FOOD & DRINK PROCESSING & PACKAGING Issue 37 2022
FREIGHT BRITAIN UK food manufacturers pull forward on ‘local’ machine investments
B-HIVE Re-envisioning whole field sensing
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.
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Features
SPARC SYSTEMS B-HIVE INNOVATIONS CIMCORP BERRY GLOBAL ISHIDA COMAU VEOLIA CSB WIPAK WEG GIST PACKAGING INNOVATIONS & EMPACK GNT
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FDPP - www.fdpp.co.uk 3
Freight Britain UK food manufacturers pull forward on ‘local’ machine investments Speed, proximity and short lead times are emerging as strong influencers to the Made in Britain rationale. Particularly in the food safety arena where delays to time saving inspection machinery is not conducive to productivity, compliance and brand protection. As a British company using domestic suppliers to source materials and design, engineer, install and support machines locally, contaminant and checkweighing specialists Fortress Technology and Sparc Systems examine the competitive and cost advantages behind this accelerated reshoring drive. Today’s food manufacturing world is in a very different place to how it was 20 years, and indeed 20 months ago. With the pandemic highlighting the fragility
collaborative product range – the
the engineering support team,” notes
award winning Raptor checkweighing,
Phil.
combination and x-ray machines. Absorbing the additional 20 percent
CLOSER TO CUSTOMERS
in import tariffs from the start of
Having traded off and championed
2020 provided further impetus for UK
the Made in Britain badge since both
food manufacturers to strategically
companies were founded, Phil now
accelerate their equipment reshoring
reports a steady increase in live
plans. An issue that several new
enquires for food-grade x-ray and metal
Fortress customers bemoaned before
detection solutions from food factories
switching their business to the
seeking a swift turnaround. Emerging
Banbury-based company. “Uncertainty
less scathed than many of its market
is really fuelling this trend and certainly
peers, both companies – currently the
now has a bearing on machinery
reshoring reversal.
only known UK manufacturers of all
investments. The risk of delays, the
three food inspection disciplines - have
HGV driver crisis and diversion of cargo
For engineering companies like Fortress
been able to mitigate the rising costs of
ships away from congested UK ports
and Sparc that continued to ‘deliver
shipping and air freights, passing these
has further amplified the challenges,”
the goods’ even during the worst of
cost savings directly onto customers.
adds Phil
British R&D centre and manufacturing
“Even before Brexit, the weak pound
Premium engineered products, faster
base has turned out to big plus. Rather
and ongoing tariff negotiations
bespoke builds and the ability to convey
than having a sprawling global supply
prompted many UK food manufacturers
requests face-to-face with customers
chain, even when the largest economies
to price up their import versus
in their native language, are among the
closed their borders, Fortress continued
domestic sourcing options. A number
other reasons why over 48 percent of
to fulfil orders, attract new customers
made the conscious and pragmatic
companies are currently anticipating
and maintain its agility. The companies
decision to source their food safety
increasing their proportion of work
even persisted with the successful
equipment domestically citing the need
commissioned to UK subcontractors
development and launch of their new
for greater resilience and proximity to
moving forwardi.
of international supply chains, Fortress and Sparc Managing Director Phil Brown has observed a definite shift in attitudes towards reshoring. With Asia and EMEA once considered the go-to-hubs for distributors of machinery components, materials and builds, rising wage costs, together with other export overheads, lengthy shipping delays, quality and IP issues has significantly influenced this
the pandemic, having an established
4 FDPP - www.fdpp.co.uk
SUSTAINABLY SOURCED Balancing responsible sourcing and sustainability is another big motivation. Moving machinery across continents adds hugely to the carbon footprint. With commercial customers and their consumers demanding even higher sustainability credentials, every stage of the journey from sourcing materials ethically to build and installation must
With 90 percent of Fortress inspection machines sold to food factories, the company’s Lifespan Guarantee helps to keep sustainability stakeholders happy.
advantage. During the COVID-19 pandemic, with workforces stretched and social distancing enforced, the ability to monitor the performance of a fleet of inspection equipment proved an invaluable feature for customers. Phil concludes: “Despite the challenges of the last two years when the Covid hiatus saw many projects put on hold,
reputation as a premium food inspection
pent up demand is now converting into
machinery supplier.” These shorter
an influx of new enquiries from domestic
It’s often a question posed to Phil
UK supply chains also means faster
food manufacturers. The fact that
and the 15-strong engineering team
delivery of maintenance and repair parts,
our equipment is British made, using
located in the UK. “Our close vicinity
resulting in less machine downtime
local suppliers, mitigates against the
to customers means we can flex and
and consequently fewer production
supply chain fragility that is affecting
scale production up and down to meet
bottlenecks.
distributors of European equipment.
now be considered.
Certainly, our customers are relieved to
demand. Apart from several electronic parts, all the components are designed
With 90 percent of Fortress inspection
learn that the long lead-times and import
and made within the UK. However,
machines sold to food factories, the
delays reported across the sector aren’t
through Fortress Technology Inc. we
company’s Lifespan Guarantee helps to
an issue when dealing with us.”
also have direct access to global food
keep sustainability stakeholders happy.
safety intel and the lateral thinking
In built remote monitoring is another
www.sparc-systems.com
that’s so critical to maintaining our
time saving and production-continuity
www.fortresstechnology.com
FDPP - www.fdpp.co.uk 5
Carrier Launches HFO R-1234ze Chillers for Industrial Process Applications Carrier has introduced the
approaches. When heat reclaim is
AquaForce® Vision 30KAV
activated, the air-cooled coils are
with PUREtec™ refrigerant, a
automatically isolated to reduce
new line of high-performance,
the impact of cold ambient air
compact process cooling chillers
on the heat capacity that can be
with ultra-low global warming
recovered from the water-cooled
potential (GWP) refrigerant
heat exchanger.
R-1234ze.
This option increases heat
The new chiller line is optimised for industrial processing such as food manufacturing, pharmaceuticals, chemicals, plastics, metal industries and applications requiring ultra-reliable cooling up to -12degC. Carrier’s AquaForce Vision 30KAV aircooled, variable-speed screw chillers are designed to minimise energy consumption and impact on the environment while maximising performance and ease of
recovery by 25% at nominal
It delivers high seasonal energy efficiency, a low environmental footprint, excellent reliability, safe operation and a very low total cost of ownership over its lifetime.
load with 35 C outside air temperature, and by 100% or more when the chiller operates with low outside air temperature, compared with the traditional serial-only approach to heat recovery. The cooling capacity of the chiller is also slightly enhanced in heat recovery mode. Due to its compliance with European Ecodesign Directive requirements, the AquaForce 30KAV can also be used in comfort cooling
installation and maintenance. Energy
“The new chiller has been designed
efficient solutions like the AquaForce
and optimised for use in a wide range
30KAV chiller support Carrier’s 2030
of process cooling applications,” said
For contractors and service staff, the
Environmental, Social and Governance
William Doll, Europe Marketing Manager,
30KAV has been designed to be quick and
(ESG) Goals to reduce its customers’
Chillers and Heat Exchangers, Carrier. “It
easy to install and maintain. Its compact
carbon footprint by more than 1 gigaton.
delivers high seasonal energy efficiency,
dimensions give ready access in areas
a low environmental footprint, excellent
where space is tight, while its electrical
reliability, safe operation and a very low
system ensures compatibility with earthing
total cost of ownership over its lifetime.”
requirements in different segments. In
The chiller is available in four sizes, spanning capacities from 280 kW to 800 kW into -4degC/-8degC medium
applications.
addition, use of smart energy monitoring
temperature process cooling and from
For mission critical applications, such as
530 kW to 1300 kW into 12/7degC high-
process cooling and food manufacturing,
temperature process cooling or comfort
Carrier has developed an ultra-fast
cooling.
capacity recovery option. In the event of
For total peace of mind and to minimise
the chiller power supply being interrupted,
running costs, building owners and
the recovery option enables immediate
facilities managers can opt for one of
chiller restart following power restoration
Carrier’s BluEdge™ service support
with 100% capacity recovery within one
options to keep chillers operating at peak
minute, minimising the risk of damage to
performance and efficiency throughout
the process or products being cooled.
their life cycle. The service support uses
The unit’s carbon footprint is minimised due to its combination of ultra-low GWP HFO refrigerant, a 40% reduction in refrigerant charge due to use of Novation® micro-channel heat exchangers and outstanding energy
and onboard leak detection enable chiller operation to be monitored in real-time.
Carrier’s advanced cloud-based diagnostics
efficiency delivered by the onboard
All 30KAV models can also be equipped
variable speed drive, which precisely
with an innovative boosted total heat
matches compressor speed to load.
recovery option that allows more heat to
The chiller’s compact design, with a
be recovered during the winter, further
physical footprint one-third less than
increasing efficiency and reducing
standard 30KAV chillers, enables it to be
running costs. The heat recovery option
To learn more, visit: www.carrier.
deployed where space is tight without
uses a hybrid design that harnesses the
com/commercial/en/eu/products/air-
compromising performance.
benefits of both serial and parallel design
conditioning/air-cooled-chillers/30kavize
6 FDPP - www.fdpp.co.uk
platform within BluEdge to monitor and optimise chillers remotely, and via site visits by highly experienced staff if required.e
AquaForce® PUREtec™ w
Ne
30KAV
Dedicated to industry
AIR-COOLED VARIABLE SPEED SCREW CHILLER
Easy Installation & Maintenance
Outstanding Performance
Smaller Footprint
Environmental Sustainability
uk.info@carrier.com www.carrier.com/commercial/en/uk/ 01372 220 220
FDPP - www.fdpp.co.uk 7
Food and beverage manufacturing – improving flexibility A GUIDE FOR SYSTEM INTEGRATORS AND MACHINE BUILDERS The food and beverage industry is the UK’s largest manufacturing sector and has many manufacturing challenges. The slightest change in the weather, for example, can impact food and beverage manufacturers, requiring changes to production. As a machine builder or system integrator, knowing the key trends in the food and beverage market will help you to create an effective solution for your customers. In this guide we’ll look at the key food and beverage trends in 2022. We’ll then focus on one trend in particular: improving flexibility in food and beverage manufacturing. We’ll cover what flexible manufacturing is, its benefits to the food and beverage sector, and ways to achieve it. And we’ll suggest products that may help with increasing flexibility in your manufacturing system.
FOOD AND BEVERAGE AUTOMATION TRENDS IN 2022 Food and beverage automation integrates technology across a production line so that companies can streamline their process, saving costs and reducing the need for human labour at each stage. Here are some of the key trends in 2022: • Sustainable manufacturing is becoming the norm • There’s been an increasing focus on food hygiene and safety since Covid-19 • There’s an increased need for accuracy
• Food manufacturing automation capabilities are increasing • Developing flexible manufacturing to
chance of product recalls • A process that can adapt easily to change
be able to adapt to future changes and
• Protection of workers’ safety
innovations
• Traceability throughout production • Increased productivity and ROI
TREND: IMPROVING FLEXIBILITY IN FOOD AND BEVERAGE MANUFACTURING Flexibility helps in adapting or changing processes, such as changes in production volume, mobility and quality.
• Meeting customer needs • Reduced waste and saving on costs • Improved hygiene and sanitation
7 WAYS TO ACHIEVE FLEXIBLE MANUFACTURING
WHAT IS FLEXIBLE MANUFACTURING?
1. PRE-WIRED SYSTEMS
Flexible manufacturing means being
up in their system and ready to go so
able to adapt to the different needs of
that they can change processes easily.
customers and changes in production.
You can request products tailored to the
Customers prefer to have everything set
customer’s needs such as specific cable To be flexible, your system would be
lengths.
able to cope with production changes within a matter of hours and days –
Examples of pre-wired products:
without having to create a whole new
• Pre-assembled beacons with M12
manufacturing process!
connection and plugs with male and female threads, universal and easy to
This is where automation comes into play. Examples of automation include
install • Pre-assembled compact signal towers,
food quality inspection, robotics, conveyor
with different cable lengths available on
lines, and sealing and labelling.
request
recyclable, reusable, or compostable
WHAT ARE THE BENEFITS OF FLEXIBLE MANUFACTURING IN FOOD AND BEVERAGE?
2. ERROR RECOGNITION AND QUALITY CHECKING THROUGHOUT THE PROCESS
packaging by 2025
• Improved quality of products with less
Address problems early in the process
of inspection • Big brands are aiming to move to
8 FDPP - www.fdpp.co.uk
so you can meet demands for flexibility.
• FDA and Ecolab approved products such
Quality inspection can eliminate any
as cable entry systems are suitable for
human-related errors, and consistency can
washdown
be achieved in elements like flavour, taste
CIP CLEANING
and texture.
CIP systems clean, rinse and sanitize pipes Some examples of products used for error
to remove any excess product. A twin-
recognition and quality checking include:
screw pump, for example, enables CIP cleaning and product handling within just
• Various machine vision cameras for food inspection to test geometrics, packaging and for foreign objects, and to analyse food quality and freshness • Smart vision sensors and cameras to check whether the quality of an object is ‘good’ or ‘not good’, displayed on a computer linked to the sensor • Smart vision sensors and cameras
• Products with IO-Link interface • IIoT enabled products • Motor drives with built-in Profinet and Ethernet/IP, easily interfaced with many PLC systems • Motors and drives that work with many protocols
one pump. Twin-screw pumps ensure: • An additional CIP pump is not necessary, saving costs and time • High hygiene level • Quick product handling and CIP cleaning • OEM Automatic process instrumentation, such as pigging valves,
for quality control, identification and
5. INCREASE SAFETY FOR WORKERS
positioning. Their software guides the
Flexibility can mean that people do not
user step-by-step. This can be used, for
have to undertake complex tasks that
example, to check that bottle caps are
could put them in danger. By utilising
7. REDUCE WASTAGE
firmly secured
automation and all its various functions,
Flexibility means you can change
3. TRACEABILITY By using automation, you can trace where production faults occurred and make appropriate alterations to prevent a
people also do not have to undertake often repetitive critical tasks where consistency is difficult to achieve. Examples of safety products:
product recall or low-quality product.
• Non-contact safety switches
The following are examples of products
• Safety relays
that help to monitor and change future processes and so increase flexibility: • Smart vision sensors to check whether an object is ‘good’ or ‘not good’ • Image-based scanners for fast omni-
• Solenoid interlock switches with IP69K • Slip rings • IP69K beacons for alerting and notification
6. QUICK HYGIENE AND SANITATION PROCESSES
directional barcode scanning during the
It is critical to get hygiene and sanitation
barcode stage
right in food and beverage manufacturing.
• SWIR cameras combined with speciality lenses can be used for food inspection to
The following ideas can help you maintain
check damage within food, for example
high hygiene levels during changes in the
bruises within an apple
process, and without wasting time.
• Various industrial protocols and
pressure gauges and turbidity sensors are suitable for CIP cleaning
production direction and switch functions without wasting too many resources. Reducing waste not only saves you resources but also improves the environmental image of your manufacturing process. An example of a product that helps reduce waste is a pigging system. Here a pig is pushed into the pipe to stop media getting through, thus enabling the pipe to be quickly scraped and cleaned. A pigging system ensures: • Less waste and less use of cleaning agent • Reduction in water consumption • Lower energy consumption This guide has outlined ways of developing flexibility in food and beverage
networks such as IIOT and Ethernet-
WASHDOWN
enabled products can be more effective
Develop an easy washdown procedure
suitable products to help you create a
with well-designed equipment made from
flexible food and beverage production line.
than recognition by the human eye
4. USE COMPONENTS WITH QUICK TURN-AROUND AND EASY MAINTENANCE Flexibility requires quick turn-around times
manufacturing and suggested some
stainless steel and IP-rated equipment. Please contact us if you are interested in IP-rated products include:
knowing more about any of the products
• Cable conduits and cable glands with
mentioned above.
IP68K
and quick and easy maintenance products.
• IP69K push buttons
For more info, click here.
Examples include:
• Stainless steel motors and safety
Email sales@oem.co.uk
• Easily pluggable connectors
switches with IP69K
or call 0116 214 9454 to find out more.
FDPP - www.fdpp.co.uk 9
Master the interfacing for processing and packaging machinery Finder’s 39 Series with a width of just 6.2 mm is the space-saving solution offering the greatest number of permutations of sockets and accessories. The 39 Series range of relay interface modules includes electromechanical and solid state relay versions with push-in sockets or sockets with screw terminals. It has ‘universal voltage’ (24 V … 240 V AC/DC) versions as well as leakage current suppression models. It also has the most complete range of accessories including jumper links, marker tags, output fuse module, terminal doubler,
The system is highly versatile, has a low consumption, compact dimensions, and high build quality.
and many more.
WHAT IS THE MASTERIN SYSTEM? The Finder MasterIN System comprises a family of four series of existing relay interface modules, each differentiated by their respective rated current and number of contacts as well as different
Finder’s relay interface modules offer
sockets and accessories.
MasterOUTPUT and MasterINPUT are
MasterBASIC is the go-to relay interface
time saving. The MasterOUTPUT allows
module for general use in electrical panels as well as interfacing with PLCs. It ensures a high switching performance. MasterPLUS offers the greatest flexibility and accepts Finder’s unique output fuse modules.
special versions aimed at simplicity and for the quick and easy distribution of the supply voltage to the output side, whereas for the MasterINPUT it’s to the input side. The MasterTIMER is a multi-voltage timed interface module which has an easily accessible rotary knob.
WHY CHOOSE THE MASTERIN SYSTEM? The system is highly versatile, has a
faster connections with rapid push-in technology. This provides greater safety and higher performance, especially in conditions where vibrations are present, reducing the need for frequent maintenance and reduces costs. Push-in terminals permit the quick connection of solid wires or ferrules by their simple insertion into the terminal. It is possible to open the terminal to extract the wire by first pushing down on the push-button using a screwdriver or fingers. For stranded cable it is necessary first to open the terminal using the push button, both for the extraction and insertion.
low consumption, compact dimensions, and high build quality. It also has an
This makes it an extremely simple, fast,
ATEX/HazLoc compliant (EX nC) option
and secure installation which can save
available which makes them safe to use
installers up to 25% of time compared
in hazardous/explosive atmospheres.
with using an electric screwdriver.
The products also have CSA, EAC, RINA,
10 FDPP - www.fdpp.co.uk
UL and VDE approval (according to type)
To find out more, please visit
and UKCA declarations of conformity.
www.findernet.com.
Finder’s 39 Series relay interface modules Master the interfacing for processing and packaging machinery 39 Series Save time, space and reduce costs with Finder’s ultra slim, simple and versatile relay interface modules and accessories. Ensure high performance thanks to maximum vibration resistance. Why wait? Choose Finder.
Finder plc Opal Way Stone Stone Business Park - ST15 0SS Tel 01785 818100 finder.uk@findernet.com
findernet.com
Where is inefficiency hiding? 7 Places to look The last 6 months have seen a wrath of unprecedented increases. Materials, Energy, Fuel, Raw materials and tax have in some cases been close to 3 times their cost in the past 12 months. When the rises are in conjunction with
Pump age can also play a part in improving results, where newer more efficient designs are available for applications.
labour and material shortages with growing worldwide uncertainty, there has never been a more important time to revaluate your process, see where processes can be improved, eliminate wastage, automate tasks, or generally do more done with less as a way to improve your bottom line and gain control of those elements within your grasp. Inefficiency can hide in a number of places not always immediately apparent. Here are 6 places where inefficiency can be hiding: BULK FLUID CONTAINER UTILISATION Fluids, chemicals, flavorings or staples
consistency from what is expected. This can often lead to batches being rejected or inconsistent final recipes increasing wastage. Having a pump which can accurately dispense fluids repeatedly at the touch of a button ensures whatever recipe is
Quite often containers can be returned to suppliers, partially filled with as much as 5-10% of liquid remaining within it, usually stuck to the sides of drums, or at the bottom of IBC’s which can be
created, it is the same every time. MANUAL HANDLING Manual handling is often used during the initial stages of trialing a new
recovered providing the right pump
process or method.
technology is Invested in, with fluid
When a new process, technique,
recovery rates between 97-99%.
additive, or mixture is created, it is
Quite often it is not only the amount of liquid which is extracted from a container which is important but how
sometimes necessary for personnel to manually test it, refining procedures until they work as desired.
the liquid is handled and how accurately
But what if this new process creates an
measures are dispensed.
unforeseen issue and not reviewed after
CONSISTENCY OF RESULTS
implementation?
Some materials are shear sensitive
Manual handling is often a process
meaning they are sensitive in the way
where users see the most benefit from
decant from tubs, 205L drums, or IBCs
they are handled or transferred.
automating by reducing risk of spillage,
due to their characteristics namely their
If agitated too much fats can separate
accidents, inconsistency of results and
viscosity.
out from the liquid or mixtures change in
increase speed of dispensing.
such as butter used as ingredients within processes are not always easy to
12 FDPP - www.fdpp.co.uk
via the system, which can often mean pumps are controlled by the closing of valves to reduce or stop flow, or recirculate flow. Although the flow of a pump may have stopped, its power consumption remains the same, and if stopped abruptly or ran against a closed valve there is the potential for damage to be incurred. By utilising a variable speed drive it reduce energy usage by more than 50%, with associated savings made in spare part usage and maintenance too. PUMP SET UP & TYPE As pumps are controlled by the system they are installed in, there are certain telltale signs that equipment is not working as it should. It could sound excessively noisy, be vibrating heavily, or produce less flow than normal. Having a pump operating at full speed only within a process - in particular cooling applications is worth investigating to see if the pump and process could operate at a variable rate. Similarly if a pump is frequently operating with a relief valve open this is a sign that the pump set up can be optimized. MAINTENANCE
colour, recipe or production changes are
Frequent spare part usage can often
carried out reducing downtime.
be a sign that something is not quite right within a process. Sometimes it can
Should a pump be operating for over 10
be taken as a given, that Mechanical
hours a day its energy efficiency rating
Seals, O Rings, Stators, Diaphragms or
should be checked as older motors are
Peristaltic Pump hose failure are a cost
rated as IE1 which can be between
of the process. By undertaking failure
5-20% less efficient than premium
analysis with a trusted pump supplier
efficiency IE3 or IE4 motors.
insight can be obtained if the rate of failure is normal and is as expected.
Pump age can also play a part in
Sometimes small changes may be
improving results, where newer more
required such as the changing of a
efficient designs are available for
packed gland seal to a mechanical seal
applications. Often the greatest cost
to help recover any fluid lost which is not
of ownership derive from maintaining
charged for. On other occasions it could
and running the unit, so it often pays to
be that the pump type needs altering.
upgrade should the unit be several years old.
If Pump cleaning is performed manually, automating it for cleaning via CIP, or
SYSTEM CALIBRATION / SET UP
changing to a low maintenance pump
Pumps are not intelligent by design.
design can accelerate the speed in which
Their performance is typically controlled
PRESSURE REDUCING VALVES In systems where pressures are too high for the next stage of a process, pressure reducing valves can be used to reduce incoming pressure. When these are used the energy within the liquid is dissipated and wasted within the valve. If pressure reducing valves are used frequently in plants operating 24/7 there are possibilities to recover this energy via a Pump as Turbine which recovers the energy as reducing the pressure. If you are looking a ways to improve a process, minimize wastage, improve productivity or downtime, speak to North Ridge Pumps on 01773 302 660, via Live Chat, or email sales@northridgepumps. com to discuss your process and see how we can help. www.northridgepumps.com
FDPP - www.fdpp.co.uk 13
Mixing-technology solutions from Lödige for iodising salt The consistently precise composition and very good level of homogeneity of the mixed material enable the necessary quality standards to be met at all times.
Mixing iodised and fluorised table salts as well as nitrite salting mixes and other salty and spicy basic ingredients for the food industry places complex demands on the process technology used. With designs tailored specifically to each application, Ploughshare® Mixers from Lödige Process Technology’s KM and FKM series can handle these demands without any problems. Across the board, suitable mixing processes can be carried out either continuously (with the KM) or in batch mode (with the FKM). A continuous process is particularly beneficial for high throughput rates of around 20 to 50 t/h or more, as is required when making iodised salt, for instance. Here, iodine – or fluorine – is added in as a liquid solution and mixed with the raw salt. When operating with smaller throughput
is exacerbated over the long term. Attention must also be paid to potential corrosion, which may occur in humid conditions or during cleaning. Across the board, therefore, Lödige mixers designed for applications like these are made from ultra-high-quality, chloride-resistant stainless steels (AISI 316Ti or 316L), which also meet the latest hygiene requirements in the food industry. The
Both methods guarantee the high
mixing tools, which are exposed to
mixing quality that is generally required
particularly high mechanical loads, are
in the food industry. For instance,
generally fitted with wear protection.
an excessively high dose of sodium nitrite – an ingredient in curing salt – can pose a health risk, especially in this application field. The consistently precise composition and very good level of homogeneity of the mixed material enable the necessary quality standards to be met at all times.
rates or adding in powdered additives,
Amongst other things, table salt (NaCl)
however, individual batches are the
will abrade all surfaces that come into
better mixing option.
contact with the product due to its
With designs tailored specifically to each application, Ploughshare® Mixers from Lödige Process Technology’s KM (shown here) and FKM series are ideal for mixing iodised and fluorised table salts as well as other salty and spicy basic ingredients. (Source: Gebr. Lödige Maschinenbau GmbH)
14 FDPP - www.fdpp.co.uk
crystalline structure, an effect that
www.loedige.de
HYGIENIC DESIGN.
THE BIG GREEN BOOK
STAINLESS STEEL COMPONENTS WITH SIGNIFICANT ADDED VALUE: MAXIMUM HYGIENE.
In a hygiene-sensitive manufacturing environment stainless steel components are true all-rounders: easy cleaning, no adhesion of dirt, germs or detergents, permanent cleanliness. They are also corrosion-resistant, durable, temperatureresistant, low-maintenance, hygienic and economical.
Find these products in our full range with more than 70,000 parts in THE BIG GREEN BOOK 2022
info@norelem.co.uk ∙ www.norelem.co.uk
Hygienic_Design_ENG_180mmx132mm.indd 1
08/02/2022 10:30
Aerosol Can Inspection Identify Direct was asked by a major aerosol manufacturer to develop an on-line system to visually inspect laser-etched engraving on the bottom of aerosol cans.
• The writing was in an annulus around the base of the can, not straight across. • The cans are moving along a production line and vary in position across the track.
ISSUES:
SOLUTIONS:
• The bottom of the pressurised can is concave and of shiny aluminium. • The writing and DataMatrix are laseretched rather than printed meaning very low contrast, making reading difficult. • Inspection had to be 100%.
• We successfully developed an in-house ‘flat dome’ which, together with a classic dome and a ring light, gave a consistently good image on all the cans. • We developed software based on a ‘polar unwrap’ tool, using the central DataMatrix mark as a ‘locator’ to position the Polar Unwrap Region Of Interest correctly on each can, using a DALSA camera to capture the images. The result is an effective on-line system that can read every can, check the quality and automatically reject bad cans or stop the line for cans that could not be reliably read. Contact sales@identifydirect.com for more information www.identifydirect.com
FDPP - www.fdpp.co.uk 15
HACCP International Food Safe Certified Flaking Knives Drum dryers and flakers are used within the food industry to convert a liquid food slurry into dry solid flakes. The process is commonly used to produce ingredients such as potato starch. On a drum dryer producing potato starch, a scraper blade is required, this is otherwise known in the food industry as a flaking knife. Typically, flaking knives provided by OEM’s are designed to be reground to allow the knife to be reused. However, reground knives could negatively impact food safety. The reground knives are transported to a workshop and then typically stored in a production area increasing the risk of contamination. In addition, reground knives increase the risk of metal contamination in the end-product. Kadant offers a line of HACCP International certified flaking knives and knife holders that are manufactured in compliance with EC1935 and FDA regulations. By using a combination of advanced material technology and expertise within scraper blade technology, Kadant provides a single-use knife that
in extended drum life. The knives are
This also improved general health and
typically changed within two minutes
safety for their operators.
which reduces production downtime and equates to higher yields. Product quality and consistency are improved with a Kadant knife compared to a traditionally re-ground knife. Kadant also offer knife holders for easy retrofit of existing clamp style OEM knife holders. Kadant recently concluded trials with a manufacturer of drum dried infant cereals who confirmed that metal contamination within the food product
offers significantly increased lifetime,
was greatly reduced when using Kadant
eliminating the need to regrind the knives.
flaking knives. Additionally, they found
Furthermore, less loading force is required
the single-use knives were much easier
when using Kadant knives resulting
to handle, safer, and quicker to change.
16 FDPP - www.fdpp.co.uk
In certain applications and operating conditions, the return on investment can be met in as little as 12 months**. The following HACCP International certified knives are specifically available for flaking: • Carbon Steel™ blades* • ProFlake™ blades • Stainlessflex™ blades *Available in the U.K. with release coating. **ROI has been proven within 12 months in European countries dcf.kadant.com
Rotary Joints for the Food & Beverage Industry Rotary joints are embedded in the
Food casings are another
the production of tea bags
operational processes of confectionery
example within the food
and coffee filters.
creation. Kadant UK, for example, has
and beverage industry
rotary joints operating in some of the
where rotary joints are
New technologies in rotary
world’s leading chocolate and sweet
prevalent. When producing
unions sealing devices,
factories. Rotary joints are also a critical
sausage casings, a rotary
steam distribution, and
component of any heated drum dryer that
joint is a fundamental
water heating increase
requires an injection of steam to allow
part of the initial stage
process efficiency, reduce
the surface of the dryer to heat product
of manufacture. A steam-heated drying
energy costs, and help companies to be
and remove any unwanted moisture from
cylinder is used to ensure the removal
raw ingredients to produce the finished
of moisture from the formed web of raw
more sustainable in their operations.
product.
materials. A similar process is also used in
fluidhandling.kadant.com
Roll Cleaning for the Food Industry Kadant UK manufactures HACCP International Certified scraper blade systems for a range of roll and belt applications within the food industry. In some applications the scraper blade is referred to as a knife, which is typical for a process called drum flaking. Kadant’s scraper blade systems are designed to provide continuous roll and belt cleaning. Our advanced material technology allows us to supply food safe blades to suit various types of roll and belt
If you are a food producer using clamped
downtime. Furthermore, Kadant are
covers. In addition, for flaking applications
style scraper systems, you will know that
experts in scraper blade alignment,
Kadant has developed patented long-
these are time consuming to maintain
which negates the need for operator
life metal blades that provide significant
and align. Kadant bade holders allow
adjustments.
increases in blade life.
quick and safe blade changes, to minimise
BENEFITS Improved food safety management processes Reduced production costs Increased food safety standards Supports compliance with industry standards Verified food safe equipment SUITABLE APPLICATIONS Cereal flaking Starch flaking Oven band cleaning Polyurethane and Teflon conveyor belts Chocolate refiner rolls Gauge and pinning roll dcf.kadant.com
FDPP - www.fdpp.co.uk 17
Re-envisioning whole field sensing with B-Hive’s Tuberscan Placing actionable insights at the hands of growers to minimise wastage supports packers and retailers further along the supply chain
LEADING agri-tech business B-Hive Innovations continues to deliver innovative solutions for the fresh produce industry via an open and collaborative approach to addressing supply chain issues. Through developing TuberScan - an above and below ground crop sensing technology - it has taken a
“We want to empower growers with meaningful data-led insights to make better-informed management decisions based on potato size, count and variation. When developed, TuberScan will help growers to more confidently identify areas of poor performance, when to make all-
major leap towards eliminating potato
growers to understand the performance
important burndown decisions, and
food waste.
of the whole crop underground. With
where growers should target inputs of
TuberScan we are trying to address this
fertilizer or irrigation. All these choices
lack of clarity.
can ultimately make or break a crop’s
The research and development project for TuberScan is funded by Innovate
marketable yield.”
UK’s Research and Innovation scheme
“The current practice of random
- collaborating with Branston Ltd,
sampling followed by data extrapolation
In its current iteration, the TuberScan
The University of Manchester and
to cover the field does not always
system comprises of radar, GPS units
Harper Adams University to create
account for variance within the crop and
and an in-field camera that surveys the
demonstration units.
can lead to inaccuracies in forecasting.
field throughout the growing season.
At B-Hive Innovations, we asked: why
The project has utilised and adapted
Effie Warwick-John, project manager
use labour-intensive sample data when
field-based technologies that were
on TuberScan at B-Hive Innovations,
cutting-edge technology will achieve
originally developed for the military -
says: “Potato growing is not precision
more accurate data across the whole
reapplying the knowledge and tools to
agriculture so it can be challenging for
field.
the arable farming environment.
18 FDPP - www.fdpp.co.uk
Vidyanath Gururajan, managing director
additional assurances on the quality
B-Hive is working closely with growers to
at B-Hive Innovations, says: “At B-Hive
of their potatoes, prior to hitting the
tailor the product to overcome the issues
our core purpose is fourfold: reduce food
shelves.
they face on an individual and everyday basis. As the TuberScan technology
and energy waste, increase marketable yield, enhance produce quality and
“By both understanding more closely
evolves, B-Hive hopes it will be a catalyst
add value to farming fresh produce
what they will be harvesting and the
towards further innovations of precision-
businesses.
opportunity to enhance marketable yield, farmers are better placed to market
“Placing actionable insights at the
their produce, strengthen supply chain
hands of growers to minimise wastage
relationships and attain the best value
supports packers and retailers further
based on their supply of potatoes and
along the supply chain and provides
relative demand.”
based equipment such as intelligent sprayers. Vidyanath adds: “B-Hive Innovations is constantly refining and developing new technologies - through groundbreaking collaborations - to increase the accessibility for intelligence-led planning to potato farmers of varying scope and scale. By improving marketable yield and reducing crop variation, this technology aims to ultimately reduce the carbon footprint in the potato supply chain.” www.b-hiveinnovations.co.uk
FDPP - www.fdpp.co.uk 19
EcoCooling Evaporative Cooling The simple, safe and efficient way to cool your facility With the rapid increase of energy costs, businesses are looking at reducing their electricity usage while maintaining comfortable and compliant conditions for products and staff. EcoCooling offers a cost-effective cooling solution for food storage and processing facilities. With blanket or spot cooling options available, evaporative cooling offers a flexible approach to process or people cooling that can be easily retrofitted to the majority of buildings.
Key Benefits: Evaporative cooling adds humidity to the air, which can be beneficial to some food storage environments such as bakeries, wine and chocolate producers, cereal manufacturers and more, with some of the leading UK brands utilising our equipment for the processing or packing facilities, including Subway, Hotel Chocolate, Premier Foods, Greggs.
Refrigerant free cooling and ventilation As part of a balanced ventilation system, evaporative cooling is achieved through the natural process of direct evaporation of water into supply air, which is extremely effective in temperate climates like the UK. Air supply temperatures off the coolers do not exceed 25C, without the need to utilise any refrigerant
Typical installation options cooling-based solution is the cost of
A proven and flexible system
installation, which is a fraction of that of
With over 500 installations for some
the equivalent refrigeration system.
Increasing productivity by keeping people and processes cool Having a well ventilated, comfortable work or storage area has been shown to increase productivity, product stability and improve the wellbeing of staff
of the largest manufacturers and distributers in the UK, EcoCooling evaporative cooling systems are a proven, flexible solution which can be deployed quickly to address overheating and ventilation issues. From compact workshops to large warehouses, there are many reasons why evaporative
technology.
throughout the year. This is especially
The most energy efficient cooling system for large spaces
without an effective cooling solution some processes may need to be halted
Why EcoCooling systems
Even on the hottest days, a standard unit
altogether, and excess heat becomes a
EcoCooling are UK based, with stock of
safety and quality concern for staff and
coolers and spares available from their
products.
Suffolk warehouses. They can provide
covering a 250m2 area or spot cooling a 15m diameter zone can operate at a cost less than 13p in electricity and 1p in water per hour, based on service costs of £0.12/ kWhr and £1.20/cum respectively (2021 figures). This gives an energy saving of 90% on an equivalent refrigeration-based
true in the summer months, where
A well-balanced ventilation system is particularly important for businesses looking to maintain consistent and efficient operation in light of the ongoing
system with a 35kW cooling load.
COVID risk, while also helping to remove
An additional benefit of an evaporative
the air.
20 FDPP - www.fdpp.co.uk
unwanted dust and particulates from
cooling is becoming a first-choice option for many businesses.
specific ROI figures and offer options on temperature and humidity control as part of their standard installer quotation package, the operational data is based on 4 years of legacy weather data across the UK. www.ecocooling.co.uk
COST EFFECTIVE COOLING SYSTEMS
EVAPORATIVE COOLING • Runs at less than 10% compared to refrigerated air con • Ventilation-based cooling - reduce COVID transmission • Increase productivity, hygiene and condition compliance • No harmful refrigerants - only 100% fresh air • Avoids air recirculation - improves air quality/reduces smells • Energy efficient natural cooling - decreases carbon footprint • New build and retrofit with solutions to fit a range of applications
EcoCooling: the established leaders in evaporative cooling UK-based with over 3500 installations worldwide; with clients including BT, Marks & Spencer, Carbogen AMCIS pharmaceuticals, Cummins Diesel, Premier Foods, Net-a-Porter and Cambridge University. Case studies online! Industrial Cooling: Provides 35kW of cooling for only 1.5kW of electricty. 14,000m3/hr of cool air for less than 12p per hour. ROI in under 3 years. Large UK wide network of installers ready to quote on a solution to fit your needs.
sales@ecocooling.co.uk | T: 01284 810586 www.ecocooling.co.uk Case studies include factories, warehouses, gyms, laundries, pharmaceutical storage
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.
22 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 23
Encore REF30cn is a carbon neutral BOPP film that also provides the required technical performance for this application.
Reduce the carbon footprint of your packaging with Bopp Films Innovia Films is focused on producing new BOPP flexible films that aid the reduction of the carbon footprint of packaging, while providing technical performance, simplifying structures, and maintaining full recyclability. At Packaging Innovations, Innovia will be presenting examples of their solutions
The misconception that flexible packaging cannot be recycled is leading some to poor environmental choices, fortunately, things are changing.
to: • Reduce the use of fossil resources • Enable on pack recycling label
Stephen Langstaff, Business Development Manager, Packaging at Innovia Films highlights “Last year’s
• Extend shelf-life – less food waste
COP26 summit reminded us of the
• Simplify pack structures
importance of reducing our carbon
• Facilitate material substitution • Contain post-consumer recycled waste • Maintain food contact compliance
24 FDPP - www.fdpp.co.uk
footprint. Food production is a major contributor to global warming and resource efficient packaging plays a vital role in reducing the carbon impact
by reducing waste and extending shelf life. The carbon footprint of packaging is usually comparatively small when compared to the product it is wrapping. This is one of the big advantages of flexible packaging. Due to its light weight, it is far more resource efficient than cans, bottles, tubs, or trays”. The misconception that flexible packaging cannot be recycled is leading some to poor environmental choices, fortunately, things are changing. Come to Stand F82 in Hall 1 to discuss your current packaging challenges. www.innoviafilms.com
Unifiller’s Servo Multi Depositor is the Solution to the Food Industry’s COVID-19 Workforce Shortage Unifiller Systems, a global leader in portioning equipment and a subsidiary of the Linxis Group of Companies, designs and manufactures over 30 different depositors and pumps. The Servo Multi Depositor is the perfect solution for food and bakery plants looking into automated solutions for staffing or sanitation problems stemming from the COVID-19 pandemic. As with all of Unifiller’s machines, the Servo Multi is designed for a host of benefits, bringing convenience and efficiency to any food manufacturer looking to maintain high speed production rates. Its innovation was developed through decades of experience with pneumatic multi piston depositors and provides ease of use beyond any traditional piston depositor. Unlike pneumatic depositors, the Servo Multi features programmable touch screen controls,
flow-able products into shells, pans, and other applications. Available in 6, 8, 10, and 12 nozzle configurations with a large deposit range from 0.3 to 10 oz. (10 to 299 ml) per nozzle, the Servo Multi is able to achieve smaller minimum portions than most other pneumatic depositors.
capacity to store 100 recipes, and six depositing modes to choose from. It also possesses a built-in ability to control a pan conveyor or act as a slave to an automated conveyor-based production system to add further efficiency to the overall production process. Gentle portioning ensures product integrity with little to no breakdown. The Servo Multi is also compatible with the full range of Unifiller nozzles. It can be integrated into a nozzle bridge with computer controlled 1.75” diving action over a conveyor to deposit
Sonia Bal, Director of Marketing at Unifiller Systems, weighs in on the benefits of turning to automated equipment. “There are growing factors impacting the way food producers work. Over the years, changes in minimum wage, fewer people entering the trades, and boomers transitioning to retirement, have all led to the need for more automation. More recently, COVID-19 has demonstrated that businesses are heavily impacted when staff are difficult to retain due to health and safety concerns. The current pandemic has been eye-opening. Automating what was previously done by hand – for example, using the Servo Multi for large-scale product depositing – can simplify a business’ daily operations.” www.unifiller.com
Mechanical Two Position Sensor Cyntech are happy to announce the new Microprecision mechanical position detection sensor. This series of mechanical sensors is designed to detect two positions within one single product. The distance between the two positions can be customized to the user’s application between 0.3mm and 1.5mm. The fixed NC and NO contacts activate with no measurable hysteresis. Repeatability is better than 5 µm and depending on cable selection, the operational temperature can go from -40°C up to 130°C. The cable termination can be supplied with a M12 connector. This unique patented switching mechanism is designed for low voltage applications up to 30 VDC. It is self-contained and can easily be inserted in multiple forms and shapes of housings. The IP67 rated standard housing sizes are M8 and M12 with a pin or ball plunger. Website: www.cyntech.co.uk Email: sales@cyntech.co.uk Tel: +44 1908 373927
FDPP - www.fdpp.co.uk 25
Cimcorp modernizes intralogistics with softwaredriven automation The company will showcase its automated order fulfillment solutions at Europe’s leading intralogistics exhibition, LogiMAT in Germany
Intralogistics system integrator, Cimcorp,
of groceries in the discount segment,
and vegetable pallets, a solution that
will be exhibiting at LogiMAT, which takes
is automating its logistics for fresh
meets the requirements of our stores –
place from 31 May to 2 June in Stuttgart.
produce with Cimcorp, making Netto
fast, reliably and cost-effectively.”
The global company will demonstrate
the very first German retailer to use this
its holistic solutions to ramp up the intralogistics of major players in the food retail industry. Cimcorp meets customers’ supply chain challenges by integrating its advanced robotic technologies and software with leadingedge material handling systems.
NETTO MARKEN-DISCOUNT AUTOMATES LOGISTICS CENTER WITH CIMCORP
system.
If the system is successfully
“Getting fresh fruit and vegetables
implement additional automated
from producers to the retail floor is an
logistics systems at its other storage
absolute race against the clock,” says
locations. Cimcorp has already
Christina Stylianou, Head of Corporate
successfully deployed automated
Communications at Netto Marken-
facilities in the fruit and vegetable
Discount. “In many cases, only a few
sector in other European countries.
hours pass between receipt at our
commissioned, the retailer plans to
logistics centers and delivery to our
FRESHNESS IS PARAMOUNT
stores. In Cimcorp, we have found a
Cimcorp solutions are designed to speed
service provider to supply us with a
up warehouse operations, which is vital
German food retailer Netto Marken-
solution for fully automated order
for perishable food items in order to
Discount, boasting the largest range
picking of ergonomically packed fruit
maximize their freshness.
26 FDPP - www.fdpp.co.uk
Cimcorp’s solutions are designed to meet the modern demands of distribution, including shorter lead times, SKU proliferation and challenging seasonal peaks amid labor shortages.
“Freshness is synonymous with quality in grocery retail,” explains Kai Tuomisaari, Cimcorp’s VP, Sales. “With limited sales windows for fresh food,
Automated systems fulfill orders in
goods (FMCG) and postal services
faster order processing means that
stages so new products can arrive and
industries.
freshness is maximized at the retail
be picked immediately to guarantee
store, giving a longer shelf life for
freshness. Cimcorp’s solutions are
MEET THE TEAM AT LOGIMAT
perishable products.”
designed to meet the modern demands
Visitors to LogiMAT are invited to
of distribution, including shorter lead
discover more about Cimcorp automation
times, SKU proliferation and challenging
for warehouse and distribution
SOLVING TOMORROW’S CHALLENGES
seasonal peaks amid labor shortages.
applications and book a meeting with the
With fresh food, especially perishables,
The company has developed unique
Cimcorp team at the company’s booths
time is essential. The faster products can
order fulfillment and storage solutions
(Hall 1 #1B81 & Hall 1 Gallery #1OG90).
be delivered to stores, the longer they
for the tire, food and beverage, retail,
will be on sale – resulting in more profit.
e-commerce, fast-moving consumer
www.cimcorp.com
FDPP - www.fdpp.co.uk 27
Powerful and robust electrical components for modern industrial applications Power supplies for DIN rail or wall, UPS, EMC filters, etc. DUST, HUMIDITY, EXTREME
PROTECTION CLASS GREATER IP68
TEMPERATURES, VIBRATIONS
Versions with permanently molded
LARGE PRODUCT RANGE - MADE IN GERMANY
FEAS GmbH specializes in electrical
connection cables make it possible to
FEAS GmbH, located near Hamburg,
increase the already high degree of
develops and manufactures its more
protection from IP68 to IP69K in a few
than 800 different products entirely in
steps.
Germany. Carefully tested, they meet
components for demanding industrial use. Fully encapsulated in high-quality aluminum or polycarbonate housings, power supplies, UPS and other electrical modules are tropicalized and ideally protected for use even under the most adverse conditions. Neither high humidity, nor extreme dust or strong vibrations can affect the power electronics. The use of high-quality electronic components further increases operational reliability.
28 FDPP - www.fdpp.co.uk
all required international standards according to VDE, EN, UL and CSA. e.g. FEAS UPS family LDR80, LDR40, LDR30, LDR20 buffer times up to 270min
Fully encapsulated in high-quality aluminum or polycarbonate housings, power supplies, UPS and other electrical modules are tropicalized and ideally protected for use even under the most adverse conditions.
POWER SUPPLIES • up to IP69K • with boost function or fuse mode • top hat rail or wall mounting • ASi power supplies • 19 inch rack • high temperature battery DC UPS • maintenance-free or • with battery for long buffer times • with RS232/ RS485 interface • Mini UPS OTHER ELECTRICAL COMPONENTS • EMC filter • DC/DC converter • couplers • redundancy modules • motor motion controller • softstarter • rated value distributor FEAS GmbH An der Strusbek 56 22926 Ahrensburg, Germany +49 (0) 4102 - 420 82 www.feas.com
Top right, as an example of the wide range of FEAS power supplies: The switching mode power supply series SNT130-K, 12VDC, 24VDC or 48VDC up to IP69K, boost 150%, fuse mode, large setting range. Right, e.g. FEAS DC filters of the SFK38 and SFK70 series for the suppression of conducted interference.
FDPP - www.fdpp.co.uk 29
Berry’s Technical Innovation Enables Iconic Pot to be Made with Recycled Plastic Leading-edge material technology is enabling Berry Superfos to produce the signature mortar-shaped pot for Spanish food producer Choví Group’s garlic mayonnaise brand, Allioli, incorporating 25% recycled plastic. The new pot retains its iconic shape and sunny yellow colour that ensure maximum brand awareness on-shelf but is now able to contain 25% recycled polypropylene (PP) that is the same quality as virgin material. The recycled content of the packaging has been allocated using the ISCC mass balance approach. In addition, the entire pot can be recycled where appropriate facilities exist. Both the saving of virgin materials and facilitating the reduction in the amount of plastic waste going to landfill support the move to a circular economy. The change in material composition of the injection-moulded pot was made possible by an alliance between Choví, Berry Superfos and supplier of the recycled polypropylene Repsol. All three companies hold the ISCC PLUS
Our partnership with Choví is an example of the kind of relationship that we strive to establish with all our customers every day “The process path of developing our iconic Allioli pot to include recycled
“Our partnership with Choví is an
material has been a long but rewarding
example of the kind of relationship
road, and the result is excellent,”
that we strive to establish with all
commented David Moya, Choví’s
our customers every day,” confirmed
Industrial Director. “It was made
Berry Superfos Iberia’s Commercial
possible thanks to our alliance with
Director, Ignacio Igea. “It involves being
Berry Superfos and Repsol who have
innovative and providing state-of-
been perfect travel companions for us
the-art technology, dedicated service
in this pioneering project to increase the
and commitment to more sustainable
sustainability of the Allioli pot.”
development.”
materials is due to new advanced
This successful collaboration also
For further information on Berry’s
pyrolysis technology. This has enabled
underlines the strength of the over 25
circular solutions and food grade PP
the recovery of waste streams that are
years’ partnership between the Choví
packaging with recycled material,
not suitable for mechanical recycling and
Group and Berry Superfos that will
visit: www.berryglobal.com/en/
which, when converted, produce material
ensure the continuing development of
sustainability/sustainability-strategy/
of virgin plastic quality.
packaging solutions for the customer.
product-impacts
certification which is required to allow the use of recycled material for food product packaging. This certification ensures credible claims for circular materials, as well as traceability throughout the chain of custody. The breakthrough for the food industry that allows food packaging to be made of polypropylene with recycled
30 FDPP - www.fdpp.co.uk
IMA has been providing customers with the finest measurement and analysis solutions since 1991–utilising the latest technology and innovation available.
Our aim is to work with our customers, combining our expertise with our customer’s knowledge of their operations, to provide bespoke measurement solutions for that company’s needs. We specialise in improving measurement and process efficiency for a range of applications and processes, here are just a few: • Ultra-fast gas chromatography for gas and liquid concentrations • Oil on water leak detection • Steam water analysis and sample systems • Oil in water • Dew point • Relative humidity, and • Watercut measurement Ad dre ss:IMA LTD, 1G S apper J or dan R o ssi P ark , Baildon , B D17 7AX Ph on e:+44 1943 878877 Em ail:info@ima.co.u k We bsit e: ima.co.uk
Ishida’s gentle handling helps preserve potato perfection The innovative design of the ‘Gentle Slope’
Potatoes are transferred carefully
multihead weigher from Ishida Europe
from the dispersion table to the pool
has been instrumental in delivering a
and weigh hoppers. The weigher then
high-quality packing solution for a range
calculates in a fraction of a second
of microwavable potatoes from leading
the combination of weights that most
Spanish potato processor, Patatas
closely meets the required target
Meléndez.
weight, which is discharged into the pack.
Based in the municipality of Medina del Campo in the province of Valladolid,
Each weigher is dedicated to one
Patatas Meléndez’s 24,105m2 facility is
pack format, with special distribution
one of Europe’s biggest potato production
systems for the efficient transfer of
plants. For its gourmet microwavable
product from the weigher to the bag or
potatoes, available in both tray and bag
tray. Target weights are 400g for the
formats, the company uses only the finest
bags and 325g for the trays, with the
varieties of small potatoes, which undergo a rigorous sorting and inspection process to ensure selection of the very best product for this premium range. It was
The two 14-head CCW-RVE-GS models from Ishida incorporate gentle slopes and reduced angles throughout the weighers
Ishida weighers delivering excellent accuracy to within xx%. Speeds are governed by the bagging machine and tray sealer at around 40 packs per
therefore essential that the quality of the
to ease the passage of the potatoes,
potatoes be fully maintained during the
importantly avoiding any bruising or
– well within the weighers’ top speed of
weighing and packing operation.
damage.
60ppm.
32 FDPP - www.fdpp.co.uk
minute (ppm) and 25ppm respectively
The two 14-head CCW-RVE-GS models from Ishida incorporate gentle slopes and reduced angles throughout the weighers to ease the passage of the potatoes, importantly avoiding any bruising or damage. “We needed an advanced weighing
The carefully selected small
solution to ensure that these premium
homogenous varieties are double
potatoes retained their quality,” explains
washed with ozonised water and then
Francisco Javier Pérez, Technical Director
undergo further inspection and sorting
at Patatas Meléndez.
before being transferred via conveyor to the weigher. The trays are sealed
“The Ishida Gentle Slope weighers are able
with a double microperforated film that
to achieve this without any compromise
enhances product preservation, while
on speed or accuracy. The weighers are
the bags incorporate a safety valve that
also extremely reliable and easy to set up
ensures perfect controlled cooking of the
and operate.”
potatoes.
The microwavable potatoes – available
Established over 20 years, Patatas
in six different varieties for the tray range
Meléndez combines potato growing,
– provide a delicious and healthy meal
based on classic farming tradition
accompaniment. Microwaving optimises
and know-how, with cutting-edge
the cooking process without affecting their
technological innovation applied to the
taste, nutritional value or appearance.
potato sorting and washing processes.
In its supply of potatoes, the company can guarantee their origin, where they are sown and the way they are grow, to deliver the best product to consumers for their enjoyment. www.ishidaeurope.com
FDPP - www.fdpp.co.uk 33
Comau introduces its N-220-2.7 New generation robot to unlock higher performance and cost-effective automation Comau is expanding its product portfolio
also make it easier to install, use and
with the new N-220-2.7 (N-220), a 220
maintain. Manufactured at the Comau
kg payload robot featuring a modular
headquarters in Grugliasco (Torino),
set up, direct kinematics, absolute
Italy using a state-of-the-art robotic
calibration, and enhanced algorithms.
assembly line, it reliably automates
These characteristics deliver significant
assembly, spot welding, packaging and
ease of use, straightforward integration,
material handling operations, in addition
and faster post-installation maintenance
to continuous process applications such
while ensuring precision, flexibility,
as 3D printing and gluing.
repeatability, and minimum backlash. Manufactured via a fully automated production line directly in our Turin (Italy) Innovation Center of Advanced Robotics, Comau’s increased generation robot offers new levels of quality and supply chain flexibility in addition to cost-effective operation, as required by today’s high-growth market segments. Target Market: Since the 1970s, Comau has built an unrivaled experience in robotics applications in the Automotive industry. The introduction of the more capable, flexible and effective N-220 will consolidate Comau’s position in Automotive while enabling the expansion in high-growth industry segments including Metal, Food & Beverages, Fulfillment and Plastic & Chemicals. “Based on the 2021 IFR (International Federation of Robotics) Report, we expect 160-220 kg payload articulated robots to represent an estimated 30% of the total installed market, composed of 250,000-300,000 units in 2022, with a potential Compound Annual Growth Rate (CAGR) ’22-’26 of 2%” said Nicole Clement, Chief Marketing Officer. “This
traditional manufacturing, with the aim of enhancing cost-effective automation for businesses of all sizes.” Comau’s N-220 is available immediately on a worldwide basis. Design specifics: Comau’s new N-220 industrial robot features an innovative architectural approach based on progressive modularity, component reduction, advanced motors and APC drivers. With its wide working area and Performance Level D cartesian safety features, the high payload (220 kg) robot is perfect for a vast range of industries including automotive, food & beverage, fulfillment and logistics,
improves cycle time, motion quality and path control. Thanks to the use of a nitrogen balancing system on axis 2, and larger stroke-ends on axis 3, the N-220 enjoys increased agility and a wide backward working area that is ideal for bending and handling applications. And because the N-220 uses only two motor sizes, and a single oil type, replacing a faulty motor becomes quick and easy. An additional benefit of the simplified, modular architecture is easier overall maintenance and improved Mean Time Between Failure (MTBF) due to a 50% reduction of robot componentry.
among others. It has a hollow forearm
Recognizing that the integration speed
and an integrated application dressing.
has a direct impact on production
The N-220 robot also benefits from
potential, the N-220 implements
its use of direct kinematics, absolute
Nodal speech-based coding language
calibration and evolved motion
for open, easy programming. The
algorithms. All of which combine to
easy dressing solution is made of
deliver best-in-class repeatability and
two, separate, flexible harnesses
precision. Furthermore, the robot comes
(robot and application power supply)
fitted with integrated forklift adapters
which facilitate an easy and fast
and optional high-torque washers for
upgrade, or replacement. Similarly, the
automatic anchoring base fixing, easier
direct assembly between the motor
relocation and faster installation.
and gearbox simplifies mechanical
new generation robot, which strengthens
The first of a new generation of 6-axis
ourproduct portfolio, generates clear
articulated robots, N-220 addresses
customer advantages thanks to its
the specific market need for cost-
innovative design and state-of-the-
effective and easy to integrate robotics
art advanced robotics technology;
that also deliver high-speed industrial
thus allowing us to better target new,
performance. The holistic design and
high-growth industry segments beyond
modular architecture of the N-220
34 FDPP - www.fdpp.co.uk
Comau’s e-Motion software algorithm
transmissions and minimizes power loss and backlash, thus increasing efficiency and reducing consumption. In short, everything has been designed to maximize performance, durability, safety, maintainability and ease of use. www.comau.com
7 + ( + 2 0 ( 2 ) 9 ,6 & 28 6 3 8 0 3 , 1 * 6 2 /8 7, 2 1 6
Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.
A sample of products we already pump… ᅚHoney ᅚPetroleum Jelly ᅚMascara ᅚSauces ᅚLanolin ᅚLip Gloss ᅚEssences ᅚEye Ointment ᅚMeat Paste ᅚParaffin Wax
T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk
ᅚFace Scrub ᅚTeething Gel ᅚTomato Puree ᅚMedical Adhesives ᅚVeterinary Creams ᅚFruit Paste ᅚToothpaste ᅚMalt ᅚJam ᅚWax
Hall 4.1 Stand C043
Over three quarters of British businesses still unaware of Plastic Packaging Tax With a few days to go until its
The survey found that only a fifth
“The UK’s Plastic Packaging Tax is the
implementation, Veolia reports that
(22%) of the manufacturing and retail
right way to start getting businesses to
77% of British retail and manufacturing
businesses asked had already opted
push sustainability up the agenda, but
businesses are still unaware of the
for recycled content in their packaging.
it needs to go further. A tax escalator
impending Plastic Packaging Tax.
To reach the UK’s Net Zero goals, far
would make choosing to incorporate
more businesses must reduce their
recycled content in packaging both
reliance on virgin materials. The majority
economically and environmentally
of British retail and manufacturing
preferable to using virgin materials.
Research conducted by YouGov, on behalf of Veolia, explored the views of Britishbased senior decision makers across retail and manufacturing businesses on the incoming Plastic Packaging Tax.
businesses also support an escalator in percentage of recycled content threshold (63%) and cost charge (50%) as
“Not only could the UK save up to 2.89 million tonnes of carbon emissions
an incentive to use recycled content.
every year if all plastic packaging
packaging if they do not include 30%
Veolia Northern Europe Zone Senior
also incentivise investment in domestic
recycled content and will come into force
Executive Vice President, Gavin
infrastructure which could make the UK
from 1 April 2022.
Graveson, said;
a world leader in plastics recycling.”
The tax places a £200 per tonne levy on producers or importers of plastic
36 FDPP - www.fdpp.co.uk
included 30% recycled content, it would
The UK’s Plastic Packaging Tax is the right way to start getting businesses to push sustainability up the agenda, but it needs to go further.
can ensure compliance with the complex legislation involved in the reprocessing of these materials, and Veolia’s own Sustainable Packaging Academy. The British retail and manufacturing
Working from three dedicated sites in
Globally Veolia aims to recycle 610,000
businesses who had made changes to
London, Essex and the Midlands, Veolia
tonnes of plastic waste a year by 2023,
their plastic packaging reported:
operates a full process to recycle plastic materials from homes and businesses,
• Two thirds (66%) have reduced the
and turn them back into plastic pellets
amount of unnecessary or avoidable
ready to be used to manufacture new
plastic packaging
plastic items. This can process over
• Over half (58%) now use recycled
100 different grades of plastic from
content
consumer, commercial and industrial
• 54% have changed the packaging
sources, and pass these materials back
design to make it more recyclable • 39% have chosen alternative materials to plastic for their packaging
into the supply chain for reuse. Backing the operations is the support team that
equivalent to 16,944 million 4 pint milk bottles. Veolia is part of the international cross value chain Alliance to End Plastic Waste (AEPW), currently made up of nearly thirty member companies, and this has committed over $1.0 billion to develop large scale solutions that will minimise and manage plastic waste and promote solutions for used plastics. www.veolia.co.uk
77% of British retailers and manufacturers are still unaware of the imminent Plastic Packaging Tax In 2022, Veolia commissioned a survey to find out what British retailers and manufacturers understand about the new Plastic Packaging Tax. UK producers or importers of plastic packaging will be charged £200 per tonne if it does not include 30% recycled content.
63%
If all packaging in the UK had 30% recycled content save the it would equivalent of
2.89million tonnes
of decision-makers support increasing the 30% recycled content gradually.
of carbon emissions every year.
50%
50% would
save the equivalent of
tonnes 5 million
of carbon emissions every year.
22%
Only also support a gradual increase in the £200 per tonne charge over time. Source: 507 senior decision-makers across British retail and manufacturing businesses. The survey was conducted by YouGov Plc in 2022 on behalf of Veolia. Fieldwork was undertaken between 21st - 27th February 2022. The survey was carried out online.
said they currently include recycled content.
FDPP - www.fdpp.co.uk 37
CSB ERP solution provides cost savings and informed business decisions Coherent data capture throughout the production process and detailed analyses, using an ERP solution devised by leading specialist CSB-System, has enabled US meat producer Courage Production to maximise yields and efficiencies throughout its operation, enhance data collection and planning processes, and deliver valuable cost savings. Courage, based in California, specialises in hot dogs, beef jerky, poultry and delicatessen products. To better support government regulations and the increasing documentation requirements
flexibility to respond quickly to short-
for its business, the company introduced
notice orders.
ERP software from CSB, which greatly simplified the processes.
As part of this, the CSB Advanced Planning and Scheduling (APS) module
“In the past, everything was rather
takes the five most important factors
complicated with some 50 pages of
into account for planning - product
paper being passed onto production,
group, label, wrapping films, allergens
such as bills of material, recipes and
and set-up changes. This provides an
work instructions,” explained Courage Production’s president, Rob Engelhart. “We have now digitised and streamlined this to a great extent. At the same time, we have really intensified our data capturing.” One particular example of this is the efficiency gains that have been achieved in the company’s four smoke houses. Around 350 different items go through the smoke houses, where they each lose part of their weight. By weighing every smoking cart before and after smoking, using PC racks specifically set
The availability of such information has allowed optimal planning and distribution of the raw materials to the
optimised planning proposal, which can be adapted dynamically and in detail by managers.
different positions in the chambers.
Several additional optimisation
The numerous minor improvements
measures have further increased
achieved, such as a two per cent
transparency. Overall, the ERP system
increase in hot dog yields and one
and its data on purchase orders, order
per cent less water for beef jerky, has
entries, invoices, calculations, production
translated into a major cost saving.
orders and inventory movements will
“This allows us to optimise the yields
become the ‘workhouse’ and growth
of every item in every smoke house,
driver for all Courage Production’s
and to reduce our losses to an absolute minimum,” said Engelhart.
business decisions. “We want to double our production and
up for this purpose, the ERP system was
As well as high levels of efficiency,
able to aggregate the data to provide a
digital optimisation has also enhanced
precise overview. This enabled Courage
planning and control, with predictive
managers to identify in which smoke
machine planning helping to ensure
house specific products had the lowest
the best possible utilisation of the
www.csb.com/en/the-erp-from-the-
loss.
production lines, while providing the
industry-specialist
38 FDPP - www.fdpp.co.uk
expand our products throughout the United States over the next five years,” said Rob Engelhart.
Pepperl+Fuchs Presents New Portfolio of Vibration Sensors for Optimum Plant Availability From milling machines to pumps and fans to wind turbines—wherever vibrations occur, condition monitoring and predictive maintenance play a crucial role in ensuring personnel and plant protection. To perform reliable measurements of vibration velocity and acceleration in low or high-frequency ranges, Pepperl+Fuchs offers three new vibration sensor series. These devices for global applications come with approvals for hazardous areas up to Zone 1/21 and Div. 2 and certifications for functional safety SIL 1/ PL c and SIL 2/PL d—meeting the highest safety requirements.
THREE DESIGNS FOR VARIOUS REQUIREMENTS Unlike comparable products, Pepperl+Fuchs vibration sensors boast a particularly wide measuring range, capable of measuring vibrations of up to 128 mm/second. These sensors stand out with encapsulated electronics in a rugged, compact housing due to
In turbines and other machines, the vibration sensors by Pepperl+Fuchs reliably measure vibration velocity and acceleration. their maintenance-free operation and exceptionally long service life. They are available in three designs with different functional ranges: The VIM3 sensors (coming soon) are the most miniature vibration sensors in the series, suited for less complex applications. They are certified up to SIL 1/PL c for use in safety applications. The sensors of the VIM6 series are designed for use in high-temperature areas, where they are deployed to measure temperature and vibration.
An analogue output is available for each measured value. The VIM6 series is available with duplex steel housing and is approved for use in hazardous areas up to Zone 1/21. The VIM8 series with encapsulated electronics (coming soon) is designed for use in harsh environments and Zone 1/21 hazardous areas and offshore applications. The sensors come with SIL 2/PL d approval and a temperature range of -35 ... +125 °C. In addition, the vibration sensors are equipped with many sophisticated functions. For example, by means of the integrated crest function, the condition of machine bearings can be monitored, and machine downtime or failures can be prevented before damage occurs. Optionally, users can define two limit values via rotary switches. Once these values are exceeded, they are output via two relays for predictive maintenance purposes. This eliminates the need for extensive software development to evaluate the signal values in a PLC. www.pepperl-fuchs.com
Building on experience. Driving technology. Maximizing performance.
Ultrasonic Sensor Series UC18GS with IO-Link
The new UC18GS series combines the advantages of ultrasonic technology with powerful features to create a sensor solution that meets virtually any application challenge.
For more information, visit
pepperl-fuchs.com/pr-UC18GS
FDPP - www.fdpp.co.uk 39
Wipak UK’s Advanced Paper Butter Wrap Set to Disrupt Market Innovative packaging supplier, Wipak UK, is set to launch a UK-first recyclable paper wrap for butter, which can be recycled at kerbside within the paper waste stream and boasts a 68% carbon footprint reduction when compared to market-standard wraps1 Made from renewable, FSC-certified paper, the highly decorative butter wrap is aluminium-free and covered in highly advanced, ultra-thin natural coatings, which have excellent oxygen and water vapour barrier properties compared
With growing pressure from consumers, brands and retailers need to take decisive action with disruptive sustainable packaging solutions that challenge traditional methods. Gater. “Although made from renewable resources, coated parchment papers do not promote a circular economy as
and runs on existing butter wrap machinery.” Having successfully passed shelf-life trials following packing on automated wrapping lines, Wipak UK’s recyclable butter wrap has also scored an A+ rating in recycling tests2 carried out by the BioComposites Centre at Bangor University. “This classification is the highest possible score that can be achieved for paper recycling efficiency, whereby the pulp recovery must be a
they’re not easily recyclable.
minimum of 98.5%,” continued Keith.
“Unlike existing butter wraps on the
UK-set guidelines for claiming paper
market which are complex material “Most butter wraps in the UK market
recyclability, which require a minimum
structures, our consumer-friendly
are made of parchment paper or
paper solution is fully recyclable within
paper content of 85%.”
a grease-resistant paper which is
the kerbside paper and cardboard
The butter wrap format is one
commonly made into composite
waste stream once it has been cleaned.
of several exciting new product
laminates with aluminum and
What’s more, it maintains the look and
development projects developed using
polyethylene,” explained Wipak UK’s
feel of a traditional butter wrap, can
Wipak UK’s state-of-the-art combi
Technical Development Manager, Keith
be fully printed with brand imagery,
laminator - part of a recent £5million+
to standard paper, as well as superior grease resistance.
40 FDPP - www.fdpp.co.uk
“Our wrap is also compliant with
machinery upgrade to significantly
consumers, brands and retailers need
To find out more, call the Wipak UK
enhance the packaging supplier’s
to take decisive action with disruptive
Sales Team on 01938 555255 or email
sustainable product offering. This
sustainable packaging solutions that
info.uk@wipak.com. Alternatively,
significant investment is helping Wipak
challenge traditional methods,” said
please visit Wipak UK on stand A94 at
UK move closer to its goal of reducing
Keith. “Solutions like Wipak UK’s butter
the Packaging Innovations Birmingham
its company carbon footprint and
wrap will not only have significant
trade show between 25 – 26 May at
achieving carbon neutrality by 2025.
environmental benefits, but will help to
“With growing pressure from
competitive market.”
keep brands relevant in an increasingly
the NEC. www.wipak.com
FDPP - www.fdpp.co.uk 41
Ulrick & Short & Silverson machines partner up for plantbased mayonnaise concept Equipment Manufacturer & Clean Label Developer Run Plant-Based Mayonnaise Trials in Joint Project In the UK, consumer demand for plant-
Using the innovative pumping rotor design, high viscosity products such as Mayonnaise can be successfully mixed on this hygienic pilot scale mixer.
based products has boomed in the past few years, leading to an explosion in plant-based NPD across a wide variety of sectors. For instance, since 2017, plantbased mayonnaises & dressings have experienced a CAGR of 16.6%! In response, Ulrick & Short & Silverson Machines have worked together to demonstrate the manufacture of a plant-based mayonnaise application, utilising U&S’s latest clean-label egg replacement technologies, and Silverson’s high viscosity in-line mixers.
CLEAN EGG REPLACEMENT INGREDIENT SOLUTIONS
manufacture of products such as sauces,
throughout manufacturing, and that the
including ketchup, mayonnaise and
oil and aqueous phases do not separate,
sweet sauces and for applications in the
or ‘break’. It also provides the thick texture
pharmaceutical, cosmetics and chemical
& creamy mouthfeel characteristic of a
industries. Silverson’s Flashmix powder/
‘conventional’ mayonnaise.”
liquid mixers are also suitable for higher viscosity products where large amounts
Lesley Smith, New Product
of powders need to be dispersed
Development Engineer at Silverson
and hydrated. Silverson offer mixers
said “Following on from the success
suitable for the production volumes of
of our Flashmix Powder/Liquid mixers,
Ulrick & Short have developed a new
mayonnaise from 10 to 500L. In addition
we’ve developed a pilot scale version.
ingredient specifically for plant-based
a full range of equipment from laboratory
This new mixer is an ideal mixing system
mayonnaise & dressing applications.
scale to full production is available for
for recipe and process development.
The ingredient, called ovaproxTM 11, is
other applications, meaning the results
Large enough to represent full scale
the latest addition to the company’s egg
obtained in the laboratory can easily be
production and producing sufficient
replacement range. ovaproxTM 11 has
reproduced on the production floor.
batches for consumer testing, yet small
dual functionality, firstly acting to replace
enough to be bench-mounted and used in
the emulsification function of egg in
Ulrick & Short’s R&D Technologist, Tobias
mayonnaise, and secondly acting as a
Powell, said “ovaproxTM 11 doesn’t only
stabiliser, meaning the product does not
replace the functionality of the egg in
require the addition of hydrocolloids with
emulsifying, but it also acts as a stabiliser.
pumping rotor design, high viscosity
less consumer-friendly declarations, such
This means the mayonnaise doesn’t
products such as Mayonnaise can be
as like guar and xanthan gum.
require the addition of hydrocolloids,
successfully mixed on this hygienic pilot
which often carry label declarations that
scale mixer. Designed with scale-up in
are not always perceived as positive by
mind, processes can easily be scaled
consumers, such as gums.”
up to larger Silverson mixers such
ovaproxTM 11 carries with it a clean-label declaration, as well as being non-GMO, and allergen free – ensuring consumer friendly ingredient declarations.
HIGH VISCOSITY IN-LINE MIXERS
Powell added, “ovaprox 11 is one of 3 formulations which have been tailored to work at different oil content levels –
a test kitchen.” Smith added, “Using the innovative
as the Mayonnaise plant, achieving consistent results without the need for reformulating.”
Silverson’s range of high viscosity In-
anything from a 50% to 70% oil recipe.
www.cleanlabelingredients.com
Line mixers has been developed for the
This ensures the product is stable
www.silverson.com
42 FDPP - www.fdpp.co.uk
Powder/Liquid Mixers From Laboratory to Production Scale
Introducing the Silverson FMX5 Laboratory Scale Powder/Liquid mixer. Silverson can now offer Powder/Liquid mixing solutions to customers mixing from the Laboratory to full scale production. The FMX5 provides a simple, effective and hygienic means of powder/liquid mixing on a laboratory scale and provides an accurate and easy means of predicting the performance of the Flashmix in the laboratory.
For more information please visit: www.silverson.co.uk Email: sales@silverson.co.uk • Telephone: (+44) 1494 786331
FDPP - www.fdpp.co.uk 43
Blowing hot and cold LAES and the future of energy storage Liquid Air Energy Storage (LAES) facilities
solar and tidal — while they are far less
renewable power, the challenge of storing
provide a new way of storing electrical
damaging to the planet than fossil fuels
energy — and the ability to quickly release
energy. Using large gas compressors to
— are notoriously difficult to predict. This
it when demand is high — is becoming a
turn air into liquid, LAES provide a method
fluctuation creates issues when balancing
significant conversation in industry.
of storing this pressurised energy for future
energy supply and demand.
use. With no geographical constraints, little
HOW DO LAES WORK?
environmental impact and no depletion on
Consider this as an example. A wind
LAES facilities can provide a solution to
scarce materials, it’s no surprise that LAES
farm operating in the North of England
fluctuating energy supply. Their large gas
have been cited as the future of energy
may have several days of intense energy
compressors turn air to a liquid and then
storage. But, what does it take to get a
generation due to high wind speeds
store it in insulated, pressurised tanks,
LAES facility operational? Here, Marek
causing consistent movement of the
which keeps it as a liquid.
Lukaszczyk, marketing manager for WEG
plant’s turbines. However, if the United
Europe and Middle East explains.
Kingdom’s wider energy grid is already
LAES, alongside other energy storage options, will prove to be critical as the world continues to transition to renewable power. Renewable sources, such as wind,
44 FDPP - www.fdpp.co.uk
saturated with power, there becomes a dilemma of where to store the wind farm’s
In order to generate power, the air is then heated and allowed to expand again, and the pressure pushes a gas turbine around
excess energy.
to generate power. Using this method,
As the world continues to transition to
created in this environment is air.
energy is stored, and the only emission
The beauty of this system is that each component part of the process is built using tried and tested technology, which we know works and has established performance parameters. Air turns to liquid when refrigerated to -196°C, which is usually achieved by a cycle of compression, cooling and expansion, it can then be stored in conventionally insulated, ambient pressure vessels at very large scale. Exposure to ambient temperatures causes rapid regasification and a 700-fold expansion in volume, which is used to drive a turbine and create electricity. Several years ago, WEG took part in a project designed by Highview Power Storage, to deliver the world’s first full scale LAES.
MAKING LAES OPERATIONAL
“Halifax has developed its centrifugal range
Highview Power Storage’s technology drew
to maximise energy efficiency and WEG
from established processes from the turbomachinery, power generation and industrial
offers a very energy efficient IE3 motor as standard so this also influenced our
gas sectors.
decision. Every little helps in this situation.”
Stuart Nelmes Head of Engineering at
The energy storage plant uses the same
Highview explained, “The beauty of this system is that each component part of the process is built using tried and tested technology, which we know works and has established performance parameters. The centrifugal fans sourced from Halifax Fan, one of the UK’s leading suppliers, driven by WEG motors, one of the worlds most recognised brands, therefore fitted our remit very closely.”
principle used to make your kitchen fridge cold — but more akin in scale to the effect you see freezing moisture in the air creating slabs of ice that crack off the surface of a space rocket as the fuel tanks empty. In the aforementioned project, Highview needed a very reliable, well-proven blown air solution to regulate the temperature and airflow around some of the key components in the system and so the Halifax Fan / WEG
“The LAES system comprises of three
combination was a good option.
primary processes: a charging system, an energy store and a power recovery stage,”
In addition, WEG’s after sales service
Nelmes continued “The energy efficiency of
and extensive support network could
each stage is crucial to the economic viability
ensure that the technology would be
of the project. Because we have to power
reliable for years to come.
the system with the electricity we generate or buy it from the grid the energy efficiency
GREEN MACHINES
of each component is very important.”
A key benefit of LAES are their green credentials. Once constructed, the commercial installations will be close to environmentally neutral, as the output is simply air. Or in the case of this test unit, inert Nitrogen supplied by BOC, which makes up 78 per cent of the atmosphere. LAES are very effective for storing energy from renewable sources such as wind turbines, solar panels and tidal pools. Particularly, when there is a grid surplus as it provides a method to store and then feed energy back into the grid when demand peaks. These facilities have masses of potential for the future of energy storage. And as the world continues to aim towards ambitious emission reduction targets and renewable energy goals, energy storage will become a crucial mechanism of balancing energy supply and demand. More information on WEG and its support and experience in energy storage, generation and other power related projects, please visit www.weg.
FDPP - www.fdpp.co.uk 45
Gist launches trial of Sunswap’s zero-emissions transport refrigeration unit Logistics specialist Gist has partnered
the Government’s commitment to reach
commitment to creating a greener, more
with cleantech engineering firm
Net Zero by 2050 and the ban of red
efficient distribution fleet.”
Sunswap to trial a zero-emission,
diesel use from 1 April 2022.
solar and battery powered transport
Michael Lowe, Sunswap’s CEO, said:
Dependent on weather conditions,
“Sunswap is thrilled to be working with
Sunswap states the solar panels on the
Gist. They operate one of the largest
fleet.
Endurance TRU can provide 65 to 80 per
chilled distribution fleets in the UK
cent of the charge needed throughout
and their commitment to reduce their
Sunswap is a start-up business
the year to operate the refrigeration
emissions is perfectly aligned with our
developing electric transport
unit, considerably reducing the time and
mission to decarbonise the cold chain.
refrigeration technology that utilises
cost to charge. The Endurance is able
energy prediction software, adaptive
to operate at 10 per cent of the running
“With diesel now more expensive for
battery capacity and a solar energy
costs in comparison to a diesel-powered
TRUs and emissions targets getting
recovery system to help decarbonise
TRU.
closer, the logistics sector has responded
refrigeration unit (TRU) within its temperature controlled distribution
refrigerated trailers in the cold chain.
fantastically and is actively looking for Kate Brown, Gist’s Communications
innovative solutions to achieve net
The trial, operating from Gist’s
and Sustainability director, said: “Gist
Chesterfield depot, forms part of Gist’s
is actively collaborating within the
commitment to explore innovative
industry to understand new, developing
solutions to reduce carbon emissions,
technology that can minimise our
particularly among its distribution fleet.
impact on the environment. We are
As an industry, the need to explore
always looking to trial new innovations,
www.gistworld.com
alternatives is more pressing following
such as Sunswap’s TRU, as part of our
www.sunswap.co.uk
46 FDPP - www.fdpp.co.uk
zero. We are excited to continue our customer deployments and help more fleet operators cut diesel from their temperature-controlled trailer fleet.”
Packaging Innovations and Empack returns to Birmingham’s NEC Packaging Innovations and Empack 2022 will bring together the industry when it returns to Birmingham’s NEC on 25 and 26 May. Leading exhibitors from across the entire packaging spectrum will display their cutting-edge designs and products, with guests able to get handson with a broad range of technologies and systems designed to help assist their packaging requirements.
NEW INNOVATION The event will feature a sold-out exhibition floor, with many exhibitors launching their latest innovations live at the event. The Label Makers will display its range of sustainable label solutions, including those for recyclable bottles. The bespoke service is aimed at delivering the strongest on-pack message, to ensure maximum shelf stand-out. Expac will promote its wide range of bottles, tubes, jars, and glassware, designed for use in the personal care and household sectors. The company has invested in its sustainability credentials, by developing a range of bag-in-box refill products which house a variety of
semi-automatic volumetric filling
solutions to a panel of judges including
machine. The technology is suited
Ocado and Pret A Manger. Also, The Big
to a busy production environment,
Debate will tackle the latest challenges
where flexibility, accuracy, and rapid
in packaging regulations and assess
changeovers are required. Volume and
whether these guidelines will have a
flow rate is electronically controlled,
positive impact on reducing waste and
with a fill accuracy of +/- 0.5%. The
improving recyclability.
machine is fully upgradable, with automation options including conveyors, capping, rotatory tables, and labelling
Easyfairs’ Divisional Director, Renan Joel, notes: “The range of exhibitors
machines.
coming to this year’s show is greater
EVENT FEATURES
and Empack caters for every part of
than ever before. Packaging Innovations
The Packaging Innovations and Empack
the packaging supply chain, no matter
emulsions, and liquids.
2022 seminar programme will run
how niche. Our visitors will no doubt
across three stages, demonstrating the
enjoy getting hands-on with the latest
Epson’s Colorworks range of desktop
event’s commitment to address the
industry tech, designs, and innovations,
label printers will also be featured at
plethora of issues currently affecting
and will be able to take away some
the show. The printers can be used for
the industry. The Empack Technology
invaluable advice from our expert-led
several procedures, including food and
stage will feature content specifically for
seminar programme. There is so much
drink labelling, pharmaceutical and
manufacturing, processing, and logistics
to look forward to this year, and we
shelf labels, chemical, horticultural,
professionals, whilst the Innovation and
can’t wait for the doors to open in May!”
and badge labelling. The C6000 series
Design stage and the Ecopack stage
offers up to 4-inch print widths, with the
will focus on the latest developments
C6500 offering up to eight inches. The
in packaging technology, with a specific
C7500 model can produce a wide range
focus on sustainability.
please visit the registration page. For
Further to this and in association with
the Packaging Innovations and Empack
with a matte or gloss finish.
OPRL, the Ecopack Challenge will
NEC 2022 website or contact the
make its long-anticipated return, with
show team on +44 (0)20 196 4300 or
Also present will be Excel’s EX-FILL-S
innovators pitching their cutting-edge
PackagingUK@easyfairs.com.
common food products, such as oils,
of media, including continuous tickets, fabric labels, and synthetic die-cut labels,
48 FDPP - www.fdpp.co.uk
To register to attend Packaging Innovations and Empack NEC 2022, any further information, please visit
Packaging Innovations & Empack
25 & 26 May 2022 | NEC, Birmingham
The future of packaging technology! Empack is the UK’s premier show that, alongside Packaging Innovations and the special feature Contract Pack & Fulfilment, covers the entire packaging value chain. • • • • • •
Meet over 280 innovative suppliers Network with and learn from packaging experts on the dedicated Empack stage Discover 100s of NEW technology and packaging solutions See the latest innovations within • Smart Packaging • Industry 4.0 • Industrial Robots & Automation • E-commerce fulfilment
Register to attend Scan this QR code or use code 1152
www.packagingbirmingham.com
The show is the perfect place to see and meet with everyone in the industry – you can’t beat it. Sasha Nelhams-Fielding, Sales & Marketing Manager, FMP Ltd
Everything we needed all under one roof, great to be able to take your product ideas with you and look at the filling capacity , bottles, pack of and shipping logistics all in one day saving hours of trying to find the right companies online. Ellie Dunmore, General Manager, Penny Price Aromatherapy Ltd
GNT launches first EXBERRY® Coloring Foods made from organic safflower concentrate to the market, opening up
GNT has expanded its range of EU organic-certified EXBERRY® Coloring Foods with new yellow and green shades made from organic safflower. The organic market is seeing exceptional growth as modern consumers pay closer attention to food and drink products’ health and sustainability credentials. In response to the rising demand, GNT has launched two new EXBERRY Organics ®
products.
Suitable for a wide variety of food and beverage applications, the new products extend an EXBERRY® Organics range that already features red, purple, blue, and orange options.
exciting new possibilities for organic brands.” Based on the principle of coloring food with food, EXBERRY® Organics are created from edible fruit, vegetables, and plants using traditional physical processing methods. They are certified organic in accordance with EU regulations and qualify for completely clean and clear label declarations throughout much of the world.
EXBERRY® Organics ‘Fruit & Veg Yellow’ is made from organic safflower and organic apple, while EXBERRY® Organics ‘Veg Green’ is made from organic safflower and organic spirulina. Both are compliant with Organic Regulation (EU) 2018/848.
that already features red, purple, blue, and orange options. GNT Europa’s Managing Director, Petra Thiele, said: “EXBERRY® Organics can be used to create spectacularly vibrant food and drink while maintaining perfectly
EXBERRY® Organics concentrates are also 100% vegan-friendly, halal, and kosher. In addition, the fully traceable raw materials are grown using sustainable methods by farmers working as part of GNT’s vertically integrated supply chain.
Suitable for a wide variety of food and
clean ingredient lists. We’re delighted
beverage applications, the new products
to now be able to introduce Coloring
For more information on EXBERRY®
extend an EXBERRY Organics range
Foods made from organic safflower
Coloring Foods, visit: www.exberry.com
®
50 FDPP - www.fdpp.co.uk
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