FOOD & DRINK PROCESSING & PACKAGING Issue 32 2021
ÂSmart 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.
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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
The The ‘Atmos’ ‘Atmos’ sensor sensor which which can can be be used used as as
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
T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk
✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax
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
Company to help create a new system
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
filters. Our hire fleet are available 24/7
and we will have any piece of equipment
operating conditions, our Unique
through our Quantum Prime service.
in transit within 30 minutes of your call.
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
Switchgear Panels
Sine & Harmonic Filters
Harmonic Data Loggers
Diesel Generators
Mains Cable
Call our UK 24/7 Emergency Support Line to access our Rental Services or email us at:
Distribution Panels
Step Up / Down Transformers
Flow Meters
0330 9000 247
rental@quantum-controls.co.uk
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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Optimized Cooling Optimized Cooling for the Plastics Industry for the Plastics Industry
Microgel Up to Microgel 60% energy cost savings Microgel
Up to 60% energy cost savings
The Microgel offers a unique,savings UpMicrogel toline 60% energy The line offerscost a unique, space-saving approach that directly The Microgel line offers a unique, space-saving approach that directly addresses the needs of plastics molders. space-saving that directly addresses the approach needs of plastics molders.
addresses the needs of plastics molders.
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%."
in partnership with in in partnership partnership with with in partnership with
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
01827 213401 01827 213401 01827 213401 @SummitSystems @SummitSystems @SummitSystems
@SummitSystems Summit Systems Ltd
Summit Summit Systems Systems Ltd Ltd Summit Systems Ltd
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