Food & Drink Processing & Packaging - Issue 32 2021

FOOD & DRINK PROCESSING & PACKAGING Issue 32 2021

­Smart sensors taste success at one of the world’s premium vodka producers AIB & Fortress keep food contaminants in check Arjowiggins answers food brands demand for sustainable packaging with revolutionary new translucent barrier paper

EPAL PALLETS ARE: • ISPM15-compliant as standard – so if there is no deal Brexit, they won’t cause unnecessary delays • Kiln-dried as standard, giving them extra strength and durability • Specified ‘as new’ whenever they are repaired • Safe for loads of up to 1.25 tonnes

uk-irl.epal-pallets.org

Contents

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

Digital Sales Manager Jessica Bennett T: 01227 392571

Business Manager Josh Holmes josh@mhmagazine.co.uk

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

Publishing Director Martin Holmes martin@fdpp.co.uk

Studio Designer Richard Bland richard@mhmagazine.co.uk

M H Media Global Ltd.

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

Features ISHIDA GEA BUHLER AIB LEUZE ARJOWIGGINS VERTICAL FUTURE NKS EUROPE ULMA

< 04 < 10 < 22 < 28 < 36 < 44 < 54 < 57 < 58

Tel 01304 806039

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

Please mention FDPP when responding to items in this issue.

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.

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FDPP - www.fdpp.co.uk 3

New belt design enhances grader performance Ishida Europe has enhanced its market-

The Slack Belt weigh bed incorporates a

Equally important, the Slack Belt’s

leading FLEX-Grader for fresh poultry

single belt mechanism which eliminates

hygienic construction to IP68

and meat with the introduction of a

product transfer issues to and from the

certification is fully protected against

weigh bed. This creates a more stable

water ingress, making it ideal for

weighing environment for even greater

harsh, high care environments; the

new high accuracy weighing platform which allows for more accurate grading and improved Overall Equipment Effectiveness (OEE).

accuracy. In addition, the weigh bed features a scraper that removes any product debris, which ensures a more consistent and accurate auto zeroing of the load cell.

belt can also be easily removed for cleaning. A wind shield is provided as standard to ensure protection against environmental factors during the weighing process, “Working closely with customers is key to understanding their specific challenges, in particular tackling areas of inefficiencies,” explained Ciaran Murphy, Ishida Europe’s Business Manager EMEA – Quality Inspection Control. “For the FLEX-Grader, our focus was to develop a solution that helped to minimise the impact of product giveaway and food wastage, while maintaining hygiene standards.”

4 FDPP - www.fdpp.co.uk

The Ishida FLEX-Grader offers a highspeed and accurate solution for the grading of fresh poultry and meat to a variety of different specifications, including specified weight, minimum weight or number per pack. It can also deliver target batching with tolerances and priorities, including product overlapping. An intuitive touch screen remote control ensures ease of set up and changeovers.

The FLEX-Grader features a modular design that is easily integrated into existing processing and packing lines which can be modified and adapted for changing requirements.

It can incorporate between four and 32 collection bins in a variety of

low-density contaminants such as bone

configurations including single, double

fragments in chicken fillets.

and twin line layouts, handling pieces from 100mm to 400mm in length at

Ishida’s global network provides full

speeds from 175 to 500 per minute.

local support for every FLEX-Grader installation to ensure optimum

As part of Ishida’s ability to supply

performance. The company’s aftersales

complete turnkey lines tailored to

service has continued to support

individual customer requirements, the

customers across the EMEA region

company also offers a full range of

throughout the current pandemic using

complementary machines including

the latest in support technology, such

multihead weighers, tray sealers, leak detectors, checkweighers and X-ray inspection systems, with its IX-G2 model specially designed for the detection of

as Augmented Reality for the delivery of remote training and servicing. www.ishidaeurope.com

FDPP - www.fdpp.co.uk 5

Shining a light on innovative solutions to energy-efficency Suresense Suresense Technologies Technologies Ltd Ltd has has been been offering offering uniquely uniquely innovative innovative energyenergysaving saving solutions solutions to to the the food food industry industry for for the the last last decade. decade. Being Being aa UK UK manufacturer, manufacturer, Suresense Suresense owns owns all all its its intellectual intellectual

The The ‘Integra’ ‘Integra’

property property thus thus the the products products on on offer offer

unit unit offers offers aa soft soft

cannot cannot be be acquired acquired anywhere anywhere else. else.

start start which which has has mechanical mechanical and and electrical electrical

Suresense Suresense produces produces all all its its own own highly highly

benefits benefits and and energy-saving energy-saving

intelligent intelligent LED LED high high bay, bay, low low level level lighting lighting

when when the the motor motor is is up up to to speed, speed,

the world world leader leader in in fixed fixed speed speed and and is is the

particularly particularly useful useful on on granulators granulators or or

variable variable load load energy energy saving saving motor motor

shredders shredders which which are are usually usually left left on on for for

controllers. controllers. Fixed Fixed speed speed energy energy saving saving

long long periods periods of of time time without without actually actually

being being the the key key words words here, here, most most

being being used. used. The The Integra Integra unit unit also also has has the the

companies companies do do not not realise realise that that there there is is

option option built built in in to to automatically automatically switch switch

another another option option other other than than aa variable variable speed speed

motors motors off off when when not not in in use. use. Typically Typically in in

drive drive to to save save energy energy on on electric electric motors. motors.

these these cases, cases, the the end end user user enjoys enjoys aa 70% – – 80% 80% saving. saving. massive massive 70%

The The ‘Eluma’ ‘Eluma’ LED LED lighting lighting comes comes with with aa

Suresense Suresense products products for for that that matter) matter) have have uncharacteristically, uncharacteristically, aa huge huge amount amount of of

very very attractive attractive 10 10 year year warrantee warrantee and and is is

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practical practical experience. experience. This This results results in in the the

designed designed to to optimise optimise every every LUX LUX per per watt watt

aa standalone standalone sensor sensor is is built built into into every every

products products being being designed designed around around real-life real-life scenarios. scenarios.

means delivered. delivered. In In simple simple terms terms this this means

‘Eluma’ ‘Eluma’ unit unit and and is is the the brain brain behind behind

massive massive savings, savings, typically typically in in the the region region of of

achieving achieving huge huge energy energy savings. savings. The The Atmos Atmos

85% 85% -- 90%.

90%. The The operational operational benefits benefits also also

works works on on RF RF (Radio (Radio Frequency), Frequency), the the main main

Although Although Suresense Suresense produces produces its its own own

cannot cannot be be overlooked, overlooked, in in aa production production

benefit benefit of of this this is is data data transfer, transfer, lights lights can can

products, products, itit is is more more about about providing providing aa

environment environment where where down down time time is is money, money,

be be set set individually individually or or as as aa group. group. The The

solution solution to to aa problem problem – – in in this this case, case,

not not having having to to worry worry about about your your lighting lighting for for

advantage advantage of of setting setting lights lights in in groups groups is is

its customers customers aa energy. energy. Suresense Suresense offers offers its

the the next next decade decade or or more, more, is is aa huge huge benefit. benefit.

uniformity uniformity – – all all lights lights react react to to

free free survey survey to to establish establish what what can can be be

Usually, Usually, there there is is always always aa relationship relationship

environmental environmental changes changes without without

achieved achieved and and also also delivers delivers aa report report which which

between between maintenance maintenance and and energy-saving, energy-saving,

with one one another. another. The The interfering interfering with

is is targeted targeted at at ‘decision ‘decision makers’ makers’,, giving giving

here here customers customers get get aa double-whammy. double-whammy.

Suresense Suresense R&D R&D engineers engineers that that have have

them them all all the the information information they they need need to to

Statistically Statistically purchasing purchasing cheap cheap LED’s LED’s will will

developed developed the the Atmos Atmos sensor sensor (and (and all all the the

make make an an informed informed decision decision to to implement implement

always always end end in in time time and and money money being being

the the technologies. technologies. All All Suresense Suresense products products

wasted, wasted, and and unnecessary unnecessary problems problems

are are designed designed to to deliver deliver aa return return on on money money

created created by by failures. failures. One One failure failure can can

invested invested in in any any given given project. project.

cost cost up up to to £500 £500 to to correct. correct.

Suresense Suresense sees sees its its projects projects through through to to the the end end and and its its practical practical approach approach to to lighting lighting designs designs are are always always appreciated appreciated by by its its customers. customers. ItIt prides prides itself itself on on the the ‘personal ‘personal touch’ touch’..

To To understand understand more more about about what what Suresense Suresense can can offer, offer, please please email: email: survey@suresense.co.uk survey@suresense.co.uk www.suresense.co.uk www.suresense.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

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Quantumâ&#x20AC;&#x2122;s Hire Fleet creates improved process, reliability and efficiency at Sugar Facility Its peak season for processing sugar beet

Weatherproof Variable Speed Drives were

and we received a request from a Sugar

the only VSDs on the market for this

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application. Because this was initially a

that improves the cleaning pump process

trial to test the new system, a super silent

and more importantly, the reliability.

and efficient generator was also supplied,

This new system had to be super silent,

this was to save on mains modifications in

efficient and be able to withstand

the timescale allowed.

weather conditions of the outdoor site environment.

The new system was trialled and proved a success, the units will stay on hire for a

We partnered with a Pump Supply

further 12 weeks while a new permanent

Company to give the best solution to our

system is installed.

customer, a new pump system, a 22kW Hire Variable Speed Drive and Generator (both from Quantum Controls extensive hire fleet) were supplied to the customer.

This gave the system extra flexibility with variable speed control and pump reliability.

Quantum Controls have an extensive range of hire equipment, not only Weatherproof Variable Speed Drives up to 4.5MW power rating, we have a fleet of; electric motors, mains cables, data loggers, flow meters, transformers, generators and harmonic

One call to 0330 9000 247, day or night,

Due to the location and such harsh

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8 FDPP - www.fdpp.co.uk

Our hire services give you fast access to our broad range of well-maintained, market leading ABB & Schneider Electric Drives and application engineering expertise. You get solid engineering advice and hire equipment for emergency, temporary bypass or semipermanent application within hours.

Services include round the clock access to over 1500 Weatherproof VSDs up to 4.5MW power rating ensuring a first time fix forany drive failure. Our engineers can deliver and install a suitable temporary drive toyour site anywhere in UK within hours.

As well as Weatherproof Hire Drives, we have a range of Ancillary Products to support your full temporary solution: Electric Motors

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The modern GEA VARICOVER® product recovery systems allow real-time monitoring of the pig position via magnetic sensors.

GEA VARICOVER® reduces water consumption sustainably and minimizes product losses The water consumption of dairies,

High-quality product thus remains in

Consistent automation, such as is

breweries or in the production of

the process instead of being lost with

possible with these solutions, simplifies

cosmetic products is continuously under

the wastewater. Considerable additional

the setup for fully validatable processes

scrutiny. A traditional process, the

optimization potential for sustainable

and, with a modern IO-Link plant control

so-called pigging of product-carrying

plant technology lies in the ongoing

system, enables early integration in

pipelines, makes it possible to save

digitalization of all process technologies.

Industry 4.0 environments, for example.

water in the long term during pipe

Like most valve systems, pigging

The possibilities extend to networking

cleaning and to minimize product losses

technology is already today generally

with the company’s Enterprise Resource

in liquid processes. Product recovery

integrated into automatic process

Planning system (ERP) for optimal

systems from GEA ensure that raw

sequences via centrally connected control

resource utilization.

materials are used with as little waste

heads. Electronic control heads of the of

as possible, while at the same time

the latest generation enable increasingly

THE TRICK WITH THE SLIDER

optimizing water consumption during

simple, error-free setup and operation,

As a rule, processing media such as

the complex process of pipe cleaning.

as well as advanced functions for process

yogurt, smoothies or care creams flow

As liquid process technology advances,

control and monitoring. The modern GEA

through pipe systems that are completely

this principle is gradually finding its way

VARICOVER® product recovery systems

sealed off from the outside and as free

into the world of batch process plants.

allow real-time monitoring of the pig

of dead space as possible with closely

In the processing of dairy products,

position via magnetic sensors. Their

timed CIP/SIP cycles (Cleaning In Place/

beverages, free-flowing food or care

mechanical and electronic components

Sterilization In Place), in which all

products, the pig serves as a hygienically

form a coordinated unit based on the

surfaces in contact with the product are

clean gate valve to expel valuable product

combination and service-friendly GEA

cleaned without residue and, if necessary,

residues from pipelines to be cleaned.

VARIVENT® modular system.

sterilized before the next product batch.

10 FDPP - www.fdpp.co.uk

First, however, the majority of any remaining product residues must be

GEA VARICOVER® reduces

removed or - less resource-friendly -

water consumption

rinsed out each time.

sustainably and minimizes product losses.

At the heart of product recovery systems is the so-called pig or scraper, a movable plug whose principle is derived from monitoring technology for oil and gas pipelines. The pig, equipped with sensors for control measurements, is moved through the pipeline to the control section to be examined. This is done by a propellant medium such as air, water, carbon dioxide or nitrogen. The pig is made of various elastic plastics that seal the pipe well. The fact that this additional step means that much less rinsing water is required for subsequent cleaning is proving to be an important step forward for ecologically sustainable water use.

Like the product flow and the pipe cleaning, the intermediate pigging process should also run without interfering with the closed piping system.

For this purpose, modern recovery

potential varies depending on the product

advantages of the recovery technology

systems have an automatically operating

and plant structure. “The more viscous

in all process stages, from raw material

pig launching station attached to the pipe

the product, for example yogurt, and the

reception to transport to process

at the beginning of each pipe section.

longer the piggable pipe section, the more

and storage tanks to filling. Here too,

It receives the pig as long as product,

recovery and the greater the savings in

there is a guiding principle for the

rinsing water or cleaning media flow

water consumption,” is the formula used

optimization potential: “The closer

through the pipe. In GEA systems, the

by Christian Blecken, responsible for

to the filling process, the nobler the

pig housing is extended in diameter

System and Application Support at GEA’s

product to be recovered,” explains

and is equipped with special grippers

Competence Center for Hygienic Recovery

Pascal Baer, the senior GEA product

and springs. The pig is continuously

Technology in Büchen. The frequency of

manager responsible for aseptic

surrounded by the flowing media with

batch changes, for which the pig can be

components in Kirchberg, Switzerland.

a defined range of motion and thus

used, also plays a role.

These are necessary when processing

remains hygienically clean. If the pig

flow media in the more contamination-

is subsequently used, a pig catching

The investment in pigging technology

sensitive hygiene classes UltraClean

station awaits it at the end of the pipe

can pay off in new construction, but

and Aseptic, such as UHT milk

section and the return to the sending

also when retrofitting plants. Christian

products. In aseptic pigging systems,

station. Two valves each control the

Blecken enumerates the prerequisites:

for example, all built-in valve rods

required inflow and outflow of the motive

“It is only important that the pipe section

are additionally sealed against the

medium.

has a constant diameter and does not

atmosphere.

have any internals so that the pig does

POSSIBILITIES OF RECOVERY SYSTEMS ARE FAR FROM EXHAUSTED

not get stuck or lose its sealing effect”.

Pigging systems are also available in

In contrast, ordinary pipe bends and

explosion-proof versions, for example

T-connections are no problem for the pig,

for alcoholic products. Due to the

Depending on how advanced a plant is in

especially not in the one-piece double-

wide range of solutions, the recovery

carrying out these and other processes,

sphere shape preferred by GEA: “This

technology can be used for almost

there are great differences in water

smart shape has the advantage that the

any type of flow product. There are no

consumption from plant to plant. The

pig does not even have to bend in the

limits for companies and plants.

possibilities of recovery systems are far

bend”, Christian Blecken is pleased to say.

from exhausted, but the optimization

Quite a few companies use the

www.gea.com

FDPP - www.fdpp.co.uk 11

North Ridge Bespoke Pump Kits Ensuring the production process meets all the current hygienic and food safety regulations is one of the main challenges facing any wholesale bakery business, when the budget is simply not there to have a fully automated food production system, handling different products in a safe sanitary manner can prove quite difficult. The North Ridge bespoke food grade pump kits are the solution to this.

A traditional family run bakery established for over 50 years required a fully hygienic, easy to clean mobile pump to transfer Fruit Jams, Toffee Sauce, Fruit curds and Whipped cream. The variety of products posed a real challenge to ensure

the unit was easy to clean by fitting a

components did not wear prematurely,

stainless-steel shroud that covers both

that damage could not be easily performed

the motor and the gearbox.

to the pump and that the customer had a low maintenance solution.

Besides having an integrated inverter, the control panel has several other safety and

Some of the products are directly

operation features, such as start/stop

dispensed from a cooking kettle into

switch, reverse (clockwise/anti-clockwise)

the pump at an average temperature of

switch, emergency stop, alarm for motor

100 - 110 °C whilst others are incredibly

overload protection and temperature

viscous as they are stored in a fridge

control sensor, with alarm to prevent

before being used. The customer needed

damage (dry running protection).

a bespoke multipurpose solution for their processes, which was sanitary grade,

There is also the added feature of

capable of handling all the products in

controlling the inverter via the panel or

question, suitable for high viscosities and

by the use of an App through Bluetooth

temperatures up to 120 °C. It also had to have a very gentle pumping action due to the shear sensitivity of the whipped cream. High temperature liquids can have a negative impact on seals, NPSH and the overall pump lifespan so careful consideration must be taken during pump selection.

semi-automatic liquid filling machine.

We supplied a completely bespoke pump system consisting of one DX hygienic progressing cavity pump, mounted on a mobile trolley, with an integrated control panel. The pump is 3A sanitary certified, which means it is suitable for CIP

Their current procedure involved manually

(cleaning-in-place) and SIP (sterilization-

transferring sauces via totes and buckets,

in-place) furthermore, is specifically

however the customer wanted to improve

designed without dead zones or areas

their process to automate food transfer,

where product can build up ensuring the

reduce the likelihood of burns or accidents,

internal components are fully clean after

and eliminate manual lifting and tipping of

operation and guaranteeing zero cross

containers. They needed a custom cost-

contamination when handling different

effective unit that operates similar to a

liquids. We also ensured the exterior of

12 FDPP - www.fdpp.co.uk

where operators can also view the status of the pump. This feature is extremely beneficial for the customer as the pump has to operate at a slow speed when handling whipped cream.

We are proud to say that thanks to our pump kit the customer improved their production efficiency dramatically, which in the food industry translates as an increase in profitability. The layout enabled users to operate the unit with very little training due to the simplicity of design but also built-in protection ensures the unit cannot be damaged easily. www.northridgepumps.com

We’re pump specialists, so you don’t need to be

Sanitary Pumps Engineered for Your Process Optimise performance with specialist support

Whether you’re dealing with clogging, separation, downtime, or other issue it’s costly. Time wasted troubleshooting and lower production mean missed targets and less profit. A sanitary pump is the solution but choosing the right one feels like stepping into a minefield. You know what you need it to do but with so many options, it’s difficult to know which is best for your process and parameters. + + + + + + + + +

Accelerated stator wear Clogging Changes to fluid consistency Clean-in-place and sterilise-in-place hygiene issues Crushing of sensitive products Inconsistency in finished product Inaccurate transfer of flavourings or ingredients Liquid separation Seal wear or failure

We’ve been engineering sanitary pumps for sectors such as distilling, brewing, food manufacturing/processing, and more, for 20+ years. We understand industry-specific processes and know what it takes to optimise performance through better-suited pump design - giving you complete peace of mind.

EXPERT GUIDANCE:

Our expert engineers understand your process and guide you through the options, so you can confidently select the most suitable sanitary pump.

Want to optimise performance sooner? Speak to one of our specialists.

+44 (0) 1773 302 660

sales@northridgepumps.com | www.northridgepumps.com

EXAMPLE PRODUCTS: + Abrasive mixtures + Creams, milk & ice cream + Edible oils & fats + Fish & meat + Fruits eg. cooked apples, plums, berries, grapes + Grains & seeds + Pastes & purees + Syrups, juices & alcohols + Vegetables & peelings + Waste eg. trimmings, packaging & offcuts + Sheer sensitive liquids + Solid laden or viscous mixtures

­ mart sensors taste success at one of S the world’s premium vodka producers Brith Isaksson, Global Food and Beverage segment manager, ABB Motion, discuss how ABB AbilityTM Smart Sensors keep global production running at Absolut Vodka.

Absolut Vodka, one of Sweden’s most iconic export products, has only a single production line serving the entire world.

That makes process reliability critically important to the company’s profitability.

After researching various methods to optimize condition-based monitoring and maintenance, the Absolut distillery in southern Sweden received an offer it found hard to resist. ABB suggested the distillery install its ABB AbilityTM Smart Sensors as the basis for a cost-effective and easy to use condition monitoring solution.

Historically, the high cost of installing vibration monitoring equipment had been

but it turned out to be a valve that had

the single biggest obstacle at the distillery.

shifted accidentally resulting in pump

“With ABB’s Smart Sensors, however,

cavitation.

we realized they had the potential to give us the continuous monitoring we

“The sensors offer us an easy way to

wanted, but using inexpensive and less

gain a deeper insight into our mash

complex wireless communications,” said

preparation, with the possibility to find

Jonas Nilsson, Absolut’s Maintenance

even small problems and address them

Supervisor.

before they become a major issue. By understanding the condition of our

Smart Sensors, each about the size of a

equipment, we can plan maintenance

mobile phone, were installed on motors

activities and align them with planned

in the ‘mash preparation’ process – a continuous function critical to the overall distillery operations. The production of Absolut vodka, which amounts to about 130 million bottles per year, is done

in-depth analysis confirmed that there was indeed a faulty bearing. Detecting the defective bearing before it failed allowed Absolut to fix the problem

using high-quality Swedish winter wheat

during a planned shutdown, avoiding

that gets digested, fermented and then

lost productivity caused by unexpected

distilled.

downtime.

production stops,” said Absolut’s Automation Engineer, Tony Knutsson.

Here, Smart Sensors offer a cost-effective condition monitoring solution that can measure vibration, temperature, and other critical factors. The Absolut team are impressed with the benefits and are now looking to use more Smart Sensors

EARLY DETECTION

At the same time, the sensors uncovered

on other pieces of equipment, especially

Right after the sensors were fitted to the

a second possible problem - significant

motors in hard-to-reach areas of the

motor housings, an abnormal vibration

vibration in one of the pumps, also on the

plant.

curve was detected on an agitator motor,

mash preparation line. At first, engineers

indicating possible bearing failure. More

thought it might also be a bearing issue,

14 FDPP - www.fdpp.co.uk

http://www.abb.com/smartsensor

PROCESS CARTRIDGE HEATERS to Your Exact Specification in just days Lojer Components Heaters are typically but not solely used in sealing, melting and moulding applications. These cartridges are precision made (Machining Code H7) for a better fit, which allows for an improved heat transfer, reliability and a much longer life.

There is a very wide range of cable and mounting options available, including many standard flanges and screw plug variants. These can rapidly be combined to meet the exact specification of the cartridge required, including any diameter required (upto 32 mm) and the specified length, in just a matter of days using the express production service.

OPTIONAL EXTRAS include: • For Precise Control Internal Temperature Sensors • Active & Inactive (Cold) Zones placed in specific sections of the cartridge, for example to allow a protrusion outside the tool for ease of maintenance • The Heating Coil wire can be specially wound to distribute a higher wattage at the ends of the cartridge i.e. to compensate for the cooler exposed ends of a bar where heat loss occurs • An IP65 Water Resistance can be achieved with an internal Teflon disc to seal within the cartridge and Teflon coated wire within a flexible silicon sleeve covering where regular cleaning is required

• Any Voltage or Wattage can be supplied, subject to a maximum Watts/Sq.cm • A variety of wire insulations include silicon, Teflon and Fiber Glass upto 1000C with sleeves of silicon tube, twisted mesh and armoured stainless steel Full technical support on our heater is available for your application, please contact: Lojer Products Ltd 01635865882 www.cartridge-heaters.co.uk sales@lojerproducts.co.uk

Food Box Specialists S Lester Packing Materials are the UK’s leading big box manufacturers.

Our supply chain solutions, from Octabins to Meat Shippers, are ideal for storing and transporting all kinds of produce, from potatoes and grain through to pumpkins and meat. Like all of our boxes, they’re 100% recyclable and made from a renewable source, available in a wide range of grades from C flute to Triple Wall, and can be printed to provide an eye-catching finish.

Ideal For: ■ Abattoirs

■ Farmers

■ Growers

■ Bulk Ingredient Suppliers

To find out more about how our state-of-the-art design and production facilities can help you to maximise your packaging

visit www.slesterpacking.co.uk call 01543 68 37 74

S Lester Packaging_Food & Drink Processing_180x132mm_final.indd 1

14/12/2020 15:52 FDPP - www.fdpp.co.uk 15

A New Generation of Thermoforming Plug Assist Materials for Food Packaging Applications Manufacturers of food and beverage

Trelleborg’s R&D team looked at the

Designed for general forming and cost-

packaging need to ensure materials,

existing thermoforming plug assist

sensitive applications, Syntac® CIS (Core

machinery and processes support

technology, with the aim of enhancing the

Industrial Solutions) is suitable for use up

the creation of packaging that is

materials and their properties to meet

to +180 OC. With the option of additional

both effective and meets required

customer requirements.

pre-fitted customer specific inserts,

design aesthetics. Following feedback from customers, Trelleborg’s applied technologies operation has developed three new thermoforming plug assist materials to enable manufacturers

Zaki Akhtar, Product Development Manager, Trelleborg’s applied technologies operation in Rochdale, England, says: “Our customers need a range of materials,

the material can be polished to achieve an extremely smooth surface finish, making it perfect for everyday tooling applications.

each of which is designed for a specific

In high-heat, high strength tooling

plug assist application; versatile materials

applications, Syntac® HTS (High

that run at elevated temperatures, high

Temperature Solutions) provides

strength materials that can easily produce

excellent material uniformity,

Over a six-month period, Trelleborg

deep draw end products, or materials

whilst maintaining product quality.

collaborated with several key

that are tough and durable for multiple

Suitable for use up to +220 OC, the

manufactures of food packaging

production runs. Customer feedback

material offers excellent uniformity,

across Europe to develop new material

on our new range is excellent and we

maintaining hardness even at maximum

formulations. With two PHD Chemists

are really pleased to have achieved our

temperature, to produce high clarity

leading the development project,

original aim.”

packaging.

to increase their productivity, reduce downtime and maintain the high product quality needed for food packaging.

16 FDPP - www.fdpp.co.uk

Allowing for super-fine detailing with

Kerry Lyons, Business Development

attractive appearance of goods, such

reduced breakage, Syntac® STS (Strong

Manager, Trelleborg’s applied

as confectionary, requires a high clarity

Tough Solutions) is wear and abrasion

technologies operation in Rochdale,

finish. Poor plug assist material selection

resistant, providing high levels of

England, says: “Our Syntac® range of

can result in clouding to the end product,

repeatability whilst maintaining product

materials are specifically developed

or an uneven, inconsistent finish. Syntac®

quality. Suitable for use up to +180

to meet the changing needs of our

HTS and Syntac® STS produce a high

O

customers and are engineered to be

clarity end product across a range of

durable with consistent performance,

lightweight, durable and tough, offering

temperatures, meeting the requirement

making it suitable for food packaging

a cost-effective alternative solution to

for application specific materials.

requiring a deeper draw (mold) and high

wood, nylon and aluminum.”

C, Syntac® STS is strong, tough, and

clarity finish.

For packaging applications that require

Kerry Lyons, continues: “Our Syntac® range of materials are available off the shelf with shorter lead-times than

Trelleborg’s Syntac® CIS and Syntac®

a deeper plug, Syntac® STS provides

HTS materials are made from high-

a hard wearing, abrasion resistant

grade epoxy resin and hollow glass

solution. Suitable for use up to +180 OC,

microspheres (HGMS), while Syntac® STS

Syntac STS is durable, and supporting

uses a novel thermoset polymer matrix.

high levels of repeatability, ensures

Each of the new Syntac® materials are

consistent, high quality performance.

available in sheet, bar and cast versions.

Packaging manufactured using Syntac®

improving productivity and uptime.”

Syntac® is easy to machine and finish,

STS can have super-fine detailing

offering a cost-effective alternative to

with reduced breakages, improving

For more information on our

traditional aluminum materials.

production efficiencies.

The latest materials in the Syntac® range

Packaging for fresh produce or designed

are available as a castable system. By

to highlight the bright colors and

casting the plugs instead of machining,

previously offered, with manufacturing taking place in our UK facility. Downtime is a real issue for manufacturers, by helping customers to select the right material, they can increase efficiency,

Syntac® range please contact us at appliedtechnologies@trelleborg.com

customers can reduce the amount of wasted material and save time by removing the need for CNC machining or outsourcing for those customers without access to in-house CNC-machining.

Cast plugs can be used instantly or quickly finished, reducing delays, and providing a fast hot-swappable solution. As part of the casting process, Trelleborg can add in customer specific aluminum inserts to support the easy attachment of the plugs to either the ceiling or bed plate of manufacturing equipment.

FDPP - www.fdpp.co.uk 17

Providing the automation and space needed for social distancing With the introduction of social distancing

In a manual packaging environment,

to the packaging line to be applied by

measures, end-to-end automation

where typically between two and

hand, poses the risk of the wrong label

to facilitate fewer people along the

four people are needed to complete

being applied, which is a major security

production line will be the aim for some

the process from erecting the boxes,

issue. Thereâ&#x20AC;&#x2122;s also the waste to factor

manufacturers as the pandemic rumbles

packing, sealing, labelling and

in; as the clock strikes midnight and the

on. For those companies who have

palletising, operating in a confined

codes are revised to reflect a new date,

partially automated the process already,

space is no longer an option under

pre-printed labels become unusable

extending automation beyond production

current social distancing guidelines.

and get thrown away. Print and apply

and into packaging processes will make

Spacing people two metres apart

a print and apply labelling system an

labelling systems create the label in real

is causing major problems in this

appealing option.

time, on the line, with the security of

environment, drastically reducing the

built-in barcode verification, enabling an

speed of throughput and slowing down

efficient workflow and reducing manual

production. What weâ&#x20AC;&#x2122;re observing now

labour costs.

are manufacturers taking this as an opportunity to plug the gaps in their

Of course, with cost effective, quick to

automation process which previously

deploy cobots so readily available on

may not have been considered a priority

the market you can quickly automate

and this is where print and apply

the box packing, pre-label and seal and

labelling systems can help.

auto palletise post label and seal. Cobalt

The benefits of a print and apply solution, of course, pre-date social distancing restrictions. Manual printing

18 FDPP - www.fdpp.co.uk

can supply a case sealing and labelling system in one small footprint thatâ&#x20AC;&#x2122;s ready to run.

and applying of labels, where batches

01270 539800

of labels are pre-printed in bulk in a

sales@cobaltis.co.uk

designated print room and brought

www.cobaltis.co.uk

PRECISION MACHINING

IN-HOUSE PRECISION MACHINING BESPOKE AND BATCH CAPABILITIES COMPLETE IN-HOUSE ENGINEERING SERVICE • Multitask CNC Machine Tools

• TSE Certified cutting fluids

• Fusion 360 CAD/CAM programming

• 24/7 production capacity

• Manufacturing in accordance with

• Aerospace accredited

ASME BPE standards

• ISO 9001:2015, EN 9100:2018 (AS9100D and JISQ9100:2016)

HIGH QUALITY COMPONENTS AND ASSEMBLIES Our skilled engineers face the demands of multi-sector activities daily, specialising in High Quality CNC Machining. Custom Manufacturing, Complex Shapes or Super-Precision Aerospace and Nuclear components in Stainless Steel, Duplex, Hastelloy, Titanium, and Aluminium.

DEVELOPMENT CAPABILITIES Fusion 360 computer aided design (CAD) combined with computer aided machining (CAM) integrates the mechanical and technical development of your product into a single platform, saving time and avoiding costly mistakes. The system supports 2D & 3D design, prototyping, animation, and simulation capabilities, whilst being fully compatible with industry standard file formats such as STEP, DWG, DXF, STL and OBJ.

FULLY INTEGRATED IN-HOUSE SUPPORT • Engineering Design • Product and Process development • TIG welding, Spot welding and Orbital welding • Bead-Blast, Mechanical and Electro-Polishing to pharmaceutical standards • Full Traceability & Certification • 100% inspection

Phone: +44 (0)1792 883882 | Email: info@axiumprocess.com

Cablevey Conveyors Corporate Description Cablevey Cablevey Conveyors, Conveyors, aa family family owned owned company, company, was was founded founded in in 1971 1971 to to service service the the agriculture agriculture industry industry primarprimarily ily conveying conveying grain grain and and seed. seed. HeadHeadquartered quartered in in Oskaloosa, Oskaloosa, Iowa, Iowa, the the center center of of the the grain grain belt, belt, allowed allowed the the company company to to offer offer complete complete customer customer satisfaction satisfaction for for this this important important indusindustry. try. The The success success in in the the USA USA turned turned international international with with product product distributed distributed throughout throughout over over 65 65 countries. countries.

Over Over 40 40 years years of of reliably reliably conveying conveying products products led led Cablevey Cablevey to to engineer engineer and and build build high high qualityindustrial qualityindustrial conconveying veying systems. systems.

Currently, Currently, Cablevey Cablevey Industrial Industrial Division, Division, hasconfidently hasconfidently conveyed conveyed approxiapproximately mately 900 900 different different products products for for the the top-tier top-tier food food processors processors globally globally and and other other Fortune Fortune 500 500 companies. companies.

Technologies Cablevey Cablevey Conveyors’ Conveyors’ cable cable and and disc disc technology technology gently gently move move products products through through an an enclosed enclosed tube tube without without the the use use of of air. air. Systems Systems can can convey convey up up to to 1,240 1,240 cubic cubic feet feet (35 (35 cubic cubic meters) meters) per per hour. hour.

Facilities Coffee, Coffee, nuts, nuts, snack snack foods, foods, cereal, cereal, flakes, flakes, powders, powders, pellets, pellets, shavings, shavings, crumbles, crumbles, granules, granules, fluff fluff and and dust dust can can all all be be handled handled with with ease. ease.

Numerous Numerous layouts layouts available available using using multiple multiple inlets inlets and and discharge discharge points points customized customized to to your your specifications. specifications.

Product Product separation separation and and degradation degradation are are practically practically eliminated. eliminated. Cablevey Cablevey replacreplaces es Bucket Bucket Elevators, Elevators, Screw Screw Conveyors, Conveyors, Pneumatic Pneumatic and and AeromeAeromechanical chanical Systems.

Systems.

Markets Served

The headquarters facility in Oskaloosa, IA includes: engineering, research and development, assembly, marketing, sales and a product testing lab.

Major Products All systems utilize cable and disc technology and operate at convey speeds which average 100 ft. (30.48 meter) per minute.

Inspection Video Camera & Conveyor Monitoring System

Cablevey conveys materials for food processing, coffee, pet food, cereal, tea, chemical, plastic, paper, waste-water, petro-chemical, wood, soap, paper, pulp and wood industries.

Brush Boxes for Cable Conveyor Maintenance Side Access Brush Boxes

For For easy easy cleaning cleaning and and cable cable conveyor conveyor maintemaintenance nance of of your your tubular tubular drag drag conveyor, conveyor, consider consider integrating integrating Cablevey’s Cablevey’s side side access access brush brush box.A box.A brush brush box box is is simply simply aa housing housing that that the the cable cable and and discs discs pass pass through through that that contain contain roller roller brushes brushes removing removing particles particles that that cling cling to to the the discs discs and and cable. cable. This This easy-to-install easy-to-install unit unit will will save save you you time time and and labor labor in in your your cable cable conveyor conveyor cleaning cleaning regimen. regimen.

Install Install aa conveyor conveyor monitoring monitoring system system camera camera to to ensure ensure proper proper installation installation and and maintenance maintenance of of your your Cablevey Cablevey conveyor. conveyor. Our Our cameras cameras are are diagnosdiagnostic tic tools tools that that run run through through tubular tubular drag drag systems systems to to ensure ensure that that conveyors conveyors are are installed installed correctly. correctly. All All cameras cameras are are equipped equipped with with removable removable micro micro SD SD cards cards and and self-contained self-contained LED LED lighting lighting units. units.

Cablevey Conveyors P O Box 148, 2397 Highway 23 Oskaloosa, Iowa 52577 U.S.A.

1 (800) 247-3344 Email: info@cablevey.com www.cablevey.com

Boost Profit with Gentle Conveying of Valuable Product Without Using Air For For food food processing processing companies companies with with high-value high-value product product susceptible susceptible to to damage damage such such as as nuts, nuts, cereal, cereal, coffee, coffee, snacks, snacks, and and dry dry pet pet food, food, material material breakage breakage and and loss loss is is aa very very costly costly problem problem that that can can harm harm the the bottom bottom line. line. Even Even aa difference difference between between 1% 1% waste waste and and 5% 5% can can mean mean the the differdifference ence between between profit profit or or loss. loss.

transport transport that that could could impact impact its its integrity, integrity, while while still still meeting meeting high high throughput throughput requirements. requirements. Given Given this this need, need, some some food food processors processors are are reconsidering reconsidering conveying conveying fragile, fragile, high high value value products products using using high high velocity velocity air air power power through through tubes, tubes, bends, bends, or or sweeps sweeps before before itit is is unceremoniously unceremoniously dumped dumped into into bins bins or or containers. containers.

In In the the coffee coffee industry, industry, for for example, example, processors processors go go to to great great expense expense to to roast roast whole whole beans. beans. However, However, the the beans beans can can be be damaged damaged by by high high velocity velocity air air conveyance, conveyance, compromiscompromising ing flavor flavor and and aroma, aroma, according according to to Gary Gary Schliebs, Schliebs, aa Process Process Engineer Engineer and and Director Director of of Plus Plus One One Percent…

Percent…

Engineered Engineered Solutions, Solutions, aa consulting consulting firm firm that that works works in in the the food food industry industry and and markets markets food food industry industry conveyor conveyor equipment equipment globally. globally.

To To convey convey such such delicate delicate food food product, product, processors processors should should avoid avoid conveyors conveyors that that may may force force the the fragile fragile materimaterials als through through stressful stressful phases phases during during

A Gentler Approach Boosts Profitability According According to to Schliebs, Schliebs, aa gentler gentler alteralternative native to to protect protect sensitive, sensitive, high-value high-value food food products products is is to to utilize utilize tubular tubular cable cable conveyors. conveyors. These These systems systems move move product product through through aa sealed sealed tube tube using using aa coated, coated, flexible flexible stainless-steel stainless-steel drag drag cable cable pulled pulled through through on on aa loop. loop. SolSolid id circular circular discs discs (flights) (flights) are are attached attached to to the the cable, cable, which which push push the the product product

“Many “Many high-value high-value food food products products can can be be fragile fragile and and need need very very gentle gentle hanhandling. dling. Otherwise, Otherwise, whole whole forms forms can can be be broken, broken, crushed crushed to to bits, bits, and and even even turned turned to to powder. powder. This This significantly significantly lowers lowers the the value value of of the the product, product, and and damaged damaged portions portions may may need need to to be be removed removed or or disposed disposed of of to to prevent prevent perceived perceived quality quality issues issues that that could could prompt prompt customers customers to to turn turn to to other other brands,” brands,” says says Schliebs.

Schliebs.

When When aa whole whole macadamia macadamia nut nut is is broken, broken, its its value value can can drop drop by by half. half.

Instead Instead of of aa premium premium price price for for whole whole nuts, nuts, damaged damaged nuts nuts are are often often sold sold at at aa substantial substantial discount, discount, and and often often

The Limitations of Air Conveyors While While aeromechanical aeromechanical conveyors conveyors have have aa different different method method of of conveyconveyance, ance, these these enclosed, enclosed, high-capacity high-capacity mechanical mechanical systems systems can can also also degrade degrade delicate delicate product. product. With With these these systems, systems, aa wire wire rope rope with with evenly evenly spaced spaced discs discs within within aa tube tube travels travels at at high high speed, speed, running running in in sprockets sprockets at at each each end end of of the the conveyor. conveyor. This This generates generates an an ininternal ternal air air stream stream traveling traveling at at the the same same high high velocity velocity as as the the discs discs that that carry carry product product along along in in the the tube. tube. However, However, these these conveyors conveyors may may also also force force vulnervulnerable able materials materials through through stressful stressful phases phases during during transport, transport, which which could could impair impair their their integrity. integrity.

crushed crushed for for use use in in cooking cooking or or proprocessing cessing further further upstream upstream in in the the food food industry. industry.

shavings, shavings, crumbles, crumbles, granules, granules, regrind, regrind, chunks, chunks, parts, parts, prills, prills, and and powders powders with with numerous numerous layouts layouts using using multiple multiple inlets inlets and and outlets. outlets.

“To “To minimize minimize product product damage, damage, itit is is important important for for food food industry industry manufacturmanufacturers ers to to not not only only transfer transfer gently, gently, but but also also get get product product in in and and out out of of the the conveyor conveyor safely safely and and gently gently as as well. well. That That is is more more achievable achievable with with aa conveyor conveyor like like Cablevey Cablevey that that allows allows product product to to slide slide down down rather rather than than drop drop out out the the end,” end,” says says Schliebs.

Schliebs. at at low low speed speed through through the the tube tube without without the the use use of of air, air, preserving preserving product product integrity integrity and and minimizing minimizing waste. waste.

“Food “Food industry industry manufacturers manufacturers can can decrease decrease product product damage damage down down to to 1-2% 1-2% with with aa slower slower process process like like aa Cablevey Cablevey Conveyors Conveyors tubular tubular cable cable system. system. With With it, it, product product is is gently gently transferred transferred at at low low speed, speed, so so there there is is minimal, minimal, to to no no damage,” damage,” says says Schliebs.

Schliebs.

In In the the food food industry, industry, the the conveyors conveyors are are utilized utilized for for products products such such as as nuts, nuts, cereal, cereal, coffee, coffee, snacks, snacks, pet pet food, food, beans, beans, and and seeds. seeds. The The systems systems can can convey convey up up to to 2000 2000 cubic cubic feet feet per per hour hour (56m3/hr) (56m3/hr) of of flakes, flakes, pellets, pellets,

In In fact, fact, most most tubular tubular cable cable conveyors conveyors have have interchangeable interchangeable components components that that allow allow the the conveyor conveyor to to be be easily easily expanded expanded or or reconfigured reconfigured to to change change the the length, length, conveying conveying path path and and the the number number of of inlets inlets and and outlets. outlets. These These modifications modifications are are more more complex complex and and time-consuming time-consuming with with aa pneumatic pneumatic conveying conveying system system because because itit has has more more components components and and electrical electrical connecconnections. tions.

www.cablevey.com

Agreement between Bühler and swisca, installed fleet of Bühler high precision scales surpasses 150,000 Several long-standing Bühler

It has continuously translated these

employees terminated their

learnings into improvements for existing

employment contracts with Bühler

products and feeds them into new

in February 2018 and founded the

platforms and product generations such

company swisca in September 2018.

as Tubex Pro.

swisca operates in the market as a

Bühler has unique operational experience

competitor of Bühler in certain product segments.

throughout different weighing and

Due to the rapid market entry of

environments. For a few years now,

swisca, a dispute arose between the

Bühler is coupling this production

dosing products and all production

Johannes Wick, CEO Grains & Food at Bühler.

knowledge with its latest digital

The parties had different views on this

competition after the settlement of their

connectivity and its digital platform,

matter and the facts of the case were

dispute and are convinced that this is in

Bühler Insights. This makes weighing

subject to legal proceedings.

the interest of customers.

solutions crucial for plant improvements,

Bühler and swisca are pleased to

OVER 150,000 BÜHLER SCALES NOW IN OPERATION

parties regarding the use of intellectual property and know-how by swisca.

announce that they have been able to settle their dispute out of court. swisca and Bühler have agreed on how to compensate the use of Bühler’s intellectual property and know-how, which enabled the rapid market entry of swisca. The parties have agreed not to

In 2020, the installed base of highquality, high-precision Bühler scales has surpassed 150,000 units operating in the field. Bühler’s weighing and dosing solutions build on more than 100 years

solutions enabled through advanced

allowing for more yield, more traceability, and better remote support.

“For us, this is only the next step to further enhance the most comprehensive and value driven weighing and dosing products and services in our industry,” says Johannes Wick, CEO Bühler Grains & Food.

disclose the settlement.

of knowledge. The company consistently collects and analyzes feedback from

Find more information on Bühler’s

swisca and Bühler look forward to fair

this enormous installed base worldwide.

weighing and dosing solutions here.

22 FDPP - www.fdpp.co.uk

LEDsynergy electronic displays

Lusin® Lub O 32 F enhances quality and process efficiency in PET stretch-blow moulding bottling lines Chem-Trend, a global leader in the

subject to particularly stringent food

polycarbonate. The product is developed

development, manufacturing, and

hygiene requirements.

to be environmentally conscious and

marketing of high-performance

contains no solvents, silicone and halogens. The highly efficient Lusin®

formulations that do more than merely

PROCESS AID FOR SEVERAL STEPS IN THE PET BOTTLE MANUFACTURING PROCESS CHAIN

release products. With Lusin® Lub O

Starting with the moulding process

After moulding PET preforms undergo

32 F, Chem-Trend offers a product to

of PET preforms and the subsequent

several handling steps which might lead

reduce processing cost and increase

stretch-blow moulding production and

to scratches (illustration 1) and other

processing efficiency. The product acts

bottle filling lines, the food-compliant

imperfections on the preforms. On the

as a release agent as well as a lubricant

Lusin® Lub O 32 F offers significant

one hand such defects have a significant

for thermoplastic processing and not

advantages at each step of the process

impact on the heat absorption of PET

only reduces processing time but makes

chain.

preforms when passing through the

release agents, purging compounds, and other ancillary moulding products, believes in creating business-changing

the need to purchase multiple products

Lub O 32 F can be used at temperatures ranging up to 200 °C.

blow moulding line, on the other such

unnecessary as well. Lusin® Lub O 32 F

When used as a release agent in the

defect may lead to so called “lost”

is NSF H1 registered and EU (2002/72/

injection moulding process Lusin®

bottles in the stretch-blow moulding

EG) certified and is thereby suitable for

Lub O 32 F is suitable for all forms of

process because of imperfect design

the manufacture of products that are

thermoplastics, with the exception of

parts of the finished goods.

24 FDPP - www.fdpp.co.uk

Not only does lubricating the preforms

market. Unnecessary production line

Acting as a lubricant, the product is

with Lusin® Lub O 32 F after moulding

downtime must be prevented as even

applied at very low dosages at key

significantly reduce the occurrence

the shortest halt results in the loss of

points along the PET bottle production

of scratching during transport and

hundreds of manufactured bottles. Yet,

process on the outside of preforms or

handling, but a strong barrier against

blockages are a problem that often arise

bottles. The food compliant lubricant

dust is provided, too, leading to

in post moulding air conveyor systems

allows for reduced friction between

enhanced gloss of blown bottles.

due to bottle-to-bottle friction. Moulded

bottles thus eliminating the jamming of

Also, using Lusin® Lub O 32 F helps to

bottles move with instability through

optimize the bulk box filling levels as

conveyor systems, then stick together

bottles. Jam reduction allows for fewer

more preforms fit in one box by simply

on the line (illustration 3), which is

smoothly shaking the box (illustration

generally spotted only when production

2). As a result, this leads to lower overall

stops.

transport cost.

When applied directly on the preform

LUSIN® LUB O 32 F ELIMINATES JAMMING

before the stretch-blow moulding

Moulded bottles passing through

process, the lubricant helps to enhance

the transport conveyor system need

surface definition on the blown bottles,

to rotate freely (illustration 4). This

leading to a sharper more defined

technical requirement is most critical

appearance.

at the curves and rises of conveyer systems where any forced rotation will

PREVENTING BLOCKAGES IN BLOW-MOULDING BOTTLE LINES

automatically lead to a blockage. Lusin®

PET stretch blow moulding plants run

improves the transport efficiency of

at high speed to meet with efficiency

moulded PET bottles through these air

expectations in a highly competitive

conveyor systems.

Lub O 32 F is the product of choice that

production delays, less loss of labour time and increased safety due to fewer manual fixes. The coating also provides a protective layer for preforms that continues to function well beyond blow moulding process and transportation stages.

“The development of Lusin® Lub O 32 F underscores our commitment to delivering tailored solutions for highly specialized applications,” notes ChemTrend European business director for thermoplastics Michael Woodcock.

“For many years now, Chem-Trend has been a partner that thermoplastics manufacturers can count on. Together with our customers, we are successfully meeting increasingly stringent industry quality, environmental and process efficiency requirements.”

Chem-Trend’s portfolio to the thermoplastics industry includes purge compounds, release agents, mould protectants, mould cleaners, surface cleaners, and surface degreasers. The Chem-Trend portfolio is continually expanding as new products are developed to address the constantly shifting requirements of our customers and the markets that they serve.

For more information, visit CHEMTREND.COM

FDPP - www.fdpp.co.uk 25

Smart never gets old: Ultra-reliable OEM diode laser system iBeam smart celebrates 10th anniversary 20 years of industrial diode lasers at

keep the iBeam smarts in metrology

portfolio. A significant power upgrade

TOPTICA, 10 years iBeam smart, close

tools in semicon as well as in advanced

up to 450 mW in the 405 - 460 nm

to 5,500 units in the field, and still

experimental setups in all areas of science.

wavelength range, extraordinary 200 mW

illuminating the scientific and industrial

The iBeam smart’s cost-effectiveness

at 647 nm and 660 nm, as well as more

world – obviously, smart never gets old.

supports industrial design-to-cost as

wavelength options in the near IR permits

In all this time the customers can rely

well as the tighter budgets in university

TOPTICA to serve even more industrial

on TOPTICA’s profound expertise and

research. Being plug-and-play and

applications and research fields.

professional care, no matter whether their

conveniently computer-controlled,

need is hundreds of units or just a few

integration and installation of iBeam

With cw or analog, digital, and mixed

pieces. Customization for specific use

smarts is simple and permits a flexible

modulation operation, the iBeam smarts

cases has been standard procedure for the

reaction to new demands and setups in

support a broad variety of applications

TOPTICA team.

the years of science to come.

in biophotonics, microscopy, semicon inspection, industrial manufacturing and

iBeam smarts shine strong as one of

More power and additional wavelengths

the critical components in industrial

Driven by the ever-innovating photonics

test and measurement applications

world, multiple requests for novel

For any further information please

as well as in numerous labs around

wavelengths and of course more power,

consult our web page at:

the globe. Reliability and performance

TOPTICA has broadened its iBeam smart

www.toptica.com/smart

26 FDPP - www.fdpp.co.uk

homeland security.

More than a century of steam control For 110+ years, Horne Engineering Ltd has pioneered thermostatic control technology using steam and hot water for a variety of storage and process applications across a variety of industries: food and drink production, brewing, dairy, abattoirs, chemical manufacturing, pharmaceutical and cosmetics production, industrial laundries and dishwashing, as well as for packaging processing and manufacture.

For large volume, instantaneous hot water production, for wash-down or rapid vat/tank filling applications, use the Horne Steam-Water Mixing Valve.

Both thermostatic and pressure balanced, the SWM1 is the world’s safest, most accurate and reliable valve of its type for delivering non-storage, temperature controlled hot water.

The Horne Steam Injection Heater, SIH, is often used in conjunction with the Horne EA-1 ‘Standard Valve’. As the world’s first automatic steam control valve, invented in 1909, the EA-1 provides accurate temperature control of hot water storage vessels. The SIH enables very rapid and highly efficient heating of cold water; tiny bubbles of steam are injected directly into the cold water where they collapse, releasing both real and latent heat. The steam bubbles are sized such that the SIH operates with minimal noise and vibration and, because there are no moving parts, it requires zero maintenance. http://b.link/HorneSteam

FDPP - www.fdpp.co.uk 27

AIB & Fortress keep food contaminants in check Fortress Technology’s latest Food

part of a root cause analysis, highlights

fully comprehend the inner workings

Safety First podcast zones in on

Jeff throughout the two-series podcast.

of the technology.” Yet machines, if not understood fully, can also exacerbate

foreign material control, including the sources and preventative measures

Given the numerous critical control

that companies can take to stop

points in a food manufacturing plant,

contaminants of all types entering the

Jeff advises taking a systematic

Knowing how to set and calibrate the

food chain. Featuring renowned expert

approach to identifying potential food

machinery is one area that can be

speaker and Vice President of AIB

safety hazards. From identifying raw

overlooked. This is where universal

International, Jeff Wilson, together with

material hazards, having processes

machine simplicity can help. As digitally

Fortress Managing Director Phil Brown

in place to isolate glass and ceramic

‘smart’ as Fortress Metal Detectors

recap on the risks, facility considerations

packaging breakages, to recognising

are, the company rarely deviates from

and technology features that form part

equipment and structural plant risks,

its simple to use strategy explains Phil:

of the total contaminant control picture.

the key he explains is to have detailed

“If a food processor is running a high-

protocols in place that identify and then

speed product line, our clients don’t

action these potential hazards.

really care how many megabytes per

Pest control, good manufacturing

food contaminant issues.

second the microprocessor inside is

practices, machine maintenance, facility design and performing foreign material

KNOWLEDGE CHAIN CUSTODIANS

capable of handling. Quality managers

inspections at various stages of the

Although foreign material control is

simply want the detector to perform,

supply chain are all steps that food

inherently process driven, if people

reject contaminated product accurately,

manufacturers can take to prevent

aren’t trained to understand what

without incurring high levels of false

consumers biting into a foreign body.

could go wrong and what to look for,

rejects.”

Yet, even the most robust processes

food integrity can still be compromised.

are not infallible. In addition to well-

Touching upon this in the podcast, Jeff

To increase speed and ease of set

documented contaminants, including

explains: “Thankfully there is a high level

up, plus eliminate human error, user-

stones, bones, pips, shells and stalks,

of understanding about foreign material

friendly features like automated single

extraneous materials introduced from

control across the food manufacturing

pass learning and calibration can deliver

equipment or packaging, or even the

sector. Yet often, inspection equipment

an accurate system set-up within

fabric of the facility itself, need to form

can be tested by those who don’t always

seconds.

28 FDPP - www.fdpp.co.uk

ENVIRONMENTAL CONTROLS Equipment interference is another common challenge that food manufacturers frequently misjudge, claims Jeff during the podcast. “During a food safety audit I frequently hear people express their disillusion in new inspection metal detectors. Usually it’s a simple thing. They haven’t factored in vibration and signal interference caused by industrial equipment radio signals and conveyors running in close proximity to their shiny new machine.”

To counteract this issue, a built-in noise immunity structure can dramatically reduce the effects of external electrical noise, again resulting in fewer false product rejects. This technology is built into the Fortress Bulk, as well as Fortress digital Metal Detectors and the new Raptor checkweighing series.

through a 600-micron screen to remove

BUILD A SAFETY PROGRAM

the smallest of insects. Additionally,

Overall, there are multiple steps a food

PEST PREPAREDNESS

changing a supplier, sourcing from

manufacture can take to help control

Equally important for food safety

a different country, or altering the

the introduction of foreign material into

custodians is understanding which

process and product flow raises many

food products. Instilling a food safety

natural contaminants are more likely

other questions. Has your ingredient or

culture and routine audits can help.

to be prevalent in harvested or raw

product been sourced from the same

foods. For example, pips, shells, stalks,

country? Is it the exact same product

Both Jeff and Phil suggest a deep

bones, stones and insects. Upstream is

your inspection system is calibrated to?

dive internal review of all food risks

often the best place to identify these

Jeff notes that if the origin has changed,

and processes at least once a month,

contaminants. Although gravity metal

there might be a slightly different

including an inspection of everything

detection inspection systems can be

moisture or salt content.

from production lines and all machinery,

used, screening and sieving ingredients is

to refrigeration and the outside roof.

more typical, particularly when trying to

In fact, any change, even between

eliminate insects.

Jeff also advocates mixing people’s

seasons can impact the product

skills up and creating a truly multi-

characteristics. To put this into context,

disciplinary team, including finance,

Jeff observes that the protein levels in

engineers and quality control. He cites

flour, for instance, can be different at

it as the ideal way to spread knowledge

the start of harvest compared to the

and embed an inspection culture that

end of the season.

becomes natural.

Additionally, moisture levels, the air

Jeff ends the podcast with: “Nobody can

bubbles and density in baked bread can

do everything … But everybody can do

change minute to minute. Even in the

something,” clarifying that everyone has

same batch. This can impact a metal

a role to play in consumer and brand

detector’s ability to distinguish between

protection and keeping all contaminants

any metal contaminants that may have

out of the food supply chain.

Taking flour as an example, Jeff emphasises the importance of sifting

been introduced during the mixing process and the false signal given by

For more details, listen to the free

the combination of product attributes.

Fortress Technology food safety

By conquering this product effect, the

podcast series here https://www.

Fortress Interceptor Metal Detector

fortresstechnology.com/food-safety-

can clearly differentiate between these

first-episode-5-part-2-foreign-

signals and any metal contaminant.

material-control/

FDPP - www.fdpp.co.uk 29

NEW FOR 2021

®

Stage 1. Manufacture

Stage 2. Sale

Introduce an additive to the plastic to make Biojet®

Packaging on the shelf

Stage 3. End of life Microbes like Biojet® and start breaking down the packaging

Biojet® packaging has been created to deliver biodegradable transparent tubes, boxes and clampacks.

Stage 4. Biodegradation Microbes break down Biojet® in a much shorter period of time

Stage 5. Gone Microbes consume the whole pack and leave organic matter CO2 & CH4

will only happen in the correct environment where microbes exist.

As people seek better environmental packaging solutions, Bell Packaging is delighted to announce the introduction of this exciting new product which means we can now offer a complete environmental range for new packaging projects in 2021.

VIRGIN – REUSABLE – RECYCLABLE – RECYCLED – BIODEGRADABLE Traditionally biodegradable / compostable products are very expensive. In some cases the cost has been two or three times more than virgin products which often makes the packaging cost prohibitive and is therefore not widely used. There has also been concerns expressed about the viability of biodegradable products questioning what remains after the degradable process has been completed. ®

Biojet answers both of these challenges. It is a much lower cost solution and has many exciting environmental credentials.

Traditionally plastic products use crude oil to create polymer which is then converted into plastic which we use to make PET boxes, tubes and clampacks. Our challenge has been to make these designs biodegradable but not affect the performance of the packaging whilst it is in use. ® To make Biojet we introduce an additive which attracts microbes that uses plastic as their source of food and energy. These microbes can be found in landfill, the ocean floor, rivers and swamps where bacteria and microbes thrive. When the microbes meet the plastic, the biodegradation process is accelerated as the plastic is consumed. This process

www.bellpackaging.com

What used to take thousands of years to break down plastic now takes much less time as the microbes consume the entire product. After the process has been completed, the microbes leave behind the same bi-products as decaying organic matter – humus (soil), CO2 and CH4 both of which can be captured to produce clean energy. ® Biojet packaging is 100% recyclable through the normal PET recycling centres.

This additive has been independently tested and complies with the Intertek Greenleaf Biodegradability Standard. ®

The additive used in Biojet is 100% organic and is comprised of non toxic raw materials which are independently approved for direct contact with food.

The additive also complies with other domestic and international requirements for the absence of toxic or other potentially harmful substances.

The additive is FDA Title 21 Part 177 compliant for food contact and fully compliant with EU REACH Regulation No 1907/2006. ® Testing to date shows that Biojet packaging made with this additive performs in the same way as standard recycled plastic. The shelf life, appearance, clarity and strength of the packaging all remain constant with the same characteristics as packaging made using virgin or recycled polymers. ®

Biojet is a Registered Name owned by Biojet® Bell Packaging Limited. Biojet® has an EU & UK patent pending and is Designed only available for supply to to keep our Bell Packaging clients. oceans

www.faceguards.co.uk

+44 (0) 1582 459292

cleaner

®

NEW FOR 2021

Biojet® packaging has been created to deliver biodegradable plastic tubes, boxes and clampacks.

Traditionally biodegradable / compostable products are very expensive.

In some cases the cost has been two, three or even four times more than virgin products and therefore not widely used….Biojet® is a much lower cost solution that has many exciting environmental benefits.

Biojet®

Designed to keep our oceans cleaner

DESIGNED & MANUFACTURED

IN GREAT BRITAIN

www.bellpackaging.com

www.faceguards.co.uk

+44 (0) 1582 459292

Tasty solid formulations Image: ©Fette Compacting GmbH

Health and well-being are more popular now than ever before and since the beginning of the coronavirus pandemic in particular. It is no wonder therefore that the markets for nutrition supplements and biological special products are undergoing rapid growth.

Equally, there are also increases in the technological and regulatory demands on manufacturing.

Consumers’ appetites have been whetted. Studies are forecasting global growth of more than 8% by 2027 for the nutrition sector. As a result, biological products harbor a special potential.

According to a prognosis by Meticulous Research, the market for plant-based foodstuffs will achieve a value of 74.2 billion USD by 2027. This corresponds with an annual growth rate of up to 12%.

At Lofthouse, the FE55 tablet press from Fette Compacting offers an efficient and flexible solution for the production of Fisherman’s Friend pastilles. and preventive medicine. Many people

example, which is similar to nutrition

use nutrition supplements as a way

supplements and in some cases makes

regional, and sustainable production.

of ingesting additional vitamins and

special demands on solubility in order to

minerals. These also include dietary

display its optimal effect inside the body.

One particular driver in the sector of

foodstuffs for certain groups such as

But this trend is also associated with the increasing demand for ecologically-safe,

nutrition supplements is represented by the coronavirus pandemic. Many

athletes, vegans, pregnant women, or

Products in these groups are often

senior citizens.

pressed to form tablets or filled into capsules. Solid formulations offer the

people are using these preparations to augment their nutrition and give

2. Special biological products

advantage of facilitating standardization

their immune systems an extra boost,

Purely natural substances of ecological

and dosing of the concentration of

whereby the boundaries often disappear

origin are very popular among

ingredients. Manufacturers benefit

between pharmaceuticals whose

consumers. The more natural essences

from easy production with good

contents are pharmacologically effective

contained in the final product, the better.

reproducibility, particularly in the case of

while nutrition supplements and other

Stability plays a key role in processing.

large product volumes.

foodstuffs cannot be advertised with

In terms of process reliability and

claims of healing properties.

product quality, it is imperative that the

FOCUS ON PROCESS RELIABILITY

production technology works absolutely

At the same time, producers are obliged

MANY PRODUCTS – A SINGLE CLAIM

reliably.

to meet the high demands on food safety

All in all, the nutrition sector comprises

3. Confectionery

is expressed as Good Manufacturing

a huge variety of products ranging from

This production area could hardly be any

Practice (GMP) which requires production

large series through small batches with

more colorful or varied: confectionery

technology working entirely reliably even

unusual natural substances such as the

includes all kinds of candy, gum, and

as batches increase in size and product

Chinese caterpillar mushroom. Basically,

lozenges, production of which is often

changes are frequent.

they can be divided into three groups:

high-volume and very complex on

in all cases. In regulatory terms, this

account of special product characteristics

With its entire range of machines and

1. Classic nutrition supplements

such as adhesive tendencies. A special

services, Fette Compacting has stood

A trend has become apparent all over the

area is represented by functional

for efficiency and quality in nutrition

world which promotes health awareness

confectionery such as dextrose, for

production for decades.

32 FDPP - www.fdpp.co.uk

Image: ©Fette Compacting GmbH

The technological range comprises the tried-and-tested machines of the i-series and P-series through to the high-performance tablet presses in the FE series and the capsule filling machines in the FEC series. Initial users are also working successfully with OSDi digital tools and exploring continuous manufacturing using the direct pressing method. But know-how also includes experience in the stable processing of natural substances whose material properties can be subject to strong fluctuations. The machine experts at Fette Compacting are also masters in hygiene concepts which reduce the risk of cross-contamination, for example. This is supplemented by individual consulting services concerning tablet design and capsule size through to special shapes, complex curves, and engravings.

LOFTHOUSE: STRADDLING CONFECTIONERY AND MEDICATION

The FEC40 capsule-filling machine at Standard Process runs under full load – with 140 cycles per minute. stubborn substances such as licorice and

this level of performance, the engineers

salmiak – wet. In both cases, the machine

developed a double capsule-filling

interior and individual components

process. The FEC40 at Standard Process

Lofthouse is an example of complex

are easily accessible and manageable.

features twelve stations and 24 capsules

production requirements. The British

Accordingly, the tablet press can be

per station. Even during the test phase,

family-owned company complies with

swiftly fitted for the next flavor.

it was possible to transfer more than 40

a variety of tastes and markets with

percent of overall capsule production to

its Fisherman’s Friend brand. But the

STANDARD PROCESS: HIGH OUTPUT

this machine. Where such output levels

manufacture of these menthol pastilles

A goal which unites almost all

are involved, it has proven practical to

is governed by state-of-the-art quality

manufacturers of nutrition supplements

process those products with the highest

standards which exceed the requirements

is that of maximizing output at a

volume under full load on the FEC40.

of the confectionery industry. In some

constantly high level of product quality.

countries, the pastilles are regarded as

Let’s take an example from the area of

After the test phase, the capsule filler

“health-related products” on account

capsule production: the US nutrition

commenced regular operation. But the

of their menthol content – and even as

manufacturer Standard Process largely

services availed of by Standard Process

medication in the USA.

supplies nutrients as they occur in nature.

extend beyond the actual machine: they

For this, it grows more than 80 percent

also include training courses with the

Lofthouse was on the lookout for

of the ingredients it uses on its own farm

operators and maintenance technicians,

new technologies for this production

and processes the raw materials under

telephone support, and online

environment and the company found

permanent quality control. In an effort to

troubleshooting via a direct offsite-login

an efficient solution in the FE series

comply with the growth in NEM demand,

to the machine. These are significant

offered by Fette Compacting. The fact

Standard Process was on the lookout for

factors for success, particularly during the

that the machine can be smoothly

an efficient technology for its capsule-

coronavirus crisis.

integrated in production and swiftly

filling segment.

converted for various flavors was decisive

Contact: tablet@fette-compacting.com,

for Lofthouse. The FE55 is particularly

During a field test, the FEC40 capsule-

suitable in this regard as this high-

filling machine offered by Fette

performance rotary-table press can be

Compacting lived up to its performance

used to produce more than 90 percent of

promise: with an output of up to

all products without requiring additional

400,000 capsules per hour and 140

investments or complex conversions.

cycles per minute, it sets new standards

www.fette-compacting.com/nutrition

in efficiency. High output reduces Cleaning is also easier with the FE55

production costs per 1,000 capsules

as it is in a dry state or – in the case of

by up to 30 percent. In order to achieve

FDPP - www.fdpp.co.uk 33

Mettler-Toledo adds Augmented Reality Customer Support to raise the bar on uptime Mettler-Toledo Product Inspection is leading the way for product inspection manufacturers with the inclusion of remote Augmented Reality (AR) Customer Support.

WHAT IT CAN BE USED FOR The new service enables remote identification of the cause of product inspection equipment issues and facilitates Mettler-Toledo engineers to instruct on-site manufacturing staff, irrespective of knowledge, how to rectify the problem. This helps to maximise production line uptime, save costs and comply with COVID-19 social distancing requirements.

The state-of-the-art service allows manufacturers to securely connect remotely to the Mettler-Toledo Service Team to deliver diagnostic and repair services for both hardware and software.

aspects and adding text annotations

new Augmented Reality Customer Support

to a live video stream of the product

offering, that is about to change,” said

inspection equipment. Manufacturing

Fabian Kramer, Service Product Manager,

staff do not need any prior knowledge or

Mettler-Toledo Product Inspection. “This is

engineering expertise about the product

a really slick, intuitive and interactive tool

In addition, it can be used to support the

inspection equipment as the Mettler-

delivery of Remote User training and

Toledo Service Team will demonstrate

equipment start-ups.

step-by-step what is needed to rectify

that will set new standards in fast breakfix support times, putting our engineers right there, next to our customers,

the issue.

wherever they may be in the world. Most

AR works by enabling the users to

LIFE-CHANGING

significantly less downtime, helping them

interact with real-world objects by placing

“No-one has ever considered remote

virtual spatial markers, highlighting

support to be life-changing, but with our

HOW IT WORKS

importantly, customers will benefit from to operate at peak performance for longer.

Plus, AR makes social distancing measures easier to maintain.”

OVERALL BENEFITS Service support plays a key role in controlling costs and maximising uptime and performance of product inspection equipment and software. Available on a range of different levels, service contracts provide peace of mind that product inspection equipment is optimised, delivering preventative maintenance, onsite and remote support, plus performance verification. www.mt.com/service-pi-pr

34 FDPP - www.fdpp.co.uk

Enhance Your Service Experience

Benefit from our extended service offering with Augmented Reality support – anytime, anywhere.

Find out more:  www.mt.com/service-pi-pr

Increase productivity, reduce waste In addition to the demands on

processors. This means: They need

systems. Currently in test operation

productivity, high expectations of

intelligent technologies and services to

at Sesotec is the DRT 25C switching

consumers and retailers weigh on food

allow them to meet the high standards

sensor from Leuze with a completely

manufacturers and processors. They

with regard to food safety as efficiently

new operating principle based on

expect not only safe and qualitatively

as possible, in compliance with

Contrast Adaptive Technology (CAT). This

perfect foodstuffs.

guidelines and while making the most

sensor is ideal for complex, customer-

efficient use of resources.

specific applications that cannot be

HIGH REQUIREMENTS OF CONSUMERS AND RETAIL CHAINS

The objective and philosophy of Sesotec,

In addition to the demands on

a leading manufacturer of product

productivity, high expectations of

inspection and material sorting systems

THE CUSTOMER IS KING

consumers and retailers weigh on food

in Schรถnberg, Bavaria, is to support

Consumers demand not only long shelf

manufacturers and processors. They

the food-producing industry in the

lives but also constant availability of

expect not only safe and qualitatively

profitable manufacture of safe food and

the entire selection. Moreover, the

perfect foodstuffs.

to create less waste in the process. To

food should be of high quality and

do this, the company offers appropriate

free of any contaminants or foreign

In addition to adhering to legal

application solutions for all process

objects. Consumers also increasingly

regulations, they increasingly require

levels, products and conveying types as

want to know the source of their

additional certifications from their

well as for all critical control points of

products: where, with what ingredients

suppliers. To simultaneously comply

the production process.

and how they were produced. At

solved with a standard detection

with the legal requirements, meet the

method.

the same time, calls for food that is

standards of the retail chains and satisfy

In the area of materials handling,

free of gluten and allergens and is

the expectations of the consumers,

various sensors from Leuze that have

completely vegetarian or vegan are also

functioning automation technology is

proven themselves over the years are

increasing. Food demand is thereby

essential for food manufacturers and

in use at the foreign object detection

becoming significantly more specialized.

36 FDPP - www.fdpp.co.uk

UNICON metal detector system from Sesotec, consisting of conveyor belt, detector coil with control unit and ejector unit.

MINIMIZE WASTE TOGETHER Sesotec is very pleased with the used Leuze sensors, which have been installed standard in the machines and systems for years. In the area of metal detection, these are primarily sensors from Leuze’s 25 series.

Sesotec customers in the food industry confirm their reliable function, cost effectiveness and long service life in an environment that is subject to the highest hygiene requirements and regular cleaning cycles.

Nevertheless, Sesotec is always open to new ideas and technologies. One such example of this is the recent test operation of a completely new Leuze sensor, the DRT 25C with a fully new operating principle based on Contrast

This results not only in an additional

The risk of any foreign objects present

challenge but also in increased costs for

in the food not being detected thereby

the production process.

increases.

To detect metal contaminants - such

process chain. And not only consumers

as from wires or shavings - metal

but retailers are also placing high demands on the food manufacturers and processors. In addition to product quality, other topics include transparent traceability as well as fast reaction paths in the event of any recall actions. On top of this are increased requirements on logistics systems and supply chains.

PRECISE TECHNOLOGIES ENSURE EFFICIENT PROCESSES The food industry has become a complex, globally networked system with many participants: raw materials are purchased internationally at various price and quality levels. They are often sold, stored and processed far from where they were originally produced.

Increasing food transports, longer transport paths and multiple loading

company philosophy is very closely aligned with that of Leuze. We don’t view ourselves as a standard supplier

Producing the required quantities of food requires an increasingly automated

Adaptive Technology (CAT). “Our

of individual metal detectors. We are instead focused on offering our

detectors like those manufactured by Sesotec can be used. For the detection of contaminants from non-metallic materials, e.g., glass or plastics, Sesotec offers X-ray systems. In his function as R&D director, Sammer has already been working together with Leuze for many years. Always with the goal of solving the sometimes tricky applications of

customers specific, complete solutions that are tailored to their respective application and requirements. And these consist not only of our own components. Also included here is all of the sensor technology. Only in this way are we able to help our customers increase the cost effectiveness of these solutions in spite of the additional costs that arise though a mechanical

his customers even better and more efficiently. For reliable detection as well as proper labeling or assignment, optical technologies from Leuze are used here.

They ensure that exactly what is on the

product inspection,” explains Sammer. Brigitte Rothkopf, Director Corporate Communication at Sesotec, emphasizes:

label is actually in the package.

Since 2019 Sesotec is a supporting member of the initiative »SAVE FOOD» and is actively engaged against worldwide food waste and losses.

processes result in a growing risk of contamination. “Manufacturers need precise technologies to comply with the legal standards regarding food safety,” explains Hermann Sammer, Director of R&D at Sesotec. However, an increasing degree of automation means less personnel and fewer inspections by employees in the production chain.

FDPP - www.fdpp.co.uk 37

technical center. A wide range of objects and packaging are being used here. The objects travel into the metal detector on the conveyor belt. Prior to entry into the metal detector, they are always detected by the DRT 25C at the front edge and over the entire product length - all from above. “The view from above is a big advantage. Irregular shapes can thereby be significantly better detected.

The sensor solutions currently on the market have so far only been able to perform this task to a limited extent,” confirms Sammer. Test experiences thus far are very positive. Even in difficult work environments, such as with quickly moving and, in some cases, strongly vibrating conveyor belts.

Leuze’s detection expert - the DRT 25C - reliably meets the high requirements of packaging machines with innovative reference technology.

The DRT 25C reliably detects from above. reliably detected,” explains Andreas

POSITIVE TEST RESULTS FOR COMPLEX APPLICATIONS

Eberle, Key Account Manager Packaging

The DRT 25C shows it strengths

at Leuze. Hermann Sammer from

exactly where conventional sensors,

Sesotec adds: “The problem often

which scan from the side, are

manifests itself in the form of multiple

pushed to their limits. In the test

triggering - especially at high conveyor

environment at Sesotec, no effort

speeds.” He has had this experience

is being spared to test the DRT 25C

above all with irregular shapes as

under “real” application conditions in

occur, e.g., with fish and meat. This

detail: “After all, it needs to function

usually involves individual pieces that

properly afterwards in our customers’

do not have the exact same length and

food waste and loss around the world.

application environments and be free

shape. The same holds for plastic outer

of any malfunctions that would slow a

This is a joint initiative of the Food and

packagings of fruit or vegetables.

machine or system or, worse, bring it

“As important as cost effectiveness is, so too is making a positive contribution to the minimization of food waste. After all, this is not only an ethical problem for us, but an economical one as well.”

Since 2019, Sesotec is a founding member of the “SAVE FOOD” initiative and is actively involved in preventing

Agriculture Organization (FAO), of the

to a standstill,” explains Michael Maier,

environmental program of the United

Sesotec is currently putting the DRT

developer in the product inspection

Nations (UNEP), of Messe Düsseldorf

25C through its paces in the company’s

department at Sesotec.

and of Interpack, the world’s leading trade fair for packaging and processes.

NEW ON THE START LINE: THE DRT 25C FROM LEUZE Leuze’s new DRT 25C switching sensor promises to reliably detect every type of object and type of product packaging such as are examined in the food sector with Sesotec metal detectors and checked for contamination. Fully independent of their color, shape and surface structure. Regardless of whether flat, glossy, with openings or transparent. “Such objects are not so easy to detect using conventional sensors, which scan from the side.

Above all because the front edge of packaged products cannot always be

38 FDPP - www.fdpp.co.uk

Michael Maier, Developer in Product Inspection at Sesotec and Michael Schafferhans, Technical Sales Consultant at Leuze.

Pleased with the positive test results: Hermann Sammer, Director of R&D at Sesotec and Andreas Eberle, Key Account Manager Packaging at Leuze As a result, Sesotec intentionally wets,

DRT 25C therefore works with an

Once the sensor has been “taught,” no

soils or gums up conveyor belts in the

object’s environment as a constant

additional settings or readjustments

test situation as is often the case in

reference surface instead of with the

are necessary. Not even if the object is

actual use, e.g., due to stuck labels or

object itself. In packaging systems,

changed, as the sensor operates together

chocolate residues. “From these test

this is the conveyor belt. This serves

with the conveyor belt as a reference.

results, we deduce possible product

as a teachable reference. Once the

improvements or further developments,”

sensor has been taught the contrast

THE ALL-ROUNDER SENSOR

says Michael Schafferhans, Technical

information of the conveyor belt, it

The DRT 25C dynamic reference diffuse

Sales Consultant at Leuze. “This allows

only needs to be intelligent enough

sensor from Leuze is based on the

us to determine where we need to

to adapt this knowledge to a possible

intelligent CAT technology and represents

readjust and improve further,” he

change of environment. This is precisely

a new operating principle. It thereby

adds. Leuze takes this feedback from

what CAT technology does. With this

sets new technological standards on

customers and partners very seriously

reference technology, Leuze has created

the market and is another milestone in

and is actively working on additional

a new operating principle in the field of

the innovation history of Leuze. Once

sensors based on the CAT technology.

switching sensors. The DRT 25C learns

again as forerunners, the Sensor People

After all, it always comes down to

the signal parameters of the conveyor

thereby precisely meet their customers’

providing the customer with the best

belt at the press of a button and stores

requirements for reliable detection and

possible support with his application and

them as the “standard zero.” Every object

make them successful in an industry that

making him even more successful. This

that is transported on the conveyor belt

is ever evolving. After all, the success of

is the goal and aspiration of the Sensor

now generates a signal. If this deviates

their customers is their aspiration and

People.

from the zero state, the DRT 25C reliably

goal. Reduced downtimes, increased

detects the object as a “deviation from

machine throughput as well as higher

CONTRAST ADAPTIVE TEACH INCREASES THE THROUGHPUT

the reference.” The performance of the

production quantities, all with maximum

device is optimized through the choice of

flexibility without readjustment when

“The DRT 25C is based on a completely

teach level. There is, for example, a teach

changing objects - that means increased

new technology: the Contrast Adaptive

routine for conveyor belts that become

cost effectiveness for their customers.

Teach Technology (CAT),” explains

heavily soiled over time. Another teach

www.leuze.com/drt25c

Eberle. The basic idea is simple: The

level exists especially for the detection

object can change at any time. The

of very flat or even transparent objects.

www.leuze.com

FDPP - www.fdpp.co.uk 39

A sticky situation results in business benefits Caramel can be a challenging material to extract, particularly when delivered in one tonne totes. One of the ways the Burtons Biscuits came up with, was to put totes into a warm room to enable the caramel to flow easier from the tote via a pump then into a hopper. However, they found that one of the main drawbacks on this process of totes was that the caramel would stick to the inside walls of the tote as the pump sucked out the caramel. At times this would mean that between 10% to 30% of the caramel would be left in the tote, unable to be extracted. The method was to connect a pump to the bottom outlet of the tote and transfer the caramel to a hopper, which worked well until the level of caramel in the tote fell to between 10% and 30%. From this point the pump cavitated and could not draw the caramel in, resulting in between 10% and 30% of the contents of the tote being returned to the supplier, costing anything between ÂŁ50,000 and ÂŁ140,000 per annum in unused caramel.

One idea that came from the Continuous Improvement team while looking at available options to reduce this waste or increase the yield was to revert to 200L drums of caramel rather than the tote.

Kecol were asked to make proposals for transferring the caramel from the 200L drums to the line hopper and offered a Kecol H800SN Maxiprime unit c/w 10:1 ratio piston pump.

Kecol supplied a trial unit to Burtons for a two-week trial period to enable evaluation of the proposed system. Whilst the system transferred the caramel at

Burtons purchased 2 x H800SN

the required rate and reduced the waste,

Maxiprime systems and have reduced

the drum loader used by Burtons could

the waste caramel to less than 1%,

not place the drum into the Maxiprime

significantly reducing expenditure and

in the correct position. To resolve this,

increasing yield.

Kecol worked with Burtons Engineers and modified the standard Maxiprime to suit

A video of the systems in operation can be

the existing drum loader.

seen here.

40 FDPP - www.fdpp.co.uk

Web: www.kecol.co.uk E-mail: sales@kecol.co.uk Tel: 01746 764311

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Indirect adiabatic air conditioner FDPP - www.fdpp.co.uk 41

Fluoropolymers offer limitless possibilities to the food & drink industry Thanks to their sterile and non-stick properties and resistance to high temperatures, fluoropolymers in food and drink applications help provide a safe and effective workspace. Specialist in fluoropolymers, UK manufacturer Adtech Polymer Engineering supplies a wide range of PTFE, FEP and PFA products to the food and drink industry.

WHY FLUOROPOLYMERS ARE ESSENTIAL TO THE FOOD & DRINK INDUSTRY Also known as fluoroplastics, fluoropolymers are high-performance plastics with exceptional sterile properties and limitless possibilities. Not only are they inert and non-stick, fluoroplastics are also pure, non-toxic, bio-compatible and can be sterilised. In addition, PTFE, FEP and PFA benefit from other unique properties: • Very high temperature resistance • Total resistance to chemicals, acids and solvents • Low friction characteristics and tensile strength • Resistance to weather, UV light and corrosion From cooking equipment to food coverings, conveyor belt rollers, UV lamp coatings, temperature sensor casings and non-stick surface covers, PTFE, FEP and PFA bring an abundance of benefits to the food and drink industry. Fluoropolymers can meet diverse environmental conditions and are ideal for keeping products uncontaminated, workers safe and productions running smoothly.

THE USE OF FLUOROPLASTIC PRODUCTS IN FOOD & DRINK APPLICATIONS

of PTFE, FEP and PFA products to the food

Using thermoforming, welding and

and drink industry:

flanging processing techniques, Adtech

• FDA, NSF and EU 10/2011 compliant

can also produce custom fabrications in

tubing: For increased safety • Laser marked and printed tubes: For identification and traceability • Encapsulated temperature and level

PTFE, FEP and PFA in any size and in any shape. From coiled and flare-tipped tubing to ready-cut tubing and tubing assemblies with applied fittings, custom fluoroplastic

detection sensors: For consistent,

components are manufactured to fit

accurate readings

applications precisely and save time,

• Shatterproof lamp coatings: To contain

hassle and money.

glass fragments and protect food if damage occurs • FEP roll covers: To eliminate the

To find out more about fluoropolymer products for the food & drink industry,

cleaning process, improve the potential

contact us at sales@adtech.co.uk and

To help provide a safe and effective

for a quality concern and ensure minimal

01285 762000, or visit our website

workspace, Adtech supplies a wide range

machine downtime

www.adtech.co.uk.

42 FDPP - www.fdpp.co.uk

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®

•

Modular network connection - cloud or on-premises, 5G ready

CALL +44 - 20 - 3868-0909 OR EMAIL FLEXEDGE@REDLION.NET TO REQUEST A DEMONSTRATION www.flexedge.net

Arjowiggins answers food brands demand for sustainable packaging with revolutionary new translucent barrier paper As part of its mission to help food brand

marine degradable and made from

oxygen, aroma, mineral oils and fatty

owners and retailers create a circular

renewable raw materials.

foodstuffs.

paper manufacturer Arjowiggins has

Sylvicta’s distinct advantage is its

Additionally, Arjowiggins is working

launched Sylvicta – a ground-breaking

very high barrier to oxygen – the

continuously with food brand owners

new sustainable alternative to plastics

leading cause of food spoilage – which

and packaging converters to open up an

in packaging.

means it can help reduce food waste

endless array of applications — from

by prolonging shelf life during the

windows in packaging to make the

Truly revolutionary, Sylvicta is a

transportation, retail and consumer

content visible, pouches for dry fruits,

translucent, functional barrier paper

phases of the value chain.

bags for salads, and flow-packs for

economy society, world-renowned

that has been proven to preserve the

chocolate bars, all the way through to

quality of food and cosmetics just as

Through precision fibre refining,

metallised versions of Sylvicta for butter

well as conventional plastics – all the

Arjowiggins’ experienced R&D teams

or margarine packaging.

while ensuring limited impact on the

have developed this unique translucent

environment. Testament to its unique

paper with a natural bonding, without

Answering the market’s need for

sustainable properties, the pioneering

the need of any harmful chemicals.

sustainable alternatives to single-use

paper is fully recyclable, compostable,

The result is a paper with a barrier to

packaging and flexible laminates, with

44 FDPP - www.fdpp.co.uk

look no further than Sylvicta – the product is simply revolutionary. It can help to create the circular economy society we all desire.”

When running through conventional converting lines, Sylvicta offers limitless creative possibilities: it can be foilstamped, glued, embossed, printed in offset, gravure, and flexography, metallised, or coated with heat or coldsealable materials.

Sylvicta also benefits from the exceptional environmental standards set by Arjowiggins Translucent Papers business. Like all of its products, Sylvicta

Sylvicta food brands can reduce or even

Until now, most of the existing offer,

eradicate the use of plastics in their

mainly in single-use packaging, use

packaging. It’s the ideal solution for

unrecyclable, multi-layered laminates

creating a globally sustainable, circular

is carbon-offset through the World Land

incorporating plastics or aluminium foil”

economy as it can integrate into existing

Trust’s Carbon Balanced programme.

explains Christophe Jordan, Managing

recycling schemes.

Director of the Translucent Papers

is FSC and PEFC-certified, produced on a site that’s ISO 14001-compliant, and

#ChoosePaper

division at Arjowiggins.

“Despite the ongoing movement towards

To find out more about Sylvicta

more sustainable packaging, plastics still

“The good news is retailers looking for

remain a popular choice for food brand

translucent barrier paper by

a fully recyclable, compostable and

Arjowiggins go to:

biodegradable paper packaging need

sylvicta.arjowiggins.com

owners, largely for practical reasons.

FDPP - www.fdpp.co.uk 45

The innovative partner for consultation on and distribution of laser products RAMAN LASERS FOR FRUIT QUALITY CONTROL Raman spectroscopy is a new method to control the quality of fruits. It allows a non-destructive investigation of the freshness of fruits and to sort out those fruits that are no longer attractive to consumers. Another application is the non-destructive, rapid and accurate detection of pesticide residues on the surface of fruits. FLC offers a great variety of Raman Lasers for Raman spectroscopy in the visible and near infrared wavelength range.

LINE LASER MODULES FOR ALIGNMENT OF FRUITS Sorting and quality inspection of fruits is still a time-consuming task because of the low level of automation. Natural products exhibit a greater variance compared to manufactured products regarding quality and dimensions, which complicates their automated processing.

By means of a red line laser like a laser from the ML2040-Series or the HAML-F in combination with a color CMOS camera and a specially trained Convolutional Neural Network it is possible to determine the orientation of fruits. The accuracy of the orientation prediction is approximately 5 degrees, which presents very promising results for the automation of fruit packing systems. www.frlaserco.com

46 FDPP - www.fdpp.co.uk

Manufacturers and retailers want more sustainable packaging SUSTAINABLE PACKAGING STUDY

BY INVERTO Everybody wants sustainable packaging, but nobody knows exactly what it is.

That’s because there’s no exact criteria for what it takes for packaging to be sustainable. However, according to a study

by INVERTO, the Boston Consulting Group subsidiary specializing in procurement and supply chain management, sustainable packaging is very important today for half of all respondents to a survey about this topic. 86% assume that the demand will continue to increase in the next years.

Consumer wellbeing, a healthy society and fair business practices were defined as the most important sustainability goals by more than 50% of the study participants.

CHALLENGES ON THE WAY TO SUSTAINABILITY IN PACKAGING High product complexity, limited material availability and limited capacity in procurement inhibit sustainable packaging solutions: only 23% of those surveyed have sufficient capacity in procurement to drive new packaging projects. In addition, more than half of the respondents admit lacking an adequate market overview.

RELEVANCE & FUTURE DEVELOPMENT OF SUSTAINABLE PACKAGING When it comes to sustainability, it

market accordingly. Depending on

competitive advantage and significant

is important to keep an eye on new

whether the focus is on renewable raw

brand enhancement. In addition, prices for

developments, as a lot of research is

materials, recyclability or CO2 footprint,

conventional packaging will continue to

carried out on new materials and recycling

the packaging solution differs. Cost

rise due to the planned taxes, duties and

options are constantly evolving. In addition

calculations should take into account not

other government regulations. So, in the

to consumers, politicians are also exerting

only material costs, but also additional

long term, sustainability will pay off for

pressure: The requirements for material

expenses that arise, for example, from

both customers and manufacturers. “

properties are increasing and quotas are

new machines or changes in production

being set for the use of recyclates.

speed.

Companies that want to switch to

However, not only the cost side is

of the results with recommendations

sustainable packaging or increase

important, emphasizes Thibault Lecat,

for actions free of charge: https://

their share should first define focal

Managing Director of INVERTO UK: “

www.inverto.com/en/publikationen/

points and gain an overview of the

Those who invest now will secure a true

sustainable-packaging-study-2020/

For current figures and detailed information, download the presentation

48 FDPP - www.fdpp.co.uk

Optimised Food Texture Analysis FTC texture analysers are measurement instruments specifically designed for texture analysis of products and ingredients in all food industry sectors and other industries to include pet/animal feeds, cosmetics, pharmaceuticals and nutraceuticals. Texture analysers are ideal systems for use in education and scientific research.

Full software control permits a wide variety of texture tests such as peak firmness and penetration resistance. A large selection of test fixtures, load cells and methods are available to define and compare the quality and texture of your products. Spectronic CamSpec’s expertise in texture applications is broad and can be applied to any product for which physical texture is a significant factor in product quality and customer acceptance.

The FTC Tenderometer is a highly specialised texture measurement system for accurate analysis of tenderness in fresh peas. Used at multiple points during pea harvesting and processing, the system provides a rapid return on investment by optimising quality. The Tenderometer indicates pea maturity with industrystandard tenderometer reading (TR) which directly correlate with pea quality grades. The systems can be used in the field for instant tenderness results directly from the vine, triggering the decision to harvest, ensuring peas remain in the highest quality band, maximising profits.

Download Brochures

Work safer with our innovative materials and meet increasingly demanding customer needs Metal & X-Ray Detectable Belts Safe food processing continuously deals with the issue of foreign bodies.

Volta Belting’s materials are resistant to cuts and breakage.

So food-grade metal & x-ray detectable belts can meet the high demands of quality assurance. This allows the production teams to be confident that their products will meet the strictest food safety requirements.

No more dealing with: • Friable plastic that deposits untraceable fragments into food • Removal of broken plastic • Missing belt segments or cleats Start using Volta's hygienic and durable belting solutions with thermoplastic material.

UV-C Resistant Belts UV-C rays lamps are being used for sterilization in the food industry and overexposure can cause damage to plastic belts. Volta food grade belts have been tested rigorously for a simulated operating period of 5 years under irradiation of 0.1 mW*s/cm2 across the entire belt. There was no degradation of belt surface and no loss of flexibility, only a minor loss of color over time.

marketing@voltabelting.com |

www.voltabelting.com

FDPP - www.fdpp.co.uk 49

Effective and Efficient Sanitizing The coronavirus pandemic has driven huge changes within cleaning and hygiene, with every industry needing the cleaning sector like never before. It has brought sanitization to the forefront of all companies’ agendas to ensure safety and security for the community. Creating a sudden demand for sanitising and disinfecting equipment. New products, technology, and processes have been developed rapidly to offer innovative and effective solutions to help counter the dangers brought by Covid-19. Two products available today to safely and effectively sanitize are the Comac E-Spray and TMB OptiMist.

The food processing and distribution sector is put under pressure, in times like this, ensuring the food supply chain is running and reducing the impact from field to consumer. Therefore health and safety of staff becomes paramount. One way to ensure safety is cleaning communal work areas and sanitizing high touch-point areas to prevent cross-contamination. The Comac E-Spray and TMB OptiMist make sanitizing these areas quick and effective.

Comac E-Spray is a professional gun sprayer that uses the principle of electrostatic induction to distribute

sanitization for several hours without

The mist is diffused quickly and evenly

being restricted by a cable. The Comac

throughout the target area, remaining in

E-Spray is perfect for:

the air before settling on surfaces, even

• Door handles

in the hardest to reach areas.

• Office desks and chairs

TMB OPTIMIST ADVANTAGES:

• Elevators

One-handed Operation: The easy to

• Stair handles

press lever on the hand-held trigger

• Customer reception or meeting areas

makes it manageable with one hand.

COMAC E-SPRAY ADVANTAGES:

Compact and Agile: The spiral tube

Sanitization Quality: The sprayed solution adheres quickly to surfaces and is evenly distributed providing 360-degree coverage.

Sanitization Time: Quick distribution guarantees time saving and up to 6 hours continuously.

connecting the nozzle contracts down to a very small size when not in use but can be elongated up to 3 meters during use to reach areas which would normally be impossible to target.

Sanitization which has always been at the forefront of professional cleaning, has gained a prominent position as a

disinfectant solutions effectively and

The TMB OptiMist is a compact and

fundamental and indispensable element

uniformly on surfaces. Germs and bacteria

agile machine that allows effortless

in professional cleaning procedures.

are quick to spread and settle in tight

sanitization in small spaces such as

Their proven effectiveness has

corners and hidden spots. The E-Spray

restrooms, changing rooms, locker rooms,

contributed to making them essential

electrostatically charged spray can reach

elevators and all high touch-point areas.

tools in the fight against infection,

the entire target area, evenly sanitizing

The OptiMist significantly reduces the

helping to make this world a cleaner

every part including those hidden spots.

time to sanitize and disinfect areas that

and safer place. Contact IFM Comac for

It is light and comfortable, powered by a

would otherwise be extremely time

more information on the Comac E-Spray

lithium battery, allowing you to carry out

consuming using traditional methods.

and TMB OptiMist: sales@ifmcomac.com At Industrial Floorcare Machines Ltd (IFM Comac) we supply a wide variety of professional focused cleaning solutions.

We provide customers with the best machinery for their individual needs.

For more information visit www.ifmcomac.com. You can also find us on Facebook, Twitter and Linkedin.

50 FDPP - www.fdpp.co.uk

Comac E-Spray

E-Spray: Electrostatic Hygienization Technology Disinfect efficiently and effectively across all high touch point areas.

Germs and bacteria are quick to spread and settle in tight corners and hidden spots. The E-Spray electrostatically charged spray can reach the entire target area evenly sanitizing every part including those hidden spots.

OptiMist: Compact and Manageable Sanitization Equipment Sanitization equipment that efficiently distributes disinfectant solutions. In a professional cleaning context the TMB OptiMist significantly reduces the time to sanitize and disinfect areas and surfaces that would otherwise be extremely time consuming using traditional methods.

Comac E-Spray and OptiMist are available at IFMComac.

Contact us for information on machines and training: sales@ifmcomac.com Watch a Demo of the Comac E-Spray and TMB OptiMist

At Industrial Floorcare Machines Ltd (IFM Comac) we supply a wide variety of professional focused cleaning solutions. We provide customers with the best machinery for their individual needs.

An ideal partnership for fine baked goods The Micro Croissant® from La Petite Bretonne is the star product in the Canadian bakery’s portfolio. The familyrun company from Quebec, established 52 years ago, produces up to 1.2 million Micro Croissants® every day. An efficient production process calls for a high degree of automation. To expand its production, La Petite Bretonne relies on the proven expertise of the Schubert company, the

and packed into flowpacks. First the

leading manufacturer of TLM packaging

longitudinal seam of the flowpack is sealed

machines from Germany. The Canadian

by an ultrasonic sealing unit. This is then

company recently ordered a lightline

followed by Schubert’s patented heat-

Flowpacker for its main production site in

sealing technology with the flying cross-

Blainville, Quebec.

sealing unit. It automatically adapts to the speed of the upstream pick & place robots

“La Petite Bretonne would need countless

and therefore enables constant sealing

employees to be in the position to satisfy

times with outstanding sealing quality.

the high demand,” says Julian Conway, Sales Account Manager at Schubert North

COST-EFFECTIVENESS AND SCALABILITY FOR THE FUTURE

America and responsible project manager.

Julian Conway and Serge Bohec, the

Packaging machines from Schubert stand

owner of La Petite Bretonne, have enjoyed

out with their cost-effectiveness, high

a close working relationship for more than

degree of automation and very wide

a decade. To adapt the existing processes

performance spectrum. These are all

to the increasing production volume, the

advantages that Bohec also praises: “It’s

bakery was looking for a high-quality automation solution that is highly flexible, very compact and also cost-effective.

The producer had already been operating several individual machines for end-ofline automation when he heard about Schubert’s new flow-wrapping unit, the Flowmodul.

THE FLOWMODUL ENABLES MAXIMUM EFFICIENCY

fascinating that we can now package reliable operation with high system

numerous products and formats on

availability.

a single line. I’m convinced that with Schubert, we have the right partner at

At La Petite Bretonne, the new lightline

our side to successfully take on current

Flowpacker would have to pack, among

and future challenges.”

other things, filled Danish pastry (Danoise) and chocolate-filled croissants

Facts & figures

(Chocolatines) in different sizes on one

• Products to be packed:

line, while gently handling the fragile,

- A flowpack with a Danoise

heat-sensitive products. Schubert meets

- A flowpack with a Chocolatine

The Flowmodul from Schubert is a flow-

all these requirements in a complete

- A flowpack with a Mini Chocolatine

wrapping unit which is also integrated

system that comprises four pick & place

• 183 Danoises per minute

into the Flowpacker from Schubert’s

robots, a 3D scanner and the Flowmodul.

• 220 Chocolatines per minute

lightline machine series. This range

The 3D scanner checks the position,

• 280 Mini Chocolatines per minute

consists of three preconfigured, compact

shape, volume, orientation and degree of

• Flowmodul in use

and highly efficient packaging systems.

browning of each product and allows only

• Patented heat-sealing technology

It boasts short planning and installation

perfect baked goods to pass on to the

• Fully automatic ‘chain flight’ changeover

times as well as attractive procurement

next packaging step. The baked goods are

• 99% efficiency

costs. The proven TLM standard modules

then carefully placed into the Flowmodul’s

and intelligent robot technology ensure

feed chain by four pick & place robots

52 FDPP - www.fdpp.co.uk

www.schubert.group

Welding can Induce Loss of Corrosion Resistance in Stainless Steel Tubes Welding carried out on many stainless steels can result in a significant reduction in corrosion resistance, a significant consideration in the food and drink industry.

Stainless steels owe their resistance to corrosion to the formation of a very thin surface layer of chromium oxide. During welding at high temperatures in the presence of oxygen this film breaks down and presents sites for corrosion.

Whilst the upper weld surface is protected by the torch gas, the underside is exposed to oxygen in the atmosphere.

Underside protection is thus essential and this can be achieved by providing inert gas coverage.

To meet the need for total internal protection, called ‘weld purging’, dedicated equipment has evolved over the past 25 years.

Fig 1 Complex pipework in typical dairy processing plant

Pipe and tube purging Systems for weld root protection are based on sealing the inside of a pipe on either side of the weld zone then displacing air with an inert gas. The seals must be reliable and leak tight and easy to insert and remove.

The most effective solutions are based on the use of inflatable dams and fully integrated systems are now available covering pipe and tube diameters between 25 and 2400 mm. The recommended residual oxygen content for total protection is 20 parts per million These systems are quite capable of providing protection down to 10 parts per million.

Fig 2 ‘Argweld inflatable pipe and tube purging concept.

The product range, which includes QuickPurge®’ and PurgElite®’ designs is used globally for applications in the process industries. ®’

Alternative purging systems are available to accommodate pipe diameters as small as 10mm.

Residual oxygen measurement instruments Any effective weld purge process needs to be supported by monitoring with sensitive oxygen detecting equipment. The PurgEye® instruments from Huntingdon Fusion Techniques, HFT® read down to 10 ppm with extreme accuracy. These can be integrated easily into Argweld purge systems for continuous monitoring and control of oxygen levels.

•

The entire Argweld product range is supported by an extensive library of publications including Technical Notes, White Papers, Conference Proceedings and peer-reviewed International Articles. These are available on-line by application to Huntingdon Fusion Techniques Ltd. Food and Drink TP-01-12-2020 ME

Huntingdon Fusion Techniques HFT® Stukeley Meadow Burry Port Carms SA16 0BU United Kingdom (UK) Telephone +44 (0) 1554 836 836 Fax +44 (0) 1554 836 837 www.huntingdonfusion.com Email hft@huntingdonfusion.com E&OE. Copyright © HFT. All rights reserved. This publication may not be reproduced by any means without the written permission of Huntingdon Fusion Techniques HFT® Tradenames and logos are the property of HFT and registered ownership of HFT.

Vertical Future’s new vertical farm launches with a giant leap in efficiency for global food production With a completely fresh approach

hardware advances and smart-learning

to vertical farming, Vertical Future’s

systems – all designed in-house

new 1,500m3 Southeast London

and manufactured in the UK. Vertical

farm provides a yield increase of 172%

Future’s software system (Diana)

per m3 and approximately 60% less

works in tandem with thousands of

energy consumption compared to other

sensors to monitor individual crop

vertical farms, making it one of the

growth and optimise production at

most efficient in the world. The site

a granular level, including the use of

is focussed on leading research and

radio-frequency identification (RFID).

development as well as serving for

The system automatically adjusts

the B2B food and beverage industry

lighting wavelength and intensity,

with world-class, sustainable, beyond-

nutrient concentration and distribution,

organic produce.

and water flow rate, in addition to many other variables. If a crop needs

An emerging market leader in the

a change in light, Diana liaises with

controlled-environment-agriculture

5 different forms of LED lights to

(CEA) space, Vertical Future has brought

automatically adjust the combinations

together both automated technological

and intensity.

54 FDPP - www.fdpp.co.uk

With no need for pesticides, herbicides or fungicides, and minimal human interaction, Vertical Future offers a product that goes beyond organic.

Vertical farming – when implemented correctly – uses far less of the planet’s resources and significantly less water, while producing much closer to the point of consumption. Founder and CEO Jamie Burrows says: ‘Hundreds of seeds of micro broccoli have the same footprint as one seed for a full head of broccoli but if you harvest broccoli at 10 to 15 days maturity, it has 40 times more vitamin K and far higher levels of sulforaphane.’. Vertical farming operations use derelict urban and rural spaces, distributing food on a hyper-local basis, lowering transportation times and

damaging to our environment and

discussion, several already underway

slashing emissions to solve many of the

vertical farming offers one long-term

in various geographies, and an exciting

problems associated with food miles.

solution. We take vertical farming a

research and development programme,

giant leap further, adopting a holistic

this is the next exciting step in Vertical

In Jamie’s words: “We have launched

approach by offering fully automated and

Future’s journey to improve the long-

an advanced, intelligent, end-to-end

intelligent systems that offer endless

term health of the planet and its

system providing superior tasting and

possibilities.”

inhabitants – one leaf at a time.

food and pharmaceutical production – at

Vertical Future’s production system is

For more information please

an affordable price-point. Exploitation

one of the most advanced in the world

contact alex@nudgepr.co.uk,

of land, loss of biodiversity, and overuse

– and with over 100 pipeline projects

07776 144 979

of the earth’s natural resources are

across four continents currently under

https://www.verticalfuture.co.uk/

better crops for the future – for both

FDPP - www.fdpp.co.uk 55

Modified and Controlled Atmosphere Systems Since 1993, Emproco Ltd, established on 1975, has been designing and manufacturing a wide range of Modified and Controlled Atmosphere Systems for application such as food packaging, storage of fruit, vegetables, grain and flowers and CO2 enrichment for greenhouses. Products were developed in conjunction with the Volcani Institute of Agricultural Research Center in Israel.

Our range of instrumentation includes on-line food packaging monitors for quality control of modified atmosphere packaging of products such as coffee, cheese, processed meats, herbs, flour etc. Nitrogen and /or CO2 are used to extend the shelf life of these packaged products. We have developed instruments that measure very small volumes of residual Oxygen and CO2 to ensure the integrity of the packaging.

For storage of fruit, vegetables, grains, etc., we have designed multiple programmable systems that control the storage atmosphere according to pre-set parameters of Oxygen and CO2. These systems use our propriety software to optimize quantity of gases required to reach the programmed concentrations in minimal time and to maintain these concentrations within close tolerances.

CO2 enrichment of greenhouses for flowers and some types of fruit and vegetables provides improved the quality and quantity of produce. Our systems use propriety software to optimize and maintain the CO2 levels over the complete growing cycle in multiple greenhouses.

We can also design and manufacture systems per customer requirements and parameters. All our instrumentation are designed for high reliability with minimum maintenance, which in most cases, can be carried out by the end-user.

For more information visit our website at www.emproco.com

56 FDPP - www.fdpp.co.uk

Optimisation of linear guides in food production: Bakery enjoys tenfold increase in service life When linear guides in the food and packaging industry fail to last for their expected service life, it can make sense to use solutions equipped with integrated lubrication units. These units release lubricant continuously over a long period of time. By switching to this type of linear system in its dough slicing machines, a large bakery is saving more than €200,000 a year in maintenance and downtime costs.

The linear guides serving the processintegrated band cutters in the bakery´s dough slicing systems were failing every three weeks on average. Despite being coated with an Armoloy finish - and using food-grade grease - the desired performance criteria could not be met.

To overcome its issues, the bakery sought a linear guide that would not only offer long service life, but be capable of higher speeds as the company planned to boost the productivity of its dough slicers from 250 to more than 300 cycles per minute.

food-grade lubrication unit. After an initial trial had been completed successfully, it prompted the bakery to fit all of its dough slicing machines with this proven solution.

The NH/NS series is designed to perform precise linear motion (even at high speeds), with stainless steel versions particularly suited to food and beverage manufacturing environments. Long service life is not compromised even when subjected to frequent and deep cleaning cycles.

The new NSK K1-L lubrication unit offers twice the service life of the K1 series Within the framework of NSK´s AIP (Added Value Programme), company experts performed an on-site assessment of the application´s environmental conditions, as well as linear guides that had failed.

Once complete, the team recommended the use of NH/NS series stainless steel linear guides in combination with a K1

NSK´s K1 lubrication units provide a clean and FDA-approved solution in the truest sense of the word because the lubricant is incorporated in a carrier medium and released little by little to ensure supply over a long time period. Meticulous sealing prevents contaminants from reaching the running surface, and far less lubricant is released into the surroundings than with conventional solutions. www.nskeurope.com

Forerunner Yesterday. Today.

Tomorrow.

The Sensor People have been setting technological standards in industrial automation for more than 50 years. In the field of safety at work, we convince right from the start with trend-setting inventions, such as the development of the first protective sensor ever, to our latest safety innovation, “Smart Process Gating” – the space-saving solution for access guarding on conveyor lines. This is how we ensure the success of our customers in an industry that is ever evolving.

www.leuze.co.uk

FDPP - www.fdpp.co.uk 57

Making minced meat packaging more sustainable With a recent Ubamarket survey stating that 82 per cent of British shoppers believe plastic use can and should be reduced in food and drink packaging, ULMA Packaging UK is advocating the use of trayless solutions in minced meat applications.

Food manufacturers and supermarkets are under increasing pressure from consumers to reduce plastics used in packaging, with the same poll stating these businesses should take the lead in adopting sustainable solutions. In order to help the meat industry meet these expectations, ULMA has relaunched a campaign on how to package minced meat safely with minimal environmental impact.

Trayless minced meat packaging is one of ULMA Packaging’s most sustainable packaging solutions, and has been proclaimed by the business as a potential gamechanger for reducing plastic use and changing consumer buying habits.

As part of the campaign, ULMA is stressing the importance of flow wrapper technology for food manufacturers working with minced meat.

Specifically, the company is highlighting how by implementing modified atmosphere packaging (MAP) on horizontal flow wrap packaging lines, companies working with minced

has to be balanced with maintaining

through smaller pack volumes. ULMA’s

product quality,” explains Dave

own solution, for example, requires

Berriman, Technical Sales Support

80% less space to transport compared

Manager at ULMA Packaging UK.

to tray-based packaging, and 30%

“Consequently, MAP’s ability to provide

less space to transport products to

trayless minced meat packaging,

retail spaces, resulting in lower CO2

without compromising product

emissions and cost savings due to

integrity, means that this technology could provide a sustainability breakthrough for the food industry.

“With this in mind, we would strongly advocate that food manufacturers working with minced meat review their existing packaging machinery and look into MAP solutions. The fact this technology can achieve plastic reductions of up to 60 per cent while

meat can provide sustainable

reducing waste going to landfill makes

trayless packaging. By using MAP

it ideal for futureproofing operations as

with pillow packaging, for instance,

sustainability becomes an even greater

substantial plastic savings can be

priority.”

made compared to trayed solutions, while also protecting products with no discolouration, leakage, or compromise

ULMA is also advising companies to look at the possibility of using films

logistics efficiencies.

Dave, concludes: “It is vital that all stakeholders in the meat industry look for ways to improve the sustainability of their operations. Minced meat is a proven area with green benefits that can be realised with the right packing technology, including pillow and shrink packs.

“By replacing rigid plastic trays with a flow pack using MAP, we can ensure all of the usual benefits of packaging are achieved, while limiting the use of unnecessary plastics in line with consumer expectations.”

To find out more about ULMA

on shelf life.

that can form trayless minced meat

“Tackling excessive plastic use in

thinner, recycled films suited to shrink

packaging remains a key priority in the

packaging, food manufacturers can

Further product information can be

food and beverage market, and this

make additional sustainability savings

found at www.ulmapackaging.co.uk

58 FDPP - www.fdpp.co.uk

shrink packs with MAP. By using

Packaging UK’s minced meat packaging solution, click here.

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Bringing you World-class equipment from the best suppliers in the industry

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wereitfinding it impossible to maintain our mould "We were"We finding impossible to maintain our mould "We were finding it impossible to maintain our mould temperature of 8°C. Summit installed a duel temperature of 8°C. Summit ChilledChilled installed a duel temperature of 8°C. Summit Chilled installed duel zone Microgel combined unitwe're and we're zone Microgel combined unit and nowanow zone Microgel combined unit and we're now maintaining a perfect 8°C mould temperature and maintaining a perfect 8°C mould temperature and and maintaining perfect 8°C mould temperature Patterson & Rothwell have reducedaour cycle time by 20%."

Patterson Patterson & & Rothwell Rothwell have reduced cycleour time by time 20%."

Patterson & Rothwell haveour reduced cycle by 20%."

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www.summitprocesscooling.co.uk www.summitprocesscooling.co.uk sales@summitprocesscooling.co.uk www.summitprocesscooling.co.uk sales@summitprocesscooling.co.uk sales@summitprocesscooling.co.u sales@summitprocesscooling.co.uk

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