Food & Drink Processing & Packaging - Issue 40 2022

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

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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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Tel 01304 806039

www.fdpp.co.uk All web addresses are interactive, simply click the web address of your choice to view the company website. There is also a useful tool bar where you can search for a specific product.

Features

SPARC SYSTEMS B-HIVE INNOVATIONS CIMCORP BERRY GLOBAL ISHIDA COMAU VEOLIA CSB WIPAK WEG GIST PACKAGING INNOVATIONS & EMPACK GNT

<4 < 18 < 26 < 30 < 32 < 34 < 36 < 38 < 40 < 44 < 46 < 48 < 50

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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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