Food & Drink Processing & Packaging - Issue 30 2020

FOOD & DRINK PROCESSING & PACKAGING Issue 30 2020

Grading facility puts its eggs in the Rotamec basket Proseal solutions meet quality pet food packing requirements HARTING launch a connector solution for the food and beverage industry Sustainable wheat ingredients for functional concepts

If you have rotating machinery on your production & packing lines, and need to keep them running, then you should be looking at the affordable, easy to use, Vibration Analyser range from

TPI Europe Ltd Easy to use solutions – with or without trending software

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High End Analyser inc. Data Collector & 2 Plane Balancer

TPI Vibration Analyser Range Starting from: -

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For technical information, solution range, applications, prices and where to buy - Contact TPI Europe on: 01293 530196 w sales@tpieurope.com w www.tpieurope.com

Contents

The Team Editor Amanda Buckingham editor@fdpp.co.uk Business Manager Josh Holmes josh@mhmagazine.co.uk

Digital Sales Manager Jessica Bennett T: 01227 392571

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

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.

Features PROSEAL HRS CAN MAKERS BRILLOPAK SUMITOMO FOOD SAFETY GOUNDSMIT

Office 15, Second Floor, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, CT13 9FD

KG GROUP

Tel 01304 806039

ROMATEC

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

Please mention FDPP when responding to items in this issue.

Every effort is made to ensure the accuracy and reliability of material published in Food & Drink Process & Packaging however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers.

No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

FORTRESS TECHNOLOGY KAWASAKI ISHIDA LORYMA RITTAL SEEPEX UNIPAKER STAUBLI

< 04 < 10 <12 < 14 < 16 < 20 < 22 < 23 < 24 < 26 < 28 < 32 < 36 < 40 < 44 < 48 < 50

FDPP - www.fdpp.co.uk 3

Proseal solutions meet quality pet food packing requirements Proseal tray sealing technology is

techniques and processes, with the

The tray sealers also include several

enabling pet food manufacturers to

corresponding need for appropriate

Proseal-developed features that help

meet growing demand for high quality

quality packaging to reflect this

to maximise performance, reliability

products and packaging, as well as

premium image.

and efficiency, such as the company’s

providing mass customisation solutions

pioneering Eseal® energy saving The comprehensive Proseal tray sealer

technology, ifilm™ intelligent film

range has the flexibility to perform in a

monitoring, and ProTect™ RFID access

ordering for home delivery services.

wide range of disciplines, including Gas

login system that provides full audit

Flush Modified Atmosphere Packaging

trail visibility and layered security.

A recent report from Transparency

(MAP), Vacuum MAP with lid control

Market Research has predicted a CAGR

and Skin Packaging. In particular, the

of 6% in the global pet food market

company’s advanced sealing systems

in the ten years from 2019, reaching

ensure absolute control and integrity of

an expected value of US$168.3 bn by

the seal between the lid and the tray, a

autumn 2029. Increasing consumer

vital requirement for applications that

demand for premium quality products

incorporate a substantial controlled-

has led manufacturers to use high

retortion-process or other High

quality materials and ingredients

Pressure sterilisation processes after

while streamlining their production

sealing.

that can help businesses in the sector to diversify and introduce online

4 FDPP - www.fdpp.co.uk

In addition, Proseal’s AP60 linear conveyor tray sealing system is able to provide bespoke automated solutions for high speed applications and demanding production conditions, based around individual customer production processes and requirements.

Among the system’s many features,

“As the pet food market continues

We are delighted that our expertise can

the length and width of the indexing

to expand, we were keen to provide

help companies to achieve a point of

conveyor can be customised to

solutions for companies requiring a

differentiation in the competitive pet

accommodate particular de-nesting

significant upscale in their production

food sector.”

and filling requirements. Full or partial

of core products in new packaging

vacuum systems can be incorporated

formats, which could be met on one

to enable post seal processes such

machinery platform,” said Tony Burgess,

as retort or High Pressure Processing

Head of Sales and Control Systems,

(HPP), and X-ray inspection systems

Proseal.

sealing tools for food industry markets

“The flexibility of our technology and

part of the US-based JBT Corporation

the wide variety of machines available,

in 2019. JBT is a complete solutions

including fully integrated conveyor

provider to the growing pet food sector,

systems, mean we can offer a full

committed to exceeding customer

turnkey production line solution which

expectations.

and checkweighers can be included after sealing for enhanced quality control. The AP60 also offers seamless integration with third party process equipment including depositors, multihead weighing applications and CIP systems with sealing speeds of up to 240 packs per minute.

is key for this particular market.

Founded in 1998, Proseal designs and manufactures high quality tray sealing machines, conveyor systems and worldwide. The company became

www.proseal.com

Furthermore, Proseal’s AP60 benefits from shared technology across the Proseal machinery range. Options can be specified and retro-engineered at the customer request, allowing a more flexible approach to each distinct application.

All Proseal machines offer a userfriendly interface and easy to maintain design, with a rugged and hygienic food industry approved construction geared to full washdown protection.

FDPP - www.fdpp.co.uk 5

The Delta Speed Air: A Game Changer, Inside & Out ENERCO is pleased to launch the Delta

for your people (and equipment) to

Speed Air, an innovative high-speed

move efficiently around your premises,

door that pairs proven self-repairing

wish to increase privacy or need a

technology with an adjustable air

quality door to deliver a superior seal

curtain which significantly enhances the

around the full perimeter of your

doors efficiency.

opening, ENERCO’s Delta Speed Air is a fine choice. It also comes with a

Designed to intelligently separate areas

24-month warranty (subject to a service

where the traffic is high, the Delta

contract being taken out at the time

Speed Air is a perfect match for internal

of installation based on their intended

and external applications. It makes easy

operational usage). Whilst standard

work of confined spaces with different

sizes will meet most operational

temperature and humidity levels,

requirements, ENERCO recognises that

making it suitable for warehouses,

in certain situations a bespoke solution

factories, food processing facilities,

is best. Their team can provide a truly

car washes and many other industrial

tailored service to ensure your Delta

environments.

Speed Air exceeds your operational requirements, utilising proven high-

Made for minimum maintenance to maximise reliability and reduce the need for costly maintenance, the Delta Speed Air is simplistic in its design, and available in standard sizes up to 4.5m wide x 8.0m high. The galvanised side columns ensure high resistance and exceptional durability, whilst they are self-lubricated with directional air vanes for a smooth and fast action.

VISION PANELS ELEVATE SAFETY The 1300g curtain includes vision panels (available as standard), allowing workers to see the other side clearly, minimising potential dangers from approaching traffic. Multiple vision panels manufactured using clear PVC or mesh for air flow can be included if required.

Boost speed, manage traffic flows and prevent temperature fluctuations with a rapid operating speed and

speed and self-repairing technology. hygiene, improve safety and maintain optimum room temperatures. The

With over 25 years of experience,

vertical air curtain is fitted to both

ENERCO has developed longstanding

columns maximising the barrier effect

partnerships across a diverse range of

across the full width of the door.

industries including construction, food, retail, manufacturing and logistics.

EXTREMELY EASY TO OPERATE The motors can be front or sidemounted and the standard 3PH inverter controls are simple to use. The door can be equipped with a single-phase 230V supply, available up to 9m2. The door is 100% fail safe with its light grid and soft edge bottom rail technology and will accept all forms of activations devices as well as traffic light and interlocks.

ENERGY SAVING The Delta Speed Air reflects the company’s commitment to helping businesses boost energy efficiency, improve goods flow and minimise

excellent seal, the Delta Speed Air

energy costs in industrial and

facilitates efficient traffic flow while

commercial environments.

minimising temperature variations. This applications, guaranteeing a strong,

HOW CAN THE DELTA SPEED AIR IMPROVE YOUR OPERATIONS?

secure and robust barrier to maximise

Whether you want to make it easier

makes it ideal for a broad spectrum of

6 FDPP - www.fdpp.co.uk

The Delta Speed Air is an exciting addition to the collection because it delivers on speed, energy-efficiency and flexibility, whilst it’s also very versatile, being suited for internal and external applications. The door can help organisations reduce heat loss, save money, keep the temperature constant, control hygiene, enhance the work environment, reduce noise and maintain security.

If you’d like to learn more about its features or wish to discover ENERCO’s full range of high speed, self-repairing doors, other industrial doors and loading bay solutions, please visit WWW.ENERCO.co.uk.

ENERCO launch the Delta Speed Air ENERCO is pleased to launch the Delta Speed Air, an

innovative high-speed door that pairs proven self-repairing technology with an adjustable air curtain which significantly enhances the doors efficiency.

A GAME

CHANGER

INSIDE & OUT

www.enerco.co.uk/air 01525 289322

Significant energy saving

Air

Vermin and insect contaminant protection Self-repairing with rapid opening and closing Helps prevent ice build up Ideal for high traffic areas Colour, finish and size options

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.

K

ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries.

Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste.

Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm.

Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications.

Typical applications in the food industry include transferring tomato

The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste

8 FDPP - www.fdpp.co.uk

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables.

Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

Kecol’s articulated pump systems

The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products.

As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@kecol.co.uk www.kecol.co.uk

See us a

t

Stand N

o. 4E 02

THE HOME OF VISCOUS PUMPING SOLUTIONS

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… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax

T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

Increase the pressure with annular space heat exchangers Annular space heat exchangers, such

treatment (sometimes as many as 20 or

as the HRS AS Series, work by passing

30 elements), the product needs to be

the product through the gap between

pumped at considerable pressure. The

the inner and outer tubes (the annular

physical properties of such fruit purees

space), which makes them suitable for

mean that this high-pressure handling

thick, highly viscous products such as

does not adversely affect the quality of

fruit purees, thick sauces, honey and

the product.

syrups.

For such applications, HRS offers The advantage of such a design is

a high-pressure version of the AS

that it ensures even heating or cooling

Series. This includes thicker tube walls

of the product, while the use of HRS

around the product, while the service

corrugated tube technology increases

fluid (usually water or steam) remains

heat transfer and energy efficiency, as

be achieved as standard on the product

at standard pressures of around 10

well as reducing product fouling on the

side, but for some applications even

bar. The design means that process

tube surfaces.

higher pressures are required.

pressures of up to 150 bar can be

HRS produces both a three- and

One common example is the

of the heat exchanger, making it ideal

four-tube version of the AS Series (the

sterilisation of tomato puree using

for applications such as pasteurising

AS 3 and AS 4) to facilitate different

multiple heat exchanger modules.

and sterilising tomato and strawberry

arrangements and couplings of service

Because of its viscous nature and the

purees.

fluid. The thicker wall on the AS 4 series

number of heat exchanger modules

means that up to 25 bar of pressure can

that may be involved in large-scale

accommodated on the product side

10 FDPP - www.fdpp.co.uk

www.hrs-heatexchangers.com

Erca, the inventor of the form, fill and seal technology, enlarges itsâ&#x20AC;&#x2DC; machine portfolio and offers now also FS machines The first machine in the enlarged portfolio is the EFS-L, the recently developed new format flexible indexing platform for preformed cups. Utilising new technology enhances the available options and ease of operation and maintenance procedures.

Modular in design with stainless steel construction and servo-operations it allows for flexibility with filling stations, pre-fill and post fill for wet or dry ingredients. The chainless solution for the cup transportation enables format flexibility and precision index positioning throughout the machine.

Capable of filling cups up to a diameter of 130 mm, the FS machine is suitable for products such as yoghurt, fresh cheese, white cheese, single and multilayer desserts, aerated mousse products, deli salads, dips, hot filled sauces, soups, jams, fruit purees, sweet spread, pet food, etc.

Key benefits of the EFS are the format flexibility (quick release, tool free), the chainless drive (no chain stretch, no regular adjustment, less cup cassettes),

the modular design and construction, the recipe functionality, and itsâ&#x20AC;&#x2122; improved hygiene options (UVC, Pulse light, H2O2).

The machine will be available in the hygiene levels: clean or ultra-clean.

For more information please contact p +44 740 884 06 02 www.imadairyfood.com

FDPP - www.fdpp.co.uk 11

Can Makers confirms appointment of new chairman The Can Makers, the industry trade body

promote the beverage can as the preferred

address the challenges that initiatives such

representing drinks can manufacturers in

format for drinks packaging.

as DRS will bring.

“I would like to thank Marcel for his

“The beverage can is already the most

enthusiasm, hard work and commitment

recycled drinks pack in the world and it is

its new chairman.

during the last two years. His work has

critical that any DRS implemented follows

been instrumental in helping the Can

best practice and that all packaging formats

Simon has taken over from Marcel Arsand,

Makers to raise the profile of the beverage

are included as well as a variable deposit

Head of Sustainability at Ball Beverage

can as a sustainable packaging format and

Packaging EMEA who was held the role

there are now a greater number and variety

fee based on size.”

since July 2018. Simon brings more

of drinks commonly packaged in cans than

Previously General Manager at Ball Trading

than three decades of experience in the

ever before. The rise of craft beers for

UK and Director at Ball Packaging Europe,

packaging industry to the role and was

instance has been phenomenal and all the

Simon has held commercial and latterly

previously chairman of The Can Makers

signs are that wine in cans will see similar

general management positions in the

from 2006 to 2008.

growth.

industry including overseas assignments in

Simon said: “This is an exciting and

“At the same time, we have seen the UK

challenging time for industry and the Can

recycling rate for aluminium beverage cans

Makers. We have yet to see many of the

increasing year on year to a new high of

Simon has held his current role at Ardagh

effects that we know the pandemic will

76%. We will continue to showcase the

have, although the industry has already

environmental and sustainability credentials

for five years. He completed the Ashridge

demonstrated its innovative spirit and

of the beverage can and as chairman, I will

resilience, while the Can Makers are

continue to work in partnership with the

progressing a number of new initiatives to

Can Makers members and stakeholders, to

the UK, has confirmed the appointment of Simon Gresty, General Manager Metal – Beverage UK & Ireland, Ardagh Group, as

12 FDPP - www.fdpp.co.uk

Russia, Africa and more recently four years in Zurich.

Business School Directors Programme in 2007. www.canmakers.co.uk

HARTING launch a connector solution for the food and beverage industry The newest addition to the Han® portfolio is the Han® F+B, a range of connectors which have been specially designed for the requirements of the food processing, bottling and packaging industries. Within these sectors, hygiene and safety are key considerations, meaning machines and equipment must be both easy to clean and designed so dirt pockets and bacteria cannot accumulate.

The Han® F+B has been specifically developed as a suitable product for the food zone and primarily the splash zone and there are several innovations which make it the ideal solution. Firstly, all hoods, housings and seals are IP69K rated, so the connections are fully protected and resistant to the water jets used to clean equipment.

They also have large nooks and surfaces in accordance with the guidelines of the European Hygienic Engineering & Design Group (EHEDG), which allows cleaning and disinfecting agents to flow unhindered. For secure identification and easy traceability, the connectors are blue, although a black version is available.

The range is Ecolab approved, which means it is resistant to the highly

aggressive cleaning agents used in the

power, a versatile connector concept

food and splash zones. As the housings

which makes it possible to configure

are constructed from polypropylene,

future-proof machine design for

they conform to the directives of FDA 21.

processing units, including Ethernet.

All surfaces also have a smooth finish, which prevents impurities and bacteria from accumulating, whilst the portfolio can function in a wide temperature range

To learn more about the Han® F+B and download our FREE whitepaper, which gives more detailed information about

from -40 to +125° C.

using connectors in food and beverage

As well as hygiene and safety concerns,

UK/en-gb/connectors-food-industry or

HARTING have also considered the

email salesUK@HARTING.com.

facilities, please visit www.harting.com/

impact of machine downtimes, designing in features which keep disruptions on the production line down to a minimum.

With the Han® F+B, operators do not need to open any cable glands on the control cabinet in order to decouple field devices, eliminating the complex disconnecting and reconfiguring of fixed wiring. This solution also allows for faster replacement of defective components and a more efficient method of changing equipment, allowing businesses in the food industry to shorten set-up times and reduce production stoppages.

The housings can be used with hybrid contact inserts for all types of industrial transmission, including data, signal and

FDPP - www.fdpp.co.uk 13

Rather than picking up the entire stack and relying on gravity to despatch the bottom crate, the Crate DESTAKer clamps the bottom crate down, lifts the rest of the stack up, and then despatches the bottom crate

Case stacks up for new dual crate destacker Brillopak has launched a new Dual

to a game-changing operating principle;

UNIQUE OPERATING PRINCIPLE

Crate DESTAKer for feeding empty retail

rather than picking up the entire stack

The Crate DESTAKer uses pneumatic

crates to food packing lines at high

and relying on gravity to despatch the

clamps to grip both the bottom crate

speed with maximum flexibility. Based

bottom crate, the Crate DESTAKers

and the upper (remaining) section of

on the same proven operating principle

clamps the bottom crate down, lifts

the stack. The upper clamp is powered

as the original Crate DESTAKer system,

the rest of the stack up, and then

by two servo motors, which lift the

the new Dual Crate DESTAKer destacks

despatches the bottom crate.

crates up to enable the bottom crate to

two stacks simultaneously, enabling

be moved out of the stack and indexed

handling of 18 crates per minute and

In a typical packing hall set-up, crates

into the downstream automated crate

servicing of multiple packing lines.

are transported to the line via forklift by

packing system. The use of servo

the pallet load (usually around 30 to 40

motors makes the destacking system

Brillopak’s Crate DESTAKers are

crates high). The pallet load is pushed

infinitely adjustable – the operator can

employed in packing facilities for food

onto an accumulation conveyor that

change between crate sizes, change the

products ranging from fresh fruit and

feeds stacks (usually five crates) into

speed at which the system accelerates

veg to meat, baked goods and pizzas.

the crate destacker, leaving operators

and decelerates and alter the height

The innovative system is prized for the

free to focus on other tasks while the

to which the stack is lifted – all via the

unrivalled flexibility and reliability it

machine continues to destack onto the

system’s user-friendly HMI.

offers versus the competition, thanks

line.

14 FDPP - www.fdpp.co.uk

CRATES NEVER GET STUCK

lines; rather than conveying crates

of 8-9 crates per minute. By lifting two

Brillopak’s innovative approach to crate

individually around the hall at very high

stacks simultaneously, the new Dual

destacking has several advantages; one

speeds, crates can be sent in stacks of

Crate DESTAKer is capable of handling

problem encountered with conventional

two or three at much lower speeds, then

16-18 crates per minute, giving food

systems is that when releasing the

destacked at the entrance to the packing

producers and packers a high output

bottom crate sometimes the one above

system, via a second ‘mini’ destacking

option.

comes with it because the two are stuck

module.

The Crate DESTAKer range of crate

together. On the Crate DESTAKer this is never an issue as they are automatically

“Food packing operations rarely give

destackers can be supplied as a stand-

separated when the bottom crate is

much consideration to the crate

alone system, to integrate with a

clamped. In addition, the clamps on the

destacking operation, but the design

factory’s existing packing automation

Crate DESTAKer have PU (polyurethane)

of this system can have an important

system, or in conjunction with

faces to prevent damage to the crates.

bearing on overall line efficiency. If crates

Brillopak’s award-winning UniPAKer

This is in contrast to the metal teeth that

get stuck together, the line might have

robot packer, which has revolutionised

some rival systems use.

to be halted and operators will have to

the packing of bagged fresh produce

intervene to manually separate them

into crates. In this configuration, crates

Servo-motion for unmatched flexibility

before packing can continue. Large

leave the Crate DESTAKer and are

This design also means the process

packing halls with multiple lines in

indexed into the UniPAKer cell. The

is inherently more flexible; whereas

particular will reap the efficiency rewards

UniPAKer checks the bale arms are fully

most crate destackers can only handle

of a more flexible crate destacking

open before placing bags into the crate

individual crates, the bottom clamping

operation,” explains Peter Newman,

(it can happen that the bale arms move

unit on the Crate DESTAKer is adjustable,

Technical Director at Brillopak.

out of position and impede the crate packing operation).

so factories can easily switch to dispensing two or three crates at a time,

DUAL STACKS, DOUBLE SPEED

if required. This can be desirable for high

In its original single stack configuration,

Check out the new Dual Crate DESTAKer

speed packing halls operating multiple

the Crate DESTAKer operates at speeds

here: https://youtu.be/CxE1ZpX5K4I

Brillopak’s new dual Crate DESTAKer which feeds empty retail crates to food packing lines at high speed with maximum flexibility

FDPP - www.fdpp.co.uk 15

Balancing packaging safety, security and sustainability post COVID-19 Comment from Nigel Flowers, Managing Director, Sumitomo (SHI) Demag UK Around the world, health has taken priority over sustainability. As we begin to cautiously emerge from the pandemic, Nigel Flowers, Managing Director of Sumitomo (SHI) Demag examines how brands can move forward with their sustainable packaging initiatives and discusses the consumer behaviours and attitudes towards single use packaging that may stick around in the foreseeable future.

In the early days of the COVID-19, sentiments towards sustainability diminished. Although this was anticipated to be a short-term shift, concerns around hygiene, sanitation, crossinfection and the protection of health took priority. Initiatives like bring your own containers and resusable coffee cups were suspended. Substrate choices veered back to the ‘perceived’ enemy plastic. The big question facing packaging producers now is how much consumers in the future will be prepared to trade off product safety, security and hygiene against sustainability and whether there

the market has been moving more

machine and tooling give the optimum

towards novelty solutions that improve

blend of speed, quality and consistency.

performance, functionality and shelf impact.

NEW EXPECTATIONS Until March, eschewing plastic was

is a middle ground.

Most companies operating in this

the campaign of the day. The tide was

For several decades now light-weighting

competitive arena produce millions of

turning. And I’m in no doubt that public

and consumer convenience have given

packaging containers, caps and closures

rallying for circular packaging will resume

packaging manufacturers the strong

every year. Volume, raw material waste

in the next six months. Attitudes and

commercial incentive to do more with

and precision are fundamental to each

actions will inevitably shift again.

less. No strangers to responding to

packaging manufacturers’ financial

demographic and lifestyle changes and

viability, with many facilities operating

What this pandemic has clearly illustrated

balancing a wide range of variables,

20+ machines to meet supplier demand.

however, is the context in which decisions about packaging need to be made.

including cost, increased strength, recycle rates and functional requirements,

To successfully succeed in the thin

Exploiting people’s fears about reinfection

lightweight formats have become the

walling arena, injection moulders need

and sanitation should not be used as an

industry norm. Especially in food and

to examine every potential application to

argument to revert or redefine legislation.

medical packaging. More recently,

ensure that the selection of materials,

Understandably, the UK’s ban on plastic

16 FDPP - www.fdpp.co.uk

straws, cotton buds and stirrers has

need to be factored into the mould,

is aimed squarely at high volume

been delayed for six months by DEFRA

machinery, and packaging component

manufacturers of polymer products,

until October 2020. This is a temporary

design.

including caps and closures, thin wall

measure, but concurrently must not

containers and lids.

threaten progress towards more

Even when using less raw material,

sustainable packaging.

packaging forms the protective layer so

With the introduction of a new control

still needs to be engineered to provide

valve regulating the hydraulic pressure

MANUFACTURING CONSIDERATIONS

strength. Choosing the best machine

during the loading of the accumulator,

for your packaging application is critical.

the range consumes up to 15% less

As a material, plastic is inextricably

Understanding the melt stability and how

energy that previous generations

linked with energy and resource savings.

the plastic will perform as an end product

of El-Exis machines. These savings

Its low weight makes it both cost

should form the basis of all decisions.

are dependent upon the packaging

effective and flexible to use, adding to

application, moulding cycle time and

the sustainability score when measuring

To support these efforts, Sumitomo

environmental, social and governance

(SHI) Demag continues to pioneer the

(ESG) performance. If anything, this

development of packaging machines. The

Additionally, all-electric drives set a

pandemic has presented retailers, brand

companyâ&#x20AC;&#x2122;s El-Exis SP range, available

new benchmark for achieving absolute

owners and packaging manufacturers

globally, now comprises 10 machines,

processing precision, accuracy and

with the opportunity to review, realign

with a clamp force range of between

dynamics. These are essential criteria

and reinforce the value of their packaging.

150 and 1,000 tons.

in the quest to achieve the highest

process parameters.

process consistency, as well as reducing From a machinery performance

Capable of delivering dry cycle times

scrap to a minimum during start-up and

viewpoint, thinner wall sections bring

of less than two seconds, the latest

during ongoing production. The fast and

changes in processing requirements.

generation of EL-Exis SPâ&#x20AC;&#x2122;s are specifically

precise response of these direct drives

Among them, higher pressures and

designed to withstand the higher

also enables special processes to be

speeds, faster cooling times, and

stresses and injection pressures that

implemented with pinpoint accuracy,

modifications to part-ejection and gating

are so critical in achieving repeatability,

opening up new possibilities for

arrangements. These process changes

particularly in thin walling. This range

packaging moulders.

FDPP - www.fdpp.co.uk 17

AHEAD OF OUR TIME Like any other business, economic viability is just as important a consideration for packaging moulders.

Low unit costs, high output coupled with energy savings all need to be factored in. Thatâ&#x20AC;&#x2122;s why so many packaging manufacturers today are prepared to invest in new high-performance plant.

Increasingly, packaging moulders are looking to injection machinery suppliers to provide turnkey solutions, including robotic product handling, advice with tooling, training and testing and all the know-how and support that underpins efficient manufacturing.

Automated vision quality control is one area where significant advances have been made. At K-2019, we showcased our fastest closure turnkey exhibit to-date featuring the inspection Capwatcher Q Line from Intravis. Comprising eight highresolution cameras, this technology collects, visualises and provides up to 144,000 cavity-based measurements per minute. It also sources a unique

has probably superseded sustainability

packaging. While food and medical

inline temperature measurement for

as an immediate priority. Attracting new

packaging saw rises in demand, other

each closure, which allows moulders

people with the appetite for innovation

categories softened.

to determine the shrinkage behaviour

is as critical as ever.

of each and every closure. From a

Responding to a pandemic of this scale

quality control perspective, this is

Workforce and skill shortages can have

will always be a series of educated

groundbreaking stuff and significantly

a profound impact on cost, overruns

guesses. Iâ&#x20AC;&#x2122;m personally encouraged

reduces production waste.

and quality. Demands to create smaller,

to hear how packaging moulders are

lighter parts have made thin-wall

flexing to this unknown landscape and

Another way to achieve thinner yet

moulding one of the most sought after

acknowledging the fragility as well as

stronger packaging containers is to

capabilities in the injection moulding

the resilience of their product portfolios.

apply injection compression techniques

community.

Equally, the climate emergency has not

to stack moulds. With this, packaging

been forgotten.

moulders can increase output while

In mid-June the company reopened its

reducing the wall thickness of

training facility doors. To further assist

As public health concerns gradually

containers and lids from 0.45mm to

moulders of all sizes and sectors, this

ease, I suspect demand for reusable

0.35mm. This saves around 25% in raw

July Sumitomo (SHI) Demag will also

and sustainable solutions will swiftly

polypropylene materials compared

host a free series of Webinars covering

resume. However, the exact timings

to the standard injection moulding

some of the basic principles of injection

will be very much determined by

process, while maintaining comparable

moulding. The first discusses how to

consumers. Understanding how

mechanical properties.

calculate a correct clamping force

people interact with packaging and the channels they purchase through will

COMPLETING THE CHAIN OF CUSTODY

Packaging businesses we are in daily

be a clear driver, ensuring consumer

contact with are very much back to

safety, product security and future

Sustainability and production efficiency

business. Nevertheless, the pandemic

sustainability are evenly balanced.

is also intrinsically linked to skills. As we

has forced another re-think to our

reopen our society, resource efficiency

way of living and future reliance on

18 FDPP - www.fdpp.co.uk

http://uk.sumitomo-shi-demag.eu/

How leasing can support business development when cashflow is tight How do you invest in the equipment your business needs during uncertain times?

Finance leasing from AJ Products can provide the answer.

Even when cashflow is tight, businesses need to be able to invest in the future by having the right equipment to maintain safe and efficient work practices throughout the company.

With affordable fixed monthly payments and no deposit, finance leasing allows any business to improve cashflow, complete projects with immediate effect and provide high-quality modern equipment for your staff when you cannot afford to make the

won’t change throughout the duration of

business improve workplace productivity,

effective way to spread costs over

the lease, allowing you to manage your

boost employee wellbeing and support

a period of up to five years to ease

budget effectively. In the meantime, you

social distancing. We can lend to

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will have the cash available to invest in

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business forward. Furthermore, as all

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ups and sole traders for projects from

leasing payments are tax deductible, it

safeguard essential outgoings, such as

£1000 to £1,000,000. For your peace of

is a solution that will save the business

staff costs and rental payments.

mind, security is levied on the equipment

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money and is beneficial no matter your

rather than your property, minimising

financial circumstances.

Launched in January 2020, AJ Products

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AJ Products is a full-service supplier of furniture and interior solutions for offices, warehouses and industrial facilities, offering everything from design suggestions and planning to quick delivery and installation. www.ajproducts.co.uk Email: info@ajproducts.co.uk Tel: 01252 359760

FDPP - www.fdpp.co.uk 19

Cerberus guards the food safety gates Automation of inspection processes is on the rise, particularly in High Care food production environments where COP compliance and food safety assurance are integral to productivity. Driving down production costs while ensuring an accurate and reliable inspection process results in time and cost savings. With the Cerberus combination machine from Sparc Systems, automated metal detection and checkweighing, with the option to integrate label verification, are delivered in one space-saving unit.

The inspection machines market is projected to rise at a CAGR of 5.5% between now and 2024, with combination systems estimated to grow the most during the forecast period.1 A number of factors are attributed to the increasing adoption of integrated technologies, from demand for inline product inspection to growing need to comply with GMP requirements. However, the efficiency of integrated inspection lines is yet to be realised by many UK

To address the unique challenges posed

ensures fast and accurate rejection of up

by the food manufacturing sector, Sparc

to 200 out-of-tolerance or contaminated

is one of the few global inspection

packs per minute. An integrated metal

suppliers that offers cohesive reporting,

detector identifies ferrous and non-

data capture and COP testing in a combination system. Rather than slotting two systems together, the Cerberus provides complete mechanical and electronic integration with single point controls and trend feedback.

food manufacturers who continue to monitor performance manually or by a

Specifically designed for High Care food

machine-by-machine basis.

production environments, the Cerberus

ferrous particles down to 1.5mm, and stainless steel down to 2.0mm in bags weighing up to 60kg. Sparc’s European Sales Manager Charlie Graham explains: “Designed, engineered and constructed to the highest High Care, Food Grade engineering standards, no other system in the world comes close to this performance and sensitivity.”

DRIVING DOWN PRODUCTION COSTS Despite projected market growth, UK food suppliers are facing increasing pressure from all directions. With volatile market fluctuations and input costs squeezing already fragile margins, increasing output and installing reliable machinery are essential to drive down manufacturing costs and ensure productivity. The impact of machinery downtime alone costs Britain’s manufacturers more than £180bn every year.2 For checkweighing systems, reliability and accuracy is paramount to minimise downtime, false readings and food waste.

20 FDPP - www.fdpp.co.uk

Sparc addressed these issues by

which typically use pusher or air blast

market in the years to come.3 Every

designing the Cerberus with a heavy,

reject systems, the Cerberus uses an

retailer COP requires food manufacturers

stainless steel frame. Whereas other

all-electric direct drive which dips 90

to test their metal detectors and

suppliers are reducing weight, Sparc

degrees and 45 degrees to segregates

checkweighers regularly and document

engineers maintain that a heavier

metal contaminated products from

the results. But for staff completing

framework reduces vibrations from

weight rejects.

the tests by hand, the costs in time and

the factory environment to eliminate

money can be vast and the process is

the potential for false readings. Charlie

BRC-approved reject bins are located

comments: “In addition to its smart

beneath the conveyor framework

design, the high-spec checkweighing

rather than to the side, keeping the

To ensure absolute traceability and

station offsets the potential for both

machine footprint as compact and

compliance, Sparc designed the Cerberus

costly product giveaway and incomplete

slimline as possible. By containing these

with a single swipe touchscreen HMI and

packages reaching the market. In some

components within the body of the

paperless audit software with unlimited

cases, our customers have reported a

machine, plant flexibility and factory

pre-programmed COP. Believed to be

55% reduction in product giveaway.”

footprint are enhanced.

the most transparent system of its type,

subject to human error.

contract packers and manufacturers Keeping quality control front of mind,

“As a high-end combination metal

supplying multiple retailers can select

the system utilises a precision metal

detector and checkweigher, the Cerberus

from an unlimited list of retailer COP by

detector to inspect packaged food

was designed to eliminate emergency

product type. When a routine Quality

products. Identifying metal contaminants

product recalls with minimal operator

Assurance machine test is due - typically

with high sensitivity drives increased

intervention at inspection set up or

hourly - , a visual alert is issued to

security and reduces the risk of costly

product changeover. Furthermore, the

operatives. Steps cannot be skipped.

recalls. Food items involving numerous

in-line, electric-powered reject system

And if not performed to the set retailer

production steps where the potential for

removes the need for compressed air,

parameters, this is also flagged by the

metal contaminants to enter the supply

which has been proven to save some

machine and in the data reported that’s

chain is higher (sliced meat and cheese,

manufacturers up to £4,000 a year on

transmitted to the factory’s Quality

frozen products and convenience meals

running costs.

Assurance manager.

consistent inspection process.

COP COMPLIANCE WITH PAPERLESS AUDITS

When upgrades are issued, Sparc simply

UNIQUE CONVEYOR CONCEPT

Regulatory mandates in the food

which operatives can insert and upload

As a single unit, the Cerberus has two

industry to maintain compliance with

to the machine via the built-in USB.

reject bins to separate contaminant

retailer Codes of Practices and HACCP

and weight rejects situated beneath a

principles mean that the fully automated

Food factories are also able to select

three-position dipper conveyor. Notably,

machines segment is expected to

and bring to the HMI foreground their

unlike most other combination systems

dominate the inspection equipment

preferred operational parameters.

etc.) benefit from this repeatable and sends the new retailer COP parameters,

Charlie adds: “By generating constant feedback on operational statistics such as volume, weight and speed, downtime is reduced. And, the data capture element is fully integrated, making it simple to send information direct to the server or wireless devices.

“With the Cerberus, nothing gets passed these food safety gates. No other combi system can accurately inspect 200 food packs a minute without compromising on any other aspect of performance.

It is literally the most transparent and integrated combi system on the market today.” sparc-systems.com

FDPP - www.fdpp.co.uk 21

Magnetic separator for chocolate flakes We received a request from a producer

and carries away the metal-containing

of chocolate garnish for cakes, biscuits

product. The clean product falls directly

and yoghurt. The garnish is in the form

into the packaging machine.

of chips and granules that could possibly contain tiny pieces of metal less than

CLEANING

<1 mm in diameter. This is a common

Hygiene is of the utmost importance,

problem in the production of chocolate.

especially in the food industry. This

We were asked if we could filter the

is something we considered carefully

pieces containing metal out of the product flow, without loss of product.

while designing the HG separator. A separator, because with the latter you

quick release system makes removal

have to slow down the metal particle

and replacement of the conveyor

HIGH GRADIENT MAGNETIC SEPARATOR

before you can capture it. In addition

belt quick and easy. The special open

to chocolate, the magnetic separator

construction and covers that easily

To achieve this, we developed a high

is also suitable for other dry, granular

swing out of the way make the system

gradient separator with a strong

products, such as herbs and spices.

easy to clean.

the food industry. With this system we

HOW IT WORKS

For more information, please contact:

achieve exceptionally high separation

The process itself is simple. A vibrating

Arthur Jonkman â&#x20AC;&#x201C; Sales Engineer

efficiency, not just for iron particles,

chute feeds the chocolate flakes and

Goudsmit Magnetic Systems BV Tel.:

but also for weakly magnetic stainless

pellets onto the conveyor belt and

+31 (0)40-2213283 mail:

steel particles, such as AISI 304 and

distributes the products in a single layer

magnetic conveyor roller, specifically for

AISI 316. The high gradient separator is more effective than a free-fall magnetic

22 FDPP - www.fdpp.co.uk

over the belt. The conveyor belt turns around the magnetic roller that captures

AJ@goudsmit.eu Or send an e-mail to: pe@goudsmit.eu) /www.goudsmit.co.uk

KG Group Invests 20M EUR in New Plant in Lithuania European demand for instant noodles,

the existing production capacity and at

an Asian food staple, is increasing,

the same time allows to maintain the

while the Covid-19 pandemic is

same level of quality control.

leaving many supply chains broken. As

The 6.5 thousand square meter

European instant food buyers, such

production facility houses state-of-

as supermarket chains, are looking

the-art equipment, which the company

for local producers, Lithuanian instant food company invests 20M in a new

acquired from leading German, French,

local production facility. This is the

Swiss, and other manufacturers in

second company’s production facility in

today will be increased up to 180 million

Europe, complying with the latest

Lithuania.

units per year.

quality standards (the highest AA

September 7, 2020. Global Instant

KG Group is already operating in the

Noodles market, according to a new

UK, producing noodles, pasta, oatmeal

report, is growing despite the Covid-19

porridges and rice for this market. In

The commercial range of instant foods

crisis, and is estimated to reach USD

2019 more than 34 million units were

produced by KG Group includes instant

32.1 Billion by 2027. Up till now, most of

sold in the UK, while in 2020 this number

noodles and porridges in cups and

this instant food has been produced and

rose to 56 million units (sold until July,

pouches labeled with brands well-known

bought from different Asian countries.

2020). The products of KG Group may be

in Lithuania and abroad, such as Sun Yan,

found in most large supermarket chains

Activus, Dorea, and Just Inn. More than

of the UK. The new production facility is

forty major foreign companies, including

expected to fill a significant portion of

large supermarket chains trust their

demand for instant noodles in the UK

private label production with KG Group.

grade according to BRC Global

However, the coronavirus pandemic is affecting the market of this Asian staple food, among many others. As many companies are looking to alter their supply chains to be less dependent on

and to decrease the country’s reliance on

Standards Version 8).

Asian suppliers.

The technological features of the

Covid-19 crisis, they are exploring the

“We are glad we will be able to meet the

competencies and knowledge of the

options of local production. Exclusive

increased demand of local buyers, many

R&D Department even more effectively

reliance on Asian suppliers has shown its

of whom are European supermarket

introducing new products. KG Group

drawbacks as supply chains were cut or

chains. A new production plant in Alytus

produces new categories of instant

unreliable during the pandemic.

city is our response to the rapid growth

products in cups such as pasta, cereal

of consumer demand, and changes in

mixes, granola mixes, and couscous.

In order to satisfy the need for instant

global supply chains,” said Tautvydas

Private label services are available as

noodles and porridges in the European

Barštys, Chairman of the Board of KG

well.

FMCG retail market, including the

Group. He added that Alytus city is

UK, KG Group - one of the biggest

strategically favourable from a logistical

KG Group started the instant product

agriculture and food groups in the Baltic

point of view, as KG Group exports 95

business eight years ago, when the

States - is launching a modern instant

percent of instant food production.

first production facility, operating

Asia, especially China, in the wake of the

noodles production facility in Alytus city, Lithuania, after having attracted 20M

The new facility is an important addition

EUR investment.

to the KG Group chain of production.

The newly introduced technologies

quality the group exerts control over and

will not only increase the production

takes responsibility for all processes of

capacity, but they will also enable a

production from field to table. KG Group

greater variety of products and speed up

buys grain from Lithuanian farmers,

the production process by 4-5 times. The

selects it with care and uses the group-

capacity of forty million units of instant

owned mill to ensure the highest quality

food in cups that KG Group produces

of flour. The new local facility expands

To ensure the highest standards of

production facility help to embrace the

to date, was opened in Kėdainiai city.

Further plans of the company include the development of products and the range of items, an increase of sales volumes, a supply of new products to consumers, development of export volumes. The main focus is on exports to Western Europe, Spain, Great Britain, and Scandinavian countries. www.kggroup.eu/en

FDPP - www.fdpp.co.uk 23

Grading facility puts its eggs in the Rotamec basket When shopping at the supermarket or eating at a restaurant, you want to be assured that your food has undergone proper quality checks. These checks can be quite the challenge for a foodstuff as delicate as eggs. Grading eggs is a specialty of grading facilities, which quality check eggs from nearby prior to distribution. One such facility operates a wide array of specialist equipment on-site and trusts Rotamec, an electromechanical engineering service provider,

“We have to react quickly to minimise

This customer does present specific

to deliver repairs and source spares.

downtime. For example, the customer

challenges though, as Darryl reiterates:

required a double-sided open length

“One repair job required us to source

Eggs are a staple food for many of us,

timing belt to keep a conveyor operational

which means that there is a high level

specialist foam material that cushions

after a failure of the OE part. The cost

of demand for the produce irrespective

the eggs during grading. The egg comes

of downtime on this machine is around

of season. Consumers will only settle

£3,000 an hour, so lead time was all

through to a sensor, where it taps

for quality produce, so grading facilities

important. In this case the maintenance

assesses each egg that reaches its

team decided to order two parts, one from

processing lines from partnered farms

us and one from the OEM, to maximise

before packaging. By checking for any

their chances of getting the machine back

imperfection with specialist equipment,

up and running the same day.

grading ensures every egg is in optimum condition before it is packaged and

“We were able to deliver the belt in 2

delivered to customers. With millions of

hours, while the OEM took 6 hours. Ours

eggs passing through grading facilities

was installed and the OEM item added

each year, keeping specialised equipment

to spares. All in all, we managed to save

running is especially important in helping

them roughly £12,000 in downtime costs.”

shops meet the demand.

However, the more specialised your equipment, the harder it is to repair or replace parts in the event of a failure. Lead times from OEM’s are often unforgiving, which in the pressurised world of food

The egg grading facility operates varied motors and gearboxes, reliable supply of a wide range of standard parts from a single supplier is important in keeping equipment running. Thanks to existing warehouse stock and in-house distribution

against the foam, which detects any hairline cracks as part of the quality control process. Improper foam will crack the egg, so only an exact solution will do. Th grading facility required replacement foam for the machine, but the OEM lead time was going to take too long, so we were approached. It was a bit different from the mechanical issues we typically deal with, but we managed to source the foam within the required timeframe.”

Both the grading facility and Rotamec understand that reducing downtime is one thing, but preventing it is another.

This is why engineers from both businesses are building redundancy

capabilities, Rotamec is able to deliver

into maintenance and repair operations.

standard parts quickly – typically same

By undertaking asset inspections and

day if required. Further, its in-house

identifying ‘showstoppers’ - equipment

machining capabilities mean that bespoke

that risks overall uptime if it fails – the

items such as shafts in various bore sizes

engineers are prioritising maintenance

can be easily produced too. Specialising in

to focus on the most critical assets.

motor repair and refurbishment helps as

Rotamec has also enacted a policy

well, with Rotamec able to offer 24-hour

of ordering spares from relevant

Reducing downtime via responsive

turnarounds on motors and gearboxes.

OEMs during each repair, ensuring

maintenance is very important to this

So, despite different configurations and

facility, as Darryl Beecham, Business

equipment throughout the site, Rotamec

maintenance work is backed by a

Development Executive at Rotamec

can still offer reduced repair and sourcing

explains:

lead times.

supply adds further stress to operators.

For one grading facility, keeping the machines running and eggs moving demands the assurance of a dynamic service provider, which is where Rotamec - a leading service provider for engineered equipment - comes in.

24 FDPP - www.fdpp.co.uk

growing spares inventory. www.rotamec.com

An industry leader in the supply of environmentally responsible & HACCP compliant preventative controls & detection systems to the regulated food industries

MAGNERSCAN Chemical free surface integrity & crack detection testing

GAPPSCAN Heat exchanger integrity quantification for multiple PHE plates reducing downtime

PASFLO Non-intrusive pasteurisation residence & flow validation for the liquid dairy, brewery & juice industries

BACTISCAN Isolating BioFilms, bacteria, mould & contaminants using wave alternating UV to reduce product recalls or worse

To discover more, contact us today: enquiries@eit-international.com or visit:

www.eit-international.comFDPP - www.fdpp.co.uk

25

Compact inspection systems become the ‘new normal’ When it comes to buying criteria

However, producers have a duty of care

systems on the same conveyor results

for inspection equipment, whilst

to operators to ensure they are working

in a far smaller footprint than stand-

commercial viability will always make

in a safe environment. Rather than

alone units would occupy.

or break decisions, the COVID-19 crisis

reconfiguring production line layouts,

is pushing space-optimised design and

companies are looking at how they can

Combi metal detector/checkweighers

remote diagnostics to the fore.

redeploy and organise operators in a

are not a new concept, but last month

safer way, for example, by altering shift

[May], saw Fortress unveil its first ever

patterns. In other words, the focus is on

offering in the space under the Raptor

moving people rather than machinery.

marque. Developed in collaboration with

Footprint has long been a consideration when choosing packaging and processing equipment – factory space is at a premium and the ever-increasing

As factories adapt to these new ways

cost of real estate means each cubic

of working, Phil Brown, Managing

metre has to be maximised.

Director of Fortress Technology, expects

In production and packaging facilities where every inch counts, establishing

equipment compactness to become even more important.

new practices that will enable factory

“From a factory floor perspective,

personnel to work safely during

adapting to COVID-19 is all about

the COVID-19 pandemic is a huge

creating space. Smaller footprint

challenge. Preventing the spread of the

equipment creates more space for

virus within the workplace is all about

people to move around without being

creating distance and physical barriers

restricted to certain pathways,” he says.

between workers, but space is in short supply in most facilities.

COMBI SYSTEMS COME INTO THEIR OWN

MOVING PEOPLE, NOT MACHINERY

One of the ways in which companies

Redesigning factory layouts is not easy,

combined checkweighing and metal

requiring considerable investment.

detection system – mounting these

26 FDPP - www.fdpp.co.uk

Sparc Systems, the integrated system delivers hygienic and user-friendly operation on a compact footprint.

The machine’s footprint has been minimised via several design features.

Clever configuration of the reject mechanisms, for example, means that they occupy 50% less space than a conventional design.

“You can’t get away from the fact you need separate rejects for weighing and metal as the rework required for rejected products is very different.

However, we have designed the system

can save line space is to opt for a

with opposing rather than end to end rejects, reducing the length of the reject system from one metre to 500mm,” explains Brown.

“500mm might not sound like a lot

lines, where multiple components are

and supermarkets have grappled with

of space, but it can be the difference

added manually. Here, where individual

unpredictable purchasing behaviour and

between a safe working space and one

working space can’t be maintained,

patterns. Issues with equipment have had

that doesn’t meet requirements. Also,

factories have had to install physical

to be resolved as quickly as possible, with

if you equate it to the amount you are

screens to separate operators. Either

minimal disruption and person-to-person

paying per sq ft, it translates to a tangible

solution increases the line space required

contact. In these circumstances, remote

cost saving,” he adds.

to safely perform this operation, so

troubleshooting is the ideal solution,

downstream equipment space savings are

and even if the issue cannot be resolved

needed to free up space.

remotely, it can serve as a first line

Another way in which the Raptor Combi system can offer space-saving advantages over rival systems is through

DISTANCED DIAGNOSTICS

the flexibility this platform offers. Whilst

approach, arming engineers with valuable information so that site visits can be as brief as possible.

Fortress manufactures a standard Raptor

As well as creating a further driver for

system for customers wanting a short

more compact systems, the COVID-19

Now that companies have started to

lead-time system for handling products

pandemic is accelerating adoption of

realise the benefits of remote assistance,

up to 400mm in size and up to 8kg in

remote access functionality on inspection

Brown believes it is unlikely that the

weight, it will also manufacture custom

equipment.

industry will revert to a more traditional

systems for smaller products and space-

face-to-face approach and that it will be a

restricted areas.

“Most modern metal detectors and

“A lot of our competitors will just produce

diagnostics but until now this function

Likewise, the food industry will continue

a standard system that can accommodate

has been under-utilised. However, recent

to demand inspection systems with

any product up to 500mm. However, if

months have seen it taking on increasing

ever more compact dimensions. Whilst

you are running a 250mm product, you

importance as companies seek to protect

technological progress will continue to

don’t need such a long system. In that

staff and reduce travel and face-to-face

forge ahead in this area, there comes a

situation, we can engineer the system

contact,” notes Brown.

point when both physics and the need

down to 1.2m instead of supplying a standard system that is 2m in length,”

checkweighers have in-built remote

There are several reasons for this shift

says Brown.

in behaviour. Some areas of the food

One scenario where space-optimised

demand in recent months as consumer

combi systems can really come into their

spending has shifted from the out of

own is on labour-intensive ready meal

home hospitality sector to retail grocery,

industry have faced unprecedented

focus for innovation in years to come.

to guarantee product quality place limitations on reducing system size. It is about finding that sweet spot, where footprint, reliability and cost of ownership can all be balanced. www.fortresstechnology.com

FDPP - www.fdpp.co.uk 27

Food for thought: Robot stacks sandwiches in 800 milliseconds Although simple automation can

frequent shortage of labour. Their

give some manufacturers the boost

production lines were understaffed,

needed to increase production and

and they were always missing people

product consistency, more complex

from their optimum shift capacity,”

applications often require intelligent,

says Kyran Findlater, Mechatronics

flexible robotic solutions that can

Designer at TechBrew. Obviously

adapt to variable products and picking

TechBrew had to consider national

locations. In the case of a large-scale

food safety regulations when designing

sandwich producer, growing production

this solution, and in this case the

demands coupled with a major labour

integrator used the cleanroom version

shortage provided motivation for

of Kawasaki’s 5 kg payload RS005L

them to robotically automate a high-

general purpose robot. As standard it

speed sandwich stacking application.

offers a pressurized cavity, ISO Class

To resolve the challenge, TechBrew Robotics, a Kawasaki Robotics Preferred Integrator based in British Columbia, Canada, designed a custom solution using Kawasaki’s R series robots and F60 controller.

The robots’ task may seem simple: after the sandwiches are halved in the cutting machine, the robots need to pick up and rotate to stack one half on top of the other, making them easier for human workers to package manually further down the line. However, this application was tricky to automate for a number of reasons. The sandwich halves vary in their position as they come out of the cutting machine, so the robot would need some sort of vision intelligence to recognise and understand the location of each half on the conveyor. They also needed to be able to stack the sandwiches in practically the blink of an

the sandwich cutting machine itself.

To maximise throughput, the robots face outward, stacking sandwiches on two different conveyors which are running simultaneously. There are many variables in this application, so TechBrew used a laser range finding system coupled with conveyor tracking to detect the shape and location of the sandwich halves as they emerge from the cutting machine. Once the sandwich halves have been stacked, they travel down the conveyor to a place where human workers are waiting to place the product into triangular cardboard boxes.

TechBrew designed a custom gripper specifically for this application. The pneumatic end effector is controlled directly by the F60 Controller, allowing for quick movements. A controllable pressure plate comes down to hold the

5 cleanroom specification, and comes with an aluminium arm cover, rubber outer seals and a chemical resistant epoxy paint finish for easy wash down.

The patent-pending end effector’s tool-less design makes it easy to disassemble for cleaning purposes, and it is constructed with stainless steel and food-grade plastic.

The combination of Kawasaki’s AS programming language and its F60 controller easily handled the complexities of this project. Findlater was able to program this application directly on the robot, without a coprocessor, which reduced costs and simplified the installation. The Kawasaki F60 Controller’s high processing speed handled real-time scanning and data analysis on the sandwich halves, and output the robot coordinates in under 200 milliseconds, while processing a

eye.

product in place as two stainless steel

Because TechBrew needed to integrate

lift it. Once lifted, the actuator spins the

its solution into the customer’s

sandwich half through 180°, and force

existing production line, it meant

The entire sandwich stacking process

dampers at the end of the rotation keep

making creative use of limited space.

takes just 800 milliseconds and

the sandwich and its ingredients intact.

according to TechBrew, it didn’t take

paddles slide under the sandwich half to

To this end, the R series robots were inversely mounted on a cantilever

Like many other manufacturers, the

beam attached to the cutting machine,

customer struggled, sometimes daily,

and the F60 controllers’ compact

to keep up with production goals

size made it possible to save further

due to absent workers. “The main

space by stacking them on top of

driver for the end user here was the

28 FDPP - www.fdpp.co.uk

queue of sandwiches at a rate of 60 per minute.

the customers’ line managers long to adjust to their new robotic co-workers.

Throughput has increased significantly as a result of the robot’s consistency. https://robotics.kawasaki.com/en1/

Hassia’s form-fill-seal machine F600 for sachets produces four-sided sealed sachets at a pace of up to 80 cycles/min Among other differentiators, the F600 offers single-roll functionality, an improvement over two-roll formats. The units run a single wide roll, which is located at floor level for easy changeover and front-and-back sachet

registration – an option offering more printing choices than traditional two-roll machines. The F600 can handle rolls as wide as 1.200 mm with a diameter of 800 mm, which can yield up to 16 hours of run

time between roll changes; the result is significantly reduced downtime and boosted productivity.

The F600’s careful product handling places a premium on quality assurance, and its CIP and SIP-suitable dosing units can be adjusted per specific product requirements.

Exemplary filling accuracy and hygiene standards are assured, and the hermetic pack seal produced by the F600 is secure yet easy to open for consumer convenience.

The F600 is also flexible: A range of pack designs are possible, and sizes can be configured to align with production capacity.

The machine’s control concepts are highly versatile and include opportunities for integration with customer-specific systems.

The unit can handle all common packaging materials suitable for heat-sealing.

For more information please contact p +44 740 884 06 02 www.imadairyfood.com

FDPP - www.fdpp.co.uk 29

The New SRP Cobot by Phoenix Handling Solutions The new SRP Cobot from PHS is an

scanning system to the front. Should

• 6 bar air pressure

extremely compact, versatile and fully

a person be detected by the radar, we

• Lease purchase, hire purchase, lease

automatic, low-cost modular robot

automatically slow down the Robot into

only or outright purchase options

palletizing system, based on a Hanwha

Cobot mode, ie it runs at a lower speed

available

HCR-12 industrial collaborative robot.

for safety reasons.

Designed for easy, low-capacity palletizing on a very small footprint.

The system is available in two versions.

Given the vast experience of PHS in end of line automation, Cobots were a natural progression for our business for existing and new customers alike.

Should your business be considering Advantages

a low cost palletizing solution, then

• Low investment, fast ROI

please contact Phoenix Handling

• Standardized system - fast delivery

Solutions Limited:

and installation • Very compact footprint, easy to re- locate by pallet trolley or forklift • Collaborative industrial robot -

They are simple to install and do not

safety fencing and safety radar

require masses of conveyors to feed

scanner included – CE certified

them. Hence they can be easily placed at

• Easy product change-over

the end of a production line picking and

• Can handle Euro 1200 x 800 or

placing product 24/7 if required.

Chep style 1200 x 1000mm pallets x 2 positions

Safety plays a huge part of the PHS

• Optional layer sheet inserter

solution, as we provide a fully guarded

• Up to 6 cycles per minute, either

cell to follow the strict guidelines for CE

single or multi picking according to

T: 0845 265 7570

marking Cobots, with safety guarding

gripper type and dimensions

E: admin@phs-uk.com.

at each side of the machine and a radar

30 FDPP - www.fdpp.co.uk

• Single phase power supply

www.phs-uk.com

Ishida Solutions support Danish Crown’s China expansion Ishida Europe has designed and installed a series of bespoke packing lines for specialist meat producer Danish Crown’s new greenfield factory in China.

Working in close partnership with the customer, Ishida has supplied its own and ancillary equipment for the four lines, which are handling a variety of products including minced and diced pork, ribs and steaks, as well as quality control for thermoformed packs of pork.

The factory is now in operation and will have a capacity for 14,000 tonnes of meat to be processed and packed each year when it is up to full speed.

Ishida’s ability to devise complete solutions in line with customer requirements and efficiency and throughput targets, along with the excellent performance and reliability of its equipment, were key reasons for the company’s selection by Danish Crown.

32 FDPP - www.fdpp.co.uk

“We felt that Ishida offered the most

variety of products and pack types. For

inspection systems and DACS-G-015

relevant experience and the best

example, the multihead weigher is able

checkweighers are also providing

solutions,” explains Nicolai Linde,

to discharge diced meat directly into

quality control and weight checks on

Senior Manager Projects, Production

trays, or transfer ribs to a batching

two separate thermoforming lines.

and Supply Chain. “Having a single

table for styling in the trays. Similarly,

point of contact helped to speed up the

the QX-1100 tray sealers which

Danish Crown is one of the world’s

process. In particular, the close working

currently seal MAP trays are also

largest exporters and one of Europe’s

relationship established between our

able to handle skin packs, which will

largest producers of pork. The new

two teams and the continuing dialogue

enable Danish Crown to meet growing

China factory in Shanghai was

between them ensured that any issues

demand in the Chinese market for

established to meet growing consumer

or problems could be discussed and

bone-in products.

demand in the Chinese market for high

quickly dealt with to keep the project on

quality meat products, supplied via

time and budget and enable us to meet

“Although we were not previously

our performance targets.

familiar with Ishida’s tray sealers, they

“In addition, the company has an office in China which ensures a fast response in terms of service support and spare parts.”

The Ishida models installed at the factory include the company’s

supermarkets and e-commerce.

have proved to be very reliable and

“Our objective was to build the new

deliver consistently high-quality seals,”

factory to Danish standards,” explains

comments Nicolai Linde.

Nicolai Linde. “For this reason, we focused on sourcing the very best

As another example of the excellent

European equipment throughout.”

performance of the Ishida machines, the company’s IX-GN 4044 x-ray

www.ishidaeurope.com

advanced RV-214 multihead weigher, QX-1100 Twin tray sealers, DACS-G checkweighers, IX-GN x-ray inspection systems and its weigh-price-labellers.

Additional equipment integrated into the lines includes dicers, slicers, batching tables, labellers and cartoners.

Ishida also gave factory personnel comprehensive training on all its machines and provided a technician onsite permanently during the first months of operation to ensure a trouble-free start up.

A key requirement of the overall design was to ensure maximum flexibility in the lines’ ability to handle a wide

FDPP - www.fdpp.co.uk 33

The Benefits of Automatic Metal Detector Testing

By Mike Bradley, Global Head of Sales (Metal

the metal detector. This is because they

ATS is suitable for use in vertical food

Detection) Mettler-Toledo Product Inspection

do not confirm centerline testing – the

inspection applications such as snacks,

least sensitive part of the metal detector

crisps, confectionery, infant formula,

– as the placement of test samples

bulk flour and nutraceutical powders,

passing through is generally random. In

plus granulates such as sugar and food

Traditional methods of testing gravity fed metal detectors and those installed on Vertical Form Fill and Seal (VFFS) packing lines typically involve frequent and timeconsuming stoppages, potential risks to operator safety and often generate inconsistent results. In many cases, the test methods used do not confirm that the operational specification of the metal detector is being achieved. Automatic metal detector testing systems overcome these issues and can aid food manufacturing quality, efficiency and productivity.

addition, manual testing processes can carry cross-contamination risks and can potentially compromise food product quality, as the test samples come into direct contact with the product.

Mettler-Toledo has delivered a solution to all these problems, while also helping to improve Overall Equipment Effectiveness (OEE) and productivity: its Automatic Test System (ATS) on Safeline metal detection systems, won

The “Drop-Through”, “Fishing Line”

the CFIA Innovation Award for Quality,

and “Test Rod” methods are all routine

Hygiene, Security and Environment in

performance monitoring test processes

France in 2019 and has been recognised

for vertical metal detection inspection

as accepted best practise by a major UK

systems. Manual testing often requires

high street retailer.

teams of operators to put their safety at risk by climbing ladders and reaching over machinery so that they can drop or insert test samples into a throat or gravity-fall metal detector. These test processes are unable to accurately verify the operational specification of

additives. Test samples are transported, by pneumatic control, up discreet nonmetallic tubes inside the metal detector’s aperture to a defined position within the sensing coils. The test samples are then released, simulating the presence of a contaminant in free-fall under gravity. A software algorithm correlates centerline sensitivity with edge of aperture sensitivity, eliminating the random nature of vertical metal detector testing.

Reduced Test (RT) Mode is an additional feature available on some throat and gravity-fall metal detection systems.

When RT Mode is active, the metal detector monitors its online sensitivity performance and provides an alarm should the sensitivity drop below the specified level allowing companies to reduce the frequency of testing by up to 80%, without increasing their risk. This directly, and in some cases dramatically, improves productivity as production is now stopped less frequently for testing allowing productivity gains to be realised.

Major Italian savoury snack producer PATA S.p.A has 30 throat-style metal detectors on its production line, of which five have ATS installed. RT Mode is included as standard on the MettlerToledo Profile metal detectors that it uses. ATS and RT Mode have provided several benefits for PATA and for other food manufacturers that use them:

#1 ENSURE COMPLIANCE ATS is the only method of testing that confirms centerline (worst-case) sensitivity performance. As such, it delivers test results of ongoing working performance that can be trusted.

34 FDPP - www.fdpp.co.uk

#3 ENHANCE OPERATOR SAFETY Not only will operators be safer with ATS, but fewer of them will be needed to conduct testing. For example, instead of one operator having to climb high to drop a sample through the aperture, and one to record the result and remove the sample from the production line, ATS testing can be completed by a single operator.

It virtually eliminates the need to work at height to conduct routine testing and removes the need for operators to reach across installed equipment to insert a test sample.

#4 IMPROVE PRODUCT QUALITY AND FOOD SAFETY

When connected to centralised data

a single operator in under 40 seconds,

collection and management systems,

compared to an average three to four

ATS is a non-invasive method of testing,

such as Mettler-Toledo’s ProdX software,

minutes and two operators using

so test samples do not come into

ATS provides electronic records that

traditional, manual methods.

contact with food, removing the danger

are easily stored for future reference, for audit compliance or proof of due diligence. Having electronically stored data reduces the risk of errors or loss associated with paper records. This also supports rigorous quality control regimes, production optimisation and simplified production line operation.

#2 INCREASE PRODUCTIVITY

By using RT Mode to reduce testing frequency from every two hours to every 12 hours, a typical snack food manufacturer with 24 weigher-bagger lines running at an average of 100 bags per minute could save more than 4000 man-hours and produce 25 million more packs per year.

Mettler Toledo’s online calculators

ATS tests are much faster than

www.mt.com/md-roi-rt enable food

traditional testing methods. An end-to-

manufacturers to work out how much

end 3-metal test (ferrous, non-ferrous

they could benefit from using ATS and

and stainless steel) can be completed by

RT Mode.

of cross-contamination. The higher sensitivity levels of RT Mode mean that smaller, irregularly shaped metal contaminants can be detected. RT Mode also continuously checks the performance of the metal detector to ensure it is always working to a level as good as, or better than, the food manufacturer’s specifications.

#5 ADDITIONAL FEATURE TO FACILITATE SOCIAL DISTANCING REQUIREMENTS Additional to ATS and RT Mode is an ‘Emulation’ feature which allows operators to remotely control the metal detectors by mirroring their interfaces on remote networked devices. This is ideal for testing of systems installed in inaccessible locations plus also supports COIVD-19 social distancing requirements and enhances operator safety.

Food manufacturers can try out Mettler-Toledo’s ATS ROI Calculator here: www.mt.com/md-roi-rt

For more information, download MettlerToledo’s “Five Reasons to Invest in Automatic Test System”: www.mt.com/md-ats

FDPP - www.fdpp.co.uk 35

Future ready: Sustainable wheat ingredients for functional concepts How the corona crisis has led

trends through innovative technology.

consumers to rethink their attitude to

As a result, manufacturers benefit from

food â&#x20AC;&#x201C; a statement by Henrik Hetzer,

higher quality end products using the

Managing Director of Loryma

same or optimised production processes.

The post-corona era calls for innovation

There are three megatrends at the

and more global responsibility in the

epicentre of the corona disaster that

food industry. Consumers increasingly

will prove to be true innovation drivers

demand sustainable, safe and

in years to come. The crisis has led to

uncomplicated products. Market research

a reorganization of the way we work,

institutes such as Mintel1 are forecasting

greater respect for the older generation

a long-term trend reversal in the food

and a desire to take more responsibility

market after the crisis: towards higher

for our environment. These experiences

expectations in terms of quality, as well

will have a lasting impact on peopleâ&#x20AC;&#x2122;s

as increased awareness of added health

living and consumption habits. Key

benefits and environmental compatibility.

learnings are a daily diet with less meat,

As experts in ingredients made from

easy preparation of food at home and a

the natural raw material wheat, we at

need for healthy and ethically justifiable

Loryma can respond to current consumer

nutrition.

36 FDPP - www.fdpp.co.uk

This is where the natural raw material wheat offers great potential: using extrusion technology, it is versatile and combines nutritional and technological advantages. Wheat proteins optimise the consistency of products such as meat alternatives, cereals, baked goods and convenience food. They provide high-quality amino acids and help to reduce global meat consumption, contributing to a better ecological balance. Wheat

Our great asset is the flexibility of wheat

joint production, i.e. the creation of

starches improve stability, texture

combined with the expertise we have

different products from the same raw

and flavour, while extending shelf

acquired over several decades. Loryma

material, the wheat can be utilised

life and positively influencing the

is a brand of the Crespel & Deiters

almost entirely with a yield of 99 per

nutritional profile of food products,

Group, which processes 330,000 tonnes

cent. This guarantees efficient and

for example through sugar reduction.

of wheat annually, which equates to an

resource-friendly handling. Lorymaâ&#x20AC;&#x2DC;s

The use of functional blends enables

area the size of 57,500 football pitches.

products are crisis-proof and pioneering

individualised visually and texturally

100% of the guaranteed GMO-free

convincing applications that are quick

raw material comes from the EU, 75%

and easy to prepare. This holds true

of which is harvested and processed

for a virtually unlimited number of

in Germany. The regionality of this

solutions, from breadings and vegan

renewable natural product ensures

meat substitutes to confectionery,

a reliable supply, short transport

snacks and ready meals.

routes and low emissions. Thanks to

for use in globally significant markets of the future. This also benefits the manufacturers who work with our ingredients.

For further information, please visit: www.loryma.de/en/

FDPP - www.fdpp.co.uk 37

CUSTOMISE YOUR PPE …

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PRINTED IN GREAT BRITAIN / VERY FAST DELIVERY / CE CERTIFIED VISORS PROTECT YOUR WORKERS / PRINTED VISORS ARE UNIQUE AND CANNOT BE COPIED USE DIFFERENT COLOURS FOR DIFFERENT LOCATIONS / ADVERTISE AND PROTECT

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DESIGNED & MANUFACTURED

IN GREAT BRITAIN

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The Specialists for Retail and Promotional Packaging using Recycled PET and Folding Box Board BELL Packaging One of Europe’s leading suppliers of Retail packaging opened a PPE division in March supplying a range of Face Visors which are widely used by the NHS – As companies welcome back their staff from Furlough we must protect them and Visors provide excellent protection from harmful COVID droplets.

In July BELL introduced a Tiltable visor which is CE Certified – this is very popular

+44 (0) 1582 459292

with people working in Hotels, Bars and the Entertainment sector but is also used in shops, department stores, beauty and hair salons.

For October we are launching Printed Visors …

Yes your LOGO or MESSAGE printed onto the Visor …

Minimum Order quantity is 250 Pieces with print in 1 or 2 Colours – Cost is under £4.00 / Visor for a 1 colour print plus Printing Die @ £100 & Delivery

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i.bennett@bellpackaging.com

Price subject to MOQ & approval of final artwork.

Delivery time is really fast as we hold over 10,000 Visors in stock.

Coming soon BELL have Protective screens which are 100% Recyclable and costing under £15.00 each – for more information visit our dedicated website www.faceguards.co.uk or call +44 (0) 1582 459292 and ask for a free sample

www@faceguards.co.uk

Barratt Industrial Park, Airport Way, Luton LU2 9NH

in

What does the future hold for food & beverage manufacturing?

By Emma Ryde, Rittal’s Product Manager

As digital technologies continue to

advancements. Europe has long been at

Industrial & Outdoor Enclosures

transform global markets, no industry

the forefront of these legislative changes

remains untouched, and food and

and successful companies will likely be

beverage manufacturing is certainly no

those who stay ahead of the curve by

exception.

implementing changes sooner rather

Food and beverage manufacturers of all sizes are facing huge operational challenges right now.

Sudden increases in consumer demand, shifting expectations, changes in

Let’s consider how each of these three factors can impact day-to-day operations

than later. These companies will avoid both production downtime, and the potential for higher costs associated with

on the production floor, and how leading

refits, when new legislation eventually

manufacturers are adapting to win.

passes.

be responsive, agile and flexible. There

STANDARDS AND LEGISLATION

Even in our current outcomes-based

is also the matter of ensuring seamless

In recent years, food and beverage

regulatory framework, reducing cleaning

production continuity, to ensure

manufacturing regulations have

time and ensuring impeccable hygiene

consumer confidence around maintaining

changed significantly across the globe

standards continue to be key areas of

food and beverage supplies.

due to technological and scientific

focus.

food safety legislation, and emerging technologies, all require companies to

40 FDPP - www.fdpp.co.uk

As the physical landscape of

their way to support companies who

to clean them will lower both water and

manufacturing shifts to accommodate

follow environmentally friendly practices.

energy usage.

Manufacturers that want to reach this

In order to offset the cost increases

cleanliness.

audience will need to implement changes

associated with making these transitions,

that reflect this shift in consumer

industry leaders are continuing to refine

This leads us to our next topic: the

priorities and effectively communicate

efficiency-boosting practices like CIP to

presence and proliferation of technology

the changes that have been made. To do this, you’ll need to streamline every

make production facilities greener.

in food production spaces.

the increased presence of technology, so too will our approaches to safety and

FOOD SUSTAINABILITY AND CORPORATE RESPONSIBILITY

aspect of your business with a new focus on environmental sustainability.

There’s no denying that we all have a

Whether it’s recycling production

responsibility to implement sustainable

materials to close the loop on waste

environmental practices. But from a

outputs, or reducing the energy

commercial perspective, it’s also worth

consumed during cleaning, every part of

TECHNOLOGY AND DIGITAL TRANSFORMATION At this point, we can consider the massive impact that the Internet of Things (IoT) will have on manufacturing is a sure thing.

your process should be moving towards

Telstra puts it very clearly when they

a more sustainable future, either directly

state that “In an increasingly automated

the consumer market.

or indirectly. For example, Rittal’s HD

manufacturing environment, having

The consumers of the future will

to make them quicker and easier to

place huge value on environmental

clean. HD enclosures are typically power

sustainability, and they’ll also go out of

washed, so reducing the time it takes

your time to embrace sustainability as millennials and Gen Z begin to dominate

enclosures are specifically designed

multiple machines communicating with each other and being managed and diagnosed remotely offers benefits that are self-evident.”

These smart machines pose a unique challenge to the food and beverage industry; their delicate circuitry and sensors must be on the production floor but must also be protected from contaminating or being contaminated by the manufacturing process.

Additionally, these complex computer systems need to be compliant with current and future food safety regulations and be well-suited to withstand increasingly ambitious CIP procedures.

Now is the time to consider how you can update your existing manufacturing systems to try and account for the changes that are taking place in the industry. Whether it’s investigating new, sustainable production methods, or investing in physical infrastructure that supports new technologies, now is the time to move confidently forward or get left behind.

Optimising every piece of the manufacturing puzzle is essential to maintain a competitive advantage.

Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

FDPP - www.fdpp.co.uk 41

How to Reduce Cleaning Downtime and Ensure Precision Weighing Day after day, food manufacturers

the cleaning process can be improved

WITH EASILY DISMANTLED AND

operating in harsh production

and the time it takes can be reduced by

REASSEMBLED CONVEYORS

environments face an essential but

following these 3 tips.

Food manufacturers can benefit

laborious task - to clean all production machinery.

Production line equipment, including

#1: UNDERSTAND THE HYGIENIC

from considerable time savings if

DESIGN PRINCIPLES OF PRODUCTION

conveyor belts can be easily dismantled

EQUIPMENT

and reassembled for cleaning and

checkweighers, must regularly complete

maintenance. Conveyor belts and parts

mandatory, rigorous cleaning regimes

Having a hygienically designed inspection

that can be removed intuitively and

to avoid bacterial contamination. But

machine helps to avoid bacterial

without requiring tools, dramatically

cleaning time equals downtime resulting

contamination. Hygienic design features,

reduce downtime and having parts

in a reduction of production output and

such as easily accessible machines, an

designed following the poka-yoke

profits.

open frame design with only four feet on

principle assures error free and fast

the floor, sloped surfaces and an IP69

reassembly. This further reduces

On top of this, the operator must ensure

rating help in withstanding thorough

production downtime as the equipment

that the machinery is fully operational

cleaning routines.

is put back together correctly – and

when the production line restarts.

Rigorous cleaning procedures are essential; however, the effectiveness of

42 FDPP - www.fdpp.co.uk

Download the free eGuide: “7 Points to Understand Hygienic Principles” #2: SELECT INSPECTION EQUIPMENT

quickly – for the line to resume.

Manufacturers aiming for zero

production immediately after harsh

downtime during cleaning can deploy a

washdown, without affecting

second set of conveyor belts to resume

accuracy and weighing results.

production immediately after a product change over by switching the belts whilst the first set is being cleaned.

Check out: C33 PlusLine Washdown Checkweigher and C35 AdvancedLine

To find out more How Washdown Resistant Checkweighers can Reduce Cleaning Downtime, request your free eDemo now!

Washdown Checkweigher #3: UPHOLD PRECISION WEIGHING IRRESPECTIVE OF ENVIRONMENTAL CONDITIONS A loadcell is the heart of a checkweigher, however, excessive fluctuations in temperature caused by, for example, high pressure cleaning with hot water can affect its performance.

Manufacturers looking to uphold precision weighing irrespective of environmental conditions should consider Electromagnetic Force Restoration (EMFR) loadcells. These are more accurate, measure at a faster rate, and are temperature-stabilised compared to other loadcell types. This enables the manufacturer to resume

FDPP - www.fdpp.co.uk 43

Accurate dispensing of ab mauri bakery ingredients: Concept Controls Ltd and Seepex UK Ltd provide a perfect solution A significant factor in baked goods

Flow meter, Concept Controls Ltd, in

manufacturing is the need to reduce the

conjunction with their partner company

cost of raw material delivery into dough

PVSL Ltd. (Brierley Hill), are able to

mixes. Modern research and process

meet the challenging specification

techniques have been used by AB Mauri,

requirements for A.B. Mauri. The

a major manufacturer and supplier of

detailed design phase started with 3D

bakery ingredients, to produce a range

Models of the proposed equipment

of Enzymes, Bread Improvers and

generated by PVSL Ltd.

Enhancers in a highly concentrated form.

These ingredients are highly effective, requiring very small amounts to be added to each batch.

To maximise the benefit of these concentrated products accurate dispensing of the ingredients is critical, both to ensure optimal ingredient performance, and to minimise overdosing (which can add to material usage and cost). Traditional weighing and Diaphragm Pump dispensing, even with the best of metering control, can lead to significant variations in the actual additive level to each batch of dough.

SOLUTION

peristaltic, lobe and double diaphragm pumps a higher performance pump was sought to ensure accurate repeatable dispensing of concentrated ingredients

The result is an easy to apply Dosing System, that includes bulk frame storage for IBC containers (normally in

from bulk containers.

Stores area), with buffer tanks to allow a

During the research process the SEEPEX

stock. The Seepex PC pumps are more

Progressive Cavity (PC) Pump, became a clear leader. The main benefit of the PC pump is that there is a sooth pulsation free delivery of material delivering repeatable accuracy of +/-1%. The flow rate is linear, proportional to motor speed and regulated by a simple speed

practical regime for maintaining product than capable of delivering the various products to a dosing frame mounted close to the Mixers, and hence through the associated mixer lids and into each batch of Dough.

The Dosing Frame is a small matrix of

controller over a very wide range. This

fast acting Ball Valves which allow the

was specifically useful as there is a

product to be fed either directly to the

limited time (Less than 25 Secs) for

Mixer, or via the flow limiting orifice plate.

dosing of the A.B. Mauri products when

Although A.B. Mauri has considerable

operating on a standard Bread Mixer,

The net result is a system that can deliver

in house experience at developing the

hence a high rate of delivery is needed for

as low as 50g into a batch of product, and

products, the related processes, and

rapid dispense, but a low rate of delivery

also extend to several kilogrammes, all

even the engineering of equipment, they

for accuracy of dispense.

within the 25 second window, and every

wished to use an external engineering

batch can be metered to the nearest

company with experience in Bakery and

The pressure capability of these pumps is

other process equipment to develop a

also very wide, and the Concept Controls

solution that met demands for accurate

Ltd system uses this to deliver a high

The overall benefit to the end customer,

dispensing.

pressure and high accuracy phase at the

is that they can rely on a very consistent

end of the dosing cycle. The pumps can

product, with the advantages of the most

Concept Controls Ltd (Waltham on the

also accurately dispense products with a

modern process innovations, without

Wolds) were approached, and shown

wide range of viscosities.

the potential of overdosing (i.e. wasted

some of the original systems, a number of which had performance limitations with the latest developments in ingredients. After technical analysis of

44 FDPP - www.fdpp.co.uk

By coupling this high performance PC pump, orifice plates, and a very high accuracy Endress and Hauser Coriolis

gram.

product), overall enhanced quality and reduced overall scrap. www.seepex.com

GET EVERY LAST DROP FROM YOUR EXISTING EQUIPMENT. Inefficient processes and wasteful operations can put a drain on the bottom line; but transforming your operation into a Smart Factory doesn’t always mean costly capital investment.

FlexEdge™ Edge Automation Platform All-In-One: •

Protocol Converter : > 300 protocols for more than 1000 combinations

•

Digitalisation of legacy equipment to current standards

•

Easy Edge programming with automation software Crimson®

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Innovation at high-speed: container filling machines Newtec’s High-Speed Container Filler

can streamline your applications and

(HSCF) has been designed for speed and

increase your bottom line.

versatility, in response to client requests

“It’s highly flexible and it offers high-

for a solution capable of achieving higher

capacity and high-speed,” he says. “That’s

capacity across a variety of products and packaging materials.

the main advantage of this machine. The

The HSCF can be easily adjusted to pack

of having a basic machine where you add

a diverse range of products, from harder

a set of unique tools depending on your

high flexibility comes from the concept

items such as nuts and candies to softer

The cost-effective system is operated

and more fragile foods such as cherry

by an intuitive interface, which is an

tomatoes and blueberries. The solution

important factor, as well as the easy

is capable of filling containers in various

access for cleaning and servicing if you

dimensions with or without lids.

Newtec has designed a tool for each

are changing your production many times a day.

preferred container types”.

“This means that you don’t need to buy a completely new machine if you get a new packaging material. That’s a big advantage.”

However, the machine has been designed

DESIGNED WITH SPEED IN MIND

specifically to deliver higher levels of

from running e.g. clamshell trays to

Newtec mechanical engineer, Mathias

machine,” adds Mr Eilertsen. “That was the

buckets. It has achieved this by using the

Theil Eilertsen, worked on the solution’s

main goal. With other machines, we are

following three units: the denester, the

development. The solution represents a

doing about 70 or 80 packs a minute. We

filling chute and the closing unit, which are

fully automatic system from start to finish

can do up to 100 packs a minute with this

all exchangeable.

and is just one example of how Newtec

one”.

container type and while covering complex functions each tool is very easy to change

46 FDPP - www.fdpp.co.uk

speed. “Speed was quite a big thing for this

primarily for the fruit and vegetable industry. With more than 20,000 successful installations over the last 40 years, they have maintained their position as a reputable worldwide company.

Newtec is represented in more than 50 countries with subsidiaries in Copenhagen and the UK and a joint venture in China.

Newtec has formed many strong partnerships throughout the industry, ensuring the right solutions are delivered.

They deliver cutting-edge machinery, integrated into one solution and supported by local, qualified representatives to ensure each solution continues to meet the needs of their customers.

“Customers will experience a higher

visit the customer after the installation

speed and they will notice a lot more

for the final fine-tuning and see how

production than normal.”

their vision has been realised.”

KEEPING UP WITH NEW ORDERS

Despite being able to operate at higher

“We always develop new machines

isn’t any higher than current machines

based on request and interest from

on the market. Mr Eilertsen says the

customers,” Mr Eilertsen says. “Of

feedback has been highly positive and

course, they have an interest in getting

there are more orders to follow. This adds

the machines as quickly as possible

to Newtec’s total of installing more than

when they get in touch with us.

20,000 machines during the last 40 years.

Often, our customers are taking a big automation step forward and can’t wait to start optimising their production”.

speeds, the HSCF’s energy consumption

NEWTEC Odense (UK) Ltd. 22 Fleet Road Industrial Estate, Fleet Road, PE12 8LY Holbeach, Spalding United Kingdom Ph: 01406 426 526 Mobile: 07827 973 238 Mail: dean@newtecuk.com www.newtec.com

Newtec is a leading manufacturer of weighing, packing and sorting machinery

“So there’s a bit of pressure when we are in the innovation phase aiming for the best quality on the market and working hard to exceed the expectations of our customers. For me, it is so rewarding to

FDPP - www.fdpp.co.uk 47

Unipaker variations make robotic crate packing as easy as 123 Brillopak has developed its award-

can only be achieved in real life on very

dual and triple robot configurations for

winning UniPAKer robotic crate packing

straightforward crate/case packing

our UniPAKer packing system – to help

platform with the introduction of single

applications such as packs of biscuits.

our customers meet their performance

and triple-head versions of the system,

It is very unlikely that any packaging

and payback objectives without making

following the success of its dual robot

automation supplier who is handling

false promises.”

cells in fresh produce applications. The

delicate or awkward products like

ability to incorporate one, two or three

flow-wrapped apples, bags of carrots

Working on the premise that most

parallel arm delta robots into a single

or tray-sealed meat would be able to

fresh produce packs – whether punnets

crate packing cell enables the design of

achieve anything close to those kinds of

of soft fruit, bags of sprouts or flow-

flexible systems that strike the optimum

speeds without damaging the product

wrapped packs of peppers – can be

balance between speed and gentle

in the process, it simply isn’t possible,”

packed into crates using a single

handling.

says Peter Newman, Technical Director

robot head at speeds of 30-40 packs

at Brillopak.

per minute, the UniPAKer can double

“Whilst delta robot heads might boast

or triple those speeds to achieve

mechanical speeds in excess of 120

He continues: “That is precisely the

a customer’s target by adding a

picks per minute, such high speeds

reason why we have developed single,

second or third robot.

48 FDPP - www.fdpp.co.uk

Each robot takes it in turn to take

carrots at speeds of 37 ppm per head.

this configuration, the robot performs

a pack off the infeed conveyor and

A triple-head system can achieve over

two picks, then places the packs in the

position it precisely in the crate, so the

100 ppm, which should enable the

crate, two at a time. This design works

desired crate presentation is achieved

customer to meet its two-year payback

well for tray-sealed meat packs, which

twice or three times more quickly

target.

are uniform packs with flat surfaces, but cannot be handled at very high

than with a single robot. To maintain a compact footprint, simplify operation

Another potential application for the

speeds as the film lid may tear. Speeds

and minimise capital outlay, the entire

triple-head UniPAKer is for placing

of 60-70 ppm can comfortably be

system is centrally controlled and the

products such as peppers into the

achieved on this application.

robots share a vision system, infeed

pocket of the flow wrapper. Using three

and outfeed, regardless of whether it is

robots operating at 60 picks per minute,

Brillopakâ&#x20AC;&#x2122;s UniPAKer robotic pick and

a dual or triple configuration.

the UniPAKer would be able to match

place cell was originally engineered

typical flow wrapper speeds.

for packing bags of potatoes and

The 70-80 ppm speed capabilities of

apples into crates. Designed to handle

match for flow wrapping lines handling

MULTI-PICK SPEEDS UP SINGLE ROBOT SYSTEM

fruit and veg such as apples, sprouts,

However, adding another robot is not

tomatoes, peppers and pears, with or

always the best approach for increasing

without a supporting tray.

packing speeds. In applications where

the dual-head UniPAKer are the perfect

the product is fairly straightforward to When three heads are better than two

pick, a single robot with a multi-pick

The triple-head system has been

head might be a more cost-effective

conceived with difficult-to-handle or

and space-efficient option. In

VFFS, tray-sealed or flow-wrapped packs up to 1kg, the UniPAKer has been proven over-and-over again to improve productivity and improve pack presentation on shelf. www.brillopak.co.uk

bulky products in mind.

Brillopak is currently building its first triple-head UniPAKer cell for a supermarket customer with the goal of packing bags of carrots into plastic retailer crates at speeds of 100 ppm.

Carrots are a difficult product to handle as each bag of the same weight is a different shape and size, therefore the robot has to slow down to perform the pick and position the pack in the crate; too much speed will result in the bag falling out of the gripper or an untidy crate presentation. Using a single robot head in conjunction with a flexible finger gripper, the UniPAKer can handle

FDPP - www.fdpp.co.uk 49

Now is the time to unleash the potential for robotics in UK food manufacture There are few who would argue that 2020 has been an extremely challenging year as the COVID-19 pandemic has changed the way in which businesses of all types operate and more importantly, the environment within which we work, as we strive to contain the virus and remain safe. As businesses adapt to what is likely to be the new “normal” for the forseeable future at least, and with the ongoing uncertainty surrounding the effects that Brexit may have as we near the end of the transition period, the debate surrounding robotics and automation, especially within the food manufacturing and processing sector, is reaching a new peak.

It is becoming clear that robotics and automation will hold the key to achieving the efficiency and productivity levels required for cost effective food

a growing shortage of manual resource,

surrounding COVID-19 and future

processing, especially in high-care

have been the drivers for increased

areas, and those which traditionally

uncertainty around the UK outside

levels of robotics and automation within

have been labour intensive. This article

of the European Union next year.

the food sector in recent times.

Although many of the potential benefits

by Simon Jenkins of Stäubli explains why now is the perfect time for the UK

The COVID-19 pandemic has also raised

food manufacturing sector to unleash

the stakes for the adoption of robotics

the potential that robotics holds, and

and automation as a means of removing

how companies will benefit, not only in

people from what are now being seen

addressing the short term issues within

as the high risk environments within a

the sector, but in securing their future.

range of manufacturing environments,

There is no doubt that historically people have been the highly flexible resource which has sustained manufacturing in many sectors, including food and beverage. The ability of humans to adapt to changes

including meat processing facilities.

Large numbers of people working within a chilled and sometimes confined environment have proven to be a catalyst for rapid transmission of this deadly virus.

of robotics and automation, when applied to food manufacturing, have been understood for some time, there has still been a reluctance overall to fully embrace the technology. The often perceived barriers to automating food manufacturing processes, those of limited flexibility, complexity and unsuitability for high care areas, are no longer valid with the latest generation robot systems. Many of the challenges now being realised in high care areas, such as meat processing, can be

in products and processes is, even

Stäubli’s Simon Jenkins explains further:

addressed successfully using the HE

today, unparalleled in some cases.

“The food and beverage sector is

series robots, specifically designed

However, the demands for greater

currently facing serious issues brought

in conjunction with (EHEDG) - The

quality, consistency and predictable

about by difficulty in recruitment and

European Hygienic Engineering &

high productivity levels, combined with

retention, the significant challenges

Design Group and their guidelines.”

50 FDPP - www.fdpp.co.uk

ROBOTS AS MASTER BUTCHERS An innovative solution for processing pork and removing bones from pork legs can be seen in this Japanese system, which incorporates three Stäubli sixaxis RX160 HE robots operating as master butchers. The specifications for robotics in a meat factory could not be more onerous. Chief among them are the strict hygiene requirements that apply to the handling of fresh meat.

In addition, expectations in terms of speed, precision and flexibility are set high, as no fewer than 500 pork

the latest generation technologies

the traditional short term view on

are capable of and therefore what

payback on capital projects is often

can be achieved here in the UK. In this

cited as a reason to avoid investing in

application, an X-ray system is used

new equipment or technology such

to detect the position of the bones

as robotics or automation. Taking

within the meat, and the exact incision

an alternative view, either on the

line for the robots is then calculated.

duration of the payback period and

A perfect solution, but one that is also

/ or considering flexible financing

subject to the vagaries of the meat

options such as hire or leasing, may

processing industry. The fact that

open the door to the introduction of

the meat hanging on its hook is liable

the technology which could potentially

to shift its position on the overhead

transform productivity levels.

conveyor within certain limits means that the robots must operate in a highly coordinated way to achieve the correct

Improvements as a result of this investment may actually contribute

cut and avoid the bones.”

to the security of contracts with

operating within this system are at

The de-boning system represents a

future of the business. The flexibility of

the highest levels possible, given the

high level application of robots within

robots, for example, allows them to be

special conditions prevailing in the meat

the food sector, however there are also

used for new products or new contracts

processing industry. Also, because

many other less complex applications,

and their inherent reliability means

no one piece of pork is the same as

such as handling and packing products,

that they will provide years of service.

another, flexibility is required to allow

where robots can be used to address

Having this type of technology in place

high-speed processing

the numerous issues facing the UK’s

when bidding for new contracts can also

food manufacturers.

differentiate suppliers and provide a

legs enter and leave the line each hour. The functionality of the robots

Simon Jenkins expands on the capabilities of this system: “This

Of course, this will require investment

system clearly demonstrates what

by manufacturers, and historically

customers and ultimately the long term

competitive advantage. www.staubli.com

FDPP - www.fdpp.co.uk 51

â&#x20AC;&#x201D; A plant of infinite possibilities.

Talk to us.

Are you constantly striving for increased efficiency? Working to integrate processes?

Seeking to optimize every aspect of production? Our comprehensive portfolio and consultative approach runs from power to palletizing. So whether you need total traceability or simply higher efficiency, we have the answer. Discover the infinite possibilities at our stand F80 at the PPMA show, 25-27th September or visit new.abb.com/food-beverage