FOOD & DRINK PROCESSING & PACKAGING Issue 37 2022
SUMITOMO Protecting premium Food & Beverage brand integrity
BERRY GLOBAL Benefits of New Jar from Berry Stack Up
INNOVATIVE COMPRESSED AIR TECHNOLOGIES
Air Knives
Enclosure Coolers
Air Nozzles
for blow off or drying
for all location ratings
for targeted blow off
Effectively blow off water and debris from bottles, cans, films, sheets, packages & conveyors
Keep electrical enclosures cool, clean and protected
Up to 25 times more blow off power
High velocity, laminar air curtain Available in 6-24” lengths
265 - 1465 watts of cooling capacity IP 66 & ATEX certifications in Zones 1, 2, 21 & 22
More efficient blow off reduces operating costs by up to 80% Reach tight spaces Reduce noise levels by as much as 60%
Contents
The Team Editor Amanda Buckingham editor@fdpp.co.uk
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Publishing Director Martin Holmes martin@fdpp.co.uk
Studio Designer Richard Bland richard@mhmagazine.co.uk
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Features ISHIDA
< 06
BERRY GLOBAL
< 16
WEG
< 18
WEG
< 24
SUMITOMO
< 32
NSK EUROPE
< 40
SPARC SYSTEMS
< 46
GÜNTNER
< 50
COMP AIR
< 52
NORD
< 54
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NON-INVASIVE up to 6 logs STERILIZATION Juices & wines, or honey & creams keeping its properties unchanged with our Pulsed Electrical Fields (PEF) simple to operate two-stage multi-paramater system. For piloting & small production to sterilize most common bacteria. It has an option for the PEF assisted juice extraction from vegetative cells or can combine any of two processes above. It has the industry broadest set of variable pulse parameters to fit all major processes: 5-500Hz rep. rate, 2.5-50µs positive rectangular pulses at 5-50kV/cm el. fields, 2-3kW, a timer, scope controls of pulse shapes. + HELP TO REACH YOUR STERILIZATION GOALS.
Practical Intense Pulsed (UV) Light
R&D system to sterilize up to 6 logs samples of foods and packaging from common and UV resistant bacteria, spores and fungi by using its optimal for each case pulse parameters covering most of applications: Pulse rates 1-4Hz, a timer, pulse energies 250J and 500J, 1-2 kW, one or two IPL flash lamps with the highest pulse intensities for R&D PL systems. THIS SYSTEM ALLOWS TO FIND STERILIZATION PARAMETERS for our customized Tunnels with Intense Pulsed Light.
info@wek-tec.de
www.wek-tec.de
Pulsed Light (PUV) and PEF customized processes & systems to sterilize or modify various solid, liquid or powdered food products have been developed / delivered by wek-tec with its cooperating German companies since 1996. Obtained results have been published & referenced in scientific and industrial publications, see info. #1: the use of Pulsed Electrical Fields (PEF) systems for all cases aside simplest filtered fruit juices requires a process development followed with adjusting a PEF production system. Indeed, while the basic PEF process is known since decades as stretching bacterium till its eruption by sharp pulsing electrical fields, yet each practical case requires overcoming specifics which diminish the process effectiveness even down to nothing. The advantage of our customization is in employing very broad pulsing parameters and using the latest available improvements to PEF chambers as it is shown on the adjusting page. #2: Intense Pulsed UV (IPUV) - Pulsed Light (IPL) sterilization processes & systems: We are also very experienced in those since we are ones of its first developers: respective pioneering articles were published in 1992-1994 and then in 1999-2001 by Dr. Wekhof alone and with his coauthors (info). Our charts on the left are used to find IPUV (IPL) regions with optimal ratios of UV energies to its costs and to determine if those are superior or not to the continuous UVC light, or to PEF or to non-invasive IR.
#3: Sanitation and/or modifications of nutrition powders with UV light: The lab R&D Vortex system partially shown on the left is the vortex type system where a nutrition powder is moved around a UV lamp by a forced air enriched with the Nitrogen gas. This and some modifications of this system were used for our customers. Our acquired data show good prospects of this approach. Wek-tec offers this system for long-term rent at a customer site as a DONATION to any university or a government agency which will be interested to get it.
In a week after getting your requirements you will receive our proposal.
New Ishida X-ray offers enhanced sensitivity for difficult to detect items Ishida Europe is launching its next
to noise ratio which has increased the
where they can often be overlapped or
generation IX-G2 dual energy X-ray
ability to detect bone fragments by a
presented with uneven surfaces.
inspection system which offers
factor of four compared with previous
significantly enhanced sensitivities for the detection of low-density and difficult to spot foreign bodies, including bone.
X-ray models. This further increases the ability of the machine to identify contaminants, in particular when
The enhanced sensitivity of the machine also greatly reduces the risk of false detections, which helps to maximise throughput and avoids the costs
The Ishida IX-G2-F incorporates a new
handling thicker and denser products
associated with unnecessary waste and
line sensor that provides a high-quality
such as chicken fillets, chicken breasts
the repacking of products.
X-ray image through an enhanced signal
and a wide range of poultry products
6 FDPP - www.fdpp.co.uk
Ishida’s dual energy technology incorporates two line sensors, one which takes images at high energy and one at low energy. The high performance of the IX-G2-F is supported by Ishida’s unique self-learning Genetic Algorithm (GA) technology which combines with the new line sensor to deliver maximum detection sensitivity and reliability. The GA technology focuses the X-ray machine to identify difficult to detect contaminants with a high degree of accuracy, even at high throughput rates, using image data analysis over a number of trial runs. As it is common in food production for similar contamination problems to recur, data logging can help to build up a more precise calibration protocol with each trial. This enables permanent or recurring defects to be easily identified during the inspection process. Ishida’s dual energy technology incorporates two line sensors, one which takes images at high energy and one at low energy. These are then compared, which provides a better overall image of the product with a clearer contrast between the product and any low-density foreign bodies, such as bone fragments. “The next generation IX-G2-F X-ray inspection system offers unrivalled performance and with its improved line sensor and software capabilities it has already delivered significant benefits on production lines,” comments Sibtain Naqvi, Ishida Europe’s X-ray Product Manager. “The enhanced sensitivity provides poultry processors with even greater reassurance that their high product quality standards are being maintained, and by minimising the number of false rejects, production can be maximised. We believe our IX-G2-F models represent another major advance in our X-ray inspection portfolio,” www.ishidaeurope.com/en
FDPP - www.fdpp.co.uk 7
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 £50,000 and £140,000 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.
8 FDPP - www.fdpp.co.uk
Web: www.kecol.co.uk E-mail: sales@kecol.co.uk Tel: 01746 764311
CUT COSTS
4
WAYS
With VIBRO-BED Circular Vibratory Fluid Bed Dyers, Coolers, and Moisturizers
1. Cut Purchase Costs The The inherent inherent strength strength of of the the VIBRO-BED’s VIBRO-BED’s circular circular design design eliminates eliminates the the need need for for heavy heavy sidewalls sidewalls and and braces. braces. Lighter Lighter gauge gauge shell, shell, downsized downsized motors, motors, fewer fewer weld weld seams, seams, and and only only one one air air inlet inlet and and outlet outlet dramatically dramatically reduce reduce material material and and labor labor costs, costs, especially especially when when fi finishes nishes to to FDA, FDA, BISSC, BISSC, 3-A, 3-A, or or other other sanitary sanitary standards. standards.
2. Cut Cleaning Costs No No internal internal cross-members, cross-members, fewer fewer seams seams and and corners, corners, and and quick-disconnect quick-disconnect shell shell allow allow for for fast, fast, thorough thorough cleaning cleaning of of the the machine. machine.
3. Cut Energy Costs The The light light weight weight of of the the high-strength high-strength circular circular shell shell signifi significantly cantly reduces reduces HP/kW HP/kW and and power power consumption consumption of of gyratory gyratory motors. motors. Effi Efficient cient fl flow ow of of fl fluidized uidized material material and and heated heated or or cooled cooled air air within within the the circular circular chamber chamber maximizes maximizes heating/cooling heating/cooling per per kWh. kWh.
Kason Kason off offers ers circular circular vibratory vibratory fl fluid uid bed bed systems systems in in diameters diameters from from 18 18 inches inches (457 (457 mm) mm) to to 84 84 inches inches (2134 (2134 mm) mm) for for drying drying or or cooling cooling of of bulk bulk foods, foods, pharmaceuticals, pharmaceuticals, and and chemicals chemicals — — rapidly rapidly and and uniformly, uniformly, in in batches batches or or in-line, in-line, on on laboratory laboratory or or production production scale. scale.
kason.com kason.com
4. Cut Engineering Costs Complete Complete skid-mounted skid-mounted systems systems are are prepreengineered, engineered, lab lab tested tested using using your your material, material, and and ready ready to to plug plug in in and and run. run.
Sift, Sift, Scalp, Scalp, De-Lump, De-Lump, and and De-Water De-Water with with Quick-Clean Quick-Clean CENTRI-SIFTER CENTRI-SIFTER Centrifugal Centrifugal Sifter Sifter CENTRI-SIFTER CENTRI-SIFTER Centrifugal Centrifugal Sifters Sifters with with hinged hinged end end covers covers and and 2-bearing 2-bearing cantilevered cantilevered shafts shafts allow allow quick quick pull-out pull-out of of internal internal components, components, facilitating facilitating rapid, rapid, thorough thorough cleaning. cleaning. Rotating Rotating helical helical paddles paddles propel propel on-size on-size material material through through the the sidewall sidewall of of aa screen screen cylinder, cylinder, ejecting ejecting overs overs through through the the cylinder cylinder end. end. CENTRI-SIFTER CENTRI-SIFTER units units are are also also eff effective ective at at dewatering dewatering slurries slurries and and de-lumping de-lumping materials. materials.
Scalp Scalp In-Line In-Line with with PNEUMATI-SIFTER PNEUMATI-SIFTER Separator Separator
Contain Contain Dust Dust and and Remove Remove Scraps Scraps with with VIBROSCREEN VIBROSCREEN Bag Bag Dump Dump Screener Screener
VIBROSCREEN VIBROSCREEN PNEUMATI-SIFTER PNEUMATI-SIFTER Circular Circular Vibratory Vibratory Separators Separators scalp scalp free-fl free-flowing owing materials materials in-line in-line with with dilute-phase dilute-phase pneumatic pneumatic conveying conveying systems, systems, removing removing oversize oversize particles particles and and foreign foreign materials materials from from plastic plastic resin, resin, fl flour, our, starch, starch, sugar, sugar, and and numerous numerous food food and and chemical chemical products products at at ultra-high ultra-high rates. rates.
VIBROSCREEN VIBROSCREEN Circular Circular Vibratory Vibratory Back Back Dump Dump Screeners Screeners draw draw dust dust from from dumping dumping activities activities onto onto cartridge cartridge fi filters lters that that derive derive vacuum vacuum from from aa top-mounted top-mounted exhaust exhaust fan. fan. Short Short blasts blasts of of air air from from pulsejet pulsejet nozzles nozzles located located within within the the fi filters lters dislodge dislodge accumulated accumulated dust dust hat hat falls falls onto onto the the ultra-low-profi ultra-low-profile le vibratory vibratory screener. screener. Screeners Screeners off offer er highhighcapacity capacity screening screening of of product product while while eliminating eliminating dust dust contamination contamination risk risk and and reducing reducing labor labor requirements. requirements.
Change Change Screens Screens Quickly Quickly and and Meet Meet Low Low Headroom Headroom Requirements Requirements with with VIBROSCREEN VIBROSCREEN Flo-Thru Flo-Thru Separator Separator VIBROSCREEN VIBROSCREEN Flo-Thru Flo-Thru Low-Profi Low-Profile le Circular Circular Vibratory Vibratory Sifters Sifters have have two two motors motors on on opposing opposing exterior exterior sidewalls, sidewalls, reducing reducing height height requirements requirements signifi significantly. cantly. The The bottom bottom outlet outlet is is positioned positioned directly directly below below the the top top inlet, inlet, allowing allowing material material to to descend descend in in aa straight-through straight-through path path at at extremely extremely high high rates. rates. An An optional optional Air-Lift Air-Lift device device promotes promotes fast fast access access for for screen screen changes changes and and inspection. inspection.
Replacement Replacement Screens Screens Compatible Compatible with with Virtually Virtually any any Round Round Vibratory Vibratory Screener Screener or or Centrifugal Centrifugal Sifter Sifter K-SERIES K-SERIES round round replacement replacement screens screens are are available available in in 18 18 inch inch (457 (457 mm) mm) to to 100 100 inch inch (2540 (2540 mm) mm) diameter diameter options options in in stainless stainless steel steel and and synthetic synthetic meshes, meshes, compatible compatible with with most most makes makes and and models models of of circular circular vibratory vibratory screeners. screeners. Customizable Customizable to to meet meet your your process process needs, needs, including including sanitary sanitary fi finishes, nishes, heavy-duty heavy-duty supported supported screen screen rings, rings, screen screen trays trays with with anti-blinding anti-blinding devices, devices, and and more. more.
Separate Separate Contamination-Sensitive Contamination-Sensitive Solids Solids with with VIBROSCREEN VIBROSCREEN UltraUltraSanitary Sanitary Gap-Free Gap-Free Screener Screener VIBROSCREEN VIBROSCREEN Ultra-Sanitary Ultra-Sanitary GapGapFree Free Circular Circular Vibratory Vibratory Screeners Screeners meet meet cGMP, cGMP, 3-A, 3-A, USDA, USDA, and and FDA FDA standards standards and and are are an an ideal ideal fi fitt for for food, food, pharmaceutical, pharmaceutical, nutraceutical, nutraceutical, and and other other applications applications with with strict strict sanitary sanitary compliance compliance requirements. requirements. Unit Unit design design considerations considerations include include gap-free gap-free screen screen frames, frames, quick-release quick-release “U” “U” clamps, clamps, radius radius corners, corners, aa domed domed lid, lid, an an Air-Lift Air-Lift device device to to raise raise the the frames, frames, continuous continuous ground ground and and polished polished welds, welds, aa gap-free gap-free and and crevice-free crevice-free interior interior fi finished nished to to sanitary sanitary standards, standards, and and aa washable washable underside. underside.
Replacement Replacement screen screen cylinders cylinders for for centrifugal centrifugal sifters sifters are are available available in in stainless stainless steel steel or or synthetic synthetic mesh mesh options. options. Heavy-duty, Heavy-duty, high-performance high-performance wedge wedge wire wire or or perforated perforated plate plate screen screen baskets baskets are are also also available. available. In-stock In-stock options options are are available available for for nextnext- or or same-day same-day shipment, shipment, with with Quick-Ship Quick-Ship options options available available upon upon request. request.
kason.com kason.com
To learn more, call 973-520-5150, email info@kason.com or scan the code.
Don’t take a chance on corrosion-Change! Harvesters Way, EDINBURGH , making the case for a sustainable and environmentally friendly heating system The implementation of an alternative approach to water treatment and the use of continuous monitoring in the prevention of corrosion in closed systems is not always obvious. The approach used by James Culbertson of the Keenan Consultancy at Harvesters Way explains the operation of such systems, the minimal initial cost and sustainable savings associated with this enhanced process. Control of corrosion of any closed-circuit heating or cooling system is critical as it imposes a considerable energy load on the system if fouling and debris accumulates. Premature component failure or pipework penetrations can cause catastrophic financial and reputational damage to manufacturers, contractors, designers, and owners alike. Greater knowledge of the fundamentals of pressurisation and alternative methods to controlling oxygen corrosion can result in substantially lowering of the environmental impact of systems. CIBSE CP1 2020 on Heat Networks has recently recognised the approach of alternative standards such as the German VDI 2035
Harvesters Way Project - Edinburgh good enough to fill systems without any
is adding chemicals to the water
further treatment or conditioning.
to change its properties, in water conditioning the properties of the
The key to controlling corrosion in closed
water are altered by processes such
systems is to control the level of oxygen
as demineralisation or softening. No
entry. The case of Harvesters Way and
chemicals are added.
many others show that correct pressure control, limiting water make up and the
The traditional UK method of protecting
use of steel pipework lead to corrosion
heating systems from corrosion is
levels below 5µm/y.This is well below the
through the use of chemical inhibitors.
level where damage due to corrosion or
Standards such as BS7593:2019 or
corrosion products could occur.
BSRIA BG29:2021 / BG 50:2013 leave very little option for an alternative
Part 1* in this regard.
Continuous corrosion monitoring will
approach. The problem is that many
monitor the system condition and alert
people think that because the system
The introduction of the Northern European
the building operator if events occur that
has been inhibited it is fully protected
will cause an increase in corrosion. Real-
regardless of all other parameters.
time corrosion monitors are low cost
But nothing could be further from the
guidance leads to better sustainable outcomes based on minimizing oxygen entry and water conditioning such as demineralisation as opposed to the use of chemical inhibition. This approach has been used very successfully in Germany,
and will pay for themselves within 2-4 years thus CAPEX neutral and truly OPEX beneficial.
Scandinavia etc. for decades. In many
TRADITIONAL WATER TREATMENT VS WATER CONDITIONING
parts of the UK the mains water quality is
What is the difference? Water treatment
Switzerland, Austria, the Benelux,
12 FDPP - www.fdpp.co.uk
truth. It is the amount of oxygen that enters the system that determines the amount of corrosion that takes place. Even the best inhibitors cannot cope with large amounts of oxygen entering the system.
Therefore, most continental standards are based on minimising the oxygen entry and using water with a conductivity below 100µS/cm (VDI2035 Part1). In some parts of the UK mains water would meet these requirements without any further conditioning. The low conductivity slows down corrosion and microbiological processes. Any corrosion that may occur would not be damaging and can easily be monitored. Figure 1 Continual performance monitoring and use of the evidence pack has arrived in CP1
A non-chemical approach is not only better for our environment but also offers more sustainable results and a lower overall cost The CIBSE Heat Networks Code of Practice in the UK (CP1) should be commended in its adoption of alternative approaches such as VDI 2035Part1.
CASE STUDY
The inclusion of a Risycor electronic
CONCLUSION
corrosion coupon monitor allows
The case identifies the benefits of adopting
systematic performance monitoring and to provide data for the evidence pack at hand over. The Risycor electronic corrosion monitor alarmed twice in 3
The heat network at Harvesters Way
years when maintenance on system was
in Edinburgh used the approach in
being carried out.
CIBSE document CP1. It consists of 183 maisonettes, flats and town houses with
The corrosion data recorded by the
HIUs and no hydraulic break.
monitor shows otherwise vey low levels
By using a central boiler plant of only
of corrosion meaning the system runs
400kW the efficiency of the system in
efficiently and reliably.
comparison to decentralised boilers is around 15% better.
a considered design approach to water conditioning opposed to water treatment combined with performance monitoring where quality & quantity of incoming water, enhanced design of system pressurisation and commissioning offers substantial economic justification in terms of ROI. “Corrosion tends to be the greatest mystery and astonishment of both stakeholders and FM contractors, who historically just rely on inhibitor levels as their standard bearer whether a system is going to be okay. An online corrosion monitor such as Risycor provides transparent real time and proactive assistance to the process to allow better financial, educated and long term planning for any system.” James Culbertson of The Keenan Consultancy This new technology has been widely used in other systems for a few years now, particularly where clients and
Post Practical Completion introduction of Electronic Coupon Corrosion Monitoring initial 6 weeks forming evidence of a stable system in the handover pack
manufacturers have sought greater transparency on system performance at commissioning and beyond. The benefits of the monitoring technology can be applied in all such systems regardless if the water comes straight from the tap, has been conditioned or chemically inhibited with minimal capital expenditure. On-Demand acccess to: The case for sustainable, environmentally friendly heating and cooling systems
On-Demand acccess to: The case for sustainable, environmentally friendly heating and cooling systems
www.hasl.co.uk
FDPP - www.fdpp.co.uk 13
Gastrace from ESS the ultimate tool in food grade gases monitoring Fast, accurate detection of contamination in Food Grade Gases. Food grade gases are subject to highly stringent control measures and the likelihood is that these controls will tighten. GasTrace from ESS offers the perfect solution for monitoring impurities in food grade gases. With low parts per billion detection limits and a response time of just 120mS all results are in real time.
SSV CHECKWEIGHER
M6 METAL DETECTOR XR75 X-RAY
Trusted worldwide for superior product inspection and contaminant detection. Anritsu systems deliver performance, reliability and low total cost of ownership. Plus, we back our longlasting equipment with unparalleled service and support.
Over 175,000 installations worldwide. Discover what you’ve been missing. Learn how to advance your product quality and operational efficiency at anritsu.com/infivis.
GasTrace is capable of monitoring up to 64 individual contaminants in gases such as CO2 and N2, and has the capability for automated operation from up to 64 sample points with time and date stamped individual data files for each. The ability to provide fully quantitative measurements in real time gives you the assurance that the gas you are using in food and drink packing is free from harmful impurities and reinforces the quality control that you need. www.essco.com | 01606 49400 Sales@essco.com
THE JDN MINI FOOD GRADE
The JDN Mini Food Grade is an air hoist specifically designed to meet the requirements of the food and beverage industry. This includes a motor housing of uncoated cast aluminium, along with stainless steel components. The motor is lubricated by a physiologically safe fully synthetic special grease. The chain lubricant is food grade approved. ADVANTAGES AT A GLANCE
• Corrosion resistant • Resistant to high levels of humidity • Easy to clean • Suitable for high pressure cleaners • Ex-proof YOUR BENEFITS
• Decrease of the total costs of ownership (TCO) • Safe processes in the production • Availability 24/7 • Easy and quick maintenance direct at the operation site
CONTACT US JDN UK | info@jdneuhaus.co.uk | +44 (0) 1224 722 751
14 FDPP - www.fdpp.co.uk
ANRITSU_Detect-Perfect_88x267mm.indd 1
07/01/2022 12:08
www.hasl.co.uk
Benefits of New Jar from Berry Stack Up A new stackable jar from Berry Global
The jar provides safe and easy handling
offers a valuable space saving solution
for consumers. After use, it is ideal as a
on retail shelves, through e-commerce
storage container and can be recycled
channels and in the home. At the same
where appropriate recycling facilities
time, the jar provides excellent consumer
exist.
convenience, and its effective product
This latest design underlines Berry’s
protection, reusability and recyclability
expertise in devising solutions in line
enhance its environmental profile.
with customer requirements, as John The innovative design of the 500ml
Richardson, General Manager of the
Staka jar incorporates a 63mm recess in
Berry Corby facility, explained:
the base into which the accompanying 63mm cap, also from Berry as part of a complete container and closure solution, fits snugly. This allows the jars to be easily stacked and remain very stable.
For food manufacturers and processors, the wide mouth of the jar ensures easy filling.
“Many of our customers have approached us recently, keen to develop stackable jars for all sorts of products from spices and sauces for our food clients to lubricants in the commercial
The cap itself can be specified in a
For food manufacturers and processors,
variety of colours, while the eye-catching
the wide mouth of the jar ensures easy
‘square round’ design of the Staka jar is
filling. Its multilayer construction also
ideal for labelling or sleeving, creating
allows hot filling and delivers effective
For more information on Berry’s wide
excellent brand identity and individuality
product protection for an extended shelf
range of packaging solutions, visit
on shelf.
life that helps to minimise food waste.
www.berryglobal.com.
16 FDPP - www.fdpp.co.uk
sector, so we feel confident that there is a need for this design.”
REUSED OCEAN PLASTIC Using waste plastic collected by local people from beaches and riverbanks that is then cleaned, broken down and reused to make new transparent packaging
For more information and samples contact us:
www.bellpackaging.com
+44 (0) 1582 459292
Reaching new heights WEG and distributor Technidrive supply equipment for elevator application in extreme conditions An automated warehouse is a breathtaking sight, as reams of pallets are automatically scanned and retrieved for delivery. But not all automation systems are made to endure extreme environments. Here’s how Technidrive Ltd and WEG partnered to help Moffett, an automated storage firm, design a vertical lift for extreme temperatures. Industrial elevators are usually propelled by electric motors, with the aid of a counterweight system. However, when these industrial systems are in environments of varying temperatures, the equipment must also withstand extreme temperatures as well as heavy loads. This was the case for Moffett, an automated storage firm in Ireland, taking on its first international project in Dubai. The project involved building a system for a three-storey 30-metre-high building with a throughput of 85 pallets per hour. Moffett required an automated storage system to lift and lower pallets, which could operate in temperatures of minus 25 degrees Celsius to 40 degrees Celsius. In addition, Moffett wanted to manoeuvre pallets, which weigh over 1500kg, at a rate of one metre per second, between a height of six metres to 30 metres. To put this into perspective, the average building is around ten metres tall. Moffett got in touch with Technidrive, who turned to WEG for the supply a 11kw electric motor, and a variable speed drive (VSD), along with the relevant programming software. The VSD, also known as an inverter, plays a significant role in this application.
18 FDPP - www.fdpp.co.uk
Being inverter driven, the storage system accelerates and deaccelerates at a faster rate. Similarly, as carts move through the lift to its programmed level, adjustment is required as the weight of the cart increases and decreases. The lifts therefore needed the conventional auto-correction system found in humancarrying elevators, to account for changes in weight.
Our relationship with Technidrive is very good, and we are working with them on other projects with the hope for another two or three towards the end of the year.
Technidrive. “However, this application is global, so can be anywhere in the world. We already have two more projects lined up in Amsterdam and London. “Technidrive did all the calculations and design from scratch, to make sure the motor was suitable for the application, with enough torque, speed and power. Our relationship with Technidrive is very good, and we are working with them on other
Technidrive and WEG worked together to develop an autocorrection movement within the inverter which automatically corrects the cart’s stability and keeps it passing along smoothly at the correct level. In addition, Technidrive also had to be aware of regenerative energy, which is energy that returns back into the inverter. This occurs whenever a motor
For instance, as the inverter controls the speed of the lowering elevator, energy is being generated back into the motor. That energy then comes back into the inverter as DC bus voltage, which needs to be dissipated in a break resistor or burned off as heat. The original break resistor was not large enough, which would have caused overheating problems. However, Technidrive upsized its break resistors and
decelerates, or a load descends. Raising
added thermal protection to ensure no
2000kg requires a lot of energy and, in
overheating would occur.
turn, lowering 2000kg creates a lot of energy.
“Currently, the system is being used by Moffett in Dubai and Dublin,” explained David Strain, technical director at
projects with the hope for another two or three towards the end of the year.” Not all automation systems are made to endure extreme environments. However, global motor and drive manufacturer WEG, along with Technidrive, ensured Moffett could design a vertical lift for extreme temperatures — adding another breath-taking automated warehouse to the list. Further information on WEG motors, gearboxes and drives can be found on the WEG website. www.weg.net
FDPP - www.fdpp.co.uk 19
Marion Process Solutions: Over 80 Years of Insight & Innovation Since Since 1938, 1938, Marion Marion has has been been the the industry industry standard standard for for innovative innovative mixing mixing and and blending blending equipment. equipment. We We craft craft no matter matter the the size, size, solutions solutions specifi specificc to to your your application application –– no industry. industry. We We are are the the go-to go-to process process experts experts material, material, or or industry industry and and thought thought leaders, leaders, the the industry industry standard standard of of excellence excellence in in quality quality design, design, craftsmanship, craftsmanship, and and performance performance against against which which all all other other suppliers suppliers are are measured. measured.
MIXING MIXING The The name name Marion Marion Is Is synonymous synonymous with with eff effective ective mixing mixing technology. technology. We We build build solutions solutions specifi specificc to to your your application, application, no no matter matter the the size, size, material, material, or or industry. industry.
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DRYING DRYING WaveMix WaveMix™™ is is aa Marion Marion innovation innovation that that combines combines vacuum, vacuum, mixing, mixing, and and microwave microwave drying drying technologies. technologies. The The result: result: aa cutting-edge cutting-edge thermal thermal processing processing solution solution that that provides provides precise precise control, control, increased increased accuracy, accuracy, and and effi efficiency. ciency.
SIZE SIZE REDUCTION REDUCTION Size Size reduction reduction equipment equipment plays plays aa vital vital role role in in processing processing across across aa range range of of industries. industries. Utilize Utilize our our Lump Lump Breaker Breaker to to mechanically mechanically break break down down agglomerates agglomerates into into consistent, consistent, even even particle particle sizes sizes for for your your process process solution. solution.
PROCESS PROCESS SOLUTIONS SOLUTIONS Advanced Advanced Material Material Processing Processing (AMP) (AMP) is is the the synergy synergy of of industry industry leaders leaders Marion Marion Process Process Solutions Solutions and and Kason Kason Corporation, Corporation, combining combining decades decades of of knowledge, knowledge, engineering, engineering, and and consultative consultative resources resources to to help help you you revolutionize revolutionize your your total total process. process.
800.397.6371 • MarionSolutions.com
HEARTLAND HEARTLAND SERIES SERIES
Ox Horizontal Batch Mixer
WaveMix™™
•• Quick-Ship Quick-Ship Guaranteed: Guaranteed: 4-Week 4-Week Shipment Shipment Lead Lead Time Time
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•• Ideal Ideal for for SmallSmall- to to Medium-Size Medium-Size Batches Batches & & Startup Startup Operations Operations
Fully Fully customized customized options options designed designed for for your your mixing mixing solutions solutions also also available. available.
MOMENTUM MOMENTUM SERIES SERIES
MOMENTUM MOMENTUM SERIES SERIES
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AMP AMP PROCESS PROCESS SOLUTIONS SOLUTIONS GROUP GROUP
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800.397.6371 • MarionSolutions.com
Scan Scan the the code code to to get get our our Industrial Industrial Mixer Mixer Handbook Handbook
Keys & Assets Managed And Secured Keytracker offer the widest range of key & asset management systems, our solutions are proven to save time, increase accountability & reduce costs within any organisation. Keep your daily operation running smoothly by securing and monitoring your valuable keys and equipment whilst keeping them easily accessible.
Single Unit Key & Tool Tracker Electronic Key Cabinets
Mechanical Key System & Cabinet
01215599000
Sales@Keytracker.co.uk
Electronic Smart Lockers
Key & Asset Control Software
Ensuring keys and tools are kept secure & readily available can be a tricky balance to maintain, however this is achievable with Keytrackers key & asset management systems. Shadow Boards can be upgraded by adding our Single Unit’s (T1) to them subsequently increasing the organisation and security of your valuable machine tools. Contractor and employee safety when maintaining factory machinery is vital to all food processing companies, with our Lock Out, Tag Out (LOTO) system we can ensure that you will know who is managing which machine at a glance. For the food processing industry, we offer Metal Detectable Access & Retention Pegs which means that any pegs that get lost when processing the food they are easy to detect and withdraw. Whilst keeping keys & assets secure our products also increase accountability by making sure that you can see who has which key or asset at any time simply by just glancing at the system.
01215599000
Sales@Keytracker.co.uk
Improved IP rating for WEG inverter range Motor and drive manufacturer, WEG will exhibit its latest range of industrial inverters at Aqua Nederland, held on March 15, 16 & 17, 2022 in Gorinchem. Demonstrating inverters from the CFW range, WEG is showcasing the latest version of the CFW500 variable speed drive at the show, which is now available with an ingress protection (IP) rating of IP66. Aqua Nederland is the leading event for the water industry in Holland, welcoming over 370 exhibitors to demonstrate the latest technology in water treatment and management. As an intimate trade fair, the show provides a unique opportunity for those working in the industry to discover new product launches and network with other water industry professionals. At the show, WEG will show the latest version of its well-established CFW500 frequency inverter. The CFW500 is a high-performance variable speed drive (VSD) with power ranging from 0.25 to
dedicated to engineering products that
an appropriate IP rating and peripheral
75, developed to control the speed and
can adapt to the exact specifications of
technology to support the drive once it
torque of three-phase induction motors.
an application. This includes bespoke
is in use.
The device is now available with a higher
changes to the electrical and mechanical
IP rating than ever before, boasting
design of products.
“As a specialist trade fair, Aqua
WEG has also developed bespoke
environment for WEG’s engineers to
technology for drives used in pumping
meet with potential end users and
to direct high-pressure jets of water
applications. WEG’s Pump Genius Has
discuss their current challenges for
features that include broken pipe and
motor and drive deployment in the water
Other variable speed drives from the
leakage detection and programmable
WEG range have also been improved.
industry. The team will be available
schedules with energy savings.
during the three day show at stand
IP66 rating as opposed to the previous IP20, meaning that it is suitable for applications where it may be subjected
The CFW700, CFW701 and CFW11 are now available with IP55 protection rating — making these devices ideal choices
“WEG doesn’t simply sell motors and drives,” explained Marek Lukaszczyk,
for applications in the water industry.
marketing manager at WEG. “Engineers
WEG has long provided solutions for the
ensure the drives we supply are ideally
water industry, including its control gear
suited for each application. For the water
and soft starters. Due to the demanding
industry, this process ensures that drives
environments of water treatment,
are engineered to operate in the most
management and pumping, WEG is
effective and optimal manner — with
24 FDPP - www.fdpp.co.uk
at WEG work directly with customers to
Nederland provides the perfect
J106.” More information on WEG’s devices for the water sector can be found on the company website. To arrange a meeting with a representative from WEG at Aqua Nederland 2022, please contact the team directly at: mbrinks@weg.net. www.weg.net
SOCIAL PLASTIC
COLLECTED PLASTIC
Waste plastic bottles, bags & containers are collected from beaches and riverbanks by local people who are paid for their services – these are taken to local centres for sorting and the recycling process begins.
Coastal regions are an increasingly important source of waste plastic. Every year millions of bottles are collected and reprocessed to make plastic containers, bottles and products that can be used and recycled over & over again.
BELL INTRODUCE REUSED OCEAN PLASTIC
in 2021 introduced Biojet®. In simple terms, this is Retran® with an additive that stimulates and accelerates the biodegrading process.
One of the most exciting developments in the plastic packaging industry is our ability to access and reprocess the post-consumer waste found on our beaches, riverbanks and along the perimeters of our oceans.
Whilst both of these products have been hugely successful, we recognised that even more needed to be done. Bell have worked throughout the pandemic, to identify reliable sources of plastic derived from the ocean. In simple terms this is “Reused Ocean Plastic”.
Unfortunately, plastic is now seen as a bad product – yet out of sight, beneath the surface of our oceans, there are millions of tons of other waste packaging made from glass, paperboard and metal that do not float and therefore cannot be seen.
The polymer used to produce the new packaging is being sourced from companies who organise local communities to collect plastic waste from beaches, riverbanks and ocean perimeters. Generally, these are communities who do not have the infrastructure for waste management but by paying local people to collect the plastic and deliver it to recycling facilities, the problem is reduced.
Plastic has become a key focus on social media and in television documentaries, with politicians and supermarkets looking for ways to enhance their green credentials and promote a greener world. There can be no excuse for rubbish being discarded into the environment and Bell are one of the first companies in Europe to endorse and support the collection and recycling of these materials. In 2019 Bell launched Retran® - a polyester-based material containing a minimum 70% recycled content. The credentials of this material are very high – pharmaceutical and food grade, with excellent clarity and full certification. The product has been hugely successful and nearly 80% of our customers around the world have switched to this exciting new product. The 70% recycled content meets the new plastic packaging tax being introduced in April 2022, however Bell recognised the need to keep moving forward and
www.bellpackaging.com
As we have all seen, there are large quantities of plastic waste floating in the sea. If we can help to collect and reuse some of this waste, and turn it back into useful products, then we are taking a significant step forward towards a better global environment. The new material has been extensively tested and meets the minimum strength requirements of our processes. It has excellent optical qualities and our testing to date reports that there has been no difference in the performance of the new material, compared to Retran®, Jetran® or Biojet® packaging. Bell Packaging have started converting Reused Ocean Plastic for our forming and insert divisions, with tubing & boxes to follow in 2022. Samples and more information are available from our offices in Luton.
+44 (0) 1582 459292
Experts in thermal control and measurement LAUDA continues to provide an expanding range of feature-rich, future proof solutions with energy efficiency and connectivity front of mind, serving a diverse range of industries including food & beverage , brewing , chemical, pharmaceutical, biotechnology, oil and gas, composites, automotive, aerospace, digital printing, laser and beyond. From food and drink research laboratories to pilot plant and full-scale production, with typical applications from rotary evaporators, incubators, stills and freezers to autoclaves, fermentation chambers and brewing vessels, LAUDA
LAUDA’s new range of water chillers has been designed not only to comply with the new Eco-design directive, but to surpass it
can supply the right temperature control or measurement solution matched to the precise equipment need. LAUDA’s new range of water chillers has been designed not only to comply with the new Eco-design directive, but to surpass it through the innovative use of variable speed modules that automatically reduce their duty cycle in line with the cooling demand hence reducing energy consumption and running costs, giving a tangible return on investment for the user, whilst ensuring full compliance with the latest regulations on refrigerant (fluorinated) gases. Further portfolio expansion delivers the new LAUDA ‘Versafreeze’ ultra-freezers, (deep-freeze storage down to -85°C), and higher power ‘Integral’ process
circulators, (process control from -90 to 320°C with >25kW of cooling @20°C), with pressure overlay options to increase the working range of water / glycol up to 140°C. Furthermore, for applications requiring customised solutions tailored to individual requirements, we offer a made-to-measure design service using a long-established and highly skilled team. Project engineering is a core competence of LAUDA and using the modular engineering approach we can design and scale a system specifically matched to
others. Beyond temperature control, LAUDA has a well-established suite of solutions for measuring viscosity and surface/ interfacial tension aimed at the development of surfactants, oils, and polymers. LAUDA is here to assist with your technical requirements from the first stage of the application discussion, all the way through the process to the final commissioning, and after-care services throughout the lifetime of the equipment. A strong and experienced after-sales service function provides further peace of mind, with impressive first-time fix rates, and backed up by a fully kitted workshop at our newly configured facilities near Stamford.
the application needs.
We look forward to hearing from you.
With the capability to provide accurate
Tel: +44 (0)1780 243118
heating and cooling in the range -150 to +550 °C using a variety of proven modules including heat transfer systems, process cooling systems, secondary circuit systems, fired heaters and molten salt plants, we are able to provide unique,
26 FDPP - www.fdpp.co.uk
cost-effective solutions unparalleled by
Email: info@lauda-technology.co.uk Website: www.lauda-technology.co.uk
o
The Go-To People for Spray Systems & Solutions for the Food Industry Spray technology forms a vital part of many food manufacturing processes. Whether you need a precision solution to minimise wastage of expensive coatings, a CIP system to deal with tough residues while maintaining the strictest hygiene standards or to deliver sanitising sprays to your conveyors, SNP’s technical sales engineers can advise on and deliver the best spray set up for you.
+44 (0) 1273 400092
|
info@spray-nozzle.co.uk
Hassle Reduction Our mission is to take the hassle out of sourcing spray solutions so you can focus on your operations.
Savings
At SNP, our expert sales engineers partner with you to deliver intelligent solutions which optimise your application.
Peace of Mind Our advice is backed up with robust, proven world-class products and systems from leading specialist manufacturers.
www.spray-nozzle.co.uk
HMI Solution for Food Processing In the food processing industry, the daily cleaning of automation equipment and process equipment is extremely important to ensure food safety. Therefore, the human machine interface (HMI) for food production facilities must
The high-reliability touch panel PCs offer a choice of either one 2.5” SSD HDD or one 2.5” SATA HDD for storage.
be able to withstand high-pressure and high-temperature washing and be cleaned with acidic cleaners to facilitate daily scrubbing and water washing. A suitable HMI solution for food production facilities should have: • The IP69K rating ensures the highest degree of protection in food processing environments where sanitation and cleanliness are required. • The use of stainless steel materials has high anti-corrosion efficiency.
has many factors to consider, such as whether it can withstand intensive spraying and repeated high-pressure cleaning.
OUR SOLUTIONS The GOT815W-511 and
prevents the buildup of any dirt on the bezels. • Waterproof connectors allow
GOT812W-511 are powered by the Intel® Core™ i5-7300U processor. The high-reliability touch panel PCs offer a choice of either one 2.5” SSD HDD
complete protection during the
or one 2.5” SATA HDD for storage. For
cleaning process.
flexible communication, both panel PCs
Human Machine Interface (HMI) allows direct data flow collection and communication between machines and facilities, as well as real-time monitoring and control of operating
have one full-size and one half-size PCI Express Mini Card slots for WiFi/3G kit. Moreover, they support the VESA mount and are compatible with Windows® 10 and Windows® 10 IoT.
processes, to create fast and
Axiomtek UK Ltd.
collaborative manufacturing processes.
T: 01612093680
• The surface should be easy to clean,
In addition to computing performance,
E: info@axiomtek.co.uk
featuring a seamless flat design that
HMI systems used in the food industry
W: http://www.axiomtek.co.uk/
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Making Your Factory Smarter
IP66/IP69K-rated Stainless Steel Fanless Touch Panel Computer for Food Processing Industry
GOT810-845
10.4" XGA TFT IP66 & IP69K-rated Stainless Steel Fanless PCT (or Resistive Touch) Panel Computer with Intel® Celeron® N3060 and Flat Bezel Design (-10°C to +50°C)
Waterproof Waterproof
Fanless Fanless and and Noisefree Noisefree
Stainless Stainless Steel Steel
Axiomtek Axiomtek UK UK Limited Limited Tel: Tel: +44(0)1612093680 +44(0)1612093680 E-mail: E-mail: info@axiomtek.co.uk info@axiomtek.co.uk
Optimising Control Panel Enclosure Flexibility Processing facility managers
the mounting allows the control
are under pressure to
panel anywhere in the design,
manage their space to
creating an integrated system
minimise capital and
solution.
operational expenses. The
When the enclosure houses
need to fit more equipment
valuable mission-critical
into an existing space
equipment or information,
prompts machine designers
space optimisation may take
to reduce the size and
a back seat to control panel
footprint of the machines, which challenges the control engineers to design and build control panels within a constrained footprint. Designing smaller control panels, control engineers need to consider several variables: cable segregation, thermal management, cable entry, electromagnetic interference (EMI), and cable bend radius, not to mention allowing extra space for future additions. A control engineer’s job is further complicated by safety considerations such as arc flash hazards, standards compliance, and minimum separation requirements for electronic components.
START WITH ENCLOSURE FLEXIBILITY
wire management. Enclosures need a full side mount panel with additional wire duct, relays, and grounding provisions that would have been mounted on the rear sub-panel. This design reduces the wall or machine space by 20% compared to a more common sub panel mounted design. There are several products available to help control engineers utilise this 3D space, as well as often underutilised corner space in control panels that use traditional side equipment mounting plates. DIN rail wiring ducts with two separate wiring channels enable the user to mount a DIN rail with components that would typically be installed directly to the sub-
security. An investment in the right security will be less than the cost of a potential loss, but the protection needed can vary. The expense of lost or stolen data or the cost of injury from unintentional access can be mitigated with a layered approach to controlled access. Access control and power distribution capabilities typically associated with building security can now be integrated directly into network enclosures. Electronic swing handles and built-in low frequency card readers limit access to critical IT equipment to authorised personnel. Intelligent power distribution units enable remote monitoring capabilities and improve efficiency by continuously analysing for electrical
Selecting the proper control enclosure
panel, potentially saving 30% of the space
is an essential factor when space
on a sub-panel. Corner wiring ducts can
optimisation is the objective. Enclosures
provide good wiring transition from rear
are designed to support a variety of
sub-panels to side sub-panels while
accessories that facilitate component
reducing the amount of sub-panel space
mounting based on the targeted
needed by 12%.
Control engineers must overcome
Today’s EMI noise shielding allows wiring
panels in industrial environments.
Choose an enclosure platform that allows
that would normally require six inches of
Whether the application is in oil and
full utilisation of the space between
separation to be much closer together.
gas, food, automotive, water treatment,
the enclosure door and components
Panduct PanelMax Shielded Wiring Duct
or pharmaceutical, competing design
mounted to the sub-panel in the rear of
and Noise Shield separate noisy motors
criteria influence decisions about
the enclosure. To accomplish this, the
and drive cables from sensitive Ethernet
optimising the control panel. Space
enclosure must be designed to support
or control cables and reduce the space
optimisation can provide more design
structural members along the sides, top
required.
flexibility both for the control panel itself
application.
and/or bottom, as well as on the door.
Also consider minimising the external
A designer requires full use of the interior
footprint. One consideration is the control
for component mounting and cable and
panel mounting position. Flexibility with
30 FDPP - www.fdpp.co.uk
overloads and other conditions that place critical IT/OT equipment at risk.
CONCLUSION complexity when designing control
and the plant floor and help facilitate integrated access control solutions. www.panduit.com
Is Your Infrastructure Friend or Foe? As technology advances and Industry 4.0 becomes a reality, the demands placed on your network and electrical infrastructure will only increase. To stay competitive, you need plant floor solutions that improve production efficiencies, turn operations data into actionable insights, and scale for future growth. From cable management for control panels to fully integrated industrial networks, Panduit solutions turn connectivity into a competitive advantage. To read our white paper on Edge IoT deployments, visit www.panduit.com/edgeiotdeployments. ®
INDUSTRIAL NETWORK ZONING | CONNECTIVITY | DISTRIBUTION FRAMES | CABLE MANAGEMENT | WIRING DUCT
Control_Smart-Industy_ebookAd_FP_7.875x10.5.indd 1
infrastructure for a connected world
4/1/20 9:46 AM
Protecting premium Food & Beverage brand integrity Counterfeiting in the luxury food and
packaged to deceive consumers, the
drinks industry has long been a multi-
Food Standard Agency’s National
million pound industry. The pandemic
Food Crime Unit estimates that
added to these pressures, with high
the combination of adulteration,
demand for premium products coupled
substitution, theft, misrepresentation,
with interrupted supply chains and fewer
illegal processing, waste diversion and
physical audits amplifying the risks of
document fraud costs £11.97bn per
opportunists and illicit bootleggers taking
annumii.
advantage of the disruptions. Seizures of counterfeit products Packaging specialist at Sumitomo (SHI)
provide a good indication of the scale
Demag UK Ashlee Gough examines how
of the problem. In 2020, Operation OPSON IX seized 12 000 tonnes
specialist closure and thin wall moulders
of illegal and potentially harmful
are applying the latest injection moulding
products, including 1.2m litres of
precision and In Mould Labelling (IML) techniques to step up their fight against the creative food and drink fakers to mitigate risks and safeguard brand
Ashlee Gough, Packaging Specialist, Sumitomo (SHI) Demag UK
alcohol. In a converted effort to crackdown on
integrity.
risks - 97 percent stated that they’d
groups profiting from illicit versions of
been affected by food fraud in the last
branded spirits and premium foods,
In a recent survey of senior food and
12 months - few in the industry regard
manufacturers are making labels
authenticating products as their highest
more difficult to copy and bottles
priority.
harder to refill. “One way to counteract
GFSI standard. One in five declared that
Against this backdrop, the UK food and
is through the innovative design
no checks were made as part of sourcing
drink market remains one of the worst
decisionsi. Yet, despite these prevalent
affected by counterfeiting. Deliberately
drink execs by assurance specialists The Lloyd’s Register, only a third admitted to vetting suppliers against a recognised
counterfeiting and product tampering of packaging that cannot be easily copied,” highlights Ashlee. “Until recently, this may have involved putting shrink or foil sleeve around a luxury drink brand, for example. Closure moulders especially are stepping up their efforts and investing in dedicated cells to produce high quality and anti-refill closures made up of a number of complex parts.” Due to the intricacy of these closures, moulding precision is paramount. Significant investment in high quality tooling, automation, machinery and expertise can be another major deterrent, highlights Ashlee.
Tamper evident closures is one method deployed by packaging manufacturers to counteract fraud in the premium drinks, wellbeing and pharmaceutical markets (iStock.com/bert_phantana)
“Realistically, few counterfeit operators would make the level of investment required to replicate this level of technical precision.”
32 FDPP - www.fdpp.co.uk
In a recent survey of senior food and drink execs by assurance specialists The Lloyd’s Register, only a third admitted to vetting suppliers against a recognised GFSI standard. Other overt packaging methods to deter counterfeits include concealing unique identifiers, such as a QR code, holograms or tags within the IML. While these can assist with track and tracing, Ashlee claims that they only really help to validate the origin of a container and tend to be more widely deployed by luxury food, cosmetics, pharmaceutical and wellbeing brands. “To outsmart quick-witted counterfeiters, manufacturers may need to deploy several tactics simultaneously to prevent brand value being diluted, including tamper evident bands, secure closures, snap buttons, barcoded labels and batch codes, and even chemical markers.” For packaging moulders producing thin walled containers, caps and closures by the millions, cost effectiveness remains vital. Sumitomo (SHI) Demag’s El-Exis SP range typically achieves between three and five percent more productivity when benchmarked against other packaging machines on the market. Now in its fourth generation and always aligned to evolving market trends, the EL-Exis SP series is designed to withstand the higher stresses and injection pressures that are so critical in achieving repeatability in closures and thin walled packaging products, while maintaining comparable mechanical properties. Centralised monitoring of real time machine performance and energy consumption is equally critical to reducing machine downtime. IML labels with unique identifiers, such as a QR code, holograms or tags, are other methods that can deter counterfeiting
http://uk.sumitomo-shi-demag.eu/
FDPP - www.fdpp.co.uk 33
Seeley International industrial cooler wins two coveted awards Seeley International – world leading
resulting in significant savings of energy
and productivity, as well as on their health.
Evaporative Cooler Manufacturer are
over traditional cooling systems and
Climate Wizard CW3 uses 100% fresh
celebrating winning, not one but two
refrigerant-free running”.
outside air, significantly improving Indoor
highly prestigious awards in the UK. Both accolades have been given for our latest addition & innovation to the Climate Wizard
Meanwhile the winners of the H&V News Awards 2021 were revealed on the 11th
Air Quality in the building, which these days is not a minor factor.
November. On this occasion, Seeley
Crucially, premises such as warehouses
International won in the category of
or big storage rooms, especially when
Commercial HVAC Product of the Year –
dealing with food or drinks, have specific
Cooling Technology, sponsored by Smith
temperature requirements. In all these
storage facilities.
Brothers Stores. The Judges said “Seeley
scenarios CW3 could be the right solution
have perfected a very efficient design
because it doesn’t use any sort of chemical
The winners of The Energy Awards 2021
through years of research and dedication
refrigerants to cool the air.
were revealed on the 22nd September at
which suits the sustainable needs of today
Grosvenor House Hotel, London.
and of future installations”.
Seeley won in the category Innovation
In fact, Climate Wizard CW3 industrial
solutions for commercial and industrial
of the year: Buildings technology (HVAC,
cooler can reduce carbon emissions by
spaces, please contact uksales@
range of Indirect evaporative coolers, the CW3 which is a compact adiabatic air conditioner, ideal for industrial plants involving food production, packaging or
systems and lighting) and were praised by the expert judging panel, who are drawn
If you’d like to learn more about environmentally friendly cooling
87%. Because of the reduced running costs (-88%) it is particularly suitable in
seeleyinternational.com or call 0115 963 5630.
from across the energy sector.
industrial plants where air conditioning is not an option. Most industries with high
Seeley International Website
The Energy Awards Judging Panel 2021
heat loads, such as bakeries, packaging
Climate Wizard In-direct Evaporative
said “The new approach demonstrated
facilities or premises where ovens are
Cooling
in the development and engineering
involved, have no cooling system installed,
Breezair Direct Evaporative Cooling
of their system impressed the judges,
and this impacts on the workers’ morale
CW3 Video - the Future of Cooling
34 FDPP - www.fdpp.co.uk
Cost-effective cooling for production plants and storage areas
Evaporative cooling is the perfect solution when cooling large buldings with high heat loads, to improve thermal comfort and Indoor Air Quality (IAQ) Green technology
100% fresh, filtered air
Easy installation
Low running costs Contact us for a free survey, we will suggest the solution that best suits your needs. www.seeleyinternational.com uksales@seeleyinternational.com Tel. 0115 963 5630 World leading evaporative cooling solutions
Improving production processes and cutting costs INSPIRON SYSTEMS LTD are leading
cheese, ranging from 100g up to 1.7Kg,
technology and strengthens our
suppliers of Weighing, Labelling and
reaching speeds of more than 90
partnership with Granby.
Inspection systems and we have over 25
packages per minute.
years’ experience. Inspiron is a privately run, family business who take pride in everything related to weighing, labelling and inspection, focusing on quality, value for money, customer support and building lasting partnerships with our clients.
“Everyone at Granby, management &
“The Espera Nova has been a massive
operators are extremely impressed
upgrade to the weighing and labelling
with the ESPERA Nova systems which
operation of our award-winning Manx
have advanced our labelling capability
Cheese.” Andy Thornton, Manufacturing
to a much higher level than we ever
Manager Isle of Man Creamery Ltd.
had before.” Eoin Kavanagh, Managing
Granby, renowned producer of Sausages
Director Granby Ltd.
The Isle of Man Creamery are celebrated
in Dublin, upgraded their Weigh Price
Other features installed on the
cheese makers who use locally sourced
Labellers to the ESPERA NOVA ES-
ESPERA NOVA ES-R include online
milk to make their award-winning
R, equipped with Top, Bottom and a
barcode verification, Automatic Reject
cheeses, which are then exported
Total Label Printer. An Espera user for
device (to sort non-conforming packs)
worldwide. They replaced their existing
years, Granby invested in the latest
and EspromNG, a central software
Delford machine with an Espera Nova
technology to enable higher accuracy of
solution for database management
due to its high performance, excellent
label positioning, improved throughput
and reporting, which captures average
print quality, superior level of accuracy,
speeds and increasing OEE, using the latest 4.0 technology.
weight reports and production statistics.
ease of use and on-board Predictive Maintenance software which helps reduce unnecessary downtime.
Granby followed-up their initial
The ESPERA NOVA ES-R Automatic
machines with 7 x ES-M Manual Weigh
Weigh Price Labeller with Checkweigher
Price Labellers. This investment by
functionality is now installed at the
Granby in the new generation of Espera
creamery and being used to weigh and
machines shows a great commitment
label top and bottom flow wrapped
to the new Industry 4.0 Smart factory
36 FDPP - www.fdpp.co.uk
purchase of 2 x ESPERA NOVA ES-R
If you are looking to update your production lines with technical advanced weighing, labelling or inspection machinery, or simply need an advanced software solution, please get in touch and find out how we can help. www.inspiron-gb.com
INS-MD II
INS-CW
ES-R NOVA
Silverson Machines launch three Laboratory scale mixers including a Laboratory scale version of the Silverson Flashmix Powder/Liquid mixer With advances in design
requirements, Silverson has
and manufacturing
FMX5
technology, Silverson Machines have added three Laboratory
developed the new Verso UHS. The Verso UHS is an UltraHygienic version of the standard
mixers to their product range for
machine and is manufactured
high viscosity, hygienic and powder/
with Silverson-designed hygienic
liquid mixing applications.
single mechanical shaft seals, which can be converted to
The most exciting of the developments
hygienic double mechanical
in the range is the FMX5, a laboratory
shaft seals. It has a crevice-
scale version of Silverson’s production
free construction and is
scale Flashmix powder/liquid mixers.
designed for Cleaning-In-
The FMX5 provides a simple, effective
Place (CIP) and Sterilise-In-
and hygienic means of powder/liquid
Place (SIP) operation.
mixing on a Laboratory scale and is able to process higher viscosity mixes.
All three mixers can be supplied with a Vessel Package,
The FMX5 is suitable for small scale
comprising of a vessel, stand, valve
manufacturing and R&D work and
and pipework, and conversion kits are
offers an accurate means of predicting
available allowing the standard Verso
the performance of the production
to be upgraded to a Verso-HV and
scale Flashmix, making the scale-up
an FMX5, allowing further flexibility
process a simple task. Offering proven performance on a wide range of powders including Gelatine, Guar Gum, Pectin, and Xanthan gum, as well as Sugars, flours, milk powder etc. the introduction of this new Powder/ Liquid mixer to the Silverson product ranges opens up the possibility of many more applications than were previously
within this new series of mixers.
The FMX5 provides a simple, effective and hygienic means of powder/liquid mixing on a Laboratory scale and is able to process higher viscosity mixes.
To find out more contact sales@silverson.co.uk
possible at laboratory scale. For higher viscosity mixing at a laboratory scale Silverson has developed the Verso-HV, a pilot scale In-Line mixer which matches the capabilities of the production scale
products in the food industry including gums and thickening agents and Mayonnaise. Ideal for R&D and small scale production, the Verso-HV facilitates
Silverson HV In-Line mixers. The
easy scale up to Silverson’s
Verso-HV incorporates a unique and
production scale UHS-HV
innovative “pumping rotor” design that
Series In-Line mixers as it
substantially increases its self-pumping
is built to the same fine
capacity.
tolerances.
High flow rates are maintained as
For applications
viscosity rises, often eliminating the
with more
need for an additional feed pump
stringent and
when processing many higher viscosity
demanding hygiene
38 FDPP - www.fdpp.co.uk
Verso-HV
Powder/Liquid Mixers From Laboratory to Production Scale
Introducing the Silverson FMX5 Laboratory Scale Powder/Liquid mixer. Silverson can now offer Powder/Liquid mixing solutions to customers mixing from the Laboratory to full scale production. The FMX5 provides a simple, effective and hygienic means of powder/liquid mixing on a laboratory scale and provides an accurate and easy means of predicting the performance of the Flashmix in the laboratory.
For more information please visit: www.silverson.co.uk Email: sales@silverson.co.uk • Telephone: (+44) 1494 786331
NSK Life-Lube® bearings drive cost-saving improvements in food plants NSK’s Life-Lube® bearing units are proving increasingly popular in the food and beverage industry, and with good reason. These advanced bearings combine the corrosion-resistant properties of Silver-Lube® housings with the excellent sealing and lubricating properties of Molded-Oil inserts. LifeLube® units are specifically for use in sectors where contact with water and process fluids is unavoidable, and where excellent chemical resistance and long lubrication life are primary requirements. By taking advantage of the benefits available, food and beverage plants can tap into considerable savings from reduced downtime and maintenance costs. Astute design engineering means Life-Lube® bearing units (comprising a housing and bearing insert) are adept at withstanding the often harsh operating conditions of food and beverage plants, while simultaneously preventing any contamination of the processing environment to meet strict hygiene regulations.
CORROSION RESISTANCE Primary among the design considerations is the unit’s housing material: thermoplastic polyester (PBT), which is highly resistant to corrosion. In conjunction with Molded-Oil bearing inserts and nitrile rubber seals, this design guarantees good chemical resistance and long service life. In particular, the polymer housing not only eliminates any risk of contamination from painted or coated surfaces, but its smooth finish prevents dirt adhesion and reduces wash-down time.
40 FDPP - www.fdpp.co.uk
NSK’s Life-Lube® bearing units are ideal for many food plant applications, including cutting lines. Photo: alterfalter/Shutterstock
NSK has taken great care to ensure the design of its Life-Lube® bearing units are free of crevices and ‘bug traps’ that could harbour mould or bacteria. Complementing the housing is the stainless steel insert, which delivers improved corrosion resistance for wet environments. Moreover, the MoldedOil insert cavity contains a lifetime of lubricating oil and polyolefin resin that means no re-lubrication is required for
SUBSTANTIAL SAVINGS
annual cost savings in maintenance
A major snack food producer is among
labour, replacement bearings and lost
those now taking advantage of LifeLube® bearing units. Previously, the company was experiencing frequent bearing failures on its cutter line, so it requested the assistance of NSK to help reveal the root cause. NSK analysed the failed bearings and reviewed the application as part of its AIP Added Value Programme. By following a process map survey of the site, it was evident that extensive grease washout had been taking place
the lifetime of the product.
following production line washdowns.
Another important feature for the food
costly unplanned downtime, the plant
and beverage industry is the flinger seal,
was replacing the bearings every six
which prevents the ingress of bacteria
weeks as part of preventative planned
and protects the Molded-Oil filled cavity.
maintenance, but failures would often
There is also no potential for lubricant
occur beforehand.
To help keep the line running and avoid
leaks.
BACTERIA-FREE
NSK engineers recommended replacing the existing bearings with Life-Lube®
NSK has taken great care to ensure the
housed units, commencing a trial on
design of its Life-Lube® bearing units
one production line. One year later,
are free of crevices and ‘bug traps’
the units were still performing well
that could harbour mould or bacteria.
with no failures, delivering substantial
production time. Due to this success, the food plant is currently adopting Life-Lube® bearing units on its two other production lines. Today, the plant enjoys many other benefits of Life-Lube® bearing units, which include a spherical housing seat and spherical outer ring that allows for any initial misalignment on mounting, and the availability of various locking methods as standard to ensure close-fit shaft mounting. In addition, quiet and efficient running comes courtesy of super-finished raceways. This success story is one of an increasing number across the food and beverage industry, where plants are discovering that the combination of thermoplastic housing, special nitrile rubber seals, stainless-steel bearing material and Molded-Oil lubricant makes the Life-Lube® range ideal for wet and/or contaminated environments. www.nskeurope.com
As a result, the bearings are ideal for food manufacturing environments that involve dust (dry or wet), water (spray or submerged) and wet abrasive contamination, as well as temperatures up to 80°C. Life-Lube® bearing units are also suitable for use in some starchbased environments, as well as those involving low temperatures, down to -18°C. The suitability of Life-Lube® bearing units for food applications is vast, encompassing tasks that include primary (cutting and mixing), secondary (moulding), conveying, inspection, heating and packaging processes, while beverage applications include bottle moulding, filling, sealing, inspection and packing. In these operating environments, Life-Lube® will resist excessive moisture, washdown chemicals and contamination, all while operating at continuous high speeds if required. The speed factor is maximal dn = 12 x 104 ( dn =bore diameter in mm x speed in rpm).
A cutaway section of an NSK’s Life-Lube® bearing unit, showing the stainless steel insert and Molded-Oil lubrication. Photo: NSK
FDPP - www.fdpp.co.uk 41
8 Reasons for selecting an Air Operated Diaphragm Pump for your Food Transfer Application Selecting a food transfer pump can be
Hygienic Pump Design
difficult. When there’s a possibility of changing viscosity, requirement for hygienic design, gentle handling to ensure products remain as designed and a hazardous environment, selecting a unit can be a difficult choice! One overlooked pump design is an Air Operated Diaphragm Pump. Its simplicity in design – a central air exchanger driving a piston back and forth compressing each diaphragm to deliver fluid provides many benefits. Here are 8 reasons why an Air Operated Diaphragm Pump may be the best solution for your food transfer application:
RUN DRY
hygienic design for cleaning via CIP with
As this design of pump is constructed
rotating pump head for draining another
without an internal mechanical seal,
version can be selected. All with a variety
when operated without fluid- unlike other
of sanitary diaphragms, available as
pump designs it does not sustain damage
conductive for flammable liquid handling
enabling it to be left unattended, as well as
(ATEX).
not being sensitive to dry matter.
HIGH FLOW RATE Due to the speed in which both diaphragms can be filled and compressed, air operated diaphragm pumps deliver one of the highest flowrates possible for viscous fluids
SELF PRIMING & SOLID HANDLING Pumps can prime up to 6M, and handle suspended solids without clogging. Designs are available to handle some
GENTLE CONVEYING OF PRODUCT The working motion of an AOD pump is gentle meaning product consistency remains unchanged. However when an air regulator is installed, pumping speed can
solids without damage.
be slowed reducing any shear.
output is often unrivalled.
GRADES OF FINISH TO MATCH YOUR PROCESS
SIMPLICITY OF MAINTENANCE
UNAFFECTED BY VISCOSITY
Not only are pumps available in a
without compromise to flow rate. Capable of delivering up to 54,000L/hour its high
Positive displacement design ensures that
multitude of materials but also a variety
pumping performance remains regardless
of Stainless Steels. For example if there
of viscosity. Internal components act as
is a hygienic application where the only
valves ensuring fluid output is maintained
requirement is material type - Stainless
across a variety of thick or thin fluids and
Steel can be provided. If polished stainless
temperatures.
or complete accredited (3A or EHEDG)
Due to wetted parts consisting of a few components maintenance is often quick, uncomplicated, requires little expertise, with low risk of damage during reassembly. The above mentioned benefits highlight why these pumps are used for fluids ranging from Whisky to Sauces, Creams and Gels with very little maintenance, or downtime. If you have a food or beverage application and are unsure of the right solution, contact us to see how we can help. Visit www.northridgepumps.com, Email: Sales@northridgepumps.com or contact
42 FDPP - www.fdpp.co.uk
AOD Pump Design
us on 01773 302 660.
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 Accelerated stator stator wear wear ++ Clogging Clogging ++ Changes Changes to to fluid fluid consistency consistency ++ Clean-in-place Clean-in-place and and sterilise-in-place sterilise-in-place hygiene hygiene issues issues ++ Crushing Crushing of of sensitive sensitive products products ++ Inconsistency Inconsistency in in finished finished product product ++ Inaccurate Inaccurate transfer transfer of of flavourings flavourings or or ingredients ingredients ++ Liquid Liquid separation separation ++ Seal Seal wear wear or or failure failure
We’ve We’ve been been engineering engineering sanitary sanitary pumps pumps for for sectors sectors such such as as distilling, distilling, brewing, brewing, food food manufacturing/processing, manufacturing/processing, and and more, more, for for 20+ 20+ years. years. We We understand understand industry-specific industry-specific processes processes and and know know what what itit takes takes to to optimise optimise performance performance through through better-suited better-suited pump pump design design -- giving giving you you complete complete peace peace of of mind. mind.
EXPERT GUIDANCE:
Our Our expert expert engineers engineers understand understand your your process process and and guide guide you you through through the the options, options, so so you you can can confidently confidently select select the the most most suitable suitable sanitary sanitary pump. pump.
Want to optimise performance sooner? Speak to one of our specialists.
+44 (0) 1773 302 660
sales@northridgepumps.com sales@northridgepumps.com || www.northridgepumps.com www.northridgepumps.com
EXAMPLE PRODUCTS: ++ Abrasive Abrasive mixtures mixtures ++ Creams, Creams, milk milk & & ice ice cream cream ++ Edible Edible oils oils & & fats fats ++ Fish Fish & & meat meat ++ Fruits Fruits eg. eg. cooked cooked apples, apples, plums, plums, berries, berries, grapes grapes ++ Grains Grains & & seeds seeds ++ Pastes Pastes & & purees purees ++ Syrups, Syrups, juices juices & & alcohols alcohols ++ Vegetables Vegetables & & peelings peelings ++ Waste Waste eg. eg. trimmings, trimmings, packaging packaging & & offcuts offcuts ++ Sheer Sheer sensitive sensitive liquids liquids ++ Solid Solid laden laden or or viscous viscous mixtures mixtures
of water/steam quality assurance and control in the A AU UG GU US S TTThe 2 22 2 ,,importance 2 20 0 11 9 9 food and drink processing sector.
Water Water supply supply and and quality quality is is of of paramount paramount importance importance to to the the food food and and beverage beverage processing processing industry. industry. Water Water and and steam steam are are used used in in many many direct direct food food contact contact applications. applications. They They can can be be used used as as aa raw raw ingredient, ingredient, by by direct direct injection, injection, and and for for temperature temperature control. control. Quality Quality control, control, HS&E HS&E and and plant plant integrity integrity all all rely rely on on aa water/steam water/steam supply supply that that is is consistent, consistent, safe safe and and conforming conforming to to industry industry standard. standard. The The consequences consequences of of inadequate inadequate water water quality quality can can have have significant significant effects, effects, not not only only on on quality quality and and food food safety, safety, but but also also on on the the longevity longevity of of plant plant and and efficiency efficiency of of the the process. process. Effective Effective process process design design is is essential, essential, and and to to aa large large extent extent the the process process determines determines product product safety safety and and quality. quality. The The design design also also has has aa direct direct impact impact on on plant plant lifecycle lifecycle and and optimisation. optimisation. Poor Poor design design can can be be both both financially financially and and reputationally reputationally damaging, damaging, especially especially if if the the consequence consequence is is an an inferior inferior product. product. It It is is in in everyone’s everyone’s interest interest to to ensure ensure quality quality and and process process efficiency efficiency are are maintained. maintained.
"The only way to truly verify water or steam quality is the use of ‘realtime’ continuous measurement." Many Many conventional conventional systems systems verify verify water water and and steam steam quality quality by by grab-sampling, grab-sampling, followed followed by by laboratory laboratory tests. tests.
This This
can can
be be
both both
time time
consuming consuming and and resource resource intensive intensive and and is is always always retrospective. retrospective. Crucially, Crucially, this this is is merely merely aa ‘snapshot’ ‘snapshot’ of of the the process process and and does does not not give give continuous continuous measurement measurement of of the the process process condition. condition. This This could could mean mean an an anomaly anomaly could could be be missed missed and and time time will will elapse elapse between between non-conformance non-conformance and and corrective corrective action. action. The The only only way way to to truly truly verify verify water water or or steam steam quality quality is is the the use use of of ‘real-time’ ‘real-time’ continuous continuous measurement. measurement.
This This can can be be achieved achieved through through aa well-maintained well-maintained control control system, system, in in
conjunction conjunction with with high high accuracy accuracy steam steam and and water water analysis analysis system system (SWAS). (SWAS). Installation Installation of of SWAS SWAS will will give give you you real-time, real-time, continuous continuous measurement measurement to to ensure ensure your your process process is is controlled controlled within within specification specification to to ensure ensure reliable reliable and and repeatable repeatable production, production, reduced reduced waste, waste, less less downtime downtime and and ultimately ultimately increased increased consumer consumer confidence confidence in in the the product. product.
Bradford Bradford based based engineering engineering consultants consultants IMA IMA Limited Limited have have been been partners partners with with German German based based SWAS SWAS manufacturer manufacturer Dr Dr Thiedig Thiedig GmbH GmbH & & Co Co KG KG for for several several years years offering, offering, consultation consultation and and procurement procurement services services for for the the Oil Oil and and Energy Energy sector. sector. This This could could be be anything anything from from initial initial application application suitability suitability consultation consultation to to lifecycle lifecycle and and project project management. management. We We are are excitedly excitedly extending extending this this knowledge knowledge base base and and technology technology into into the the food food and and drinks drinks production production sector. sector. For For an an obligation obligation free free consultation consultation on on how how we we can can help help to to improve improve your your process process efficiency efficiency through through better better measurement measurement and and control, control, please please contact contact us us on on info@ima.co.uk info@ima.co.uk ,, phone phone 01943 01943 878877 878877 or or visit visit our our webpage webpage on on www.ima.co.uk www.ima.co.uk
IMA has been providing customers with the finest measurement and analysis solutions since 1991–utilising the latest technology and innovation available.
Our aim is to work with our customers, combining our expertise with our customer’s knowledge of their operations, to provide bespoke measurement solutions for that company’s needs. We specialise in improving measurement and process efficiency for a range of applications and processes, here are just a few: • Ultra-fast gas chromatography for gas and liquid concentrations • Oil on water leak detection • Steam water analysis and sample systems • Oil in water • Dew point • Relative humidity, and • Watercut measurement Address:IMA LTD, 1G Sapper Jordan Rossi Park, Baildon, BD17 7AX Phone:+44 1943 878877 Email:info@ima.co.uk Website:ima.co.uk
Sparc checkweigher saves free-from bakers ‘dough’ We’ve got a crisis on our hands! The
Graham, European Sales Manager for
variables must be factored in to
recent free-from boom in pop-culture,
Sparc Systems explains.
maintain batch-to-batch consistency.
allergies, has led to free-from products
Free-from products typically
Inspecting up to 12,000 dough pieces
becoming increasingly integrated into
use expensive ingredients in the
per hour, Sparc Systems’ Hestia Dough
people’s daily diets. But with prices of
manufacturing process; some
Checkweigher provides free-from
key ingredients used in a range of free-
costing 2-3 times more than
bakers with unparalleled weighing
from products soaring dramatically, this
their conventional counterparts.
precision and speed.
industry, worth an estimated £652m to
Additionally, due to rising allergens,
the UK, needs to adapt and eliminate
segregated production zones
Producing high quality and tasty
costly giveaway.
are critical to eliminate cross
gluten-free bread with comparable
contamination. Even more essential
volumes and texture requires a degree
Rice flour is an integral part of gluten-
given the introduction of ‘Natasha’s
of experimentation using different
free bread, cakes, baby food and
law’ this October.
flour substitutes. When the perfect
on top of a growing epidemic of food
desserts. With the cost of it rising
free-from dough and process has
by 26%, bakers are scrambling for
Understanding the processing
been achieved, the next challenge is
a solution to keep production costs
formulations in all free-from products
maintaining a consistent weight and
as low as possible. This is where
is vital. In free-from bakery categories,
bake.
checkweighing comes in as Charlie
for example, several processing
46 FDPP - www.fdpp.co.uk
Sourcing alternatives to wheat, barley and rye is high cost, making repeatable weight precision even more critical for free-from bakeries Repeatably delivering a weight accuracy of 0.5 grams, the automated Hestia Dough Checkweigher can save specialist free-from bakers thousands of pounds
can cost over 150% more than
and data capture software, the robust
conventional breads. There are often
Raptor checkweigher further supports
20 or more ingredients within a free-
the rapidly expanding free-from
from bread recipe. Placing even greater
industry to mitigate costly product
emphasis on tightly controlling waste.”
giveaway. Targeting operational inefficiencies, the Raptor series reduces
Automated dough checkweighing
unnecessary rejections and waste whilst
allows for individual pieces that are
helping to maintain brand reputation.
off target weight to be removed and reworked, as well as providing
“A common approach when prices
corrective feedback to the dough
escalate is to reduce the sizes of packs
divider. The result is a rapid payback on
to counteract the rising raw material
machinery investment.
costs. For premium free-from products
every day.
it places even greater pressure on the “Sourcing alternatives to wheat, barley
need to adhere to accurate net weights,”
Connected to an automated upstream
and rye is high cost, making repeatable
Charlie emphasises.
free-from dough dividing line, if a piece
weight precision even more critical for
of dough is under or overweight by as
free-from bakeries,” reports Charlie.
little as 0.5 grams, the Hestia Dough
“Harnessing the power of smart checkweighing technology is rapidly
Checkweigher automatically rejects
Price volatility for premium ingredients,
becoming a critical part of the inspection
it. Simultaneously, the machine’s
combined with the well documented
mix. This ensures consumers continue
advanced fibre optic-controlled
global supply chain challenges, was
to have the choice of affordable free-
software communicates back to the
part of the rationale behind the
from products that don’t compromise
dough divider in real time to adjust the
launch of Fortress and Sparc’s Raptor
their wellbeing and dietary needs,” he
position of the blade for the next batch.
Checkweigher series. Using high-
concludes.
end weighing algorithms alongside Charlie expands: “Free-from ingredients
sophisticated automated adjustment
www.sparc-systems.com
FDPP - www.fdpp.co.uk 47
Lasers Support Digital Manufacturing In Carton Production The traditional methods of manufacturing folding cartons can often be complex and time consuming. Each stage in the process, from artwork approval by the brand owner, through printing, die cutting, finishing, and shipping tends to be performed in isolation. This can often lead to large quantities of work in progress and multiple set-ups to change from one product to another. However, the flexibility and power of lasers makes it possible to streamline these processes and operations into a single digital production line, which delivers the highest levels of productivity, and even allows the production of different product variants, on the fly.
The CartonsInMinutes® process is capable of producing intricate shapes on demand Several different sized and shaped folding cartons can be produced on a single sheet, optimising material usage. Furthermore, lasers offer the ability to combine multiple processes in a single run, which means cutting, scoring, perforating, and etching can all be done
CartonsInMinutes® is an automated
using the same system in one step as
process for laser cutting and scoring
opposed to many. These factors all lead
folding carton materials into stacks
to reduce lead times, setup, and tooling
of cartons ready for folding and
costs.
gluing. The ability to link the individual manufacturing process digitally within LasX’s CartonsInMinutes® digital manufacturing process, makes it possible to produce only what is needed, when it is needed. Eliminating unnecessary work in progress, set up times and product handling reduces both manufacturing timescales and
The CartonsInMinutes® process is a specific configuration for LasX’s digital finishing equipment solutions designed to meet the needs of the folding carton market. LasX’s LaserSharp® equipment uses patented laser control software and advanced vision technology to assure precise, repeatable cut-to-print
costs.
registration. Instant job change at
From a product designer’s perspective,
through programming or by reading
removing the constraints imposed by
the printed bar codes. These digital
the mechanical die-sets traditionally
manufacturing systems, which are
used in carton production offers greater
capable of using either sheet fed or roll
degrees of freedom. In addition to the
fed material, are scalable to meet the
product artwork, each item is located
needs of any production environment.
with fiducials and identified by a bar
Systems can be configured with up to
code - originating from a layered PDF
two 1000W lasers to perform mixed
file - containing the cut and scoring
converting operations while achieving
information required by the laser.
throughput speeds as high as 15,000
Complex, variable, and nested shapes
cartons per hour, still with instant order
can all be created whilst matching digital
/ product changeover capabilities in
printing speeds.
continuous production runs.
48 FDPP - www.fdpp.co.uk
production speed is accomplished either
Using LasX’s CartonsInMinutes® process, finished cartons can be available for shipping within minutes of final customer design and artwork approval Following printing and laser processing, automation also aids in the digital manufacturing workflow. Pick-andplace robots, positioned after the laser-processing module, identify each piece and stack, sort, rotate and / or shingle them as required. By organising the finished parts using automation, significant time-savings can be realised. The laser-processed pieces can then be directly sent to additional finishing processes such as folder-gluers and then packaged. Multiple conveyor belts can be used at the end of a laser-processing module to send different products to various stations. LasX’s CartonsInMinutes® process and technology described in this article are available from Bromsgrove based TLM Laser, who are the UK and Ireland distributors for LasX Industries, a technology and industry leader in high performance production class laser converting systems and services. TLM Laser also offers a comprehensive range of Laser processing systems for cutting, welding, marking, engraving, cleaning, 3D additive layer manufacturing, plus laser safety equipment. www.tlm-laser.com
+44(0)1527 959 099 +49 69 247 420 750
CartonsInMinutes
®
Using LasX Cutting Edge Laser Technology TLM Laser offer a comprehensive range of LasX laser technologies which make it possible to digitally link individual manufacturing processes to produce only what you need when it is needed. • Optimise production workflow and output of folding cartons • Streamline operations with continuous digital workflow for laser converting and robotic material handling • Leverage instant order change capabilities at production speeds - by job queue or machine vision technology
www.tlm-laser.com | sales@tlm-laser.com www.lasx.com | sales@lasx.com
Güntner launches new air cooler New Güntner mini compact air cooler packs punch in small package The Mini COMPACT Air Cooler caters to the cooling requirements in small grocery shops, restaurants, canteens, and similar small-scale use cases. It measures only 124 mm in height, making it Güntner’s flattest air cooler to date.
Users can take full advantage of the cooler’s compact size thanks to its downwardpointing fans, which allow it to be mounted flush against the ceiling.
Users can take full advantage of the cooler’s compact size thanks to its downward-pointing fans, which allow it to be mounted flush against the ceiling. Maximising the available storage space isn’t the only benefit offered by this kind of installation: It also improves hygiene by preventing dirt from accumulating on top of the cooler.
In addition, the Mini COMPACT Air Cooler’s inside needs the occasional cleaning and maintenance. This is made easy by the fold-away tray – which can be opened for convenient access by simply removing two screws – as well as the small number of
individual parts, smooth surfaces, and plug-connected fans. These features make it possible to keep the cooler up and running with minimal effort and downtime. Importantly, the cooler’s simplicity does in no way detract from its effectiveness: Compared to conventional air coolers, its energyefficient design including optimised defrost heating cuts costs by up to 30 % for ventilation and 50 % for defrosting. The high-quality aluminium casing is powder-coated to prevent corrosion. Güntner offers ten Mini COMPACT Air Cooler variants ranging from 0.4 to 2.2 kW output for use with HFCs, CO2, or flammable refrigerants. Each variant comes with a terminal box wired ready for connection and a three-year warranty. Sales will start in Europe from January 2022. For more information about Güntner brand, visit www.guntner.com or contact us.
50 FDPP - www.fdpp.co.uk
THE LIGHTLINE FLOWPACKER
NO MORE REASON TO PUT DECISIONS ON ICE.
The lightline machines from Schubert can be delivered quickly and are especially attractive in terms of price. With the preconfigured machines, customers can adapt more flexibly to market trends and significantly speed up their time-to-market. The LIGHTLINE FLOWPACKER is a flow-wrapping machine with robot-supported pick & place infeed and packs a wide variety of products in conventional and sustainable films. It offers an affordable and and highly flexible way to automate packaging processes with the most efficient technology on the market while ensuring the highest availability and packaging quality. The world’s leading FMCG and private label manufacturers rely on Schubert. www.schubert.group
FOR PACKAGING PRODUCTS OR TRAYS INTO FLOWPACKS.
CompAir launches dynamic new compressors in D-Series range CompAir has announced its latest oil-free
electronics industries. No oil is used in
savings compared to conventional
rotary screw compressors as part of its
the compression elements, neither for
compressor control, the simple, virtually-
new D-Series range, delivering reliability,
sealing or lubricating the rotors, nor for
maintenance free HPM® motor has
dynamic efficiency, lower operating costs,
cooling the compression process directly,
60% fewer components than a standard
and high-quality oil-free compressed air.
reducing the risk of costly downtime and
induction version. It has no bearings,
contaminated products.
pulleys, gears, or motor shaft seals
The range covers air and water-cooled
to wear out, leak or need replacing,
models from 37 to 75 kW and is available
For RS models, the combination of
meaning reduced service time and spend.
in both fixed and regulated speeds (RS)
variable speed operation and hybrid
The motor also requires less power at
delivering ISO 8573-1:2010 Class 0
permanent magnet (HPM®) motor
start-up (95% efficiency at start-up)
certified 100% oil-free air for the most
delivers ultra-efficient performance and
compared to other VSD compressors and
critical applications, e.g. within the food
lower energy costs. Offering best-in-
never operates unloaded thanks to an
and beverage, pharmaceutical, textile, and
class efficiency and 30% or more energy
unlimited number of starts and stops.
D37 D37
52 FDPP - www.fdpp.co.uk
D75RS
Enhanced reliability is another key benefit
temperature, reducing unplanned
ranges from 7 to 10 bar and volume flow
of the new D-Series range compressors.
shutdowns caused by high heat, and
between 3 to 13 m3/min, CompAir’s new
Stainless steel components, dual-vented
increasing productivity. Main components
D-Series oil-free solutions can be relied
seals, and precision machined rotors
are also easy to access, with no special
on to provide consistent, cost-effective
with advanced Ultracoat™ prevent
tools required, ensuring servicing is a
and virtually maintenance-free high-
downstream contamination due to
hassle-free process.
quality compressed air. D-Series range
corrosion, while ensuring a trouble-free
compressors are also offered with an The D-Series compressors feature iConn
extensive range of options to suit a user’s
as standard, too. A smart, proactive
unique requirements. For example, our
airend with precision machined gears,
real-time online monitoring service
Energy Recovery System (ERS Ready)
oversized bearings, stainless steel air
that allows operators to manage the
is one option for both fixed and variable
seals, and unique labyrinth oil seal
performance of the system through
speed units. This sees compressor
design to eliminate the risk of internal
invaluable data statistics and insights,
operating heat, usually lost to the
leaks. Meanwhile, an intuitive Xe system
iConn will alert users should a potential
atmosphere, recovered and repurposed
controller with integrated speed control,
issue with the compressed air system
for applications such as hot water,
remote communications capability, and
arise. Furthermore, PureCARE, a specially
heating, and industrial processes. This not
extensive events history, enables users
designed service plan for the CompAir
only leads to huge savings but plays an
and owners to optimise and improve
oil-free product range, will ensure
important role in contributing towards a
compressor performance.
uninterrupted and uncontaminated
company’s sustainability goals and green
compressed air based on an extended
credentials.”
and long-lasting operation. The range also features a robust
Furthermore, whereas air compressors are generally designed to operate in an environment where the temperature remains between 5°C and 40°C, the new D-Series range from CompAir is able to
warranty of 6 years. Each PureCARE service plan can be tailored to an operator’s specific application and includes CompAir genuine spare parts.
withstand the harshest environments
David Bruchof, Oil-Free Product Manager,
and 46°C maximum ambient
said: “Capable of delivering pressure
For more information on the latest 37 to 75 kW D-Series range from CompAir, please visit: https://www.compair. com/en-gb/two-stage-oil-free-screwcompressors
FDPP - www.fdpp.co.uk 53
Digitalisation in drive technology: Customer added value from drive data Predictive maintenance is the systematic continuation of condition maintenance with the aim of proactively maintaining machinery and equipment and detecting changes, reducing downtimes and increasing the efficiency of the entire plant. A status-oriented maintenance replaces the traditional time-based maintenance. Especially for drive systems in demanding production environments where industrial gear unit installations are usually used in sensitive applications and their failure can cause severe damage, for example in intralogistics, the food industry or the heavy duty sector, condition monitoring supplements the triad of gear unit, electric motor and frequency inverter with improved safety and reliability. This is where condition monitoring for
Fast, efficient and comprehensive evaluation of analogue and digital data by the intelligent PLC in the NORD drive technology forms the basis for condition monitoring and predictive maintenance. Image: NORD DRIVESYSTEMS is a key factor for oil ageing in gear
directly shift into the drive. In smaller
units. This information in combination
production areas, this scalability offers
with available gear unit parameters
the possibility to gain first experiences
and specific operational parameters
before reorganising the plant. There are
condition data in the inverter’s own PLC
make it possible to precisely calculate
three configuration levels available. At
and pre-process it together with data
the oil change time. A physical
the first level, the drive unit PLC only
of connected sensors and actuators.
temperature sensor is not required.
performs the drive monitoring. The drive
The result of the pre-processing or
The pre-processing of drive data
parameters are pre-processed in the
the complete data can be optionally
takes place in the NORD frequency
PLC and communicated to the higher
transmitted to an edge device. There,
inverter’s integrated PLC that is used
level control system that is responsible
data of all subsystems is managed
as an evaluation unit. The customer
for drive and process control. At the
and evaluated. It is then available as
can access the calculated data via all
medium level, the PLC integrates the
pre-selected and edited smart data for
common interfaces.
drive control and also runs drive-related
predictive maintenance comes into play: Based on intelligent algorithms and software in an IIoT environment, the networked drive units can collect their
further use and clear visualisation.
functions. At the higher configuration
DATA ANALYSIS INSTEAD OF JUST DATA READING
THE RIGHT PLC SOFTWARE ARCHITECTURE FOR EACH SOLUTION
A concrete application example is
The drive equipment can be optionally
control unit, a local data management
the sensorless determination of the
extended and adjusted to the respective
without internet connection can
optimum oil change time based on
automation task. Customers can select
optionally apply the data.
the oil temperature. This is based
what tasks (drive monitoring, drive
on the fact that the oil temperature
control, process control) they want to
54 FDPP - www.fdpp.co.uk
level, the inverter PLC completely replaces the higher level control system. Apart from the communication to a
www.nord.com
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Flexible and Easily Manoeuvrable Loose loading and unloading of vehicle Expandable up to 30m Reinforced, ribbed zinc plated steel side plates Increased efficiency
Highly Mobile. Extremely Flexible. Easily Positioned. Our FLEXI range is perfect for vehicle loading and unloading, parcel distribution centres, machine-to-machine linking and all cross docking applications. They can be easily moved in or out of trucks for faster, safer, easier loading and unloading.
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