FDPP - Issue 12 2017

FOOD & DRINK PROCESSING & PACKAGING

Bespoke Line Keeps The Biscuits Flowing Setting A New Benchmark For Changeovers

TOMRA and Farm Frites Donate €2,000 to UNICEF Issue 12 2017

PLUS... Taking Control Of Automation In The Food & Beverage Sector

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Contents

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

Managing Editor Antony Holter editor@mhmagazine.co.uk

Creative Director Josh Holmes josh@mhmagazine.co.uk

Assistant Editor Justine Sanders justine@fdpp.co.uk

Sales Manager Benjamin Dubois benjamin@fddp.co.uk Tel: 01227 392529

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

Publishing Director Martin Holmes martin@fdpp.co.uk

Studio Designer James Sayer james@mhmagazine.co.uk

M H Media Global Ltd.

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

Tel 01843 830249 l Fax: 08721 152240

www.fdpp.co.uk

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

Please mention FDPP when responding to items in this issue.

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Features

Burkert

< 04 HRS < 08 Borde

< 12 Premier Labels < 14 Fortress

< 16 ISHIDA

< 22 Tomrs

< 28 Veviba < 29 Badder < 32 Bebo < 33 FDPP - www.fdpp.co.uk 3

NOTE WRITTEN BY Burkert PHOTOGRAPHY BY Burkert

Taking Control Of Automation In The Food & Beverage Sector Increasing competitiveness and

years and many will now be looking

Many smaller systems and standalone

higher levels of regulatory compliance

at the next step; increasing efficiency

equipment use a centralised control

are placing greater demands on

and gathering the increasing amounts

concept, which is based around a

the food and beverage industry;

of data required for effective process

control cabinet that contains all

improving automation levels and

management and traceability.

of the necessary components to

plant integration can address these concerns. However, with every installation being unique, creating an automation solution that is specifically matched to the application

Levels of efficiency are determined by the scale of the production facility, however improving the levels of automation within a process of any

operate the control valves, including a PLC, network connections, input/ output systems and valve islands for example.

requires considerable expertise.

scale can deliver improvements to

In many cases, especially in larger

maintenance costs, production costs,

facilities, working towards a

The food and beverage industry,

reliability and, most importantly,

decentralized system of process

along with pharmaceuticals, must

quality.

control can provide a number of

maintain some of the highest hygiene standards - whilst also delivering high volume production systems. In addition, competitive forces demand that a business is efficient both in terms of the raw materials consumed and cost of manufacturing. Delivering these objectives is a crucial part of remaining in the industry.

All process manufacturing businesses will have introduced automation to a greater or lesser degree over recent 4 FDPP - www.fdpp.co.uk

Improved control and monitoring also reduces wastage of expensive

benefits compared to the more traditional approach.

compounds, provides improved

This concept uses intelligent,

production reliability while also

pneumatically operated process

delivering the continuous data

valves at the field level which can

required to meet regulatory

be equipped with all the required

standards.

automation components such as a

By making significant reductions in costs, a properly engineered production system can deliver high quality products in an efficient process.

pilot valve with manual actuation, electrical feedback units and optical status indication, field bus interfaces and even positioners and process controllers.

To bridge the gap between centralised and decentralized automation concepts, flexible pneumatic valve units and compact automation systems can be used.

These units are typically wallmounted directly inside small, hygienically designed cabinets that can be installed close to the process in question. These small, pre-configured and standardised units eliminate the long runs to valves and field devices, and can be easily kept clean.

Each and every one of these scenarios will be unique and that requires the manufacturer of the control panel

such as reducing supply chain

in a stainless-steel hygienic EHEDG

to take a very individual approach to

management costs while improving

cabinet, to locate the compact field

each project. At BĂźrkert, a network of

production agility and the use of

control box right in the process area,

specialist design and manufacturing

internal resources.

which shortens the distance to the

facilities, each known as a Systemhaus has been in operation for several years. Their purpose is to deliver precise fluid control systems designed to meet very specific process requirements and regulatory

BĂźrkert manufactures over 100,000 different products, typically valves, actuators, sensors, controllers and combined devices. Applying these products to scenarios that require

standards.

specialist assemblies requires skill and

The definition of a bespoke control

approach.

system means that the designers have to start from the ground up, working closely with the client to establish what will be delivered by the new system and how best to achieve it. Often existing technology and components will have to be integrated with unique parts and custom designs

experience as well as an imaginative

The Systemhaus combines all of these attributes and assigns a team that contains all the necessary skills and expertise to design, simulate, prototype, construct and test the finished product. Working closely with the client, this team has the ability to

in order to achieve the best solution.

ensure the most efficient methods

The principle of outsourcing this type

completed design.

of project is considered by the vast majority of OEMs as an essential part of manufacturing strategy, one that allows them to remain competitive in

process valves.

are used to develop an idea into the

Using in-house manufacturing facilities enables bespoke components to be created and

a rapidly changing global market.

matched to the application, reducing

In practical terms this strategy can

and cabinet size. Where necessary

deliver a number of improvements

the control system can be housed

component count, installation time

FDPP - www.fdpp.co.uk 5

Companies in the food & beverage

BĂźrkert offers the widest range

sector are now in a position to

of equipment to actuate, monitor,

reconcile the commercial necessity of

network, position and decentralise

a high degree of automation of their

process control into the field. In

production with the requirements of

BĂźrkert's central control cabinet

hygiene and safety.

solution, each component is the

Thanks to their modular structure, control panels based on the latest control technology can be adapted to suit many situations and applications, whereby such optimised solutions are always based on high-quality, tried and tested components with a long service life.

6 FDPP - www.fdpp.co.uk

product of cross functional mechanical and electrical engineering innovation and exacting laboratory testing.

Combining these products with the design expertise and industry experience of the Systemhaus, ensures the optimum solution is delivered to every client.

Burkert For over 70 years, we at BĂźrkert have been devoting a lot of time and energy to liquids and gases.

www.burkert.co.uk

New Closure Testing Microsite Launched By Mecmesin

Mecmesin, a leading British designer

may require torque or tension/

and creativity in design is continually

of force and torque testing equipment,

compression testing to meet

expanding the vast array of closures

has launched a new vertical solution

legislative or functional requirements.

and containers which need to be

microsite for manufacturers and end

tested for quality performance.

users of packaging closures.

Accurate and repeatable test measurement often needs custom

Due to the differing shapes and sizes

ClosureTesting.com focuses on the

fixturing, and the site showcases

involved it can often be difficult to

specific requirements for the quality

grips and fixtures designed for unique

select the best type of test equipment

testing of all types of closure and

customer samples—in addition to a

and holding fixtures to measure the

guides the visitor to the product best

wide range of standard accessories—

strength of closures – Mecmesin’s

suited to the closure material and test

alongside case studies and success

new microsite, backed up by the

type combination selected.

stories.

illustrative presentation video,

Mecmesin has supplied test solutions

Responsive web design is

to customers in all consumer

implemented for the optimum user

packaging industries; medical/

experience that is equally accessible

pharmaceutical, cosmetics and

across mobile, tablet and desktop

personal care, drinks, food/dairy

browsing devices. Video media also

and household/industrial and the

features extensively; performing

microsite provides quick access to this

international closure test standards,

Mecmesin

wealth of experience.

product overviews and best practice

Mecmesin is an established market leader

The content covers applications

for ensuring accurate test data.

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

in the design and manufacture of closure testing solutions, from simple, manual

for screw caps, tamper evident,

Mecmesin’s Sales Director and

ROPP and child-resistant closures,

Mecmesin GmbH Managing Director

automated closure testing systems.

plus stoppers and dispensers that

David Wilde comments: “Innovation

www.closuretesting.com

closure testers through to complex

FDPP - www.fdpp.co.uk 7

A food plant guide to obtaining PAS 110 Certification for anaerobic digestate

By Matt Hale, International Sales

which must be purchased, it is available

Manager, HRS Heat Exchangers

free of charge to anyone. Although there

‘PAS 110’: six characters which, depending on your point of view either strike terror into your heart or show the wider world, and customers in particular, the attention to detail and quality that

are a number of links available on the internet, to make sure you find the most up-to-date version, you should use the link on the WRAP website – visit www. wrap.org.uk and search for ‘PAS 110’.

lies behind your AD process and your

The standard was first published in

digestate.

2010 by the British Standards Institution

What is PAS 110 and why should you consider it?

Whatever your reaction, there is certainly no need for plant operators to be wary of the requirements of PAS 110.

Achieving the voluntary standard can provide significant benefits – not least an increase in the value of digestate sales – and, contrary to some perceptions, the standard is not overly prescriptive.

(BSI) and the latest (second) version was updated in July 2014. When used in conjunction with the Quality Protocol for the production and use of anaerobic digestate it provides the best evidence of the safety and consistent quality of digestate produced by an AD plant, allowing it to be classified as an organic fertiliser product rather than a waste, and certified under the Biofertiliser Certification Scheme (BCS) Rules. This provides another potential income

PAS 110 actually stands for Publicly

stream for AD plants using food waste

Available Specification number 110. As

as a feedstock, which can be increasingly

it suggests, this means that unlike many

important in the current economic

British and International quality standards

climate.

8 FDPP - www.fdpp.co.uk

The scope of PAS 110 – Understand your feedstock

The role of pasteurisation The standard does not specify the

A number of plants in the UK meet

type of pasteurisation to be used,

the requirements of the standard,

or where in the process it should

including several which handle food

occur (i.e. treatment of feedstock

and mixed organic waste.

before digestion or treatment of the

But before attempting to join them,

digestate itself).

it is important for an AD operator to

It does provide some exemptions

understand what PAS 110 is, and is

where pasteurisation is not required,

not.

such as where the plant is already

It is a voluntary industry-led specification designed to boost the market for digestate and act as a precursor for a potential full British Standard at some time in the future.

It is not a statutory document and, as such, compliance with PAS 110 does not absolve plant operators and digestate producers from other legislative requirements, such as compliance with Animal By-Products (ABP) regulations and environmental permitting.

The standard requires producers to have sufficient control processes and to undertake hazard analysis and critical control point (HACCP) planning through an appropriate quality management system (QMS). It also has specific definitions for different terms, including ‘catering waste’ and ‘source-segregated.’

Much of the standard is about ensuring that producers have the right management policies in place to prevent contamination and ensure the quality and safety of the end product.

However, it is the requirement for pasteurisation which tends to scare off plant operators considering applying for PAS 110.

covered by Animal By-Products Regulations, or where certain specified feedstocks arise within a holding where the digestate will be used exclusively.

In terms of the actual pasteurisation requirements, PAS 110 specifies: ‘all digestates shall be produced by an AD process that includes: a) a pasteurization step capable of heating all material to at least 70 °C for one hour; or b) an equivalent alternative treatment validated for its efficacy at reducing a suitable plant pathogen indicator species.’

It can be seen from this that the reasons for pasteurisation are as much to protect agricultural soils and crops from the risk of spreading crop diseases and pests as they are about preserving human and animal health.

70 oC (about two thirds as much).

But even installing a traditional single tank pasteurisation system at this stage can be very inefficient and may require additional buffer tanks to avoid slowing down the overall AD process.

A more energy efficient alternative is an HRS 3 Tank Batch Sludge Pasteuriser. This has three tanks allowing one to be pasteurised while one is emptying and the other is filling, ensuring that pasteurisation does not slow down overall throughput.

Ultimately, it is a simpler solution than a single tank option which may require buffer tanks and additional controls to restrict flow elsewhere in the process.

Furthermore, the heat exchangers used in the HRS system recapture the heat and use it again, making them up to 70% more efficient than traditional single tank ‘heat jacket’ type pasteurisation systems.

Installing pasteurisation to meet the requirements of PAS 110 need not be complicated and there are likely to be many suitable equipment solutions on the market.

This means that plant operators and

However, care needs to be taken

their equipment suppliers have a large

that the one you chose is suitable,

degree of flexibility about how and

not only to meet the standard’s

where to install a pasteurisation step.

straightforward requirements, but

Reducing energy use and maximising efficiency As the temperature of material leaving the anaerobic digester is generally warmer than the feedstock entering it (typically around 35 oC post-digester compared with 15 oC pre-digester),

also to fit in with your overall AD process without adding unsustainable energy or management costs.

HRS Founded in 1981, the HRS Group operates at the forefront of thermal technology, offering innovative and effective heat transfer products worldwide with a strong

less energy is typically required to

focus on managing energy efficiently.

heat the material to the required

www.hrs-heatexchangers.com FDPP - www.fdpp.co.uk 9

Measuring & Monitoring Compressed Air Systems Covers a wide range of choices for plant and operations managers, and the decisions taken in this area can have significant benefits for plant profitability and reliability.

Due to the high power consumption

(Pspec) by dividing the consumption

Microbiological sampling can also be

of industrial compressors compared

by the FAD giving an answer in kWh/

provided as an option for the S 600

to other plant systems, they are often

mÂł. This figure can then be used

Air Analyser. Leakage is an issue for

the focus of users looking to reduce

for cost centre allocation where

all plants in terms of contamination,

energy bills.

additional flow metering is employed

ongoing maintenance and potential

in the distribution system.

energy savings.

and power factor allow the calculation

The delivered air quality is dependent

Determining the amount of leakage

of power consumed in kW and kWh

on the air treatment installation,

using thermal mass flow meters

which will show how much of the

distribution system and the

will quickly illustrate the potential

energy bill is going to creating plant air

maintenance of both. Every plant

savings possible if the leaks can be

but not how efficient that process is.

risk assessment will highlight which

identified and repaired. Using an

contaminants are needed to be

ultrasonic detector like the S 530

monitored and in conjunction with

allows operators to quickly locate

legislation compliance or international

and highlight areas for this remedial

standards, the acceptable levels

action.

Measuring the supply voltage, current

Determining the Free Air Delivery (FAD) of the compressor at the outlet by measuring the output pressure, temperature and flow, will need a sensor selection that will cope with the high temperature and flow rate of very wet air.

The S 430 by CS-iTEC GmbH was designed for this application as an insertion type pitot tube flow meter that also measures pressure and temperature, allowing the calculation of FAD from only 1 sensor. This will allow the subsequent calculation of the compressor Specific Power 10 FDPP - www.fdpp.co.uk

for each can be determined prior to considering sensing options.

Regular if not continual, monitoring is beneficial to rapidly highlight changes in air quality to target maintenance teams and reduce the risk to product quality or operator safety. There are a wide range of fixed and portable sensors covering dew point, particle count and oil vapour units.

WRITTEN BY Red Dragon Valves PHOTOGRAPHY BY Red Dragon Valves

Red Dragon Valves Red Dragon is an independent specialist distributor of valve and instrument solutions for process control and automation applications in safe areas, corrosive, or hazardous environments.

www.reddragonvalves.co.uk

When measuring compressed air quality...

Do you prefer separate instruments?

S 505 Dew Point

S 130 Particle Count

S 120 Oil Vapour

Or an all-in-one simple to use, portable solution?

S 600 5 in 1 Air Analyser Dew Point Oil Vapour Particle Count Pressure Temperature and option for Microbiological sampling

Ask us about all the choices available: 01443 772500

Red Dragon Ltd Unit 15 Abergorki Industrial Estate Treorchy Mid Glamorgan CF42 6DL T: +44(0)1443 772500 E: sales@measuremonitorcontrol.com W: measuremonitorcontrol.com

Measure | Monitor | Control

Multihead Weigher Solution For Sticky Mushrooms An Ishida Screwfeeder multihead

by the small pieceweight of the

weigher has completed the automatic

product, which prevents gravity from

weighing process at leading French

overcoming the adhesion forces. The

mushroom supplier Borde, handling

Ishida replacement solution – chosen

the most challenging and naturally

by Borde after submissions from

sticky type of mushrooms – those

three leading multihead weigher

that have just been blanched,

manufacturers - is a 14-head

ready for canning or bottling – with

Screwfeeder model, in which the

improved throughput and accuracy.

mushrooms are received from the

Having installed an Ishida weigher to handle its dried and frozen mushrooms, Borde initially selected a weigher from another supplier for its blanched mushrooms.

However, this was not up to the job, because these mushrooms are far stickier than the dried or frozen mushrooms, clinging to feeders and hoppers, and this is made worse

12 FDPP - www.fdpp.co.uk

dispersion table into feeder troughs which contain large metal spirals (screws). These push the product gently but very firmly along to the hoppers.

The dispersion table itself is a rotating, cone-shaped unit which easily shrugs off the mushrooms falling from the infeed, discouraging sticking and moving them decisively into the screwfeeder system.

When the mushrooms reach the

Borde Chairman and Managing

ends of the troughs they fall,

Director Alain Borde is very pleased

channelled by embossed metal

with the new multihead, which can

shrouds, into non-stick plastic

handle mushrooms of all textures.

pool hoppers, from where they are released into weigh hoppers of

“We have increased production by

similar construction.

20% and really mastered our target

The doors of both sets of hoppers

and consistency, which is crucial,

open with a scraping action that

given the expensive nature of the

prises off any clinging mushrooms.

raw product,” he explains.

A further appeal of the new Ishida

For the dried and frozen

solution was the fact that it was

mushrooms, Borde uses a 14-head

Ishida Europe is a leading supplier of

a ‘drop-in’ replacement for the

Ishida weigher which is mounted on

automated solutions, meeting the ever-

rejected model, with no changes

wheels, giving it the flexibility to be

needed to the infeed conveyors or

shuttled back and forth between the

to the discharge distribution system.

two lines as required.

weights in terms of both accuracy NOTE WRITTEN BY Ishida PHOTOGRAPHY BY Ishida

Ishida

changing challenges presented by the processing of products in the food sector.

www.ishida.com

FDPP - www.fdpp.co.uk 13

Setting A New Benchmark For Changeovers Premier Labellers, who have been

is capable of ensuring extremely

P250 with Process Optimization

supplying pressure sensitive labelling

accurate and repeatable labelling

Technology to cope with labelling this

systems to the many of the

quality, regardless of technician or

wide range of different products.

UK’s leading FMCG manufacturers since 1994, will be showing their

operator. Every movable set point can now be recorded and repeated, to an

Mr Jones, Managing Director at RK

accuracy of 0.25mm”.

& J Jones comments: “We did a lot of

Technology at the forthcoming PPMA

The first P250 to be fitted with the

and found that the P250 on offer from

TOTAL processing and packaging

new system has been purchased by R

Premier was by far the most suitable

show.

K & J Jones Limited who are a family

machine for our range of products.

owned business operating at a 12-

Their new system for changeovers

acre site close to Thetford in Norfolk,

really helps us maintain the quality

UK; involved in the manufacture,

output the P250 can provide and

dispensing and distribution of a wide

keeps our downtime to below 15

range of building and decorating

minutes for a complete product

products. It is their Bird Brand

changeover.”

innovative new Process Optimization

The new system is featured on the industry leading P250 high speed front, back and wraparound labeller has been developed by Premier to greatly improve their customers process for changeover and setup.

Premier Labellers Managing Director, Tracie White, explains: “The system

products that are gaining the most recognition for a reputation for quality and value and they have chosen the

research of the current labeller market

Bird Brand’s new P250 will be on show on Premier’s stand no.C44.

Premier Labellers Premier Labellers was established in 1994 and has been supplying reliable world class labelling machine solutions across the world ever since.

www.premierlabellers.co.uk 14 FDPP - www.fdpp.co.uk

Metal detectors the natural choice for Britain’s thriving foodon-the-go SMEs Britain’s appetite for food-on-the-go

and selling everything from bread to

breakfast staples like Bircher muesli

(FOTG) looks set to continue, with

cheese, convenience salads to street-

and fruit compotes - again introducing

greater product innovations, clean

style food, either direct to consumers,

a possible metal contaminant into the

and healthy eating, ethnic foods

or via retailers, deli’s and restaurants.

food supply chain.

Large numbers of these convenience

Another good example of how metal

lines carry the ‘artisan’ label,

fragments can be introduced to

conveying a message that each

products is in the preparation of side

item has been personally prepared

salads and fresh cut produce. The

with care using quality ingredients.

cycle can involve preliminary washing,

Typically viewed by consumers as

often in a metal drum, abrasive

higher-end products, brand integrity

peeling to remove fibrous skin, coring,

and food safety is paramount. And

trimming and cutting. Some products

it’s during the preparation and

are then passed through a vibrating

packing phase where a possible metal

screen to sort produce by size. Before

contaminant can slip through the net.

the packing can commence, there’s

and artisan local produce driving consumers away from the daily sliced bread sandwich ritual. Fortress Technology’s European Sales Director Phil Brown explores the implications that this has on the 6,100-plus micro, small and medium sized enterprises* who are catering to our more adventurous pallets and explains why metal detectors are the most cost effective and popular route to protect FOTG suppliers from the most likely contaminant risk - metal.

According to statistics gathered by DEFRA for the annual Food Statistics Pocketbook, SMEs in the UK food sector account for 96% of businesses, 30% of employment and 24% of turnover. There are also an estimated 40,000 artisan food and drink manufacturers in the UK, preparing

In the raw ingredient phase, food is exposed to different processes - from slicing meat, filleting fish, grinding spice or mixing dry and wet baking ingredients. Later down the line, SMEs may be cutting salads, vegetables

often another wash cycle, sometimes several in the case of leafy greens.

All of these processes and exposure to timesaving preparation equipment increases the risk of tiny fragments entering the production chain.

and meats for appetising lunchtime

Installing a metal detection system

kits, preparing nutrient rich soups,

is the first line of defence. Even if

or cooking and mixing new office

inspecting for metal contaminants isn’t a retailer requirement now, SMEs that start to institute systems at the early stage will be ready to expand and meet the demands of the more stringent retailer Codes of Practice when its product range takes off.

Cost of equipment is naturally a big factor for SMEs, especially during the early business years. X-ray - the other food inspection alternative - is generally far more expensive than even the newest metal detector. The running costs are also much higher.

16 FDPP - www.fdpp.co.uk

Typically, an SME can expect to pay in

performance levels. The machine

Renowned for being easy to use, they

the region of £4,000 to £18,000 for a

also factors in product density,

offer an ambitious enterprise of every

metal detector. This depends on the

which continues to pose a particular

size reliability and brand protection,

size and complexity of the application.

challenge for x-ray.

setting them on the path to future

But when compared to around £35,000 to £40,000 to install x-ray,

Over 90% of Fortress metal detectors

success.

it’s quite a price difference.

are sold to UK food factories and

* www.gov.uk/government/uploads/

in the last 12 months over 60% of

system/uploads/attachment_data/

Metal detectors also tend to perform

new machine orders were installed

file/526395/foodpocketbook-

better on products that have wet or

by SMEs with fewer than 250

2015update-26may16.pdf

conductive properties. That’s because

employees. “The food SME segment

they are more sensitive to product

makes up a huge part of the overall

effect. Many FOTG products - from

industry,” observes Phil.

bread and baked goods to salads and sushi, to cold meats and cheese are especially prone to this product effect. It comes down to basic physics.

Water, like metal, is a conductive.

What’s more, most fresh produce comes in varying densities. For example, a sliced carrot compared to grated carrots, or whole mushrooms compared to sliced, will react in different ways in a metal detector’s magnetic field.

Last year, Fortress launched its new Interceptor range. Ideal for SMEs producing FOTG, the Interceptor reliably detects the range of ferrous and non-ferrous metals, including aluminium, at a fraction of the cost of x-ray but offering the same

** FoodDrinkEurope statistics

“There are more SMEs in food than any other UK sector. Europe-wide, SMEs with fewer than 249 employees account for more than 50% of the food and drink industry turnover**.

And as an SME ourselves, we understand better than most the pressure that success can bring and the importance of trust, affordability and down to earth, responsive service support.”

Made to order in the UK, Fortress metal detectors can be deployed at various food processing checkpoints, including packing conveyors, pipeline configurations or gravity systems.

Fortress Technology Fortress Technology has grown rapidly to become a world leader in the design, manufacture, and sales of metal detector systems since starting on a small-scale in 1996.

www.fortresstechnology.co.uk FDPP - www.fdpp.co.uk 17

Stonegrove Refrigeration Services Stonegrove Refrigeration Services is one of the leading independent refrigeration companies specialising in food production and distribution facilities.

WRITTEN WRITTEN BY

BY Stonegrove Stonegrove PHOTOGRAPHY PHOTOGRAPHY BY

BY Stonegrove Stonegrove

From From aa head head office office in in Harlow, Harlow,

the the Food Food Production Production Sector.

Sector.”” – – Dan Dan

Long Long term term solutions solutions -- natural natural

Stonegrove Stonegrove offer offer nation-wide nation-wide

Cashmore, Cashmore, Stonegrove Stonegrove Managing Managing

refrigerants refrigerants

coverage coverage for for after-sales after-sales service service and and

Director Director

One One of of the the biggest biggest problems problems for for

maintenance, maintenance, as as well well as as design design and and installation. installation. Established Established in in 2002, 2002, Stonegrove Stonegrove have have earned earned aa wellwelldeserved deserved reputation reputation for for bespoke, bespoke, quality quality solutions solutions to to their their customer’s customer’s

Award Award Winning Winning Cooling Cooling and and Freezing Freezing Solutions Solutions Stonegrove Stonegrove have have grown grown year year on on year, year, and and are are now now aa £multimillion £multimillion

cooling cooling requirements. requirements.

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built built upon upon establishing establishing long long term term

successfully successfully competing competing against against the the

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in in the the world. world. We We then then establish establish

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our our family family business business style style approach approach

In In 2016 2016 Stonegrove Stonegrove were were double double

that that enables enables us us to to retain retain clients clients in in

winners winners at at the the RAC RAC Cooling Cooling Industry Industry

both both the the private private and and public public sectors. sectors.

‘Refrigeration ‘Refrigeration Contractor Contractor of of the the Year’ Year’

There There is is no no doubt doubt in in my my mind mind that that

as as well well as as scoping scoping the the ‘Industrial ‘Industrial

our our success success is is only only possible possible due due to to

Project Project of of the the Year’ Year’ Awards.

Awards. Earlier Earlier

the the excellent excellent members members of of staff staff we we

in in the the year year they they won won the the ACR ACR News News

employ, employ, and and our our ability ability to to listen listen to, to,

Awards’ Awards’ ‘Contract ‘Contract of of the the Year’ Year’..

and and work work with with our our customers customers in in 18 FDPP - www.fdpp.co.uk

excess excess of of £10million £10million per per annum. annum.

refrigeration refrigeration users users recently recently has has been been the the uncertainty uncertainty created created by by refrigerant refrigerant availability availability due due to to environmentally environmentally driven driven legislation. legislation. Quite Quite simply, simply, some some of of the the refrigerants refrigerants in in use use today today will will not not be be available available in in the the coming coming years years due due to to their their harmful harmful impact impact upon upon the the environment. environment. Stonegrove Stonegrove have have always always taken taken aa long-term long-term approach approach to to their their designs, designs, and and predominately predominately used used ‘natural ‘natural refrigerants’ refrigerants’ which which are are unaffected unaffected by by the the changes changes in in legislation. legislation. Investments Investments in in refrigeration refrigeration systems systems by

by Food Food Producers Producers are are usually usually significant significant financial financial undertakings, undertakings, and and the the importance importance of of building building in in long long term term certainty certainty is is something something appreciated appreciated by by Stonegrove’s Stonegrove’s customers. customers.

Energy Energy reduction reduction

the the expectations expectations of of our our customers customers

// plant plant replacement, replacement, and and Service Service & &

In In Food Food production, production, every every penny penny

They They understand understand the the importance importance of of

Maintenance Maintenance of of plant. plant. We We tailor tailor our our

spent spent on on energy energy increases increases the the

efficient efficient operating operating costs, costs, as as well well as as

approach approach to to suit suit each each requirement, requirement,

manufacturing manufacturing cost cost of of the the product. product.

managing managing capital capital expenditure. expenditure. With With

and and ensure ensure our our client client receives receives the the

Refrigeration Refrigeration is is often often the the largest largest

aa team team of of specialists specialists we we can can design, design,

expected expected level level of of quality quality they they need. need.

user user of of energy energy in in food food production production

install, install, commission commission and and service service & &

facilities facilities of of chilled chilled or or frozen frozen products. products.

maintain maintain industrial industrial refrigeration refrigeration plant plant

Stonegrove Stonegrove consider consider this this from from the the

to to the the highest highest quality. quality.

base base is is due due to to meeting meeting these these

Ongoing Ongoing Service Service and and maintenance maintenance – –

this, this, Stonegrove Stonegrove have have an an excellent excellent

Reliable, Reliable, safe safe and and compliant compliant

level level of of retention, retention, and and continue continue to to

design design stage, stage, right right through through to to the the ongoing ongoing service service and and maintenance maintenance stages stages of of projects projects to to advise advise their their clients clients to to make make genuinely genuinely informed informed decisions decisions about about the the energy energy implications, implications, and and potential potential for for energy energy savings. savings.

Every Every refrigeration refrigeration system system is is unique, unique, all all refrigeration refrigeration systems systems require require aa

experience experience

level level of of maintenance, maintenance, with with its its own own

IfIf you you are are operate operate refrigeration refrigeration plant, plant,

maintenance maintenance schedule. schedule.

or or planning planning aa change change to to your your existing existing

improve improve performance performance and and minimise minimise the the risk risk of of system system issues. issues. As As aa critical critical element element of of any any business business using using refrigeration, refrigeration, the the importance importance of of maintaining maintaining the the equipment equipment cannot cannot be be understated. understated. Plant Plant breakdown’s breakdown’s

Stonegrove Stonegrove tailor tailor each each Service Service & & Maintenance Maintenance contract contract to to meet meet

builders builders to to propose propose new new purpose purpose built built

design design conditions, conditions, operating operating

facilities. facilities. In In many many cases, cases, this this may may be be

efficiently, efficiently, safely, safely, and and meeting meeting

the the only only and and best best solution, solution, but but not not in in

compliance compliance requirements. requirements.

and and environmental environmental impact. impact. In In fact fact Stonegrove Stonegrove have have won won awards awards for for saving saving client’s client’s money money for for repurposing. repurposing.

Design Design Stonegrove Stonegrove aim aim ensure ensure that that the the high high standard standard of of industrial industrial refrigeration refrigeration installations installations they they carry carry out out surpass surpass

the the area, area, and and enjoy enjoy working working with with the the award award winning winning team team to to deliver deliver your your company’s company’s success. success. But But don’t don’t just just believe believe us, us, this this is is what what our our customers customers have have to to say: say:

our our preferred preferred refrigeration refrigeration contractor contractor

refrigeration refrigeration systems systems run run to to the the

itit can can also also shorten shorten the the project project time, time,

from from Stonegrove’s Stonegrove’s vast vast experience experience in in

which which means means time time and and money. money.

is is very very common common for for consultants consultants and and

only only greatly greatly reduces reduces the the capital-cost; capital-cost;

miss miss out out on on the the opportunity opportunity to to benefit benefit

“Stonegrove “Stonegrove Refrigeration Refrigeration has has been been

their their customer’s customer’s needs, needs, ensuring ensuring

plant plant whenever whenever possible. possible. This This not not

facility facility or or even even aa new new project, project, don’t don’t

frequently frequently result result in in lost lost production production

When When considering considering new new projects, projects, itit

and and adapting adapting existing existing faculties faculties and and

grow grow year year on on year. year.

Benefit Benefit from from Stonegrove’s Stonegrove’s

system system will will reduce reduce energy energy costs, costs,

all. all. Stonegrove Stonegrove will will consider consider reusing reusing

performance performance demands. demands. Because Because of of

and and irrespective irrespective of of size size or or design, design,

AA correctly correctly maintained maintained refrigeration refrigeration

Reuse Reuse or or repurpose repurpose

The The growth growth of of Stonegrove’s Stonegrove’s customer customer

Working Working with with food food producers producers Stonegrove Stonegrove pride pride themselves themselves in in being being aa ‘Customer ‘Customer Led’ Led’ business, business, and and work work with with aa wide wide variety variety of of clients. clients.

These These include include Consultants, Consultants, Project Project Managers, Managers, Main Main Contractors, Contractors, Food Food Manufacturers Manufacturers & & Food Food // Perishable Perishable Goods Goods Distribution Distribution companies. companies.

Each Each customer customer has has different different requirements, requirements, whether whether itit be be new new installations, installations, Refrigerant Refrigerant Phase Phase Out Out

here here at at our our Burton Burton site site for for nearly nearly 22 years years now. now. The The levels levels of of service service we we receive receive are are second second to to none. none. We We have have seen seen vast vast improvements improvements in in reliability reliability and and efficiency efficiency of of our our plant plant which which have have helped helped us us maintain maintain our our service service levels levels to to the the customer customer and and assist assist us us to to meet meet our our green green targets. targets.

During During this this time, time, Stonegrove Stonegrove have have also also completed completed many many projects projects on on the the site site refrigeration refrigeration systems, systems, on on time time and and on on budget. budget. Overall Overall they they have have been been aa pleasure pleasure to to work work with with and and II would would recommend recommend them them highly. highly.”” -- Mark Mark Cook, Cook, Site Site Services Services Engineering Engineering Group Group Leader Leader – – Kerry Kerry Foods Foods Stonegrove Stonegrove Refrigeration Refrigeration Services Services

ed@stonegroverefrigeration.co.uk www.stonegroverefrigeration.co.uk FDPP - www.fdpp.co.uk 19

sara LBS: Keeping it cool in food distribution Thermal regulation is vital to the

while the distribution centres bristle

of automation: timers, presence

ongoing performance of the chilled

with technology to ensure standards

detectors, temperature sensors and

food distribution network, a multi-

are met and hygiene maintained.

other equipment can be fitted so that

billion dollar global industry. Getting rooms down to temperature is one thing, keeping them at that temperature in the most efficient manner is another. Nick Cox of loading bay specialist, sara LBS, explains how the right door can improve insulation to maximise profits and help preserve the perfect temperature.

Food distribution is an internationalised business these days; based on a network of distribution centres and highly efficient freighting operations. What it achieves on a macro level is truly astonishing.

For instance prawns caught off the west coast of Scotland can be with discerning consumers in Spain, France and Italy while still at the peak of freshness. And those same fishermen can enjoy out-of-season tomatoes and melons grown under glass in southern Europe. Perhaps even more astonishing, some of that Scottish seafood will be flown to India to be picked, peeled and processed then flown back to Europe as finished dishes.

Keeping food at accurately controlled, reduced temperatures is essential in such operations if it is to be kept fresh, nutritious and wholesome.

Not surprisingly then, there are strict regulations that must be followed, 20 FDPP - www.fdpp.co.uk

The core technology is refrigeration and air conditioning. Often entire buildings are cooled to carefully

the door closes automatically or an alarm sounds if the door seems to have been left open unnecessarily.

controlled levels. This is obviously

For chilled areas that need protecting

an energy intensive process, so

from ambient, outside temperatures,

good insulation and best practice

the next level down from sliding

handling operations are essential

doors would be the sara LBS range

to maximising productivity in such

of Sprint insulated, high-speed roller

environments.

shutter doors. These are available

For food distribution companies looking to keep large spaces cool and hygienic, sara LBS offers several industrial door and loading bay solutions which offer high levels of insulation.

Starting from the coldest, frozen food areas need to be kept very cold, but must have means of access for personnel and/or vehicles. In such cases we would generally look to a sliding door solution; sized as appropriate, but basically as small as practically possible in order to minimise warm air ingress. Typically such a door would be lined with around 120mm of insulation for best performance.

Ideally we recommend that freezer doors are powered, rather than manually operated, to reduce the possibility of operatives leaving the door open during non-operational periods. It also allows for a degree

with 40mm or 80mm of insulation and are typically installed between the production floors and the loading bays, where lorries arrive to deliver or receive chilled foods.

They may also be used as the outside door of the loading bay, although in some cases an uninsulated roller shutter door may be preferred. It is notable that the aluminium profiles of the Sprint 3000 range provide a â&#x20AC;&#x2DC;first line of defenceâ&#x20AC;&#x2122; against vandalism while also preventing the entry of small animals and birds in search of food or shelter.

High speed roller doors are generally recommended, especially for large openings because they can increase the amount of time they are actually shut considerably, particularly in busy locations where frequent opening is required. Again, because the doors are motor driven, levels of automation can be adopted to enhance and improve operations. In chilled food distribution centres, sara LBS often also recommends that the outer side of the loading bays are fitted with inflatable vehicle shelters, as they are very good for keep chilled air in and warmer atmospheric air out.

About sara LBS sara Loading Bay Specialists supplies, installs and maintains loading bay systems, high speed doors and industrial doors.

It has provided high quality product solutions and outstanding customer service since it was founded 30 years ago and this remains its sole focus.

Product Solutions sara LBS’s range of high quality products includes its complete loading bay packages (including scissor lifts, ramps and dock levellers), ‘Sprint’ range of rapid roll, high speed doors

Many food operations will have their

Specialist sectors include food and beverage, pharmaceutical, automotive, manufacturing, logistics and distribution.

Maintenance & Repair Sara LBS provides nationwide 24/7 service cover and rapid response times for all loading bay systems, dock shelters, high speed doors and industrial doors using its specialist engineers based across the country.

It works with end users to extend the safe working lifetime of their doors and equipment by providing both preventative maintenance packages and standard and emergency repairs.

facility divided into sections and these may require different temperature levels. In order to assist with this, sara LBS often recommends high speed roller curtain doors. These can open and close very quickly and automatically as a person or fork lift truck approaches. Further the curtain, typically made of PVC, can be transparent so that operatives can see through to them and proceed confident that their way ahead is clear and safe.

Ultimately, specifying the right door for your chilled environment can play one of the most crucial roles in how efficient your cooling operations are, yet in the grand scheme of things it’s a fraction of overall investment. sara LBS engineers have a wealth of experience specifying and installing doors in many different environments and will help you to choose a solutions that will work best for you. All of our doors are supported by nationwide maintenance and repair services so you will have peace of mind that we’ll continue to support you long after the sale.

for internal and external use, insulated sectional overhead doors and roller shutter doors.

It has extensive sector expertise and provides total packages that are tailored to meet all its customer’s needs.

Sara LBS sara Loading Bay Specialists Ltd : Louise Nurse Tel: +44 (0)1442 245577 Fax: +44 (0)1442 217117 Email: info@saralbs.co.uk

www.saralbs.co.uk FDPP - www.fdpp.co.uk 21

Bespoke Line Keeps The Biscuits Flowing Mars subsidiary Wm Wrigley Jr. Company opened a new 145,000ft² Skittles production line at its existing confectionery manufacturing facility in Yorkville, Illinois.

Greater efficiency, improved flexibility

The Ishida multihead weigher is

The new BRN/Ishida system enables

and enhanced quality control are

achieving 50 packs per minute on

these changeovers to be carried

the major benefits of a bespoke

a typical 125g tray. Accuracy is to

out in just 15 minutes thanks to

packing line created for leading biscuit

within 0.5g and overall the weigher

two important factors. The linear

and pastry manufacturer Poppies

is delivering an efficiency level in

configuration of the Ishida weigher

International by Ishida Europe’s

excess of 95% for this challenging

is ideal for fragile biscuits and it

Belgian agent BRN.

product and application. Poppies

allows two distribution systems to sit

manufactures its delicate sugar-

comfortably beneath the weigher.

The new line at Poppies’ factory in Zonnebeke, Belgium comprises an

glazed puff pastry biscuits in two shapes – Twists and Palmiers.

A special BRN-designed tray denester

weigher with a special distribution

As well as its own brand, the company

funnels that place the biscuits into

system that enables it to handle both

also produces the biscuits for many

the trays. These can be changed

trays and bags of biscuits, while an

national and international retailers.

for a second funnel that places the

Ishida DACS checkweigher and IX-GA

This equates to around six different

biscuits into individual compartments

4075 X-ray system provide weight

pack formats, both trays and bags,

on a conveyor which takes them to

and quality checks for all pack types.

in a range of sizes from 75g to 400g.

a bagmaker. Equally important, the

As a result, during a typical shift, the

three Ishida machines (multihead

company might need to effect up to

weigher, X-ray inspection system and

seven changeovers.

checkweigher) are all controlled by a

Ishida CCW-R-108P linear multihead

22 FDPP - www.fdpp.co.uk

feeds the trays to two dipping

single Control Unit, meaning that the

bags are tied with a metal clip, and

The installation of the Ishida DACS

settings for every pack format on each

these factors would prevent the metal

checkweigher has also helped

machine can be easily called up by the

detector from operating properly.”

to improve overall efficiencies.

touch of a single button on the panel.

By comparison Ishida’s X-ray system

The installation of the Ishida IX-GA

is able to detect unwanted objects

X-ray system has also delivered an

through metallised film, and its

important enhancement to Poppies’

advanced technology can also mask

quality control, as production manager

the metal clip on the bags without

Geert Vandoorne explains: “Before the X-ray, the biscuits would pass through a metal detector immediately after coming out of the oven. Nevertheless, the packing

“Previously operators simply checked the fill level of the trays or bags by sight to assess if the correct amount was in each pack,” explains Geert, “but this led to excessive giveaway on occasions.

reducing the detection performance of

Now we can be confident that every

foreign bodies. Missing or additional

pack is close to its target weight.”

clips are also identified.

The new line at Poppies incorporates

operation involves a number of

In addition, the IX-GA 4075 is able to

the company’s existing bagmaker,

additional pieces of equipment,

spot a wider range of contaminants

flow wrapper and boxing machine

so it was more appropriate for the

and can pinpoint the location of any

with BRN supplying the three new

metal detector to be placed further

foreign object despite the fact that the

Ishida machines along with transfer

down the line. This however created

biscuits are quite densely packed in

conveyors and elevators.

another problem as some of the trays

the bags and trays.

feature aluminium foil seals, while the

After baking, the biscuits are taken FDPP - www.fdpp.co.uk 23

ISHIDA Ishida Europe is a leading supplier of automated solutions, meeting the everchanging challenges presented by the processing of products in the food sector.

www.ishidaeurope.com

WRITTEN BY Ishida PHOTOGRAPHY BY Ishida

on an inclined conveyor through a

This gives time for

ventilation system that cools them

the problem to be

down before being transferred to a

fixed and, if it is likely

bucket elevator to take them to the

to take a long time,

linear mulithead weigher.

production can be

An important modification to the line here is the inclusion of a special buffering system for the biscuits.

If there is a problem further down the packing line, the feed conveyor to the bucket elevator goes into a backward and forward motion in order to collect the biscuits and hold them at this stage.

halted. Once the line is restarted, the biscuits are gradually re-fed to the bucket elevator.

Another innovation is the BRN-designed tray denester which uses suction pads to remove each tray from the stack and place it on the conveyor. This ensures gentle handling that will not deform

delivered the same high standards of accuracy and reliability and with BRN’s help with the design of the line, we now have an extremely flexible

the lightweight trays.

and efficient packing operation

Geert Vandoorne is pleased with the

products and further enhances our

new line.

reputation.”

“We have always been big Ishida fans – we have Ishida weighers in operation throughout our factories because they are fast, accurate and reliable.

The company was therefore the natural choice to help us upgrade and improve our biscuit packing operation.

24 FDPP - www.fdpp.co.uk

“The X-ray and checkweigher have

that ensures the high quality of our

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TOMRA And Farm Frites Donate €2,000 To UNICEF Dutch company specialising in fries

includes our children, who are our

improve the quantity of food available,

and potato products Farm Frites

future. All children deserve a healthy

but they also maintain the high levels

has been presented with a charity

life and we’re happy to be able to

of quality expected by consumers who

voucher worth €2,000 after winning

contribute to the good work that

are increasingly interested in what

The Golden Fry competition held by

UNICEF does.”

they are purchasing.

Sales Director EMEA at TOMRA

“The TOMRA 5B boasts a powerful

The competition was held at Interpom

Sorting Food Steve Raskin said: “We

combination of exceptional features,

Primeurs, an exhibition for the potato,

are very pleased that Farm Frites

state-of-the-art innovation and ease

fruit, and vegetable market in Kortrijk

chose UNICEF as its charity because

of use.

to celebrate the launch of the new

it’s a very worthy cause. We hope

TOMRA 5B, a state-of-the-art sorter

that the donation can contribute to a

for the vegetable, fresh cut, and

better world for children everywhere

potato processing industries.

and give them the future they

TOMRA Sorting Food.

The TOMRA 5B

It is a great addition to the TOMRA range, guaranteeing excellent results throughout the entire sorting process.”

deserve.”

processed 20kg of French fries, which included one made of gold. The representative who came closest to correctly guessing the moment when the golden fry would be ejected was awarded the voucher.

Process Engineer at Farm Frites Ron Packbier entered the competition on behalf of the company. He chose UNICEF as the recipient of the charity voucher. The charity has distributed lifesaving aid to children around the world for almost 70 years.

Ron said: “In everything we do, we strive to contribute to a more sustainable environment, which also 28 FDPP - www.fdpp.co.uk

The TOMRA 5B is the first of the next generation of innovative sorting machines. Steve added: “Recent

Tomra

developments in our technology result

TOMRA was founded on an innovation for

in more accurate decisions about

return of empty beverage containers more

the quality of the product. These

than forty years ago.

technological advancements not only

www.tomra.com

Software Solution Beefs Up Business Processes An IT solution from CSB-System is managing all the business processes at Belgian beef specialist Veviba.

WRITTEN BY CSB - System PHOTOGRAPHY BY CSB - System

The fully-integrated solution, which

manual data retrieval, controls all the

and transparent manner, and

has facilitated the company's rapid

company’s business processes – from

consequently reduce costs,” explains

growth over a 15 year period,

its own cattle breeding business, with

Diederik Verbist, Managing Director of

ensures effective planning and

some 10,000 animals on 19 farms,

Veviba.

product management, as well as total

via slaughter, cutting, production,

transparency and traceability of all

packaging, weigh labelling, to the

products.

fully-automatic high bay storage

The system unites every stage of food processing under one roof, allowing

facility, dispatch and traceability; as well as its management and

“We can also quickly access the latest operating data by means of integrated online analyses of our production. As a result, we can make decisions based

administration.

on facts.”

performance indicators at a glance,

The ease of use offered by the

Veviba, part of the Verbist group,

including production quantities,

system, which is operated from

machine utilisation and availability of

a clearly laid out control station,

required raw materials.

has led to a significant increase in

Veviba to monitor a range of detailed

It also provides data on such vital concerns as order quantities, deadlines, manpower requirements and stock consumption. In addition, the system allows users to trace meat products from package back to pasture – an important feature for today’s consumers, who are

productivity, along with a decrease in weigh labelling errors. Overall, the system structures the whole operation, allowing for optimised purchasing, up-to-date stock, onhand information at any time, reliable planning bases and meaningful reports and statistics.

specialises in "Belgian Blue" cattle, a particularly muscular breed. The company sells its products mainly in Belgium, France, the Netherlands and Greece, and last year reported sales of approximately 150 million euros.

CSB - System As a one-stop provider of software, hardware, services and business consulting, we optimize the business processes of our customers and create

more concerned than ever with food

“With the CSB-System, we can

origins. The CSB software, which

design our processes, from rearing

replaced Veviba’s previous system of

up to delivery, in an efficient

significant competitive advantages with our CSB turnkey solution.

www.csb.com FDPP - www.fdpp.co.uk 29

If you are serious about safety and security you really need to listen to the experts OWL are experienced in applications covering all manufacturing and processing industries and will recommend solutions tailored specifically for your requirements You You know know your your own own industry industry and and the the safety safety & & security security requirements requirements of of it. it.

No No doubt doubt with with legislation legislation so so strict strict with with regard regard to to all all aspects aspects of of safety safety someone someone in in your your business business will will have have carried carried out out the the necessary necessary risk risk evaluation evaluation for for all all areas areas of of your your operations. operations.

Personnel Personnel at at all all levels levels within within an an organisation organisation are are individually individually responsible responsible for for taking taking precautions precautions to to avoid avoid accidents accidents and and the the financial financial and and criminal criminal penalties penalties of of not not so so doing doing increase increase right right up up through through the the management management structure. structure.

applies applies to to every every situation situation from from the the moment moment raw raw materials materials are are received received through through the the storage, storage, handling handling and and manufacturing manufacturing processes processes right right up up to to when when the the end end product product is is dispatched dispatched and and delivered delivered to to the the user. user.

Take Take aa few few minutes minutes and and you you will will identify identify many many more more applications applications that that could could benefit benefit from from similar similar messages. messages.

With With aa variety variety of of flashing flashing beacons beacons and and background background noises noises from from plant plant and and machinery machinery and and electronic electronic tones tones or or buzzers, buzzers, itit is is no no wonder wonder that that confusion confusion can can arise arise and and people people will will become become immune immune to to sounds sounds they they don’t don’t understand understand -- with with obvious obvious possible possible consequences. consequences.

Triggering Triggering the the message message can can be be by by aa simple simple contact contact switch switch when when aa door door opens, opens, aa proximity proximity sensor sensor when when approaching approaching an an unguarded unguarded machine, machine, an an interrupted interrupted infrared infrared beam beam and and many many others others including including direct direct from from aa process process control. control.

Just Just aa few few examples examples of of solutions. solutions.

In In addition addition to to implementing implementing the the safety safety measures measures itit is is important important for for everyone everyone to to be be able able to to demonstrate demonstrate that that adequate adequate precautions precautions have have been been taken. taken. So So itit makes makes sense sense to to apply apply effective effective communication communication throughout throughout the the operation. operation.

●● “Take “Take care…vehicles care…vehicles operate operate in in this this area” area”

This This can can be be easily easily achieved achieved at at low low cost cost by by the the use use of of real real human human voice voice warning warning sounders. sounders.

●● “You “You must must wear wear aa hard hard hat hat and and eye eye protection protection before before entering entering this this area” area”

Whatever Whatever the the potential potential hazard hazard situation situation the the obvious obvious solution solution is is to to tell tell everyone everyone in in the the danger danger zone zone about about itit and and and and then then instruct instruct them them on on an an appropriate appropriate course course of of action. action.

●● “Beware…automatic “Beware…automatic doors doors closing” closing”

It’s It’s aa simple simple logical logical approach approach that that

●● “Stay “Stay behind behind the the red red line” line”

“People respond far more readily to an authoritative human voice than to any electronic beeper or buzzer” 30 FDPP - www.fdpp.co.uk

●● “Stand “Stand clear…fork clear…fork lift lift truck truck approaching” approaching” ●● “This “This conveyor conveyor is is about about to to start” start”

●● “This “This machine machine will will not not operate operate without without aa safety safety guard guard in in place” place”

You You can can specify specify any any wording wording in in one one or or more more languages. languages.

Messages Messages may may be be configured configured to to sound sound once once only only or or “x” “x” number number of of times, times, or or to to sound sound continuously continuously until until further further action action is is taken. taken.

The The client client can can specify specify the the precise precise message message and and how how itit is is operated. operated.

The The system system is is low low cost cost and and can can be be supplied supplied with with aa variety variety of of loudspeakers loudspeakers suitable suitable for for different different environments. environments.

ItIt is is easily easily bench bench tested tested to to verify verify operation operation prior prior to to installation. installation. And And itit can can also also be be installed installed by by in-house in-house personnel personnel thus thus minimising minimising overall overall cost. cost.

The The benefits benefits of of talking talking sounders sounders are are obvious, obvious, the the applications applications limited limited only only by by your your imagination. imagination.

“Safe and Sound”

There There is is aa contact contact form form on on the the web web site site www.talkingsounders.co.uk www.talkingsounders.co.uk where where clients clients can can outline outline their their applications applications and and ideas ideas and and OWL OWL will will suggest suggest suitable suitable solutions. solutions.

“The most effective way of communicating a warning message…”

Talking Sounders from OWL For safety, security or information, anywhere in your office, warehouse, factory or plant - inside or out. Talking Sounders will get the message across clearly when and where it is needed.

Clear information without risk of confusion, and clear instructions on what to do next.

Bespoke messages for your specific applications.

Loudspeakers suitable for any location

Easily installed freestanding or as part of another system.

Simply controlled by sensors, triggers or by your processes.

Safe low voltage operation.

Low-cost and proven reliability.

Independently tested and EU Type Approved.

Electronics encapsulated in loudspeaker or separate enclosure

Suitable for both static installations and mobile use on overhead cranes, plant & vehicles on and off-road.

You name it we say it Contact us with your applications or problems or just ideas and we will suggest effective solutions and quotations with no cost or obligation.

www.talkingsounders.co.uk

We supply to clients large and small in multiple languages around the world

OWL Electronic Developments 0845 643 0212 info@talkingsounders.co.uk

BAADER's New Skinning Machine for Twin or Single Lane Salmon Skinning Optimised for skinning fresh or

BAADER 240 is easy to adjust,

smoked salmon, the specially

both during operation and when

designed Easy-Grip BAADER

being dismantled for cleaning.

240 leaves no skin on the fish's tail and guarantees high-yield.

No tools are needed for

The twin lanes of the machine

additional options, such as a

run individually and it is possible

transfer plate that allows fillets

to process around 50 fillets per

to pass through the machine

minute. In addition, skinning

without skinning.

results are even due to the selfadjusting blade holders.

The machine allows for deep and shallow skinning, as well as a maximum shallow skinning.

The changeover between deep and shallow is easily achieved with only one handle.

32 FDPP - www.fdpp.co.uk

dismantling or for installing

A SINGLE lane skinning machine is also available.

With this option, it is possible

WRITTEN BY Baader PHOTOGRAPHY BY Baader

Baader The BAADER-Group is a world renowned

to re-merge the skin and a

manufacturer and supplier of advanced

smoked fillet automatically

high quality food processing machinery

after small adjustments of the discharge belt.

and solutions.

www.baader.com

Containers Deliver Effective Long Term Protect-ion A new coating for HDPE containers

packed in metal - offering plastics’

from RPC Promens Industrial is

traditional benefits of lightweight,

able to provide a long term barrier

easy handling and stacking, and

solution for solvent-based products

reduced transportation costs. RPC

for the safer handling of a variety of

Protect containers have successfully

chemicals.

undergone drop, pressure and

RPC Protect is available for containers from 5 litres up to 25 litres in size.

A 30 litre container is also currently in development. The special barrier additive, a blend of polyolefins and

stacking tests, and their barrier properties have been proven to maintain their performance for up to a year with no reduction in the effectiveness of the barrier.

inorganic silicates, forms multiple

RPC Protect can be specified across

strips on the inside of the container.

the majority of RPC Promens’ range

Importantly, unlike other plastic

of HDPE containers, giving customers

barrier solutions, used containers can

the flexibility to create family ranges

be recycled if appropriate.

with both mono and barrier versions,

The availability of RPC Protect enables plastic containers to be selected for

as well as the option for customised shapes.

an even wider range of products

RPC Protect containers are FDA and

- including extremely hazardous

EEC approved for food use, and UN

items that previously could only be

certified versions are also available.

NOTE WRITTEN BY RPC Promens PHOTOGRAPHY BY RPC Promens

RPC Promens RPC Promens delivers excellence in design and manufacturing in all the main plastics materials and processing technologies, including blow moulding and thermoforming, and we are the world’s leading specialist in rotational moulding. www.rpc-promens.com

FDPP - www.fdpp.co.uk 33

Clean air: The Key to Avoiding Contamination Incidences of product recall resulting from contamination can have a disastrous effect on a food or beverage manufacturer’s profitability. In this article, BOGE's Mark Whitmore looks at one source - contaminated compressed air - and offers some advice on how to clean up your act.

If contaminated air comes into contact

in order to prevent a food safety

This can be achieved using water

with a food product, it can affect its

hazard. Atmospheric air, if not

separators to remove the bulk of

taste, appearance, colour and shelf

treated when used for compression,

condensed water and liquid oil,

life. It may also compromise hygiene

can introduce contaminants like

followed by coalescing filters that

standards, rendering products unfit

water vapour, airborne dirt, non-

remove water and oil aerosols.

for consumption, leading to expensive

combusted hydrocarbons, pollen and

recalls and reputational damage.

microorganisms into the distribution

Further moisture reduction must be

network.

achieved by drying using refrigeration

and beverage sector, compressed

Compressors themselves can add

being the most effective. A final

air is possibly the most ubiquitous,

wear particles, while oil lubricated

sterile filter stage will be necessary to

being used in a host of process

compressors will introduce small

remove microorganisms.

applications, from product handling,

amounts of oil at the compression

through labelling, cutting and

stage in the form of liquid, aerosol,

peeling to packaging. Unfortunately,

vapour, and hydrocarbon oxidation

microorganisms and dirt can be drawn

particulates.

Of all process resources in the food

into the compressed air system along with oil and liquids that can seep

In 2007, the British Compressed Air

through worn seals.

Society (BCAS) and the British Retail

Most food manufacturers conduct a

code of practice called Food Grade

Hazard Analysis and Critical Control

Compressed Air, the latest revision

Points (HACCP) approach to food

of which is the BCAS Food Grade

safety to prevent biological, chemical,

Compressed Air Best Practice

and physical hazards affecting their

Guideline 102, which sets out three

production processes.

essential steps: identify those areas

A HACCP ‘prerequisite programme’, for example, which identifies the basic environmental and operating conditions essential for safe food production, introduces the concept of ‘critical control points’ - those points, steps or procedures in a food or beverage manufacturing process that must be addressed 34 FDPP - www.fdpp.co.uk

Consortium produced a voluntary

or adsorption processes, the latter

Removing oil from the compression stage is essential.

BOGE offers a selection of oil-free air compressors for the food and drink processing and packaging sectors, including the new High Speed Turbo (HST) compressor range, which has been designed so that the entire drive mechanism operates without any lubricants at all, guaranteeing 100% oil-free air delivery to sensitive downstream processes.

where compressed air comes into contact with product; recognise the contaminants that might adversely affect the product, and establish whether contact with compressed air is direct or indirect. It is advisable to remove contaminants from compressed air as close as possible to the point of use.

NOTE WRITTEN BY BOGE PHOTOGRAPHY BY BOGE

BOGE Your number one choice for Industrial Air Compressors, Compressed Air Systems, Equipment and Compressed Air Services.

www.boge.com

HST: The new benchmark for oil-free compressed air

est

BOGE’s high speed turbo (HST) technology represents a quantum leap in compressed air innovation! Its radical design has enabled drastic improvements in efficiency to be achieved – allowing for a 30% reduction in total cost of ownership.

Here are 10 reasons why BOGE HST is a game changer:

f

1.

Oil-free Class 0: No oil in the machine, absolutely no oil in the air

2.

High speed, redefined: Uniquely high speeds powered by an air-supported motor shaft

3.

Incredibly compact: Just half the size of an oil-free screw compressor

4.

Less maintenance: High-grade components lead to longer life and superior reliability

5.

Extraordinarily efficient: Energy use in idle state is less than 1.9% of nominal power

6.

Unbelievably low total costs: Up to 30% lower than oil-free screw compressors

7.

Scarcely audible: Sound pressure level between 63 and 69 dB(A), depending on size

8.

Extremely versatile: Available in 55kW up to 220kW to meet all compressed air needs

9.

Impressively low weight: Less than half the weight of an oil-free screw compressor

erman

ngineering

10. BOGE quality: Every HST compressor is manufactured in Germany to exacting quality standards

Call today or visit our website to learn more. +44 (0) –800 318104holding all the innovative promise BOGE a brand uk@boge.com ever needed by compressed air technology. www.boge.com/uk www.boge.com

Bauer Gear Motor www.bauergears.com

Boston Gear www.bostongear.com

Warner Electric www.warnerelectric.com

WE'RE COMMITED TO THE

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

www.AltraMotion.com