up to ten kilograms. The robot’s compact design, weighing 28.9 kilograms with a small footprint of 190 millimetres ensures a flexible packaging in industries where reliability and precision are paramount.
SMART PACKAGING In the 2019 Clean Label report, world’s
customers’ requirements and tastes. The emphasis is no longer on mass production, but on mass customisation instead. For example, bottled water used to come as a single unit, but it can now be found in packs of six, twelve or even twenty bottles. Manufacturers may produce batches of six packs one day and twelve the other day. This means that packaging equipment needs to
In recent years, Industry 4.0 has developed
leading nutrition company Kerry Group,
at a surprising rate and is predicted to reach
found out that customers are increasingly
$1 trillion by the early 2030, according to 4.0
questioning label claims, with 49 per cent
Motion control systems are designed to
of those surveyed believing that there is not
handle quick changeovers and add additional
enough information on packaging to help
functions that provide a more flexible
Research. This technological advancement is the perfect opportunity for manufacturers in the packaging industry to speed up their digitalisation strategy and respond to customers’ requirements in an efficient way.
ROBOT PALLETISING Palletising, which requires lifting heavy weights repetitively and is exhausting for human workers, can become more efficient using automation technologies. For example, collaborative robot arms can be easily programmed and redeployed depending on their tasks and can optimise the workflow especially during peak seasons. They are also cost-efficient, ensuring a fast ROI and requiring no additional costs for programming and dedicated work cells. This also means that manufacturers can implement multiple cobot arms alongside the palletising process to speed up their production and load multiple products.
them make informed decision about their lifestyle. In a supermarket, few customers would take the time to read labels carefully. Moreover, labels are sometimes teared or erased or simply incomplete. Smart packaging allows shoppers to engage deeper with their products using their own devices. This is where the IoT comes into play. Smart products are assigned IDs that can help customers in different ways. For example, they can check whether the products have been stored at the right temperature using Near Field Communication (NFC) tags equipped with temperature sensors. NFC tags are passive devices which operate without a power supply of their own and depend on an active device to come into range before they are
Collaborative robot arms can be used
activated. This means the customers can
for packaging applications in all major
simply tap their NFC enabled phones to the
industries, from pharmaceutical to
package and gather useful information.
electronics or metalworking and they are also suitable for food and beverage. They
Whiskey company Johnnie Walker is
can also manipulate delicate products
currently using NFC technology that allows
— for example, Universal Robots’ UR10
customers to check whether the bottles
can palletise small and fragile products
have been tempered with and whether they
such as eggs, though it has a payload of
are sealed properly.
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be programmed to switch quickly and often.
process. One of the strategies to achieve this is flexible programming, which means the ability to use different codes on the same controller. Smart machines can create set points that allow a single machine to run product one at a programmed speed and set features and run product two with different characteristics using distinct tools. Yaskawa developed the Singular Control architecture that can control a mix of motion equipment, including six axis articulated robots This brings increased flexibility in packaging and reduces programming, which in turn makes switching operations faster. From increasing speed to making customers feel more in control of their choices, automation technology is constantly evolving in line with packaging trends. To make sure they respond to their customers’ needs, manufacturers need to keep up with innovative technology and digitalisation trends. At EU Automation, we help packaging companies stay competitive and enhance their production by supplying automation parts from all major manufacturers in the shortest time, to ensure they keep downtime to a minimum. www.euautomation.com.
Award-winning noise and vibration damping technology acoustic close shields that convert the pipe itself into a silencer element to diminish noise.
Sound Damped Steel (SDS) is a multi-award winning noise control company which was established by Les Thompson in 2003 with the main aim being to develop, manufacture and supply materials for industrial noise and vibration control applications. SDS manufacture and supply highly damped materials, complete kits and components that have been specifically designed to solve a very wide range of noise and vibration control problems at competitive, low costs. SDS utilises and draws upon over 30 years of experience in developing new and practical applications for the technology across an expansive range of projects to help both end users and leading noise and vibration control consultants solve their problems. “SDS make steel which absorbs vibration making it sound like rubber. It is supplied to OEM manufacturers to make their chutes, hoppers and machine guards quieter, they also supply kits to retro-fit on existing noisy machinery. SDS also design and fabricate bespoke acoustic enclosures and absorbent wall panels. A speciality is gas pipelines which they have, in collaboration with the INVC.co.uk, designed creating a unique system of silencing noisy pipelines while
retaining air flow around the pipe and giving easy access for inspection.” Added Les Thompson, Managing Director. Gas, oil and other pipelines and their associated equipment such as valves, are renowned for generating high levels of noise that require a noise control solution to be applied. The current typical noise control measure that is used on pipelines, valves and other system components is the use of acoustic cladding, this however contains a multitude of drawbacks and additional associated problems. To tackle this, SDS developed the Quiet Pipe Technology system which negates all the problems associated with current technology. How this works is instead of adapting conventional cladding techniques, the new system comprises interlocking
Another service created by Les, is Soundeck. “As a Hi-Fi enthusiast I made some damping feet and a turntable mat for my record player, they worked so well that Soundeck.co.uk was launched to make these available to the public, they get excellent reviews and are sold world-wide.” Added Les. In terms of recent developments, the COVID-19 pandemic has caused disruption for many industries and affected every company differently. Seeing an increase in its services, Les remarked on how COVID-19 has affected SDS, stating, “We have benefited from lockdown as people at home through the day complained about noise from industrial sites, so we have been busy supplying noise control solutions. Also, with so much leisure time people have been listening to more music and upgrading their systems with Soundeck Hi Fi enhancing products so we have noticed increased sales as a result of this.” T (+44) 191 259 0700 www.sounddampedsteel.com www.soundeck.bigcartel.com
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Hyperspectral imaging: the stuff of science coming to an automated food line near you Vision can be deployed in a number of different ways on a food processing line to tell if food is safe to eat and meets the quality standards demanded by retailers. Now the kind of hyperspectral technology that NASA has used to study planets and plant life is being applied
Today’s hyperspectral vision systems are programmed to have a level of impartiality that human eyes just don’t have.
to the food that ends up on household plates.
Workforce fatigue and human error has meant that on super-fast packing lines, even visible defects, such as bruising and blemishes, can pass even the most observant human inspectors by. Today’s hyperspectral vision systems are programmed to have a level of impartiality that human eyes just don’t
Historically, quality assurance in
have.
For UK-based automation specialist
packhouses relied extensively on human
With many end-of-line packing stations
Brillopak, the emergence of more
intervention - someone scanning
now automated and processing in
affordable hyperspectral imaging is
conveyors as packs headed towards the
excess of 100 packs of produce a
enabling food packing plants to leverage
case loading operation and spotting and
minute, incorporating vision is becoming
sci-fi kit and apply to daily operations.
removing defective or damaged product.
increasingly commonplace. To help
In addition to offering a critical quality
However, there are obvious limitations
minimise the risk of an ‘out-of-spec’
control advantage, it helps packhouses
to visual screening. Most notably, the
product heading out of the warehouse
previously reliant on EU migrant workers
human eye lacks Superman’s x-ray
doors and onto retailer’s shelves,
and experiencing staffing pressures to
powers, while conventional cameras
Brillopak has begun to integrate
now automate their quality inspection
only see what is in the visible light
hyperspectral imaging as an option onto
process.
spectrum.
its automated case loading systems,
66 FDPP - www.fdpp.co.uk
predominantly the company’s UniPAKer robotic crate packer.
FOOD SAFETY OF THE FUTURE Providing instant results and capable of analysing an entire line of packed produce, a hyperspectral camera can be positioned at any part of the food production process. Yet, Brillopak utilises this AI technology predominantly between the packing and case loading operation where operatives previously inspected and rejected produce packs based upon sensory evaluations - sight, touch and smell. In addition to checking the quality of produce being packed, the use of hyperspectral imaging can detect multiple anomalies with greater precision and speed. This includes appraising the colour, position, count, labels, packaging
Advanced applications can even detect
containing far more colour for each
the chemical compositions of produce to
pixel than a traditional vision system,
accurately determine ripeness and the
or the human eye, which is limited to
shelf life. Some producers already use it
three primary colours. This ability to
to check the pH level and tenderness of
differentiate between similar coloured
meat, such as beef.
objects means that factories would now
For Brillopak customers, however, the ability to improve the accuracy of how products are picked and presented to
condition, print inspection, position
the packing robot at speed is where
detection (2D/3D), barcode / data code
director David Jahn sees immediate
reading.
tangible advantages. He explains:
For cooked items, like bread rolls, a change in colour may indicate burnt areas. Change in size may indicate that a partial product, for example an apple sliced in half, has been inserted into a pack during the wrapping process. On
“Using these cameras we can find the centre and orientation of products. This information is conveyed to the robot, which accurately responds, adjusting its speed and position to pick up the pack, regardless of its location on the conveyor. The result is fewer line stoppages
beverage lines, it may identify partial
to address bottlenecks and better
filling. Cameras can also check the
presentation in the retail crates.”
presence of labels, including verifying critical data such as date codes, and spot where food or debris may have become trapped, affecting the closure of packaging.
In its simplest form, the technology works by analysing how light is reflected across the electromagnetic spectrum. The camera generates a digital image
be able to spot minor blemishes, such as a small bruise on an apple. The exact vision technology deployed by Brillopak will depend on the application, continues David. “We might use a camera to select and reject products that don’t meet the quality criteria with regards to colour, size or count. Alternatively, vision might be used to sort multiple products as they move randomly down a conveyor in preparation for the next process. Critically, packs that don’t comply with labelling laws will also be rejected before the case loading process.” By 2024, the hyperspectral imaging systems market will be worth an estimated US$18.88 bn.i Although still a relatively small adopter of the technology, food processing and agriculture are expected to benefit significantly from advancements micro-hyperspectral imaging camera technology. “With food safety, quality assurance and food waste so high on the agenda, we anticipate that hyperspectral imaging will soon become the go-to vision system on food processing lines in the future,” adds David. Customers wanting a demo of vision technology can visit Brillopak’s new trial centre in Tonbridge, Kent. To book a visit, email info@brillopak.co.uk
FDPP - www.fdpp.co.uk 67
Tailor made solutions for the dairy and food industries From hygienic product protection to
Only with the new, patented punching
communication with the customer -
tools from INTECMA can multipacks
packaging must fulfil a wide range of
made of these materials be broken
functions. This includes the packaging
into individual cups just as easily as
design, product protection, ease
multipacks made from PS. The knives
of use, optimal logistics, customer
do not even have to be changed for
information and brand ambassador, but
this. Further equipment in the ZERO
also to guarantee the shelf life of the
Technology range include special
product, however the packaging must
pre-heating plates, which can be
also be sustainable. Functionality and
easily dismantled and enable simple
sustainability are on the same level in
maintenance. Further material savings
packaging development. This has to be
can also be realised by using the special
taken into consideration when developing
thermoforming moulds, which enable the
alternative packaging concepts with
use of thinner materials.
sustainable materials such as monomaterials as well as materials from
ZERO Technology offers an innovative
renewable resources.
Cutting tool
With the patented ZERO Technology tools
costs, increases the performance of the
we offer the perfect solution for the use of mono-materials such as PET, PP and PLA. The tools from the ZERO Technoloy range are the result of years of research and development. They can be applied to all cutting applications contained in an FFS machine. Their use reduces maintenance
68 FDPP - www.fdpp.co.uk
machine and have a longer punching time. By using the tools from ZERO Technology, a quick switch from PS (polysterene) to more recyclable materials such as PET, PP and PLA can be realised and customers have now the opportunity to use these materials for their thermoformed cups.
solution on the way implementing more sustainable packaging material in existing form, fill and seal machines from our brands Erca, Hassia and Intecma (and even in machines from other suppliers) or in new machines and enables improved recyclability of cups and reduces the ecological impact. www.imadairyfood.com
ZERO Technology
SUSTAINABLE PACKAGING SOLUTIONS Consumers’ expectations and regulations change, and manufacturers are confronted with a growing demand for more environmentally friendly and more sustainable packaging. With the patented tools of the ZERO Technology range we offer the perfect solution for the use of mono-materials such as PET, PP and PLA which are perfectly adaptable to the FFS machines of our brands Erca, Hassia, and Intecma. Several tools have been developed for equipping new FFS lines and adapting existing ones. ZERO Technology is the technical solution for high-quality cutting and precutting of PET, PP and PLA and thus enabling easy breakable multipacks made of these materials. Using transparent PET allows consumers to see the product, which makes it more attractive on the shelf. The cup can get a PET lid and label, making the packaging completely recyclable.
More information: www.imadairyfood.com/zerotechnology/
Fully-recyclable sandwich packaging to be trialled in UK supermarkets Greencore Group plc (‘Greencore’ or the
which commence in September 2021,
in the UK every year, or just over 1,100
‘Group’), a leading UK manufacturer
and the proposition meeting all parties’
every minute. Should the fully-recyclable
of convenience foods, is delighted to
performance criteria, roll-out of the new
skillet ultimately be adopted as industry
announce that, in partnership with the Co-
packaging will begin later in the year. In
best practice, the potential for significant
op and Sainsbury’s, it will soon commence
time, Greencore expects to make these
reductions in plastic usage and in
‘test and learn’ trials of an all fibre plastic
new packaging techniques available to the
improved recycling rates is immense.
free recyclable sandwich skillet in stores
wider UK market.
across the UK.
Development of the fully-recyclable
The packaging, developed in conjunction
skillet sees Greencore deliver on one
with ProAmpac and believed to be the
of the key commitments outlined in
first of its type in the world, marks the
its 2020 Sustainability Report. The
culmination of 18 months of research and development by Greencore. The skillet will have a plastic-free window and be made entirely from paper-based material; crucially, due to the precise level of moisture resistance the skillet provides, it will see products have the exact same shelf life as if they were they packaged in
Sustainability Report also contains a range of pledges across the areas of sourcing, manufacturing, and community engagement. Further commitments include: • All surplus product will be donated to local communities by 2022
Andy Wright, Head of Sustainability at Greencore, commented: “Consumers are increasingly aware not just of the importance of their own health but also of the impact their food has on the health of the planet. Developing a fully recyclable sandwich skillet is one of the key ways we can reduce waste and help our customers do their bit to protect the environment. “This is not a problem we can solve alone, though. The complexities of the
a traditional skillet.
• A deforestation-free supply chain by
Data shows that consumers currently find
• All raw materials will be sustainably
it challenging to separate the plastic film
sourced by 2030
from the packaging of a typical sandwich
• Product development will be equally
enthusiasm for making great food for all,
split between animal protein versus plant-
that’s accessible, healthy and sustainable.”
skillet, meaning that recycling rates are nowhere near as high as they could be. The new skillet’s all-paper construction
2025
rich alternatives by 2030.
will make the process much easier for
It is estimated that some 600 million
consumers. Subject to successful trials,
pre-packed sandwiches are consumed
challenges we face require collective action, inside and outside our industry, and Greencore is pleased to have such supportive customers who share our
Breige Donaghy, Director of Delicious Food, Co-op, said: “We’ve worked closely with Greencore from the start on the development of the compostable sandwich packaging and implemented the first trial of its use in our pop-up store at Glastonbury Festival in 2019 with great success. “The trial aligns with Co-op’s ambition to reduce the use of virgin plastic and how we’ve also worked to ensure that all of our own-brand packaging is now fully recyclable. We’re looking forward to seeing the new packaging on shelves this autumn and are confident it will resonate with our members and customers.” For further information go to www.greencore.com or follow Greencore on social media.
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Machinery Moves, Installation, Relocation and Technical Lifting project expertise for the Food, Beverage, Distilling & Brewing Process Sectors Based in project offices throughout the United Kingdom, the RRS Group is an experienced machinery relocation and installation contractor with significant knowledge in the food and beverage process sectors. Our expertise includes installation and relocation services for projects on tanks, process lines, filling, mixing and bottling lines, packaging systems, distilling process equipment, conveying lines, canning and sealing, plastics, card and corrugated packaging and all associated utilities plant moves. The RRS Group has decades of experience in project planning, health and safety, quality and commercial awareness to meet all sizes of budgets whether a single machine move or a large capex turnkey installation project under CDM Regulations. Our engineered solutions, project management, skilled site personnel and lifting and installation plant/ equipment are the core ingredients to our successfully delivered site projects.
We welcome discussions on budget proposals and future project ideas as well as planned projects or last minute requirements E: info@rapidrs.co.uk T: Projects HQ : 023 92669714 W: www.rapidrs.co.uk
Precision Laser Converting Equipment For Packaging Introducing a brand NEW wide-web equipment series to meet your flexible packaging needs.
Production level automated folding carton cutting and creasing systems using CartonsInMinutes® Flexible laser scoring and perforating equipment for easy open and breathable features Roll-to-roll or roll-to-part converting systems Sheet-fed laser finishing with automated robotic part handling
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16/08/2021 10:14 FDPP - www.fdpp.co.uk 71
Eliminate Manual Handling, Reduce Risk and Improve Safety with a North Ridge Mobile Pump Kit Manual handling is one of the most
zones where product can build up
common methods utilised for the
preventing bacterial growth and cross
transferring of ingredients and waste
contamination when handling different
within wholesale food manufacture. With
liquids. We also ensured the exterior of
over 30% of injuries reported to HSE being
the unit was easy to clean during spray
a direct result of manual handling - when
down by fitting a stainless-steel shroud
the budget is simply not available to
covering both motor and gearbox.
have a fully automated food production
Besides having an integrated inverter
system; handling different products in a safe sanitary manner can often prove quite difficult. Ensuring a production process meets all the current hygienic and food safety regulations is one of the main challenges facing any wholesale food business however one of the most often missed opportunities are investments into automating part of production to improve safety, reduce risk and wastage, increase accuracy or eliminate manual handling. The North Ridge bespoke food grade pump kits are often a solution to this.
CUSTOMER’S REQUIREMENT When a traditional family run bakery established for over 50 years required
for varying flow, the control panel has The customer wanted a bespoke
several other safety and operation
multipurpose solution for their
features, to enable Start/Stop,
processes, which was sanitary grade,
reversing of the unit, alarm for motor
easy to clean, capable of handling all the
overload and temperature control
products in question without manual
sensor to prevent damage from dry
handling, and suitable for high viscosities
running.
and temperatures up to 120 °C.
The inverter can also be controlled via
The unit also had to have a gentle
an App where operators can also view
pumping action due to the shear
the status of the pump, reduce speed
sensitivity of the whipped cream. High
which is essential with some fluids such
temperature liquids can have a negative
as Whipped Cream and further avoids
impact on seals shortening their
the repeated contact of controls by
lifespan, cause issues at pump suction
multiple personnel.
ports and reduce overall pump lifespan if careful consideration is not taken during
PROJECT OUTCOME
pump selection.
Thank to our pump kit the customer improved their production efficiency
a fully hygienic, easy to clean method
Their current procedure involved
dramatically, which in the food industry
to transfer Fruit Jams, Toffee Sauce,
manually transferring sauces via totes
translates as an increase in profitability.
Fruit curds and Whipped cream they
and buckets, however the customer
The layout enabled users to operate
approached us to see if we could help.
wanted to improve their process to
the unit with very little training due to
The variety of products posed a real
automate food transfer, reduce the
the simplicity of design but also built-in
challenge to ensure components did not
likelihood of burns or accidents, and
protection ensures the unit cannot
wear prematurely, that damage could
eliminate manual lifting and tipping of
be damaged through misuse. Social
not be easily performed to the pump and
containers. They needed a custom cost-
distancing has been easy to maintain
that the customer had a low maintenance
effective unit that operates similar to a
through the use of remote controls,
solution.
semi-automatic liquid filling machine.
and as processes are automated less
Some of the products were manually dispensed from cooking kettles at high
OUR MOBILE AUTOMATED PUMP SOLUTION
temperatures into their current process
We supplied a completely bespoke
If you would like to talk to someone
at an average temperature of 100 -
mobile pump system with an integrated
about automating a food transfer
110 °C, whilst other fluids which were
control panel. The pump is 3A sanitary
application contact us on 01773 302
incredibly viscous, were stored within
certified, suitable for CIP (cleaning-
660, or visit our website at www.
refrigerators prior to use and needed
in-place) and SIP (sterilization-in-
northridgepumps.com to see our
pumping from cold to maintain hygiene.
place) and designed without dead
previous case studies.
72 FDPP - www.fdpp.co.uk
personnel are present within confined areas.
We’re pump specialists, so you don’t need to be
Sanitary Pumps Engineered for Your Process Optimise performance with specialist support
Whether you’re dealing with clogging, separation, downtime, or other issue it’s costly. Time wasted troubleshooting and lower production mean missed targets and less profit. A sanitary pump is the solution but choosing the right one feels like stepping into a minefield. You know what you need it to do but with so many options, it’s difficult to know which is best for your process and parameters. ++ Accelerated Accelerated stator stator wear wear ++ Clogging Clogging ++ Changes Changes to to fluid fluid consistency consistency ++ Clean-in-place Clean-in-place and and sterilise-in-place sterilise-in-place hygiene hygiene issues issues ++ Crushing Crushing of of sensitive sensitive products products ++ Inconsistency Inconsistency in in finished finished product product ++ Inaccurate Inaccurate transfer transfer of of flavourings flavourings or or ingredients ingredients ++ Liquid Liquid separation separation ++ Seal Seal wear wear or or failure failure
We’ve We’ve been been engineering engineering sanitary sanitary pumps pumps for for sectors sectors such such as as distilling, distilling, brewing, brewing, food food manufacturing/processing, manufacturing/processing, and and more, more, for for 20+ 20+ years. years. We We understand understand industry-specific industry-specific processes processes and and know know what what itit takes takes to to optimise optimise performance performance through through better-suited better-suited pump pump design design -- giving giving you you complete complete peace peace of of mind. mind.
EXPERT GUIDANCE:
Our Our expert expert engineers engineers understand understand your your process process and and guide guide you you through through the the options, options, so so you you can can confidently confidently select select the the most most suitable suitable sanitary sanitary pump. pump.
Want to optimise performance sooner? Speak to one of our specialists.
+44 (0) 1773 302 660
sales@northridgepumps.com | www.northridgepumps.com
EXAMPLE PRODUCTS: ++ Abrasive Abrasive mixtures mixtures ++ Creams, Creams, milk milk & & ice ice cream cream ++ Edible Edible oils oils & & fats fats ++ Fish Fish & & meat meat ++ Fruits Fruits eg. eg. cooked cooked apples, apples, plums, plums, berries, berries, grapes grapes ++ Grains Grains & & seeds seeds ++ Pastes Pastes & & purees purees ++ Syrups, Syrups, juices juices & & alcohols alcohols ++ Vegetables Vegetables & & peelings peelings ++ Waste Waste eg. eg. trimmings, trimmings, packaging packaging & & offcuts offcuts ++ Sheer Sheer sensitive sensitive liquids liquids ++ Solid Solid laden laden or or viscous viscous mixtures mixtures
Panasonic Minas A6 Multi Servo Drive system: European design, Japanese technology Panasonic’s new MINAS A6 Multi 400V servo drive system has been specially developed for the European market. It has a slim, 50mm wide, book size format and each servo driver can control two axes allowing space requirements in the cabinet to be reduced by up to 64% compared with standard drives. Integrating the MINAS A6 Multi into an EtherCAT interface network is easy and is complimented by 18 integrated safety functions meaning the MINAS A6 Multi complies with SIL / PLe safety guidelines. The systems modular design means multiple drives can be connected to a single power supply and linked with a simple and reliable DC Bus Link system. Low, Middle and High inertia motors are extremely compact where length and weight are reduced by up to 15% over a standard motors and are currently available in the
range of 400W up to 5kW with power levels as high as 22kW soon to be introduced. All motors offer IP67 protection with robust, rotatable connectors complying with IEC, CENELEC, and IEEE standards. The 23
bit encoder offers high resolution in both absolute and incremental mode with battery less absolute operation supported. For more information contact Bob.Norfield@eu.panasonic.com
The new bar code reader. Perfect performance on the conveyor line. Our new BCL 200i bar code reader is specialized for guided container and tray identification. Its especially compact design is optimally tailored for stationary use in confined spaces. Integrated industrial interfaces and simple configuration offer you perfect performance at the best price.
www.leuze.com/bcl200i
210312_LEU20025_Anzeige_BCL 200i_148x210x3_EN.indd 1
74 FDPP - www.fdpp.co.uk
15.03.21 15:55
Precise performance cooking for outstanding results Industrial cooking technology has come a long way since GEA introduced the world’s first two-zone spiral oven in 1992. The latest model, the CookStar 1000 Gen 3, provides powerful new technology for the mass production of roasted, breaded and smoked products.
Intelligent exhaust systems monitor the environment within the oven, adjusting the volume of air as needed to maintain the precise conditions required for optimum cooking. Using energy exactly as and when it is needed, this technology reduces heat and steam losses, reducing power consumption.
The CookStar cooks powerfully yet accurately, maximizing yields using smart technology that continuously adapts, maintaining the optimum oven conditions for each product. Its three-zone cooking method controls the flow of air through the oven for consistent browning, and an enhanced impingement zone allows a higher air volume for greater efficiency.
Operating at a high dew point, the first phase uses steam to cook quickly and gently, keeping the meat succulent. Then the impingement zone blasts the product with hot, dry air, preparing the surface for roasting without drying out the core. The final phase, with a much lower dew point, completes the process, cooking products to perfection.
The CookStar’s ability to accurately control the cooking parameters is making this latest model the increasingly popular choice for industrial cooking. The CookStar 1000 Gen 3 is the only spiral cooker on the market which can dry, steam, cook, roast and smoke products in a single machine. Capturing the authentic flavors of the perfect joint or roast chicken requires the right timing, airflow, dewpoint and temperature. In most commercial ovens, the optimum setting for any individual product is a compromise: a high dewpoint improves yield but prevents browning; while a lower dewpoint browns the meat but dries it out. However the CookStar 1000 comes with built in smart climate and exhaust systems allowing increased flexibility and sustainability.
The dewpoint within the CookStar’s two cooking towers can be managed precisely by injecting steam or opening fresh air gates, and each cooking tower can operate independently, so different products can be cooked simultaneously using the same equipment. For smoked products, freshly generated smoke from condensate can be included in the airflow of the CookStar, combining the smoking and cooking processes, reducing process time and the need for manual intervention associated with traditional smoking methods. GEA’s CookStar 1000 Gen 3 offers food processors even more flexibility. Its intelligent systems allow greater control, high productivity, sustainability, reliability and consistency of outcome. gea.com/contact
Learn more
From left to right IM GROUP members: Silvio Cimenti, Global Director of Branding and Marcom; Gianluca Incerti, Global Commercial Director; ChristopheRizzo, CEO EMEA/AMERICAS; RemoCareglio, Area Sales Manager (retired): ValentinaCigna, President and Global HR Director; RobertoGuerra, CEO Asia Pacific; FrancescoNesti, Global Director of Software & Automation; EnricoMattiazzi, Global Director of Engineering, Production and Supply Chain
Inkmaker group rebrands as IM group Inkmaker Group has announced it will
“this is the evolution of Inkmaker Group,
officially be known as IM GROUP. The
which is essentially that of Inkmaker.”
launch, filmed on location at Inkmaker’s
Gianluca Incerti, Global Commercial
headquarters in Turin, Italy (now also
Director, IM GROUP explained that this
headquarters to IM GROUP), was
was one of the key reasons for forming
screened for private viewing on Youtube
IM GROUP. “Our strategy is to create
to coincide with World Earth Day to
“areas of excellence” dedicating each of
emphasise its commitment towards sustainability. The decision to rebrand Inkmaker Group as IM GROUP aligns with the group’s vision, of evolving its technology to
reliable complete supply chain—serving predominantly, but not only, the ink, paint and coatings industry—to sustain our core businesses,” explained
expand in its fields and adapt, the
Christophe Rizzo, CEO EMEA/Americas,
advantages of its products, to new
IM GROUP.
markets.
This meant restructuring the group’s
our brands to a specific expertise. In this way each brand still works individually, with its existing clients in its own markets, and when required shares that expertise—offering Total Solutions— when for example, working on large turn-key plant engineering projects. This guarantees resource optimisation and high flexibility to manage projects of all
“Since October 2019, Inkmaker has
brands into various specialities, yet
made significant investments, on
to still function as one strong force,
the acquisitions of the businesses of
hence the need to rebrand the existing
With the restructure of IM GROUP’s
Rexson and Valtech, in UK; Tecnopails,
Inkmaker Group brand, to have an
brands—Inkmaker will focus on ink
in Italy; and most recently Swesa, in
identity of its own, as an autonomous
dispensing and software design; Rexson
Germany. The driving strategy behind
holding brand positioned as a “Total
will be predominantly for paint as well
these acquisitions was to create a
Solutions Provider”. As Rizzo highlighted,
as liquid ink, Vale-Tech will focus on
76 FDPP - www.fdpp.co.uk
sizes,”
The move comes at a time of great evolution, on all fronts for the group, and in all of its locations globally. narrow-web and paste-ink dispensing; Swesa mainly for; food, pharmaceutical, corrugated packaging, cosmetics and more; Teko will remain in POS Tinting and R&D Training and; Tecnopails for Filling Solutions. The new identity—inspired from the Inkmaker logo—was designed by the group’s inhouse corporate communications division, THINK. “The focal point of IM GROUP’s new logo is a symbol of a face created from a series of triangles, that like the many brands and skills of our Group, converge to form a strong whole—a distinct ‘human identity’—depicting a technological engineering leader with a ‘human touch’.
“IM”, acronyms deriving from the name
units, which is where IM GROUP’s R&D
“Inkmaker”, which are steeped in history
is investing a lot of resources. Smart
as Valentina Cigna, Global Director of HR
factory and Industry 4.0 are driving our
and President of IM GROUP outlined,
growth and when you build complete
“they recall not only Inkmaker—as the
production lines for a paint and ink
founder of the group—but also those
company it’s important to have enough
who, in 1987 founded Inkmaker; Carlo
space to work in total safety.”
Musso, Luciano Longobardi and— especially for me—my father, Giuliano
Safety at the workplace has always been
Cigna. He would have been very proud of
a high priority for the group, along with
this moment.”
technology, but it is also evolving the way in which its products are impacting
The face is embellished with a crown,
The move comes at a time of great
representing the Group’s determination
evolution, on all fronts for the group,
to maintain its leading position in the
and in all of its locations globally. The
industries it serves,” explained Silvio
global organisation is rapidly gaining
“This was the reason for choosing to
Cimenti, Global Director of Branding,
market share across South-east Asia
launch IM GROUP, on “World Earth
Marketing and Communications, IM
especially in Philippines and Vietnam
day”, to make a global statement of our
Group, “The Colour of Trust”— the
and as Roberto Guerra, CEO Asia Pacific,
commitment in furthering our social
IM GROUP highlighted, “The big one
responsibility and sustainable practices.
for us is of course China, due to our
To action this, IM GROUP is partnering
Group’s credo— is a result of its core values of being Truthful, Responsible, Understanding, Safe and Tailormade to ultimately position the group, as the
larger premises, we can now double the number of standard machines we
leader you can T R U S T.”
ship monthly, from an average of 5 or
Great attention was given to the name
this permits us to build more complex
6 units to 10 to 12. More importantly,
the environment and the carbon footprint they leave.
with international consultants to create a roadmap to reduce our eco-impact and to align our ethical principles for a safe work environment with those of the United Nations’ Global Compact.” concluded Valentina Cigna, Global Director of HR & President of IM GROUP. “Due to its acquisitions, Inkmaker grew by 25% globally. Taking into account the current challenges the pandemic has caused; this is still on track with our vision. Now having the holding brand, IM GROUP—to steer all our speciality brands—we foresee all our brands to grow exponentially.” Concluded Rizzo. For those of who missed the launch, it can be viewed by clicking this link: https:// im-group.com/our-business.html im-group.com
FDPP - www.fdpp.co.uk 77
Gentle pumping of critical fluids with Roto’s progressive cavity pumps & AODD pumps spares. Also, Roto Pumps UK has established an intensive network of distributors and channel partners. 15 years of experience in the European market, Roto Pumps has demonstrated its expertise in application engineering i.e. understanding of complex pumping
ROTO PROGRESSIVE CAVITY PUMP TRANSFERRING HONEY
RAODD Pump in SS 316 MOC
Applications in Food, Beverages, Pharma
Pressure – Up to 10 bar
and Cosmetics industries require
Capacity – Up to 60 m3/hr
sensitive, abrasive and highly viscous
CLEANING –IN –PLACE (CIP) TECHNOLOGY
media with zero contamination. Roto’s
Cleaning is an important aspect while
food range progressive cavity pumps are
designing food grade pumps. Roto’s
made of stainless steel with the smooth
CIP feature enable pump operators to
surface finish to avoid contamination.
clean the pump by running a cleaning
These pumps are designed in a way that
agent i.e. caustic, acid or simply water
eliminates all retaining pockets.
to avoid any contamination with ease.
pumps that can transfer hygenic, shear
The rotor and stators are designed
requirements, handling critical media, optimizing pump life cycle cost.
KEY CAPABILITIES OF ROTO PUMPS UK • 15 years of strong presence in Europe • Robust supply chain network • Strong sales & service support team in the UK • Readily available pump & spare parts Stocks • Cost-effective & customized engineered packages.
C
M
Y
CM
These pumps offer a distinctive edge
to be compatible with media as well
over other positive displacement pumps
as cleaning agent. These pumps are
We at Roto Pumps believe in customer
CY
as it can be customized in wide throat
equipped with the appropriate drain or
delight; we have a team of experienced
(standard hopper & oversized hopper)
CMY
bypass system.
application & sales engineers in the UK
design which helps in transferring nonflowable fluids such as syrups, shampoo, wine must, ketchup, yogurt, dough, meat, vegetables, etc.
PRODUCT RANGE FOR FOOD & BEVERAGE INDUSTRY
ROTO PUMPS UK| 15 YEARS OF DELIVERING POSITIVE DISPLACEMENT PUMPING SOLUTIONS
Dave Bent Unit 1, St Elizabeth Park, Grey Street,
assembly infrastructure to provide
Denton
which can slow any new company’s progress. But Roto Pumps Ltd. was not new; it had a rich experience of over four decades with a maximum number of screw pump installations in critical applications across the globe. To gain a strong foothold in the European Market, Roto Pumps focused on providing customized engineered
WM Series Progressive Cavity Pump
pump packages, strong service support
Capacity – Up to 86 m3/hr
and ensuring ready availability with
Pressure – Up to 24 bar
optimum stock levels of Pumps &
78 FDPP - www.fdpp.co.uk
providing prompt after-sales support.
branch in the UK with warehouse and
New Market had its own challenges
Pressure – Up to 24 bar
concern right from receiving inquiry to
Roto Pumps Ltd. UK
to various industries across Europe.
Capacity – Up to 86 m3/hr
who completely take care of customer’s
2004, Roto Pumps Ltd. established a
positive displacement pump solutions
DM Series Progressive Cavity Pump
MY
Manchester UK, M34 3RU Tel: +44 ( 0 ) 161 477 5511 Mobile: + 44 ( 0 ) 7778 637343 E-Mail: davebent@rotopumps.co.uk www.rotopumps.co.uk
K
RELIABILITY MATTERS THE MOST KEEP YOUR FOOD & BEVERAGES INDUSTRY RUNNING AT ALL TIMES!
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Industries We Serve: Sugar • Biogas • Paper • Wastewater • Oil & Gas • Marine • Mining & Explosives• Paints • C hemicals • Food & Beverage
ROTO PUMPS UK www.rotopumps.co.uk | Email: sales@rotopumps.co.uk Global Presence : Australia | India | United Kingdom | South Africa | USA | Germany | Malaysia
What is the best conveyor belt for food safety? Running a food processing plant is
when using open conveyor systems:
not an easy task, not least because
choosing the right conveyor design,
of the complexities of dealing with
choosing the right food contact material
food safety and hygiene. This makes
to match the process conditions and
choosing the right conveyor belt to use
selecting belts that support ease of
in food processing applications a crucial
cleaning.
task. Here Anna Marcol, marketing communications manager at conveyor
A conveyor design supporting sanitary
and power transmission belt specialist
needs is one that provides easy access
Habasit, shares insights from a recent
to belting from all sides, to allow
webinar delivered jointly by experts from
operators to inspect, clean, sanitise
Habasit and NGI, who discussed how
and validate effectively. When selecting
hygiene-rated equipment and the right choice of belt type and material, are
hygiene standards in accordance with
crucial in achieving food safety.
industry guidelines such as 3-A, NSF or
While food plant managers do a good job of keeping their facilities clean, food debris and microbes can still find their way into the smallest of dead spots.
EHEDG, as well as being compliant with the food contact regulations by the FDA or EU 1935/2004, and other national regulations.
Bacteria can harbour on and in conveyor
Hygiene certified components consider,
frames, under equipment, under the belt,
among other factors, the cleanability
or even in the small gaps of a plastic
of surfaces, preventing ingress and the
modular belt. What’s more, they can elude even the most rigorous cleaning cycles, leading to excessive use of detergent, water, time and energy. When thinking about food safety and hygiene, food processing professionals should consider two key areas: hygienerated equipment and the right choice of food-contact elements, including belt type and material.
HYGIENIC APPROACH In open conveyor systems, food debris can contaminate surfaces and get into crevices and internal support structures over time. While effective cleaning and sanitation plans reduce contamination, equipment and components designed specifically for hygiene can take less time, water and cleaning agents to clean and
growth of microbes in dead spaces, selfdraining surfaces or on levelling-feet or castors and much more. However, these measures are only a means to an end. We wanted to share our experiences and participate in the dialogue on food safety, so Habasit’s Hygiene Program Manager, Bernd Roser recently delivered a webinar on food safety jointly with Niels Vindsmark, Sales and Brand Owner
the right food contact material, it’s important food processors choose a belt that doesn’t change its mechanical properties or wear quickly when regularly exposed to harsh, chemicalbased cleaning cycles, at elevated temperatures and with extended contact times. To support engineers in identifying the chemical resistance of various belt types and materials, Habasit has created a free online tool to help users decide the best belt for them. For applications exposed to very demanding hygiene conditions, Habasit has also developed Super HyCLEAN, a plastic modular belt that minimises the use of rods and hinges to aid cleaning, ideal for applications such as fish and poultry.
Program Manager at hygienic component
Whatever the food processing
manufacturer NGI.
application, choosing the right conveyor
In the webinar Niels explained, “Applying hygienic certified components will not avoid an outbreak, but the more problems you can eliminate and the more certified hygienic components you have in your production facility, the less places you have to look at and worry about if you
belt, and ensuring equipment is designed with hygiene in mind is pivotal. Not only will it help food processors comply with industry standards, but it will also ensure the industry can continue to reduce the dangers of contamination – and make it easier for plant managers to run their facility.
sanitise.
have an outbreak.”
Therefore, equipment and components
BELTING
should be appropriately hygiene certified
Bernd Roser pointed out that food plant
webinar on demand for free, visit
for food. This includes meeting minimum
managers should consider three areas
https://bit.ly/FoodConveyorWebinar
80 FDPP - www.fdpp.co.uk
To find out more about choosing the right conveyor belt and to watch the
SOLAR PANELS AND CLEAN ENERGY A typical solar panel system will provide free electricity for more than 25 years, achieve financial returns of more than 12% per annum and pay back installation costs within 6-8 years. Get a free, no obligation quote delivered safely to your inbox We provide detailed economic efficiency calculations to ensure you understand exactly how and when you can expect to break even, the structure of repayments and the overall profitability for your business in the long-term.
Solar Panels | Energy Storage | Heat Pumps | Solar Thermal | Solar Carports | EV Charging
Powering the UK towards a clean energy future. With typically large expanses of unused roof space and colossal energy bills, manufacturing, processing and packaging companies are a perfect case for installing clean energy solutions to deliver financial savings, carbon reductions and energy independence. The Tracklements Company are a food manufacturer based in the heart of Wiltshire. The award-winning company is dedicated to sustainable food production and only use 100% renewable energy.
149.81KWP SOLAR PV SYSTEM
In the summer, Tracklements operate on 100% clean electricity generated from their solar panels, with enough surplus to charge their electric fleet. For the winter months, the organisation has partnered with Good Energy to ensure that the energy they import to top up with is entirely sustainable. “We decided to generate our own clean electricity because we wanted to reduce both our operating costs and our impact on the environment. The new system is working really well. We’re very pleased with it.” Becky Vale, Marketing Director, Tracklements.
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To get a free, no obligation quote or for more information visit our website or contact us today. Email: info@solarsense-uk.com Visit: www.solarsense-uk.com
Mettler-Toledo announces Open House at new Global Centre of Excellence, helping customers improve product safety and profitability Food and pharmaceutical
Ian Robertshaw, Global Key
manufacturers and co-
Account Manager and Adam
packers can attend the
Green, Market Manager both
Product Inspection Open
from Mettler-Toledo Product
House at the new Global
Inspection.
Headquarters for x-ray in person or virtually,
“We are really excited to officially
participating in a range
open and showcase our new
of seminars, technology
Global Centre of Excellence for
demonstrations and
x-ray inspection at our Product
consultation sessions.
Inspection Open House event.
Royston, Hertfordshire, UK, 1st September 2021 – Mettler-Toledo Product Inspection will showcase new product inspection technologies, offer opportunities for face-to-face and virtual consultations, and deliver educational seminar content, at
can book a free personalised 1-2-1
The new Global Headquarters has been
consultation, either virtually or in-person,
specifically designed to become Mettler-
enabling their teams to tap into Mettler-
Toledo’s main hub for x-ray research and
Toledo’s expert knowledge of areas
development plus manufacturing x-ray
such as compliance, product safety and
innovations. The significant investment
digitalisation.
we have made into developing the x-ray
an Open House event which will officially
Mettler-Toledo’s latest product
open the new Global Centre of Excellence
innovations will take centre stage, with
for x-ray in Royston, Hertfordshire.
1-2-1 customised live demonstrations
Mettler-Toledo Product Inspection’s new x-ray manufacturing facility in Royston, Hertfordshire sets the business up for continued expansion over the next decade and more. Set across a 1.4-hectare site, it expands the company’s UK manufacturing
of a new metal detection system, a new x-ray inspection machine as well as the latest C33 Series checkweighers with FlashCell™ load cells and demonstrations of our vision inspection solutions and ProdX™ data management software.
footprint by more than 80%, enabling
The event will also include two educational
multiple development projects to be
seminars, both running at 8am and 2pm
handled simultaneously. The facility
(BST) on their respective days:
will also help to expand the customer experience, with new factory acceptance testing rooms and a production
Wednesday 6th October - How Product Inspection Innovations Improve Food
business is part of our strategic business development plans and is in response to customer demands for us to continually design x-ray inspection technologies to improve packaged product safety,” said Niall McRory, Global Key Account Manager at Mettler-Toledo Product Inspection. “Meeting customers and prospects faceto-face has obviously been difficult over the last year and a half, and we are very much looking forward to interacting with them again at our October Open House event, either in person at our new Global Centre of Excellence or virtually,” continued Niall McRory. “We’ve got a lot of gamechanging new innovations to show them,
observation area.
Safety and Automate Quality Processes
The COVID-safe event will take place over
ECPA, featuring Ton Knipscheer of the
6th and 7th October 2021, giving brand
European Co-Packers Association (ECPA);
owners, manufacturers and contract
Rob Rogers, Senior Advisor Food Safety
packers in food and pharmaceuticals
& Regulation and Niall McRory, Global
manufacturer, and that’s where our focus
the opportunity to experience the latest
Key Account Manager both from Mettler-
will be during this event. Whether they are
innovations and best practice in x-ray,
Toledo Product Inspection.
in food or pharma, there will be something
metal detection, checkweighing and vision inspection, as well as discussing their specific product inspection needs and
for Contract Packers – co-hosted with
as well as some inspirational educational opportunities to share. The challenges of product safety and operational efficiency remain front and centre for every
for every customer and prospect at the Thursday 7th October – Good Inspection
Open House, so we hope they will mark
Practice: 6 Steps to Preventing Physical
the dates in their diaries.
challenges with a Mettler-Toledo expert.
Contamination – co-hosted with BRCGS, featuring John Figgins, Senior
For more information, visit
Manufacturers and contract packers
Technical Manager from the BRCGS;
www.mt.com/pi-open-house-2021
82 FDPP - www.fdpp.co.uk
Waste Water Treatment Plants DAF Systems Biological treatment Moving Bed Bio-Reactor Plant upgrade & revamping Design, Installation & Comissioning Remote Monitoring & Maintenance
Puretech Environmental : Astra House, Cranleigh, GU6 8RZ T : +44.(0).1483 266 604 / info@puretechenvironmental.com
Specim Hyperspectral Cameras for the Food Industry INSPECTRA – Bringing Fresh Ideas to Food Quality Inspection Applications Include: Inndeo, a Spanish company founded in 2016, uses Specim’s hyperspectral imaging technology to improve the quality inspection processes in the food industry by increasing automation. With this new technology, they can detect contamination and defects in the production lines and characterise different food quality parameters. Click here to learn more about: • Replacing manual labour and old equipment with sensor fusion • Advancing from detecting defects and contamination to quality parameters • Further applications
FX Series:
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SPECIM DISTRIBUTOR IN THE UK AND IRELAND:
Quantum Design UK and Ireland Ltd Tel: +44 (0)1372 378822 Email: info@qd-uki.co.uk
For more information visit
qd-uki.co.uk/imaging-cameras
Norsk Kylling Designs Future of Food with Infor Infor have announced that Norway-based poultry producer Norsk Kylling has selected the Infor EAM enterprise asset management solution. Already live at its Støren-based operations, the solution will be extended to a new 40,000-square-meter state-of-theart factory in Orkanger to support higher equipment availability, reduced costs and tighter inventory management for the food company. Working with Infor partner Prevas, Infor EAM is expected to go live upon facility completion in spring 2021. Learn more about Infor EAM: https://www.infor.com/en-gb/ products/eam Norsk Kylling manages its entire value chain for chicken production, from brood and hatcher egg production, to hatchery, broiler production and processing, as well as owning the Solvinge chicken brand. Its new facility will represent best practices and innovation in food production, encompassing the highest animal welfare and environmental standards, and supporting the circular economy. Against this backdrop, digital capabilities and automation were intrinsic to the new facility’s design. Having selected an ERP platform for greater control over production and the value chain, Norsk Kylling set out a requirement for a maintenance system which could limit waste and reduce costs. “Excesive downtime can have far-reaching consequences in our business, so opting for a solution that can help ensure high
84 FDPP - www.fdpp.co.uk
availability of equipment and productivity across the factory is paramount,” comments Ulf Jensen, Norsk Kylling technical manager. “In addition to cost savings, a comprehensive view of equipment status, and higher availability, Infor EAM will also give us greater control over spare parts and stock. We have more than 3,000 units in the plant register and up to 15,000 parts in the article register, therefore the automatic ordering capability within Infor EAM will help us to optimise availability without incurring unnecessary costs.” “The right digital capabilities are absolutely paramount for modern food producers, particularly those in categories that are managing tight shelf lives and significant waste,” comments Infor’s Johan Made, executive VP for the Nordics. Visit www.norsk-kylling.no
How an ERP Can Help Your Business Successfully Transition to More Sustainable Packaging Options
Over recent years, the push for
in the most cost-effective way. The Food
More than 1,000 food and beverage
sustainable packaging for the food
and Beverage ERP solution designed
customers already use Aptean’s solutions,
and drink industry, driven by consumer
by Aptean, is an integrated software
built on the Microsoft Dynamics 365
demand, has led to food manufacturers,
platform which brings together all
processors and packaging companies rethinking how they package their products. With 67% of consumers globally thinking that it is important that products come in recyclable packaging, and 54% saying it is
aspects of your business, and technology stack, providing you with accurate and consistent data exactly when you need it.
ABOUT APTEAN As a leading provider of industry-specific
platform, allowing them to unlock the benefits of a reliable and scalable platform to underpin their business, and its growth plans. With over 20 years’ experience in the UK market, we have helped many companies to transform their business to continue to
software, Aptean’s Food & Beverage ERP
remain competitive and ensure that they
utilising sustainable alternatives to
is designed to meet the particular needs
are delivering best practice for today’s
single-use plastics is a key concern
of the food and drink industry. Our ERP
priorities.
for those who work in food and drink
provides you with full control of your
packaging.
growing business while also retaining
an active consideration when shopping,
There are many options available when it comes to looking for sustainability in packaging including: utilising paper packaging, reducing packaging volume, introducing refillable packaging, and
all the flexibility you require to respond dynamically to any new trends in the fastmoving food industry, from the increasing
Join Aptean on October 5th for our 2021 Food and Beverage Global Symposium to discover more about how we can help your business to scale and succeed.
popularity of plant-based foods to the
Website: www.aptean.com
demand for sustainable packaging.
Email: info@aptean.com
incorporating recycled plastics into packaging. However, evolving current practices doesn’t come without challenges, but this is where complete visibility of data and processes in one place can be extremely beneficial for businesses who are looking to implement these changes. An ERP (enterprise resource planning) solution provides your business with the perfect foundation to help you integrate new packaging materials and technologies
FDPP - www.fdpp.co.uk 85
Proseal’s decade of success with Procare customer support programme Tray sealing specialist Proseal is celebrating the tenth anniversary of its successful preventative maintenance programme, PRoCARE®, as the company continues to fulfil its longstanding commitment to delivering outstanding customer support. Launched in 2011, PRoCARE provides comprehensive aftersales service through a series of scheduled inspections and maintenance of equipment in order to minimise unexpected and costly downtime. A decade later, PRoCARE has become so successful that Proseal has established a dedicated department to co-ordinate the programme to ensure continuity of service and speed of response are maintained. “In today’s fiercely competitive markets and where consumers are expecting new products faster than ever, manufacturers need to be able to rely on their machinery to function at optimum capacity,”
Having proactive preventative maintenance support can help to significantly reduce these risks and prevent unnecessary food waste.”
while driving up efficiency: a wellmaintained machine is less likely to breakdown. The feedback has been overwhelmingly positive. Most customers have reported huge reductions in downtime as a result of going from reactive maintenance to proactive PRoCARE.
explained Daryl Henshaw, Proseal’s Key
of our business,” confirmed Bakkavor’s
“Equally important is how we have been
Accounts Manager. “Loss of production
Group Engineering Manager, Ben Cooper.
able to adapt the service to deal with
for any reason means a loss of sales,
“Indeed, the level of aftersales support
the specific challenges of the COVID-19
profit, and potentially food. Having
we receive from Proseal is often used as
pandemic. Our team were able to put in
proactive preventative maintenance
something of a yardstick for our other
place stringent procedures and provide
support can help to significantly reduce
suppliers.”
PPE to our workforce, which allowed
these risks and prevent unnecessary
for maintenance visits to continue,
food waste.”
Bakkavor has remained a participant
underlining our genuine commitment
in the PRoCARE programme since its
to customer support, whatever the
Proseal’s PRoCARE provides both on-site
inception. During this time, the company
situation.”
and remote service and advice that helps
has continued to roll out PRoCARE across
to maximise machinery performance
six of its largest UK sites, and the number
and uptime. Recognising that food
of machines that Proseal is overseeing
manufacturing is a year-round operation,
has increased from around 30 to over 80.
solutions provider to high-value
Another indication of the success of the
industry, committed to providing
the service is available 24/7, 365 days a year.
Proseal is part of the JBT Corporation family, a leading global technology segments of the food processing
programme is that every Proseal key
a service that surpasses customer
For major food manufacturer, Bakkavor
account customer is a participant, and
expectations. PRoCARE service contracts
Group, investing in PRoCARE has played
the PRoCARE division is now carefully
are available across all JBT machinery
managing around 80 active contracts
solutions, built to maximise uptime and
covering over 400 machines.
financial predictability, with the goal to
a key part in enhancing the efficiency of its operations. “Given the nature of our industry and where Proseal machinery
reduce total cost of ownership.
sits within our group, the continued
Daryl Henshaw concluded: “PRoCARE is
support of Proseal is key to the success
about reducing the risk of breakdowns,
86 FDPP - www.fdpp.co.uk
www.proseal.com
Automate with PALpack PALpack are the UK’s leading experts in Palletisers, de-palletisers, AGVs and sack fillers. They design, advise and supply top of the range machinery from European manufacturers. Once delivered, PALpack install and commission these machines and offer service contracts as well as backup and support from their offices and workshop. Adapting business processes has always been the way to compete, but it’s more important now than ever to future-proof. Automating a repetitive manual process in a production or manufacturing facility means fewer mistakes are made, there’s a faster speed of work and no breaks, plus health and safety is increased. Automation is also scalable, can be integrated into existing systems and will increase your productivity.
Adapting business processes has always been the way to compete, but it’s more important now than ever to future-proof. CONTACT
PALLETISERS AND DE-PALLETISERS
PALPACK
A critical part of the manufacturing
Choose a
process, palletisers automate the
supplier that
stacking process that can otherwise be
is an expert in
labour intensive and expensive, putting
automation and
undue stress on workers. They’re
engineering
designed to be configured alongside
project
the other production line facilities.
management.
PALpack’s palletisers are capable of
Beyond the
assembling pallets, as well as palletising
machine they’re selling, they need to
different items simultaneously and are cost-effective to install. De-palletisers
SACK AND BAG FILLING
are machines that unload items from
Bag filling machines automate the
pallets and are used to transport parts from one line to another during manufacturing. AUTOMATED GUIDED VEHICLES (AGVS) AGVs are robotic vehicles used to perform operations that would otherwise be carried out manually, or by forklifts and conveyors. PALpack’s partners at Global AGV recently
material handling, filling, sealing and weighing of packaging bags or sacks with optimal efficiency and accuracy. SUPER-DEDUCTION INCENTIVE ON AUTOMATION MACHINERY There’s never been a better time to invest in upgrading your machinery. From April 2021 until March 2023, the UK
announced that the payback period for
government is offering 130% capital tax
some of its automated guided vehicles is
allowance deduction on qualifying first-
less than one year.
year plant and machinery purchases.
understand your space, scope and the wider implications within your manufacturing environment. PALpack has been improving manufacturer productivity with automation for 25 years. For specialist advice and guidance on the equipment that will best suit your business’ needs, contact PALpack today. www.palpack.co.uk sales@palpack.co.uk
FDPP - www.fdpp.co.uk 87
Ready for business: PPMA show 2021 In a few weeks’ time, PPMA Show 2021 will return to the NEC Exhibition Centre in Birmingham, from September 28th30th. As the first major PPMA live event since September 2019, following the postponement of all live events in 2020 and early 2021 due to the COVID pandemic, exhibitors and visitors are getting ready to do face-to-face business. With a focus on supporting the processing and packaging communities with sustained business recovery following the challenges of the last year, PPMA Show 2021 will bring together
out to support our community’s
hand to discuss the latest technological
over 250 exhibiting companies, offering
business recovery.”
innovations and advantages in IO- Link
businesses a long-overdue opportunity to see emerging technologies and
Renowned by the industry as a platform
Sensors, solid state relays, motor soft starters and energy management.
explore the latest trends in the industry.
for launching new products, the 2021 show will be no exception, with multiple
• Responding to manufacturers’ end-
Recent research conducted among
exhibitors announcing plans ahead of
of-line labour challenges including staff
PPMA’ audiences reveals a strong
the show:
shortages, social distancing measures
appetite for the live event, with 70% of
and self-isolation, OMRON UK (Stand • AVE UK (Stand B40) will showcase two
B34) will show the RB1200 cobot
innovative solutions for the food and
palletiser. Developed in partnership
making future product purchases.
beverage sector with the launch of the
with OMRON’s automation partner
OMNIA B cross flow filtration system
Reeco, the systems offer a 50% cost
Leading exhibitors at the show include:
for brewers and a mozzarella ball
saving, rapid delivery within weeks,
Winkworth, Ulma, AVE, Evolution Bottling
processing line for processing and dairy
as well as modular plug-and-play
and Packaging, Mettler-Toledo, Ilpra,
visitors. The OMNIA B system delivers
system architecture. The RB1200 has a
Holmach, Stellar-Technik, Endoline and
beer clarification, product recovery
maximum payload of 10kg and a cycle
Brillopak.
and microbiological stability. With the
time of 12 picks per minute. It requires
mozzarella ball processing line due for
no system integration and has a 60%
delivery to London-based mozzarella
smaller footprint than conventional
manufacturers, Fratelli Amodio, this will
robot palletisers.
respondents seeing trade shows as an essential platform for reviewing and
Richard Little, Show Director of PPMA Show 2021 comments: “Although online platforms help people to gather information about products, our research shows that visitors want to move on from virtual product launches and events to get closer to the technologyhands-on and to speak face-to-face
be the only opportunity to see the line.
• Digital coding innovator Clearmark
• Fortress Technology (Europe) Ltd
(Stand D72) is celebrating its 20th
(Stand BO1) will debut its new zero-
anniversary with the launch of the ICE
contaminant pandemic-recovery Raptor
Vector Pallet Labelling System. The
Series including X-Ray first.
system includes unique engineering
The appetite for investment is definitely
• Carlo Gavazzi (Stand G80), a leading
controlled cabin to ensure consistent
there, as well as the enthusiasm to
manufacturer in industrial automation
print quality, a robust long-reach
resume business as usual. We’re setting
and energy management will be on
cartesian-style arm, guaranteeing
with product and application experts.
88 FDPP - www.fdpp.co.uk
differentiators such as a climate-
GS1 specification label placement in all
solved one of the biggest barriers to fully
• Ishida Europe Ltd (Stand D40) has
pallet configurations and a dual operator
recyclable secondary packaging for the
introduced a holistic complete product
interface and intelligent I/O system.
food and drink sector with the launch of
offering across its entire X-ray portfolio
• Dustcontrol UK (Stand E30) will be
ITF labels.
the Trakcoder, a low carbon alternative to
showcasing its upgraded GFF (Good For Food) range of food and pharma
• Brillopak (Stand H26) will showcase
grade dust extraction equipment. The
its new UniPAKer robotic crate packing
range is designed to offer efficient dust
platform, its most compact and energy-
extraction and cleaning of food contact areas while opening up new recycling possibilities. • Olympus Technologies (Stand A94) is launching an upgraded Universal Robot Palletising System. • Launched in 2020, Ehcolo (Stand F102) is giving visitors the opportunity to see
efficient system to date.
for larger robots. The new range of axes - 3 single-axis and 2 double-axis – introduces the belt drive with zerobacklash pulleys, simplified handling and overall efficiencies by positioning the motor on board the machine, reducing the overall weight and avoiding the need to manage cable handling. • Yamato Scale Dataweigh (Stand B14), a global manufacturer of product inspection equipment is excited to unveil its new Epsilon range of Multihead weigher, dubbed the new ‘Stick’ machine, as well as its x-ray inspection machine, the TSDN-3. On show will also be a new range of hygienic checkweighers. • Secondary packaging company, TrakRap (Stand B26) believes it has
COVID PRECAUTIONS Participants can rely on all the necessary to COVID and, to reassure visitors with
Endoline Robotics (Stand D 50) is set to
regards to cleanliness and safety, the
demonstrate the benefits of automation,
NEC has introduced advanced cleaning
and the quick return on investment which
measures and hand sanitising stations
can be achieved. • Lifting equipment specialist Lift Safe
self-propelled MA50 is designed for use
enhancement of the range intended
per annum over a 5-year period.
& Play’ robotic palletising system,
• Rollon (Stand J36) has expanded its
robotics market, as well as an
Cost of Ownership (TCO) of less than 3%
health and safety precautions relating
(Stand F74) is showcasing one of its new
aimed at the light and collaborative
mind and delivers a guaranteed Total
• Showcasing its entry level, ‘Plug
its stretch hooder.
seventh axis range with an offering
that provides customers with peace of
ranges of mobile access platforms. The by one person, providing a maximum working height of five metres • UK barcode labelling automation
are located at all entrances of the NEC and at numerous locations around the venue. Physical touchpoints will be reduced throughout the show and there is also ample outdoor space at the NEC for visitors wanting to get some fresh air and to take a break from the exhibition floor during their visit.
manufacturer, Cobalt Systems (Stand
There will, of course, be differences in
B64) will showcase its industrial
the way the 2021 event runs compared
automation solutions.
to previous years. For example, on-site
• Engilico™ (Stand H52), a pioneer in non-destructive in-line seal inspection for flexible packaging, presents a new tray inspection solution. The inspection solution uses hyperspectral imaging (HSI) technology to detect contamination in the seal of trays with a much higher contrast than standard vision cameras. • Travtec (Stand J40) is introducing new additions to their conveyor accessories range • Piab (Stand G12) are thrilled to present
catering provisions have been modified and we’re also advising visitors travelling to the show to limit what they bring. Pre-registration will be compulsory for all visitors this year register and visitors should follow the latest local guidance at the time of the show with regards to face masks, isolating and symptoms to ensure the safety of themselves and others in attendance. Registration for the PPMA Show 2021 is now open.
a wide selection of new products
To register for your FREE visitor badge,
developed to complement their existing
visit the PPMA Show website at:
range of solutions.
https://www.ppmashow.co.uk
FDPP - www.fdpp.co.uk 89
Advanced Engineering is back with a bang in 2021 The UK’s largest annual gathering of
of new business relationships after 18
morning dedicated to space and satellite
engineering professionals, Advanced
months of limited interactions.
engineering, with talks from the UK
Engineering, will return to the NEC, Birmingham on November 3 and 4, 2021. Here, the UK’s talented and vast
There will be four forums held during the two-day show, featuring some of
Space Agency, Skyrora, D-Orbit UK and the Space Applications Catapult.
the leading voices from engineering
At the automotive forum, electrification
the first time in almost two years to do
and manufacturing. A huge topic
and sustainability will also feature as
business, make new connections and
at the aerospace forum this year is
major themes, with talks from JCB, Ford,
discover innovation.
decarbonising aviation. During the
the Advanced Manufacturing Research
engineering industry can meet again for
show, there will be presentations on
Centre (AMRC), Jaguar Land Rover and
This year, there will be seven show
electrification, zero-carbon aviation
many more.
zones — aerospace, composites,
and hydrogen propulsion from the
automotive, performance metals,
Aerospace Technology Institute,
connected manufacturing, medical
Rolls-Royce, Ampaire, ZeroAvia and
devices and, new for 2021, space
ID TechEx. Supply chain management
and satellite. Also, for the first time, Advanced Engineering UK’s sister show, Lab Innovations, will take place in the same hall. Advanced Engineering UK hopes that having so many sectors under one roof will enable crossindustry collaboration and the formation
90 FDPP - www.fdpp.co.uk
is a concern for many companies this year, so Advanced Engineering UK will welcome talks from Airbus UK and ADS on supplier expectations and supply
On the composites stage, visitors can find out more about what digitalisation means for composite manufacturing, the 3D printing of composite parts and how composites are enabling the UK’s move towards its net-zero carbon emissions targets. Composites UK CEO,
chain excellence.
David Bailey will return along with the
On day two, the forum will have a whole
Digital Engineering, Marc Funnell. BAE
National Composites Centre’s Head of
This year, there will be seven show zones — aerospace, composites, automotive, performance metals, connected manufacturing, medical devices and, new for 2021, space and satellite.
and offering a lightweight power solution. The boat is zero emission and the most sustainable laminate of any RIB in the industry. More features will be announced in the coming weeks. Advanced Engineering offers a great opportunity to meet suppliers, partners and generate business leads for the first time in over a year. Already, the show’s exhibitor space is 90 per cent sold out – a sign that our industry is eager to come
Systems and Transport for London will
by Innovate UK. Here, ten chosen
also take to the stage.
start-ups will have the opportunity to
During the connected manufacturing forum, Ian Gardner, Industry 4.0 and Oracle Specialist at IBM and Stephen Phipson, CEO of Make UK, will deliver
showcase their ground-breaking product or technology, before presenting it to a panel of esteemed judges for the chance of winning a stand at next year’s show.
keynote speeches. They’ll be supported
The show already has several exciting
by speakers from the Connected Places
features confirmed, including an original
Catapult, Brunel University London and
prototype of the ExoMars rover, created
IoT North, to name a few.
by Airbus Defence and Space. The rover, commonly known as Bruno, is semi-
together again. In 2019, over 10,000 professionals from the manufacturing sector attended Advanced Engineering. 70 per cent of visitors reported that they planned to place orders as a result of the relationships formed and an impressive 93 per cent of exhibitors reported that they achieved their objectives at the show. This year, Advanced Engineering UK is also relaunching AE Connect, a digital platform that is used to schedule
As well as its impressive speaker
autonomous and equipped with all the
programme, Advanced Engineering UK
same technology as the final rover,
will be supported by some of the world’s
including the sensors, actuators and
key industry associations, such as The
cameras that allow the rover to see in
Institution of Engineering and Technology
3D while navigating Mars. Advanced
(IET), Composites UK, Make UK, the
held. After 18 months of limited in-
Engineering UK’s new show zone
Institution of Mechanical Engineers,
person meetings, it’s understandable
dedicated entirely to space and satellite
GAMBICA, BARA and the Department
that businesses might not have as many
innovation will be Bruno’s landing site
connections as they usually would by
for International Trade, all of whom now
for the show, and can be found in the
this time of year. AE Connect allows
feature as trade body partners.
existing Aero Engineering floor.
both exhibitors and visitors to make the
Advanced Engineering UK is the go-to
Also on display will be RS Electric Boat’s
show for anyone wanting to meet the
Pulse 63. The boat’s power source
world’s leading engineering companies,
is a battery pack derived from the
plus the UK’s most innovative start-
automotive industry, which harnesses a
“Advanced Engineering UK marks the
ups, thanks to the return of the show’s
RIM drive unit rather than a traditional
return to face-to-face business, which
Enabling Innovation zone, supported
propeller, increasing the boat’s efficiency
the UK has been craving since March
meetings ahead of the show. In 2019, the platform was used to schedule 588 meetings, which generated an average order value of £200,000 per meeting
most of their time at the show by filling their diaries with valuable meetings beforehand.
2020,” explained Alison Willis, Director at Easyfairs, the organizer of Advanced Engineering. “The show offers the UK’s engineering industry the chance to get together again, do business and discover the innovative technologies and products that have been created in the past year.” Are you ready to meet some of the UK’s top innovators in engineering? Register to attend Advanced Engineering 2021 on November 3–4 via the exhibition’s website, www.advancedengineeringuk.com.
FDPP - www.fdpp.co.uk 91
3 & 4 November 2021, NEC Birmingham The UK’s leading annual gathering of engineering supply chain professionals
REGISTER FREE ONLINE I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products. Kat Clarke, Wing Manufacturing Engineer, Airbus
10,000+ engineering professionals in attendance
500+
200+
exhibitors showcasing their products/services
hours of free-to-attend industry content
Benefit from co-location with: AERO ENGINEERING
AUTOMOTIVE ENGINEERING
PERFORMANCE METALS ENGINEERING
COMPOSITES ENGINEERING
CONNECTED MANUFACTURING
MEDICAL DEVICE ENGINEERING NEW
NEW
REGISTER FREE ONLINE USING THIS CODE: 7234
www.advancedengineeringuk.com +44 (0)20 3196 4358 | aeuk@easyfairs.com
Are You Still Inserting Documents and Marketing Material into Shipments Manually? Read How a Small Investment Can Save Your Business $500,000 Annually PSI Engineering is the global expert in pack station automation. We manufacture and integrate automation solutions for the last 100 feet of the order fulfillment line. With applications in any industry that packs and ships product, we can provide solutions for all your pack station needs. Case Study: A rapidly growing online grocery delivery company and their consultant were working to open new fulfillment centers designed and optimized to fulfill orders quickly and efficiently. The Company is committed to delivering fresh, locally-sourced products to customers at reasonable prices and therefore need to ensure orders are accurately and rapidly processed to keep operating costs low. Included in every order is a thank you card, a referral card (with a personalized
Introducing this automated pack line eliminated document insertion errors which got the orders out the door twice as fast.
promo code), and a flyer advertising promotions or new products. These inserts vary in size from 6.5”x7.5” to 8.5”x14”. For new customers, a welcome brochure was also included with their
wrong advertisement is inserted. Finally, since the amount of material required varied, there was often too much or not
first order.
enough material available.
At existing facilities, document printing
Working with PSI, the Customer and
and insertion is completed by a team of 10 operators at individual packing
Consultant decided that the packing tables were to be converted to a single
card with personalized promo code, and personalized thank you card and inserts it into the order. One PSI LC In-Feeder was installed downstream of the Print Feeders to include a welcome brochure if the order was for a new customer.
tables where they manually pick pre-
pack line with a straight run conveyor
Introducing this automated pack line
printed materials, print the promo code
and three in-line PSI Print Feeders (one
eliminated document insertion errors
on the referral card, and insert the right
document type per machine). As the
which got the orders out the door
documents and marketing material into
carton containing the order moves along
twice as fast. The Company now saves
orders. This manual process results in
the conveyor, the barcode is scanned
$500,000 annually on labour costs by
a high error rate where the wrong code
prompting the Print Feeder to print the
reducing the staff required to complete
gets sent to the wrong customer or the
appropriate promotional flyer, referral
this transaction. info@psiengineering.com www.psiengineering.com
FDPP - www.fdpp.co.uk 93
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