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August 2011

â‚Ź100 million investment remoulds Cadbury production in Ireland

Food & Drink Business Website:

C o n t e n t s



Coverage of British and international deals.

Taste the future at Anuga – 8th to 12th October 2011, Cologne. P AGE 19

- 9 C OVER S TORY Eur100m investment remoulds Cadbury production in Ireland.


Franck Riboud, ce, Danone.


Helen Franklin, operations manager, Lower Reule Bi.

Energy & Environment . . . . . . . . . . . 21-23 Information Technology. . . . . . . . . . . . . 26


PAGE 25 Bottling & Packaging . . . . . . . . . 27-33, 48

Fazer Group celebrates 120th anniversary.

Labels & Label Applicators . . . . . . . . . . . . . . . . . . . . . . 29-31



Leonard Russell, md, Ian Macleod Distillers.

Running the rule over Lower Reule Bioenergy.

- 25 S EAFOOD Cumbrian Seafoods plans sustainable growth.

Peter Vassallo, chairman, Cumbrian Seafoods.

Control & Automation . . . . . . . . . . . . . . 36 Storage & Distribution . . . . . . . . . . . 38-45 Temperature Controlled Storage & Distribution Exhibition 2011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Processing & Manufacturing . . . . . 43 & 48


Nicholas Oughtred, chairman, William Materials & Ingredients . . . . . . . . . . . . . 47 Jackson Food Group.


Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade

Patrick Miskelly, manufacturing director, Kraft Foods Ireland Production.

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M E E R R G G E E R R S S M Danone’s €250 Million Indian Acquisition Danone is acquiring Wockhardt Group’s nutrition business for Eur250m to enter the baby nutrition and medical nutrition markets in India. Danone is purchasing Wockhardt’s nutrition business and brands as well as its related industrial operations from Carol Info Service, based in Punjab, India. The strong brand awareness of Wockhardt’s Dexolac, Farex and Nusobee baby nutrition products and their credibility with healthcare professionals will accelerate Danone’s entry into the country’s baby nutrition market. With over 25 million children born each year, India is the fastest-growing infant nutrition market in the world. In addition, the nutritional supplement brand Protinex will give Danone a strong foundation for developing its medical nutrition business. The acquisition will provide Danone access to a distribution network with nationwide reach.

Franck Riboud, chairman and chief executive of Danone.

Greencore to Acquire Uniq For £113 Million Greencore has made a recommended £113m cash offer for Uniq to significantly strengthen its position within the UK convenience foods market, chiefly within the food to go and chilled desserts categories. The acquisition of Uniq will add new and complementary customer relationships to Greencore, in particular with Marks & Spencer. The acquisition is being funded through a fully underwritten 5 for 6 rights issue at Eur0.46 per share to raise

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A C C Q Q U U II S S II T T II O O N N S S A Greencore.” Of course, Greencore failed earlier this year in its efforts to achieve an all-share merger of equals with Northern Foods, when its bid was trumped by Boparan Holdings with a £342m cash offer.

Patrick Coveney, chief executive of Greencore.

approximately Eur80.2m, and a new debt facility. Uniq is owned by its Pension Scheme. This follows a deal last February when Uniq’s pension debt of more than £400m was exchanged for a 90.2% stake in the group. In its last financial year, Uniq continued the improvement in its performance by increasing turnover by 6.8% to £312m and reporting an operating profit before significant items of £4.1m compared to a loss of £1.9m in 2009. The food to go business increased sales by 13% to £157m and profits by 51% to £11m. Uniq’s desserts sales rose by 1.5% to £155m and losses were reduced by 6.9% to £2.7m. Greencore is projecting annual net cost synergies of at least £10m for the acquisition through the elimination of duplicated corporate, divisional and functional overheads, and the overlapping nature of the respective supply chains. “The proposed acquisition of Uniq delivers demonstrable further scale in two key categories - food to go and chilled desserts, and is underpinned by substantial synergies. Furthermore, it broadens Greencore's commercial footprint and it is perfectly aligned to our strategy,” says Patrick Coveney, chief executive of Greencore. “It represents an important milestone as we extend the scale and leadership positions of our group in the UK convenience market.” Geoff Eaton, chief executive of Uniq, comments: “It is a good offer from a strong business that provides an excellent strategic fit and, as such, represents the best outcome for employees, pension members and shareholders, as well as an exciting opportunity for

Consolidation in Scottish Seafood Associated Seafoods has concluded its second acquisition within a short period following the purchases of scampi-maker Moray Seafoods and smoked salmon producer Lossie Seafoods, both based at Buckie in Scotland. Associated Seafoods is a Scotland-based holding company set up by an experienced management team, with an objective to invest into value-added processing of seafood. It is half owned by Scottish Seafood Investment, a joint venture between Scottish Salmon Company, Scotland’s leading independent salmon producer, and Northern Link, the major shareholder in Scottish Salmon Company. Associated Seafoods’ strategy is to concentrate on value-added processing of salmon (smoking, readyto-cook, ready-to-eat, etc.) and adding other species to complement its value-added offering. Princes Completes £182 Million Canning Acquisition Princes Group, which is owned by Mitsubishi Corporation, has completed the £182m acquisition of Premier Foods’ East Anglian canning operations to extend its presence in the UK ambient foods market. The acquisition includes two major UK canning sites at Long Sutton and Wisbech in East Anglia, along with a number of brands including Crosse & Blackwell, Farrow’s and Smedley’s. The sites collectively employ over 1,000 people. A number of Premier Foods’ brands, including Branston and Batchelors, will remain under Premier Foods’ ownership but are being licensed to Princes on a longterm arrangement for the manufacture of specific products at Long


Sutton and Wisbech. These include Branston baked beans and Batchelors canned soups. The Fray Bentos brand, business and certain manufacturing assets will be sold by Princes following the acquisition as part of undertakings made by the company to the Office of Fair Trading. Until this divestment takes place, the Fray Bentos business will be run on an independent basis from Princes.

The acquisition significantly expands Princes’ portfolio of branded and customer own label products in the canned foods sector. Following completion of the acquisition, Princes will have annual revenues approaching £1.5b, 4,500 employees, 13 food and drink production sites and a portfolio of leading brands.

 DAIRY Dairy Crest Strengthens Spreads Business UK dairy group Dairy Crest has strengthened its spreads business with the £13m acquisition of MH Foods, which manufactures healthy 'one calorie' spray cooking oils and salad dressings. “It has a good history of innovation over many years, the leading brand in its sector and fits well with our Spreads business and we believe the acquisition will

Mark Allen, chief executive of Dairy Crest.



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A C C Q Q U U II S S II T T II O O N N S S A on growing its retail business by adding 34 sites and improving the overall quality of its estate. It also further expands Greene King’s presence in Greater London where the combined business will operate approximately 250 pubs. Greene King is projecting cost and revenue synergies by the end of the first year post acquisition of at least £2m.

allow us to build on our strong portfolio of lighter brands,” says Mark Allen, chief executive of Dairy Crest. Lactalis Holds 83% of Parmalat French dairy group Lactalis had secured 83.3% of Parmalat, Italy’s biggest listed food group, at the conclusion of its Eur2.5b buyout offer. Lactalis is famous for its President Camembert cheese and is owned by the Besnier family. The combination of Lactalis and Parmalat will create the world’s largest dairy company. Arla Foods to Acquire Southern German Dairy Arla Foods is preparing to strengthen its position in Germany after making an offer to purchase southern German dairy company Allgauland-Kasereien, which is in financial difficulty. Allgauland-Kasereien has 1,800 milk producers, operates four production facilities and has an annual turnover of Eur253m, of which 31% is from exports. It primarily produces cheese and butter, but also some fresh dairy products. According to Kuno Rumpel, chairman of the board of Allgauland-Kasereiens, Arla’s offer is “a necessary step towards ensuring the future of our company.” Earlier this year, Arla Foods merged with the northern German dairy, Hansa-Milch, which produces only fresh dairy products. Arla’s aim is to become one of the largest dairies in Germany. Arla’s strategy also focuses on growth within cheese, including its global House of Castello brand. Emmi Strengthens Cheese Business Swiss dairy group Emmi is purchasing Rutz Kase, which specialises in the production, ageing and pre-packaging of Swiss semihard and hard cheese, for an undisclosed price. Rutz Kase expects to generate sales of SFr40m (Eur33m) in 2011, with around 60% generated in Switzerland and 40% from its 4

international business. The deal is subject to approval from the Swiss competition authority. The acquisition will reinforce Emmi's position as the leading cheese supplier in Switzerland and as an exporter of Swiss cheese, and is in line with the company's growth strategy.

 BEVERAGES Diageo Strengthens its Standing in Chinese White Spirits Market Chinese regulators have approved Diageo’s acquisition of an additional 4% stake in Sichuan Chengdu Quanxing Group Company for £13m, which takes the global spirits group’s shareholding to 53% giving it control of one of China’s best known spirit brands. Diageo is now seeking approval from the China Securities Regulatory Commission to launch the required mandatory tender offer for the outstanding shares.

Paul Walsh, chief executive of Diageo.

Green King Expands Pubs Business With £70 Million Acquisition Greene King has beaten fellow UK regional brewer Fuller, Smith & Turner to acquire the Capital Pub Company for £70m. The deal is in line with Greene King’s focus

Ian Macleod Distillers Buys a Second Distillery Ian Macleod Distillers, the independent, family-owned Scotch whisky distiller, blender and bottler has purchased Tamdhu distillery in Speyside from the Edrington Group for an undisclosed price. Established in 1897, Tamdhu’s distillation capacity of four million litres of alcohol per year will support the continued growth of Ian Macleod’s existing

Leonard Russell, managing director of Ian Macleod Distillers.

brands, including Isle of Skye, Lang’s and the King Robert II blends. The Tamdhu Single Malt brand is also included in the sale, and Ian Macleod Distillers plans to significantly develop its sales both within the UK and abroad. “Having purchased Glengoyne Distillery from Edrington in 2003, we are delighted to be acquiring a second distillery from them, safe in the knowledge that it has been maintained to a very high standard and comes with a reputation for producing exceptional quality single malt,” remarks Leonard Russell, managing director of Ian Macleod Distillers. Ian Curle, chief executive of The Edrington Group, says: “From Edrington's perspective, the sale will further de-complex our business, allowing us to continue to focus on the growth of


our five key brands, The Famous Grouse, The Macallan, Brugal, Cutty Sark and Highland Park.” Ian Macleod Distillers recently announced improved financial results for the eighth consecutive year, with group turnover increasing 22% to £31.9m in 2010. Pivovarna Lasko Sells Juice Business to Nectar Pivovarna Lasko, the largest drinks producer in Slovenia, has sold Fructal Lasko, its fruit juice business, for Eur35.3m to Nectar, Serbia’s biggest soft drinks and jam manufacturer. The disposal will help the embattled Slovenian group to reduce its debt mountain. It is also planning to sell its stake in Mercator, the largest food retailer in Slovenia.

 CONFECTIONERY Nestle’s €1.2 Billion Chinese Confectionery Deal Nestle has agreed to acquire a 60% stake in Hsu Fu Chi, a leading manufacturer and distributor of confectionery products in China, for SFr1.4b (Eur1.2b). The remaining 40% will be retained by the Hsu family, which founded the Chinese company. Hsu Fu Chi’s current chief executive and chairman, Hsu Chen, will continue to lead the company in the new partnership. In 2010, Hsu Fu Chi reported sales of SFr669m and an EBIT margin of 17.3%. The company operates four large-scale factories in China, has excellent route-to-market capabilities and employs 16,000 people. Hsu Fu Chi's portfolio includes sugar confectionery, cereal-based snacks, packaged cakes and the traditional Chinese snack sachima. Hsu Fu Chi's products are tailored to Chinese consumers' needs and habits, and complement Nestle’s existing product portfolio in China, which includes culinary products, soluble coffee, bottled water, milk powder and products for the foodservice industry. Hsu Fu Chi's large portfolio of affordable products, with the potential for enhanced

AutoCoding Systems Works With Major Retailer to Eliminate Coding and Packaging Errors utoCoding Systems, specialists in automation of packaging line devices, A has worked in consultation with a major retailer to help them implement guidelines to ensure all products supplied to them always have the right packaging, the right label and the right date code. Suppliers are being asked to subject each finished product pack to an on-line automatic system to verify the use of the correct product packaging and coding. Each packaging line should be controlled by a line terminal or other suitable hardware. With an autocoding management system from AutoCoding Systems every line is controlled by a dedicated industrial PC housed in a stainless steel cabinet. The line terminal communicates with a SQL database holding key product information and relevant coding profiles, including date rules, promotions and concessions relating to individual SKUs. The AutoCoding system can seamlessly inte-


2D code scanned to verify correct packaging.

grate to leading ERP and planning systems ensuring the master SKU data is automatically populated to the AutoCoding system database and subsequently pushed to the relevant line devices thus eliminating the need for manual setup with the associated risk of error.


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nutritional value, fits perfectly into Nestle’s global portfolio. Nestle has been present in China for over twenty years and today operates 23 factories, two R&D Centres and employs 14,000 people. Its China region achieved sales of SFr2.8b in 2010. Main Nestle brands in China include Nescafe, Nan and Maggi as well as local brands such as Totole, Haoji and Dashan. Nestle has established several technical assistance initiatives for milk and coffee farmers in China. Barry Callebaut Selling European Consumer Business Barry Callebaut, the global manufacturer of cocoa and chocolate products, is selling its European consumer business, Stollwerck, to the Belgian Baronie Group for an undisclosed price. The deal comprises the entire Stollwerck Group including five factories in Germany, Belgium and Switzerland. The transaction also includes a long-term supply agreement between Baronie Group and Barry Callebaut for the supply of approximately 25,000 tonnes of liquid chocolate annually as well as the additional supply of cocoa beans and semi-finished products. The transaction, which is subject to antitrust assessment, is expected to close before the end of 2011. Stollwerck, founded in 1839 and bought by Barry Callebaut in 2002, is a producer of chocolate confectionery products offering an extensive portfolio to most of the important retailers in Europe. Sales revenue of Stollwerck is approximately Eur500m and volumes sold are more than 100,000 tonnes. Stollwerck’s volumes consist of private label business, branded chocolate products

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(Sarotti, Alprose, Alpia and Jacques) and co-manufacturing for third parties. The company employs about 1,700 people Baronie Group, which has its roots in Holland, produces a wide portfolio of chocolate products for national and international customers. The manufacturing operations cover branded products, private label products and third party branded chocolates. Baronie Group is part of Belgium-based Sweet Products, a privately owned family company. Blackstone Group Acquires 40% Stake in Tangerine Confectionery Private equity firm Blackstone Group has bought a 40% stake in Tangerine Confectionery, the UK’s largest independent manufacturer of sugar confectionery and popcorn, from Growth Capital Partners for an undisclosed price. Growth Capital Partners backed a £10m management buyout of Toms Confectionery, which was subsequently renamed Tangerine Confectionery, in January 2006. Since then, Tangerine has quadrupled in size, increasing turnover from £40m to £160m. Headquartered in Blackpool, Tangerine owns brands such as Butterkist popcorn, the iconic Barratt Sherbet Fountain and Dip Dabs, Henry Goode’s soft eating liquorice and Princess Marshmallows. “Blackstone’s investment in Tangerine will provide an excellent platform for growth. We are committed to building a partnership with management to take Tangerine and its brands and product range to the next level of growth, thus creating value for

both the company and our investors,” says Lionel Assant, senior managing director of Blackstone.

 HEALTH SCIENCE Nestle Health Science Acquires a Stake in Vital Foods Nestle Health Science has acquired a minority stake in Vital Foods, a New Zealand-based company that specialises in the development of kiwifruit-based solutions for gastrointestinal conditions. The terms of the transaction were not disclosed. This follows the acquisitions made in the last 12 months of Vitaflo, CM&D Pharma and Prometheus Laboratories.

Created in 1991, Vital Foods has two well-established products on the market in New Zealand, Kiwi Crush and Phloe. Both products are based on a natural kiwifruit extract, and have been clinically shown to be effective against constipation. Constipation is a common functional disorder of the gastrointestinal tract, affecting around 1 in 6 people in the general adult population in Oceania, Europe and the US. The deal is in line with Nestle Health Science’s commitment to science-based nutritional solutions for gastrointestinal health. Nestle Health Science has also announced the completion of its acquisition of Prometheus Laboratories, a company that specialises in diagnostics and inlicensed specialty pharmaceuticals in gastroenterology and oncology.

 INGREDIENTS Kerry Group Looks to Acquire Cargill’s Global Flavours Business Kerry Group, the Irish and interFOOD & DRINK BUSINESS EUROPE, AUGUST 2011

national ingredients, flavours and consumer foods group, is in exclusive discussion with Cargill regarding the acquisition of the US giant’s global flavours business. Cargill Flavor Systems has well established international flavour technology development expertise serving a global customer base through provision of flavour ingredients and flavour systems for beverage, dairy, sweet and savoury applications. Through its network of modern integrated flavour development and application centres spanning 22 countries in North and South America, Europe, South Africa and Asia, Cargill Flavor Systems has long-standing relationships with leading global food and beverage manufacturers. “The acquisition of Cargill Flavor Systems would again advance Kerry’s capability to provide unrivalled innovative integrated customer solutions across all food and beverage end-use-markets and extend the group’s market spread in emerging markets,” comments Stan McCarthy, chief executive of Kerry Group.

Stan McCarthy, chief executive of Kerry Group.

Raisio Divests Malt Business Raisio, the Finnish foods and functional food ingredients manufacturer famous for its Benecol brand, has sold its malt business in Finland for Eur17m to Viking Malt, the largest malt manufacturer in the Nordic Countries. The divestment of the malt business is part of the streamlining of Raisio’s activities. 7

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€100 Million Investment Remoulds Cadbury Production in Ireland More than Eur100 million has been invested in the Cadbury chocolate manufacturing facilities in Ireland during the past four years.


his investment has included the introduction of the latest production technology in the Coolock site in north Dublin the largest of the manufacturing sites in Ireland. This investment was part of an overall programme to improve competitiveness in order to strengthen the Coolock site’s position as a key production facility, which exports over 80% of its output. Cadbury chocolate has been manufactured in Dublin since 1932. Renamed Kraft Foods Ireland Production following the $19.5 billion acquisition of Cadbury by the US-based food and beverage company in 2010, the business comprises of three production sites in Ireland, where approximately 700 people are directly employed in manufacturing. Over 300 additional employees work in sales and services functions The main site at Coolock in Dublin incorporates 37 acres including 40,000 sq m of factory buildings. The Coolock site, which was established by Cadbury Ireland as its Irish production hub in 1956, is also now the headquarters of Kraft Foods Ireland following the integration of the two Irish businesses of Kraft Foods and Cadbury. The factory at Coolock produces some products exclusively for the Irish market as well as exporting over 80% of its output to other Kraft Foods businesses in Europe, chiefly the UK. Coolock produces all of the Cadbury Dairy Milk range for the Irish market, with the product being tailored to suit local taste preferences. The factory also specialises in producing the Twirl, Flake, Time Out, Moro, Boost and Snack Wafer brands for the Irish and British markets. Coolock is supported by a chocolate crumb manufacturing facility at Rathmore, County Kerry. Rathmore processes some 80 million litres of milk annually which are sourced from local dairy cooperatives in the Munster region. About half of the chocolate crumb is used at Coolock with the remainder exported to produc-

Patrick Miskelly, manufacturing director of Kraft Foods Ireland Production.

tion sites within Kraft Foods and also to other European chocolate manufacturers. The third site within Kraft Foods Ireland Production is a factory producing the base for chewing gum, located at Tallaght in Dublin. Established in 2006 and employing approximately 50 people, the Tallaght factory is the sole supplier for Europe. Cadbury became the world’s second largest chewing gum manufacturer, behind Wrigley, when it acquired US-based Adams and its Trident brand for $4.2 billion in 2003. Market Leadership The acquisition of Cadbury allowed Kraft Foods to overtake Mars to become the global confectionery leader, with number one positions in both the chocolate and sugar confectionery segments and a strong number two in the high growth gum segment, still headed by Wrigley, which became part of Mars in 2008. The deal also gave Kraft Foods leadership of the UK and Irish confectionery markets. Kraft Foods controls about 30% of the UK market and over 35% in Ireland. Kraft Foods Ireland Production is now part of Kraft Foods’ Global confectionery category. Within Kraft Foods Europe, the categories are broken into; Chocolate, Coffee, Cheese & Grocery, Biscuits and Gum & Candy. Confectionery is Kraft Foods’s biggest category, generating 29% of group sales, ahead of biscuits on 21%. Kraft Foods has over 60 manufacturing facilities in Europe and three of these are in Ireland. With sales in 17 countries, Kraft Foods Europe is a substantial part of the global operation, contributing 23% of group revenue of $49.2 billion in 2010.

The company is investing Eur20 million this year in a new moulded plant for the Cadbury Dairy Milk range.



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cost competitiveness in the UK. “If you look back to 2004/2005 we were at a crossroads in terms of what we were going to do with the site at Coolock. The business had grown enormously throughout the 1990s, especially with huge export growth, but as our volumes started falling back it was obvious that we were facing a massive challenge because our cost base had increased so much and undermined our competitiveness,” explains Patrick Miskelly. He elaborates: “We were faced with some hard choices. In order to secure manufacturing, we needed to radically improve our costs, our efficiencies, our ways of working and our infrastructure. We chose to make essential changes in our business and this decision brought huge investment to Coolock. We invested in the best manufacturing technology. We developed and implemented the most effective ways of working in order to deliver outstanding levels of productivity. Without doubt, we were standing on a burning platform and had to make these changes. That is the journey that we have been on for the past four years.”

Twirl Bites is a mini version of the popular ‘twirly’ chocolate fingers covered in Cadbury Dairy Milk chocolate and are ideal for the ‘sharing’ category.

Challenge “The reality is that the Cadbury chocolate business here is focused on the UK and Ireland, whereas Kraft Foods is very much focused on Europe. So the challenge and the opportunity for us is to broaden our customer base,” says Patrick Miskelly, manufacturing director of Kraft Foods Ireland Production. The Coolock plant initially manufactured all the Cadbury brands consumed in the Irish market. However, following Ireland’s entry to the EEC (now the EU) in 1973, it began to develop exports. In line with Cadbury’s strategy, Coolock started to specialise in certain products, for example it manufactures all the Cadbury Flake and Twirl bars for Europe. Cadbury Ireland has been developed from being an indigenous company to one which is 80% export focused. However, in more recent times, similar to many other Irish manufacturers with high labour costs and other business overheads, the Coolock plant became uncompetitive in international terms. The problem became particularly acute due to the weakness of sterling against the euro, which further undermined the Irish company’s

“The reality is that the Cadbury chocolate business here is focused on the UK and Ireland, whereas Kraft Foods is very much focused on Europe. So the challenge and the opportunity for us is to broaden our customer base.”

€100 Million Investment During this time, the Coolock plant has been substantially overhauled and modernised with the introduction of state-of-the-art production lines, including robot pick and place and high-speed wrapping technology, accompanied by changes in work practices and a significant reduction in the head count. “We have invested heavily in driving up productivity and improving product quality while also enhancing the people safety and food safety aspects of our business to exceed the increasingly stringent standards,” he remarks. “Customers and consumers alike have been oblivious to all the changes, so it has been a seamless transition. The only thing we want them to notice is ongoing improvements in product offerings and product quality.” He adds: “As we have introduced more modern equipment we have embarked on extensive training programmes for our people. This has been a huge challenge but the teams have not only risen to the challenge but have embraced the training and changes to ways of working magnificently.” The Eur100 million investment programme has involved the installation of new plants for the production of Flake, Twirl and Boost bars. “We are investing Eur20 million this year in a new

Flake Allure consists of crumbled folds of Cadbury Flake, dipped in soft truffle and lightly enrobed in smooth chocolate.



moulded plant for the Cadbury Dairy Milk range. This is a big commitment to the Irish business and was a decision taken by Cadbury but which was subsequently endorsed by Kraft Foods,” he points out. Energy Efficiency Kraft Foods Ireland Production has also been investing in improving its energy efficiency to achieve its target of reducing energy usage on an equivalent basis by 5% per annum. The introduction of highly automated production systems in conjunction with infrastructural upgrades to the Coolock factory have facilitated the centralisation of utlilities and plant rooms, housing equipment such as boilers and compressors, which has significantly improved energy efficiency. “This has allowed us to drop our energy usage by about 15% in the last few years,” he remarks. Similarly, energy efficiency at the Rathmore chocolate crumb factory has also been enhanced through investment in new boilers. “Every year, we set aside a certain portion of money to drive energy efficiencies,” he says. Emissions from both the Coolock and Rathmore sites are controlled under IPPC licence from the Environment Protection Agency.

Irish Confectionery Market The chocolate and sugar confectionery market in the Republic of Ireland has a retail sales value of about Eur600 million. Kraft Foods is the biggest player, accounting for about a third of sales, and its Cadbury Dairy Milk is by far the most popular brand. Although confectionery is more recession-proof than other food categories, it is still under intense cost pressure. “Our customers are struggling and consumers are also struggling and we have been trying to respond to that dynamic by providing more value for money,” Patrick Miskelly comments. “The taste of Cadbury chocolate is what differentiates us because when consumers buy confectionery, they tend to go for a high quality brand that they trust.” Product Innovation In reaction to changing consumer shopping habits, Kraft Foods Ireland has just launched two new products –Flake Allure and Twirl Bites – for both the home and UK markets. Flake Allure consists of crumbled folds of Cadbury Flake, dipped in soft truffle and lightly enrobed in smooth chocolate. Supported by £2 million ATL campaign in the UK, the new product is targeted at the singles category, where new product development is crucial for growth. Indeed, Cadbury has been responsible for three of the five biggest singles NPD launches in the past ten years. Twirl Bites is a mini version of the popular ‘twirly’ chocolate fingers covered in Cadbury Dairy Milk chocolate and are ideal for the ‘sharing’ category. The bitesize market is a market that is showing growth and offers consumers a way of connecting with others through sharing and eating chocolate. Both new products are

Cadbury Dairy Milk is by far the most popular brand in the Irish confectionery market.

intended to boost category sales through extending already popular brands to appeal to existing Twirl and Flake consumers and to a new, younger audience. Other innovations are in the pipeline at Coolock. However, there is a major difference in the taste and composition of chocolate that is sold in the UK and Ireland and that which is popular in continental Europe. Kraft Foods’s main chocolate brand in Europe is Milka, which is very different to the Cadbury chocolate so enjoyed by UK and Irish consumers. The Dublin-based company is already a key contributor to Cadbury one of Kraft Foods’ three $1 billion-plus confectionery brands. Milka is another mega confectionery brand but Kraft Foods Europe’s confectionery portfolio also includes Toblerone, Cote d’Or, Belgium’s favorite chocolate, and Freia and Marabou, the preferred chocolate brands in Scandinavia. Greater Flexibility “We will have to be more flexible in how we make chocolate and respond to the needs of European consumers.” he remarks: “We are working with our Kraft Foods colleagues to try to address some of their international market needs. So in 2012 we will see a couple of products from here being supplied as Kraft Foods products. It is a great opportunity for us to move into the European market.” Patrick Miskelly continues: “Kraft Foods has a very aggressive growth strategy and we need to see how we can contribute to that. They want their manufacturing sites to be competitive and to grow.” The removal of EC milk quotas in 2015 will also present a chance for the Irish dairy industry and for Kraft Foods Ireland Production to expand. “We see that as being a major opportunity because we are producing a milk-rich product,” he comments. “In the meantime, the pace of change will undoubtedly continue. We look to the future - to continuously improve our business, addressing our challenges and seeking opportunities for manufacturing in Ireland.” J

“We will have to be more flexible in how we make chocolate and respond to the needs of European consumers. We are working with our Kraft Foods colleagues to try to address some of their international market needs.”




Fazer Group Celebrates 120th Anniversary Fazer Group, one of Finland’s and the Nordic region’s biggest food groups, is celebrating its 120th anniversary this year. he business has evolved from a cafe in Helsinki to become one of the leading bakery, confectionery and contract catering companies in the Nordic and the Baltic countries with annual sales of Eur1.51 billion and a workforce of 16,500 people. The business was started on September 7th, 1891 when Karl Fazer opened his FrenchRussian cafe at Kluuvikatu 3, after training in St Petersburg, Berlin and Paris. At that time Finland was still an autonomous Grand Duchy of Russia. The cafe was successful and the business expanded to include the production of chocolate and confectionery, and later introduced bakery products and catering. Fazer Group was the first company in Finland to industrially manufacture sweets, chocolate and confectionery products. Indeed, many of the company’s oldest confectionery products are still made today. The oldest product still in production is Phlaja marmalade, which was launched in 1895. Fazer Group started to develop exports in the late 19th century

Swedish bakery Lovangerbrod, and acquisitions in Russia. During this period, Fazer also disposed of its biscuits business. Fazer Group’s most recent deal entailed the purchase of Swedish artisan bakery Gateau. Fazer Group is still a family-owned company, with the fourth generation now involved in the business. Finland remains Fazer Group’s largest market, accounting for 50% of total turnover in 2010, followed by Sweden, which generated 24%, and Russia with 15%.


Fazer Group was the first company in Finland to industrially manufacture sweets, chocolate and confectionery products.

Karsten Slotte, president and chief executive of Fazer Group.

with its marmalade and chocolate pralines being sold in Scandinavia, Germany, Belgium, Holland and England. The company has grown organically and by acquisition. Fazer significantly strengthened its standing within the Finish bread market when it acquired the Oululainen bakery in 1958. It has since expanded its operations to become Finland’s leading bakery company. The restaurant operations started in 1935, when the traditional Kalastajatorppa restaurant was acquired. Fazer Catering (now Fazer Food Services) was established in 1976. International Expansion International expansion has gathered momentum during the past twenty years through a series of acquisitions such as the Pick & Mix confectionery companies in Finland, Sweden, Norway and UK (Candyking), the merger with Swedish confectionery company Cloetta, the purchase of

Business Restructuring Last year, Fazer Group was re-organised from a four divisional structure - Fazer Amica, Fazer Bakeries, Fazer Russia and Fazer Confectionery – into two business areas- Fazer Food Services and Fazer Bakeries & Confectionery. Fazer Food Services (formerly Fazer Amica) is the leading contract catering company in the Nordic and the Baltic countries. Amica has been retained as an important consumer brand. The division operates almost 1,400 restaurants in Finland, Sweden, Norway, Denmark, Estonia, Latvia and Russia. Fazer Food Services increased turnover by 7.3% in 2010 to Eur575.1 million and contributed 38% of group turnover. Finland remains Fazer Food Services’ biggest market with 51% of sales ahead of Sweden

The business was started on September 7th, 1891 when Karl Fazer opened his French-Russian cafe in Kluuvikatu 3, Helsinki.



the Moscow Olympic Games in 1980. Exports resumed in 1992 and in 1997 Fazer Group acquired a majority stake in Hlebny Dom bakery in St Petersburg. In 2005, Fazer Group purchased the Zvezdny bakery in Moscow, one of the biggest producers of frozen pizza and dough in Russia, The confectionery factories are located in Finland at Vantaa and more recently acquired (chocolate products), Lappeenranta (sugar confectionery) a majority stake in Volzhky and Karkkila (chewing gum). pekar, the leading producer of fresh of Fazer Group. bread and coffee bread in the Tver While progress was achieved throughand Denmark with 27% and 14% respec- region. out 2010, work on the Fazer for Growth tively. Having invested heavily in developing strategy will continue in 2011 with a its Russian operations, Fazer Group has variety of projects. Fazer Bakeries & Confectionery emerged as one of the country’s leading Fazer Group is Finland’s top bakery com- bakers and is market leader in northwest Future Development pany and one of the leading companies in Russia. Fazer is the second largest bakery Fazer Group’s future development stratethe Baltic Sea region and Russia. Bakery company in Moscow with a market share gy is based on increased profitability and products are manufactured in Finland, of 13%. Fazer Group’s Russian business international growth utilising its strong Sweden, Estonia, Latvia, Lithuania and had sales of Eur229 million last year, up brands as it aims to increase turnover to Russia. Fazer operates a total of 21 bak- from Eur193 million in 2009. Eur2 billion during the next few years. eries. Its major brands are Fazer, “Fazer’s growth will increasingly come Oululainen, Skogaholm, Hlebnyi from international markets and new Dom, Druva and Gardesis. The product concepts. In order to group’s bakery products are exported strengthen its position, Fazer must to more than 15 countries. harness its strong brands in new ways. Fazer Group is also Finland’s leadOur customers’ loyalty is based on ing confectionery company and a the Fazer promise – first-class prodstrong player in the Baltic Sea region. ucts and services,” he comments. The confectionery factories are locatThe company is adapting to meet ed in Finland at Vantaa (chocolate changing market demands. products), Lappeenranta (sugar con“Consolidation in trade, changes in fectionery) and Karkkila (chewing distribution channels and the gum). Fazer Group’s confectionery increased importance of price mean brands portfolio includes Karl Fazer, that we must have the capacity to Geisha, Dumle, Tutti Frutti, overhaul and develop our operations. Marianne, Tyrkisk Peber, Pantteri and Challenging Environment We must be able to make an unbiased Xylimax. Confectionery products are Fazer Group’s strong brands and leading appraisal of our offering and adapt it to exported to about 27 countries. market positions allowed it to increase meet customers’ and consumers’ expectaFazer Bakeries & Confectionery both sales and profits last year and to tions,” he remarks. increased turnover by 3.7% to Eur938.5 strengthen its standing in its main marAs it celebrates its 120th anniversary, million last year. Accounting for 24% of kets despite the difficult trading condi- the Finnish food group is in sound finansales, Russia is the division’s second tions. Reflecting synergy benefits from cial health with a strong brand portfolio, largest market, behind Finland (50%) the group’s new strategy and organisa- good cash flow and a strong balance but ahead of Sweden (22%). tional model, turnover rose by 5.0% to sheet, and is well placed for continued Eur1.51 billion and operating profit growth. “As the market leader, we must Expansion into Russia advanced 31.5% to Eur58.5 million as continually seek to outdo ourselves – Fazer Group started exporting confec- the operating margin improved that’s how we’ll create the success stories tionery products to Russia at the time of from3.1% to 3.9%. of the future,” says Karsten Slotte. J In autumn 2009, the Finnish food group launched its ‘Fazer for Future’ programme, designed to enhance performance across its restaurant, bakery and confectionery businesses. “Our goal was to enhance efficiency and improve our ability to adapt to an increasingly challenging environment. We also wanted to take an even more customer- and consumeroriented approach, to create an efficient and more flexible organisation, and to introduce standardised working methods,” explains Karsten Slotte, president and chief executive Fazer operates a total of 21 bakeries. FOOD & DRINK BUSINESS EUROPE, AUGUST 2011


2G Energy AG is a leading technology provider for decentralized energy supply solutions. 2G develops and produces modules and complete cogeneration plants (CHP) within a capacity range from 50 kW to several megawatts. The plants are fuelled by natural gas or any type of biogas (digester gas, sewage gas or landfill gas) and feature highly efficient technology for applications where energy is a key cost driver.

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Running the Rule Over Lower Reule Bioenergy With the capacity to divert more than 30,000 tonnes of food waste per year from landfill and to generate 1.3MW of renewable electricity, Lower Reule Bioenergy is a family-run anaerobic digestion business operating in the West Midlands of England. he anaerobic digestion (AD) plant is situated on the family farm in Gnosall. The facility has been operating since early 2010 and currently receives food waste from a variety of sources including local authorities, waste recycling companies, a number of major food retailers, food manufactures and companies in the hospitality sector. Lower Reule Bioenergy operates a second site – a food waste depackaging plant at Four Ashes, Wolverhampton, which supplies the feedstock for the AD plant. The Wolverhampton site receives the food waste, separates it from any packaging and removes contaminants. The facility incorporates two depackaging lines, specially designed to handle a wide variety of different food wastes. The lines can deal with both naked and packaged food waste including local authority kitchen household waste and sludges. The food waste is delivered to the site in many different formats naked, packaged, palletised, food waste in bags, dolaves, drums and IBCs. After depackaging, the food waste is macerated and blended into slurry. This liquid food waste is then pumped into storage holding tanks, prior to transportation by the company’s vacuum road tanker to the AD plant at Lower Reule Farm.


Strategic Location “The primary reason for locating the food waste depackaging plant in a separate location to the AD plant was to position it as close to strategic transport routes as possible (Junction 12 of the M6, Junction 2 of the M54) and make it attractive to potential suppliers of food waste,” explains Helen Franklin, operations manager of Lower Reule Bioenergy. The depackaging technology splits the packaging away from the food waste leaving the pack-

aging pieces relatively whole. “Unlike many depackaging technologies which adopt shredding techniques, it maintains the integrity of the packaging which provides greater opportunity in the future to recycle or reuse the residual packaging. Whilst the end disposal of this packaging is quite challenging at the present time due to contamination with Animal By-products, there are a number of emerging technologies, such as plastic washing and separation, that could make this a reality,” she says. To ensure that Lower Reule Bioenergy can offer a complete ‘zero waste to landfill’ solution and secure destruction of any packaging that is removed, the packaging is currently sent to a local energy for waste plant for incineration.

bacteria to develop and thrive, breaking down the food waste to create biogas (see Panel). The biogas is burnt through two Deutz MWM combined heat and power (CHP) engines to create electricity. About. 4% of the electricity is used to run the plant whilst the remainder is exported to the National Grid. The AD process also produces digestate, a nutrient rich biofertiliser that is used to replace artificial inorganic fertilisers that are manufactured using fossil fuels. The digestate is separated into a fibre and liquor. Approximately 45% of the digestate is spread on arable crops on Lower Reule’s own 500 acre farm. The remainder is spread on neighbouring farms, which comprise grassland, cereal crops and some vegetable production.

AD Plant Lower Reule Bioenergy uses a continuous wet mesophilic anaerobic digestion process, whereby the digesters are kept at approximately 40 degrees Celsius to provide the optimum environment for the mesophilic

Key Advantage “We are a commercial food waste plant. The advantage we have is that we are on farm so that we can deal with the digestate in a truly sustainable way. It is going back to land for crop production and it is not being dewatered, which a lot of the big commercial plants are doing to deal with the volume,” she comments. The company is currently in the process of certifying its digestate to PAS110. It is estimated that Lower Reule’s AD plant will reduce emissions equivalent to 56,347 tonnes of CO2 per year, in addition to the carbon saving from the replacement of inorganic fertilizers. Lower Reule Bioenergy is also exploring business opportunities to utilise the residual heat from the AD plant. “A couple of ideas we have been exploring is to use the heat in

The Lower Reule Bioenergy AD plant.



polytunnels that house the crops Health By-product Regulations. for Lower Reule’s strawberry business or dry woodchip for the Core Values “We are a family-run business. biomass sector,” remarks Helen Franklin. We understand our plant very well because we built it ourThe AD plant was built in two selves. We are very passionate phases. The first phase, comprisabout what we do and we try to ing a digester tank, pasteurisawork with people in partnership tion unit and CHP engine, commenced construction in August to provide solutions that work well for all parties.” Helen 2009 and was completed in February 2010, providing the Franklin continues: “The suppliers of our feedstock as well as capacity to process up to 15,000 tonnes of food waste per year the farming community who and generate 536 kw of electricireceive our digestate are central to our business. Our core value ty per year. The second phase commenced in September 2010, Key members of the Lower Reule Bioenergy team (left to right): Carol Critchley, is to provide a flexible commerwas completed in January 2011 director; Ian Critchley, managing director; Helen Franklin, operations manager; cial service that is based on strong partnerships that will and effectively doubled the and Charles Kidson. farm manager. capacity. ensure that that these relationThe entire AD process is fully automated tality sector to collect food waste,” she says. ships continue to thrive.” Total capital investment by Lower Reule and alarmed. The system is also monitored remotely with full technical backup sup- Bioenergy to date is £3.4 million, includ- Future Expansion port available if required. ing private equity funds, a £750,000 capi- Lower Reule Bioenergy has plans to expand tal grant from the Waste and Resources by either bolting on another digester at its Action Programme (WRAP) and financial current site or by using the expertise already Extra Capacity With the second phase now on stream, the support from the Nat West bank. The gained to establish a new plant to serve expanded AD plant has the capacity to scheme is approved by Ofgem to receive another area of the country such as elsewhere handle 30,000 tones of food waste a year Renewable Obligations Certificates in the West Midlands or in the North West. and to generate 1.3MW of electricity per (ROCs). “We see partnerships with waste suppliers year. According to Helen Franklin, the Seven people are employed full-time as something that we are good at and plant is currently running at about 75% between the two sites. Both sites are man- would like to focus upon. So we may look capacity. “The biggest challenge with food aged and operated under bespoke to build a new plant in partnership with waste recycling is the transport infrastruc- Environmental Permits issued by the someone who has food waste. There are a ture. We are now working with a few orga- Environment Agency and have full number of local authorities that are very nizations, building capability in transport approvals for the receipt and processing of open to partnership in some capacity,” infrastructure so we can service the hospi- Category 3 materials under the Animal she concludes. J The AD Plant at Lower Reule Bioenergy The AD plant comprises a 500 cu m feedstock holding tank, two 2,700 cu m digester tanks and a service building housing control room, pumps and valves, heat exchangers, pastueriser and two spark ignition Combined Heat and Power (CHP) engines. The plant also features two biological scrubbers, two digestate holding tanks and a lagoon. All of the tanks are made from stainless steel. Each of the digester tanks is equipped with a long arm submersible agitator, which is used to circulate the digestate and encourage the upward movement of biogas to the top of the tank where it is collected inside an internal gas roof membrane. In addition, each tank has three submersible agitators positioned around the circumference of the tank that can be altered to almost any position to assist with stirring. Each tank has two portholes to enable the operator to make quick visual checks on the condition of the digester. The two digesters run in parallel to one another and not in sequence. This provides useful contingency should there be a requirement for preventative maintenance, etc. Prior to transferring the gas to the CHP units, the biogas is de-watered and de-sulphurised using a series of biological scrubbers, carbon filters and condensing units. The whole of the AD process including engine management is fully automated and alarmed. The system is also monitored remotely with full technical back-up support should there be a failure of plant of any description. The digestate is pasteurised following completion of the biogas production phase in the digester tanks. The digestate is heated in batches to 70 degrees Celsius for more than one hour to ensure that it meets with the Animal Health By-Product Regulations. “The reason we chose to pasteurise post-digestion was primarily due to the lower energy consumption


that was required to pasteurise reduced digestate volumes as compared to the initial input feedstock volumes,” explains Helen Franklin. Once the digestate has been pasteurised it is mechanically separated into a fibre and liquor. The principal reason for doing this is to ensure that the transfer and deployment of digestate is not limited by the type of pumping equipment that would be needed as a result of the potentially fibrous nature of the material. The liquor is temporarily held in a storage holding tank before being either pumped by an underground pipeline to a slurry lagoon on the farm or transported off-site to other farms, prior to spreading on the land. The fibre is stored temporarily in a bunker, prior to being transferred to concrete pads in fields, before being spread on the land.



Cost Cutting Opportunities With Green Energy he time is running out for traditional, T large, central power plants, which only generate electric power and waste valuable thermal energy. Add to this the typical losses in the overhead power lines and it becomes clear that this is not the way to proceed in the future. This old fashioned technology has been outflanked by clean and efficient Combined Heat and Power (CHP) units. Projects that unify Combined Heat and Power with innovative biogas technology are on the rise all over Europe and natural gas driven CHP systems are increasingly displacing traditional heating solutions that once relied on fuel hungry boiler technology. Not surprisingly, energy intensive industries like food and beverage manufacturing are looking for cost cutting alternatives to operate their facilities more economically and are investing heavily. For example, instead of sending waste from the food and

beverage production to landfill, it could be used to operate a digester, which generates valuable biogas. This opens a wide number of opportunities. 2G Energy, a stock exchange listed company based in Germany, is a turnkey technology provider in the field of Combined Heat and Power along with all necessary equipment such as gas treatment, steam generator, absorption chillers and heat distribution. The advantage is clear, by using both electricity and thermal energy, CHP systems reach an overall efficiency of 90% which pays off within a couple of years. Up to 70% lower energy costs and nearly CO2

free energy generation (biogas) makes this technology one of the most efficient and valuable technologies on the energy market right now. 2G Energy develops a variation of different cogeneration systems from 50kW up to several megawatt. Industries with low margins especially need to look for cost cutting opportunities and one way is to extract as much energy from a generating unit as possible. The team at 2G has the know-how to tackle the most challenging CHP projects, helping clients to keep a competitive edge. J


English Dairy Launches £3.4 Million Anaerobic Digestion Facility n English dairy has officially opened a £3.4m anaerobic digestion (AD) facility A that will turn food waste from around the county into the energy helping to produce its clotted cream, ice cream creme fraiche and yoghurt. The facility at Langage Farm, Plymouth, Devonshire, received £1.2m of funding from the Anaerobic Digestion Demonstration Programme. By the end of its first year of operation, the AD facility will process 12,000 tonnes

of food waste collected from households across the county by local authorities. The FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

facility will also process on-farm dairy wastes, converting these fuels into renewable heat and electricity. The renewable energy will not only power the dairy products production, but surplus will exported to the National Grid. In its first five years, the Langage AD facility is expected to produce 20,000 MW of energy saving the equivalent of 2,000 tonnes of CO2 per annum/£ on energy bills. J 21


£10 Million Anaerobic Digestion Loan Fund Launched in England £10 million loan fund that will help finance anaerobic digestion (AD) infraA structure across England has been introduced. The fund aims to lend up to £10 million over the next four years, with individual loans of between £50,000 and £1 million. “The Loan Fund builds on the Anaerobic Digestion Strategy and Action Plan to develop a strong and vibrant AD industry.

There are currently 25 AD sites in England which take in food waste, including food waste from industrial processes.

It will help to reduce the amount of food sent to landfill and give more businesses the opportunity to use AD to produce their own power and electricity,” explains Defra Minister Lord Henley. The fund for the first round of applications is open until October 31st 2011. The fund has been established by WRAP in England to address the gap in anaerobic digestion processing capacity that currently exists for food waste. ”Across the UK, there are now AD facilities capable of managing 656,500 tonnes of organic waste each year, diverting waste from landfill, generating renewable energy and creating green jobs. The 300,000 tonnes of extra capacity we expect this fund will create will bring the UK’s AD processing capacity close to 1 million tonnes per year,” comments Marcus Gover, director of the Closed Loop Economy at WRAP. “AD is a reliable, safe and profitable resource efficiency process supported by Government, industry, local authorities and communities.” There are currently 25 AD sites in

The fund has been established by WRAP in England to address the gap in anaerobic digestion processing capacity that currently exists for food waste.

England which take in food waste, including food waste from industrial processes. WRAP has a finite loan pool and will select projects for funding through a competitive process, with those applications most strongly meeting its criteria being offered a loan. For more information visit J

UK’s First ‘Super’ Food Waste Plant Opens he UK’s first ‘super’ anaerobic digestion T (AD) plant dealing with food waste has been launched by Biffa, a leading waste specialist. Based at the company’s Poplars waste management site in Cannock, Staffordshire, the new facility, which is the biggest in the UK, will process up to 120,000 tonnes of food waste from homes and businesses in the West Midlands every year to produce enough renewable energy to power 6,000 homes and a soil improver that can be used in the same way as compost. “This is the future of waste. It is taking food that could once only be sent to landfill

Biffa’s AD facility at the Poplars waste management site in Cannock, Staffordshire.


and turning it into something of value on a truly industrial scale. It is a key milestone in society’s drive to reduce waste, cut emissions and recover the inherent value in our waste,” comments Ian Wakelin, chief executive of Biffa. Planning permission for the facility was granted in November 2009 and construction started in January 2010. The Cannock facility is the latest in a long line of commitments from Biffa to handle more of the UK’s food waste. It forms part of Biffa’s expanding network of AD plants and follows on from the launch of its National Food Waste Recycling Service for businesses earlier in the year. Biffa already operates a number of food waste treatment facilities in the UK, enabling up to 100,000 tonnes of food waste per year to be recycled or reused. Ian Wakelin adds: “We all want to recycle more. It is initiatives like this which allow us to do so with minimum effect on our day to FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

day lives at home or at work. Every year, the UK throws away around 15 million tonnes of food waste (source: Defra/WRAP) and it is thought that around half of this comes from businesses. Much of this food waste is currently sent to landfill sites where it breaks down into methane and carbon dioxide, both powerful greenhouse gases that contribute significantly to climate change. Biffa is an integrated waste management business providing collection, treatment, recycling and technology-driven energy generation services. J


Nestle Achieves Zero Waste at UK Factory estle marked another milestone in its N commitment to environmental sustainability by achieving zero waste to landfill at its Kit Kat and Aero confectionery factory at York in the UK. In 2009, Nestle UK set an ambitious target to achieve zero total waste by 2015 for all of its 14 factories in the UK and Ireland. This latest accomplishment is also in line with group strategy to reduce the environmental impact of Nestle’s 443 factories worldwide. By achieving zero waste, the York factory – which makes over a billion of the Kit Kat chocolate wafer bars and 183 million Aero chocolate bars each year – has saved over SFr160,000 (nearly £120,000) a year. Such savings were made due to removing landfill tax costs and reducing the number of skip lifts used by 70%. Nestle UK has also generated extra rev-

enue by selling nearly 800 tonnes of leftover materials such as cardboard, plastics, metal, pallets and metallised film. “At Nestle we are committed to manufacturing and doing business in a way that protects the planet and its resources for future generations and helps our local communities thrive,” says Paul Grimwood,

chairman and chief executive of Nestle UK & Ireland. “Making such progress in reducing the amount of waste our factories send to landfill, how much water we use and packaging we produce are significant steps. I am very proud of what our employees have achieved in such a short time.” The company’s Girvan factory in Scotland, which manufactures chocolate crumb, a key ingredient used in Nestle's confectionery chocolate brands, and its Nescafe Cappuccino factory in Dalston in the UK, both achieved zero waste last year. Nestle has also continued to lead initiatives and innovative projects to reduce waste and advance environmental sustainability across its operations around the world. For example, a total of 21 factories utilise unused coffee grounds as a renewable energy source. J


CCE Invests £1.75 Million in Fleet of Biomethane Trucks oca Cola Enterprises will invest £1.75m during 2011 in a fleet of 14 dedicated C biomethane heavy goods trucks, and in the necessary refuelling infrastructure to operate them. CCE was the first in the logistics sector to trial a dedicated biomethane heavy goods truck in Great Britain. The decision to invest further follows positive results from this trial. Biomethane has a much lower carbon intensity than diesel and CCE expects the trucks to generate carbon savings of more than 50%, compared to conventional diesel. Wendy Manning, CCE customer logistics director, says: “Reducing the carbon used by our own vehicle fleet and by our third party hauliers is a key objective for CCE we put about 200,000 loads per year onto the roads of GB and so we believe we can make a real difference. All of our hopes on the environmental benefits of biomethane were easily achieved during the trial. We hope our leadership in this area and our decision to invest in a

fleet of biomethane trucks inspires others to follow.” Lord Redesdale, chairman of the Anaerobic Digestion and Biogas Association, comments: “Coca Cola Enterprises' backing for biomethane vehicles is hugely welcome, and demonstrates the unique benefits that this renewable fuel can bring. HGVs have traditionally been a difficult sector to decarbonise as they are not suitable for battery power, so biomethane is a great alternative to fossil diesel. Biomethane also offers excellent air quality


benefits. I hope that Coca Cola Enterprises' decision will inspire others to choose biomethane for their vehicle fleets, and that the UK will see significantly more biomethane lorries on the roads in the coming years. CCE worked with CENEX, The Hardstaff Group and Loughborough University on the trial, with most of the testing completed at Millbrook Proving Ground. The truck used for the trial works in CCE's local distribution fleet in and around London and uses biomethane from a local landfill site. All the new trucks will be in service next year and will be fuelled by locally sourced biomethane delivered via a specialist refuelling station to be installed at CCE's Enfield site in North London. The investment will help CCE to achieve its public commitment to cut the carbon footprint of its direct operations by 15% by 2020 compared to 2007. J 23

Returnable Packaging that doesn’t Cost the Earth Using PPS’s Returnable Packaging is a cost effective way of moving fresh food products from supplier, processor and retailer, plus lowering your carbon footprint at the same time.




Cumbrian Seafoods Plans Sustainable Growth Cumbrian Seafoods, the UK’s leading independent seafood company, is spending £7 million to expand its main processing facility at Seaham, having already invested £18 million in establishing the site in 2007. mploying 500 people, the Seaham factory manufactures a range of prepack seafood products for the UK’s major retailers. In addition to its state-of-the-art plant in Seaham in County Durham, Cumbrian Seafoods also operates a smokery at Whitehaven in Cumbria and the Border Laird shellfish facility at Amble in Northumberland. The Whitehaven business is a primary processor and smoker of both pelagic and demersal fish. It has hot and cold smoking facilities as well as automated and manual filleting lines. Border Laird’s main activities are the production of fresh and frozen whole scampi and king scallops. Cumbrian Seafoods produces a number of branded ranges including Perfect Catch, Ocean Pure and For The Love Of Fish, which features a range of exotic, spiced fishcakes. Cumbrian Seafoods reported a pre-tax profit of £2.7 million on turnover of £155.5 million for the year ended March 2010.


out Howard Sims, managing director of Cumbrian Seafoods. He says the company has been involved in a number of initiatives in recent months which have helped consolidate sales including winning the contract to become Asda’s main supplier of chilled cod and haddock and becoming the first company in the UK to display the new Icelandic eco-label. The new Responsible Fisheries Management Certification has been set up to verify that Iceland’s seafood products are drawn from responsibly managed fisheries. Sustainability Cumbrian Seafoods and its founder and owner Peter Vassallo have long been committed to sustainable fishing and environmental responsibility. Indeed, the business is founded on top quality products that are ethically and responsibly sourced. The company has led the way in this area, pioneering a number of initiatives. It recently launched an innovative scheme that will allow consumers to trace their fish back to the boat it was caught on. To this end, Cumbrian Seafoods has teamed up with US-based Trace Register to introduce an on-line traceability system, which will give detailed information on where the products it sells originated from. This initiative, believed to be the first of its kind in Europe, illustrates Cumbrian Seafoods’ commitment to best practice and has benefits for both trade customers and for the consumer. To ensure a visible and ethical supply

£7 Million Expansion The company has recently been awarded a grant from the Regional Growth Fund to help it develop additional manufacturing capacity at Seaham – with the promise of more than 100 new jobs. The funding, of an undisclosed sum, will help Cumbrian Seafoods to convert 130,000 square feet of existing storage space into a new seafood manufacturing facility. Entailing investment of £7 million, the expansion will add further capacity and flexibility to the Seaham site and will also highlight the company’s commitment to using green energy, with the new facility being largely powered by wind, photovoltaic cells and gas from anaerobic digestion. “Cumbrian Seafoods has been a successful business for many years, but after an investment program totalling £20million building new facilities at Seaham and upgrading our West Lakes Smokery at Whitehaven, we have grown substantially with all of our major customers and intend to continue this trend capitalising on new opportunities,” points The state-of-the-art factory at Seaham in County Durham.


Peter Vassallo, chairman of Cumbrian Seafoods.

chain, Cumbrian Seafoods asks all of its suppliers to register with the Supplier Ethical Data Exchange (SEDEX). UK Firsts Last year, Cumbrian Seafoods and Asda launched the first King Prawns to be sold in the UK under the Best Aquaculture Practice (BAP) certification scheme. The BAP program is an international certification system that verifies environmentally and socially responsible processes under which shrimp, fish and other seafood are produced. Seafood facilities that participate in BAP certification apply standardised best management practices in every phase of their operations. Customers can have the confidence that their seafood has been responsibly produced, with care for the environment and the community in which it was produced, as well as food safety and traceability. The launch marked another first for Cumbrian Seafoods and Asda, which together in March 2009 were the first in the UK to introduce MSC accredited Atlantic Cod and Haddock. “At Cumbrian Seafoods, sustainability is not just about the how, where and when the fish is caught, it is also about the impact it has on the community, the ecosystem and the environment,” says Peter Vassallo. J 25

Improving Profitability in the Food Sector aking money in the fast moving fresh M food industry in never easy. The challenge of managing large volumes of low cost items with limited shelf life moving at high velocity through the supply chain can be daunting. Trying to get a handle on costs such as labour, waste and packaging as they happen can prove beyond most management teams. To quote a prominent finance director in the UK’s top 100 companies, “most companies in the food sector can’t tell you where they make money.” Some questions that most management teams cannot easily answer are: “which are my most profitable lines”; “which customer yields the best return” and “which of my suppliers makes most money for me.” The problem is that it is not easy to accurately collate the data without a huge amount of manual effort. Furthermore, it is a moveable feast with seasonal supply factors, special promotions, increasing costs and margin pressures muddying the waters. For many years, the IT industry has struggled to help the food industry find solutions to these issues. The ideal scenario would be a centralised real time information store that everybody updated and used. However, many legacy applications

tend to work in batch mode, ie can only be updated at certain times of the day or night. The problem with these solutions is that they are never quite up to date. Product can have moved through the supply chain while the systems play catch-up. This makes the task of costs and inventory management tricky. While older business management systems have struggled, the good news is that modern solutions have now evolved to meet the challenges posed by the industry. These solutions are more wide ranging, flexible and easier to use. They embrace mobile and touch screen technologies that extend the reach of the systems to people on the front line. This also facilitates the

accurate capture of cost information as it happens. More importantly, the core systems operate in real time which provides management teams with full transparency throughout the supply chain. As this information is gathered within operations, it is seamlessly integrated into the financial reporting activities of the business. This enables the precise measurement of key performance indicators such as product, customer and supplier profitability. Moreover, this dynamic information is easily made available to decision makers within and beyond the finance department. This means that, rather than employing directors to be the highest paid administrators in the business, companies can use the information provided to leverage a competitive advantage in their chosen sectors. Anglia Business Solutions specialises in the supply and deployment of Enterprise Resource Management (ERP) solutions for the food supply chain sector. The company’s Microsoft Dynamics based LINKFresh suite is used by companies such as Noble Foods, Del Monte, 2 Sisters Food Group, Branston, Cumbrian Seafoods, Giumarra, The Co-Operative Farms and many others. J

PPS – The Returnable Box Specialist PS are a returnable box rental company P who work with businesses to reduce their one trip packaging waste costs and carbon emissions. They have two box washing sites, one in the Midlands and another in Lincolnshire, and have worked with food manufacturing companies for over 10 years, hygienically cleaning all different types of plastic crates and boxes. They can also supply many different types of transit equipment including insulated bins, roll cages, plastic pallets etc. PPS East based in Grimsby provide 15kg and 25kg plastic boxes to many of


Cumbrian Seafood’s fresh fish suppliers. They have worked closely with them to look at new ways of sending fresh product, and by introducing returnable boxes have helped put Cumbrian Seafood’s a step in front of other seafood processors. They have not only lowered their packaging waste but also the cost for the supply of boxes. The PPS fish boxes are designed for today’s chilled supply chain and can provide a very safe and integrated handling system to support logistics whilst contributing to preserving and protecting the freshness and quality of the catch. These boxes are rented to Grimsby suppliers in order to transport their product to Cumbrian Seafood’s sites at Seaham and Whitehaven, where it is further processed for the multiple retailers. It is PPS East’s responsibility to retrieve them FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

and have them hygienically cleaned at their box washing site in Grimsby ready to be introduced back into the loop. Kate Williamson of PPS East who works closely with Cumbrian Seafood’s fish suppliers, comments: “The consensus of the fish suppliers is to make savings where possible without detriment to the quality of products supplied. Introducing returnable boxes into their business does just that. Therefore, they are fully committed to the change, not only because they save on costs but because it helps reduce the carbon footprint of their business.” For more information on returnable packaging, box washing or lowering your packaging waste please visit J

Feel Good Drinks Demonstrates Popularity of Glass he rising popularity of glass packaging in T the soft drinks sector has been marked by a fresh retail initiative from Feel Good Drinks, the home of 100% natural drinks. Feel Good has launched its 275ml glass packed juice drinks in a 4 pack format into the grocery sector following a very successful introduction in the on trade. Steve Cooper, marketing director for Feel Good Drinks says, "Our drinks offer a better quality, healthier option as they are made with 100% natural ingredients, provide one of your five a day and contain absolutely no added sugar. The glass packaging reinforces this quality and ensures that our drinks not only look good but also taste good."

The simple, clear glass bottle, made by OI, is complemented with a natural label design which reinforces the Feel Good's product quality. The 275ml 4 packs come in two flavours - orange & mango and cranberry & pomegranate and have already secured national listing in Sainsbury's and Morrisons. Paul McLavin, UK sales manager for O-I Europe says, "This decision by Feel Good shows that glass has a great future in the soft drinks aisle. There is a chasm between what is available in glass and what consumers want to see in the material. Recent research by FEVE, the European trade association for the glass industry, revealed that

37% of consumers would prefer to buy their soft drinks in glass, but only 10% said that glass was the material they most often used for the category. This represents a huge unsatisfied demand for glass packaging." J

Faerch Plast Beats the Chill With New Frost CPET Material urther demonstrating its position as F one of one of Europe’s leading plastics container manufacturers, Faerch

erance from -4F (-20C) degrees to 430F (220C) degrees, for freezer-to-oven or microwave convenience. CPET eliminates negative effects on food flavour and aroma, giving consumers better protected, more versatile and better tasting meals. A top layer of co-extruded APET gives this type of packaging extremely good sealing properties and a superb glossy appearance. For further information contact Faerch Plast on Ttel +44 (0)20 8254 2300 or visit J

Plast has developed a high strength ‘frost’ CPET (Crystalline Polyethylene Terephthalate) material for the packaging of frozen food products. For added accuracy, the Denmark-based company also developed a new ‘real life’ test environment to ensure unrivalled impact and crush resistance at low temperatures. Færch Plast’s CPET trays feature dual ovenability and a wide temperature tolI CAPS & CLOSURES

Viscose Closures Wins Oil Contract iscose Closures of Crawley has begun V supplying ROPP closures to Farrington Oils for use on 500ml bottles of its award winning Mellow Yellow rapeseed oil and 250ml bottles of artisan dressings. The 31.5mm x 44mm aluminium caps are printed with Farrington’s around the base of the cap and carry a leaf motif on the top of the cap, which echoes the elegant design on the bottle label. The closures include an integral pourer. Farrington’s had previously been using a combination of an ROPP closure and a printed PVC capsule but feedback from customers suggested the bottles were not FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

always easy to open. Farrington’s contacted a number of closure manufacturers and chose Viscose Closures to produce a single alternative closure. “I believe we are the first rapeseed oil brand to use these caps,’ explains Duncan Farrington, managing director of Farrington Oils, “and this will help enhance our market position. The caps are good quality, look more modern and most importantly make it easier for our customers to open and store the bottles.” For further information contact Viscose Closures on Tel +44 (0)1293 519251 or visit J 27


Brand-owners Benefit From Winning Promos rying to catch the elusive sale is still the T game that brand-owners play every day. And on-pack promotions are one of the most frequently used methods of differentiating products in order to boost sales and win new customers for brands to get closer to via Customer Relationship Marketing (CRM). Everyone is looking at driving promotional activity online and that’s where multi-page labels score so highly. Fix-a-Form from Denny Bros is the market leading multi-page leaflet label helping to communicate large amounts of text on-pack including brand benefits, cross-range product details, and multi-lingual information. Incentives such as competitions, inserts, vouchers, scratch-off panels, SMS text promotions, and collectables all help to win over the hearts and minds of those with spending power. More than ever brands are looking to be bigger, bolder and more outstanding. Not just in terms of shape and form but in terms of the giveaways and prizes that are on offer, especially when the promos are linked to the web and SMS texting.

expect money-off and multiple purchases as routine and so it falls to more luxury items to turn people’s heads and these prize giveaways need professional management to enable them to work seamlessly.” Numbered promotions make these instant wins work and can include unique random numbers (URNs), variable winning numbers or combinations of the two spread evenly through the printing process. However, it is important that these campaigns are well thought through and professionally produced. There have been a few recent cases where less-than-perfect systems have resulted in huge embarrassment for promoters not to mention damage to goodwill. Just one example is that of a leading Irish airline which launched an enquiry after three passengers on the same flight each won a car in a scratchcard game worth £10,000 after a printing error was made in a promotion.

Boosting sales and making friends with numbered promos.

One-stop Shop Denny Bros offers a one-stop shop for numbered competitions and giveaways and a new and highly-professional inspection verification system at Denny Bros is helping to deliver the ultra-clean imple-

Instant Wins Nothing comes close to the excitement of instant wins and these can be easily facilitated by multi-page labels. Mobile phones have opened up access to internet connectivity and are aiding redemption rates which are now between 2.5% and 20% according to latest research. Mobile phone cameras can now point and shoot at a 2-D mobile code to connect directly to a website and it is expected that these will be used more routinely in promotions of the future. According to experts at Denny Bros, we are relying more on technology to speed up the process of entering competitions and the ‘special codes’ make it all possible. Barry Denny, managing director at Denny Bros says: “More than half of FMCG goods are now sold on some Unique Random Numbering supports big-named brand promos. sort of promotion. People


mentation of such promotions. The new software makes further efficiencies in terms of the processing of the variable data to avoid duplication. It can provide customers with a definitive soft record of the variable data ‘live’ codes printed on the Fix-a-Form leaflet, or base-label, to ensure that the promotion meets with promotion industry standards. This activity is clearly good for business which is why Denny Bros alone has helped create on-pack promotions for brands produced by companies as diverse as GlaxoSmithKline, Unilever, Hamelin Paperbrands, 3M and Fru. Promotions can be centred on big sporting activities including football, rugby and cricket, seasonal products and, of course, on global events such as the Olympics 2012. To find out how Fix-a-Form multi-page labels can benefit your brand contact Denny Bros on 01284 701381 or email J 29


Greggs Making Dough With Advanced Dynamics’ Labelling Solutions leading baker is singing the praises of A Advanced Dynamics after reporting significant productivity improvements following the installation of highly accurate labelling equipment on a morning goods wrapping line. The specialist in labelling, feeding, wrapping and bagging solutions supplied Greggs North West with a Eurokett Junior 115 for a variety of wrapped baked items at its Manchester factory, helping the food company gain a distinct advantage in the competitive morning goods market. In addition to this major endorsement of its range of label dispensers, Advanced Dynamics has also launched the new Eurokett Matrix labeller, the successor to the flexible Junior 115, which utilises the very latest stepper motor drive technology for accuracy, reliability and ease of control. Tony Spencer, Greggs Northwest's chief engineer, commends the "excellent" service from Advanced Dynamics and praises the unit's ease of handling and versatility. He says: “The Eurokett Junior 115 has played a big part in enhancing our wrapping productivity at the site. It's the first time Greggs has used Advanced Dynamics whom I found to be very supportive and professional. The unit is labelling a wide

variety of our wrapped products and is proving popular with our production staff due to it being reliable and very user friendly.” Advanced Dynamics' reputation for high-quality labelling equipment was well known at Greggs, and was a key factor in the company's decision to choose the Eurokett Junior. In fact, Tony Spencer has been so impressed with the performance of the equipment he says he has recommended Advanced Dynamics to other food companies. The Eurokett Junior is ideal for high volume production for anything from bread rolls or cakes to fresh produce and meat. At labelling speeds of around 100 packs per minute, the Eurokett Junior can keep pace with the most up-to-date packing lines. It provides reliable, highly accurate label application, eliminating the risks of missing labels or damage caused by rough handling. The system can apply both top and base labels in a single pass, with optional on-line coding for increased line efficiency. The Eurokett is also suitable for barcoding, applying additional product information and promotional flash labels. Advanced Dynamics' joint-managing director, Malcolm Little, comments: “We

Advanced Dynamics’ Eurokett Junior 115.

believe that the Eurokett Junior is the most efficient labelling equipment available. It is supermarket compliant and the workhorse of the labelling industry. It is designed to operate in unison with packing equipment, making it ideal for food companies looking to maximise their production.” He continues: “However, we are also very excited about the new Matrix range of label dispensers. This is a great development and provides us with equipment worthy of taking over from the Eurokett Junior. We will be showcasing the Eurokett Matrix range at the PPMA Show in September 2011.” J

Pago Rotary Labelling System R800 – Powerful and Highly Precise he Pago System R800 is a sturdy, powT erful and reliable rotary labelling system that incorporates the innovative and proven Pagomat labelling head series of applicators. The R800 has been developed for the application of self-adhesive labels to all kinds of products of different shapes and sizes. The Pago System R800 fully meets all kind of market needs. Highly modular, the Pago System R800 can be adapted to any production line where high output, reliability and maximum precision are required in long-term operation. Depending on the specific application the Pago System R800, in combination with the Pagomat labelling units, provides a labelling capacity of up to 1000 products per minute, depending on the container 30

shape and size and the label dimension. The Pago System R800 is easily accessible. The special turret enclosure provides

Pago Rotary labelling system R800 is userfriendly with easy access.


complete protection and meets all current European safety legislation. The use of extraction slides and special safety tunnels on the Pagomat units makes the reel change operation easier and faster whilst maintaining operator safety. In a world of multiple shift patterns and frequent line changes the Pago System R800 has been engineered to meet the needs of a continuous industrial operation and to ensure high production efficiency. The Pago System R800 is equipped with the latest generation of Pagomat labelling units. The units have been specifically designed to be a perfect complement to the rotary system to guarantee high performance, accurate label application and easy operation. For more further information visit J

Skanem Develops Superpeel Label Solution kanem has together with its multinaS tional customer Oriflame developed a ‘Superpeel’ label solution. This is an innovative concept with front and reverse printing on the adhesive side. Only one layer is now required with the option of also having much more information on the product. Oriflame sees this as a major innovation, which allows them to provide a cost effective single variant solution whilst ensuring sufficient regulatory information on products.

The solution is to be on plastic bottles and flexible tubes, aerosols and glass nail varnish bottles. Brian Olesen, Multinational Key Account Manager for Skanem, reports that one of the reasons for this project was the fact that Oriflame often has to have multiple languages on their products: “This will in many cases require a 2 or 3 ply with 3 to 5 pages Peel’n Read solution. With a combination of either

removing some text, or simply squeezing it more together, the e.g. 3 pages will now fit into 2 pages on the ‘Superpeel’ solution.” Skanem as a Strategic Partner According to Component Sourcing Manager at Oriflame, Tony Igoe, the project started with Skanem as their strategic partner due to an ever increasing regulatory demand from sales markets: “This has lead to the need for more legal text to be included on packaging. To take care of this Oriflame has had to launch multi variants of each product, up to 6 in some cases to cover the global marketplace.” He further explains that contrary to this, Oriflame has a need to be as flexible and responsive in the supply chain as possible, which multi variants do not provide. Tony Igoe adds: “Over the last 2 years there has been a push to provide a cost effective solution to the multi variants by trying to provide a single variant solution for all packaging types. Adding additional cartons to products was not an option due to costs and adding multi page booklets was also rejected on cost grounds. We came up with the concept of using the latest technology on label production to produce a 2 side printed, single ply label, with a peel and reseal side and a permanent hinge to apply to bottles and flexible tubes. This in theory had the advantage of using less material but 2 side printed, which for most of our products gave us the possibility to achieve a cost effective single variant solution. So this was the theory, but the label actually did not exist, so we started to work together with Skanem Poznan to solve the theory and make the label a reality.” A Receptive Skanem Team When asked how the process has been with Skanem as a partner, Tony Igoe says: “The Skanem team has been receptive at all times to try out new ideas and provide samples and think about the solutions being presented. At the start of the project there were some concerns about how possible this type of label was to produce, but once the team started to think in more detail about how to produce such a label, the development process was really smooth to arrive at an approved label. There were many options investigated and tested, but we always moved forward with each submission. After FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

just over one year we managed to agree on a solution that would work for our bottles and more importantly our plastic tubes. Well done to the whole development team!.” A Super Concept! Brian Olesen further explains the concept: “The new concept is also better for the environment as it uses less material and they may even be able to turn a 3 ply Peel’n Read with 5 pages into a 2 ply Peel’n Read with 4 pages, as the Superpeel solution on 2 ply will offer 4 pages. The 2 ply Superpeel is next step on the development.” The solution is made so it can be resealed again when the end-user has seen the information, Brian says: “You can say that the Peel’n Read solution is not new, but as far as I can tell, we have never seen a 1 page solution with print on both sides to go directly on a bottle and/or tube product before.’” The project is approved by Oriflame. Next step is to implement the solution on two specific products. Oriflame and Skanem are now looking forward to apply this final solution across the portfolio where suitable. For further information contact Skanem on Tel +47 51 85 97 20 or visit J



AutoCoding Systems Deliver Value Through Automatic Device and Line Set-up or its debut at PPMA, F AutoCoding Systems will be demonstrating its proven range

Management System complies with major retailers’ guidelines for coding and packaging verifiof software solutions for the cation and will, therefore, be of automatic set up and control of particular interest to food and all packaging line devices. Visit beverage manufacturers. Stand D17 to see how the The company will also be AutoCoding System sets up exhibiting a range of standard inkjet printers, labellers, barcode solutions for managing off-line scanners, and checkweighing coding, outer case and tray-end equipment, irrespective of manulabel production and the confacturer, with product specific trol of promotional labelling. data from a central database. The new off-line print room With support from Auto application enables efficient offCoding’s OEMs, visitors will see line print management of proThe AutoCoding System can set up all packaging line devices with product coding equipment from motional labels, stickers and specific information from a central database. Devices are controlled by a Domino, Markem-Imaje and sleeves or any other type of dedicated line terminal which removes human intervention and eliminates Videojet, labelling equipment packaging for increased flexibilithe risk of coding and packaging errors. from Advanced Labelling ty and control. Systems, barcode scanners from Companies who want to SICK, and a checkweigher from avoid the risk of costly and time The Stevens Group. All equipment is conAs all equipment is set up automatically consuming product withdrawals due to trolled via a dedicated AutoCoding line ter- via the line terminal, job set-up and incorrect coding or packaging should make minal, removing operator intervention and changeover time is greatly reduced resulting their way to Stand D17 to discuss how our thereby eliminating the risk of packaging in a significant reduction in downtime on standard solutions can add value to their and coding errors. the packaging line. The AutoCoding business. J

Open Date to Show Off New Ink Jet and Hot Foil Machines pen Date Equipment will showcase two additions to its range O of coding and marking equipment on stand A45 at the PPMA Show in September. The company will feature the AutoPilot high resolution ink jet printing system, made by Squid Ink Manufacturing of Minnesota, following an agreement to distribute the system. Plus Open Date’s latest hot foil coding development, the E-Coder will be demonstrated for the first time. AutoPilot is offered as an entry-level machine, printing high-resolution characters on both porous and non-porous materials. It uses Xaar piezo technology to produce razor-sharp text up to 18mm high, or logos at 180 dpi, says the company. The system can also print scannable bar codes as standard and offers multiple formats. The printer features a new ink system incorporating vacuum tension technology, which eliminates costly ink lines and fittings, according to Open Date. Ink is supplied in 200ml cartridges; almost five times the volume of competitive systems. Designed to operate in harsh industrial environments the printer 32

uses both oil-based and solvent-based inks, for a variety of substrates. Print speed is 4lm/minute at 180 dpi. Programming and editing can be done on the line using the user-friendly 12” colour touchscreen or via a remote PC and uploaded to the AutoPilot via a USB. Also making its debut on the stand is the latest development in Open Date’s hot foil coder range. The E-Coder is a high quality attachment, particularly suited to overprint batch and lot numbers, expiry dates, use by dates and prices onto flexible materials including films, labels and cartons. J


Kliklok Launches New Robot Loader at PPMA Show liklok International will be demonstratK ing their new Collating Robotic Loader (CRL) and Race Track system at the forthcoming PPMA exhibition. A brand new innovation from Kliklok, the CRL is a flexible machine ideally suited to handle the output from low to high speed wrappers and collate wrapped products into cartons or trays at up to 600 products per minute, with a maximum load of 3kg. The CRL incorporates advanced design electronic motion control technology using a combination of variable frequency control, servo motor drives and a robotic Flex Picker. Three versions of the CRL are available depending on speed and tracking distance

requirements, with optional modules such as a Carton Management System which allows cartons to be either indexed into place or to be continuously moving while being loaded. Multiple CRL units can be positioned along a cartoner’s infeed conveyor to enable

product from additional sources to be combined, enabling the full speed capacity of the cartoner to be utilised. Built-in ‘plugand-play’ style communication between the CRL units creates easy production line expansion with the addition of further units. User-friendly innovative recipe-driven menus are accessed from Kliklok’s Insight colour touch screen to ensure fast change over between product styles, sizes and collations. This also offers superior troubleshooting capability, advanced servo diagnostics and a complete digital manual. See Kliklok’s latest innovation on Stand E71, NEC, 27-29th September, 2011. J

Endoline Announces Partnership With Robotics Specialist or the first time Endoline Machinery are F set to launch complete packaging assembly lines with robotic pick and place systems as part of a partnership with ABB - one of the world’s leading engineering companies. The ABB robot will form an integral part of the new packaging module and will be built into an Endoline conveyor system. The conveyor will feed from a high speed case erector and into a case sealer – the type of these Endoline machines will be determined based on each customer’s individual needs - highlighting the diversity of this project. Endoline Machinery’s own engineers will program the robot. At the forthcoming PPMA Show (Hall 5, Stand D30) Endoline will showcase the new line using an ABB IRB1600 robot – which delivers maximum output from a smaller footprint. The move into robotics follows a staggering

300% rise in the demand for industrial robots within the UK food and beverage sector over the last three years. However this increase is still notably behind that of the industry’s counterparts throughout Europe, particularly Germany and Sweden, which boasts take up rates of up to 240 robots per 10,000 workers – compared to the UK’s 52 robots per 10,000 workers. This is particularly significant to Endoline who are currently driving international sales and has witnessed a 30% increase in exports over a 12 month period. Alan Yates, chief executive of Endoline Machinery, comments: “We are delighted to become part of ABB’s Robotic Partner Network. With their network of global offices we are looking forward to working with them to support out our worldwide activities especially in China where we are opening a satellite manufacturing unit.” J

Riggs Autopack Depositors & Filling Machines on Show At PPMA 2011 iggs Autopack will be exhibiting a selection of its Model 1000 depositors, filling R machines, transfer pumps and conveyor filling lines at this year’s PPMA Show (Stand D2, Hall 5). Visitors to the company’s stand will have the opportunity of viewing a high level twin head automatic depositor with scroll feed slat conveyor for filling jars and

bottles, low level single head Option 3 automatic depositor with a 3 metre indexing conveyor for ready meal production, and an Option 1 semi-automatic filling machine with a food grade transfer pump, designed for small to medium scale food manufacturers. Riggs Autopack's high quality Model 1000 FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

depositors and filling machines are available as a semi-automatic stand alone unit for small scale food production or as an automatic conveyor filling system for larger batch runs. They provide damage free and highly precise depositing of hot or cold liquid, semiliquid and suspended solid products, and accurately fill most container types or size. J 33


William Jackson Food Group – Combining Heritage With Modern Technology Currently in its 160th anniversary year, William Jackson Food Group is investing over £7 million in expanding two of its four businesses. aving recently invested £1.7 million to extend capacity at its prepared salads business, William Jackson Food Group is also planning a £5.5 million expansion at its bakery operation. The 160 years old company benefits from being a broadly-based food business with its activities spanning fresh produce, bakery and frozen foods. Tracing its roots back to 1851, the group is unusual in being a family business which has been passed down successfully from the founder to the fifth generation. Present chairman, Nicholas Oughtred, is the great great grandson of William Jackson. With turnover in the region of £165 million, William Jackson Food Group combines traditional values with modern production technology. Being privately owned allows the company to take a long-term approach to business development.

miles of the facility during the UK growing season, while 80% of the winter leaf is grown in the Murcia region of Spain. Since moving to the Wigan factory five years ago, Hazeldene has increased sales by 175% and the new capacity will allow it to maintain this growth momentum.


Broadly-based “We are a long established family business with real heritage, coupled with exciting and ambitious plans for the future,” says Nicholas Oughtred, chairman of William Jackson Food Group. “We strive in all we do to be ‘a business to be proud of’. This helps guide us because if we aren’t proud of our products or the way we do things, then we are doing something wrong. And if we aren’t proud then neither will our customers and our communities be – and we need their support and confidence today in order to make progress tomorrow.” The group incorporates four principal and autonomous businesses in different categories of the food market - Jackson’s Bakery, Hazeldene Foods, Aunt Bessie’s and Parripak Foods. “There is a good reason for this. One of the guiding principles from our shareholders is that the company should not have ‘all its eggs in one basket’. It is a policy that has served us well over the years and for that reason we have a portfolio of food businesses in attractive market areas which we are looking to grow and expand.” £5.5 Million Bakery Investment Established in 1851, Jackson’s Bakery is the original core business of the William Jackson Food Group. The company manu-

Hazeldene Foods is reaping the benefit of a £1.7 million expansion to its factory in Wigan.

factures and distributes a comprehensive range of quality, bespoke English breads, rolls and buns from its modern factory at Kingston Upon Hull. It sells in 29 countries to industrial sandwich makers, quick service restaurants, coffee shop chains, distributors and retailers. William Jackson Bakery is embarking on a £5.5 million investment in a state-of-theart extension to its bakery site. The extension will include a new bakehouse, a new bread line to increase production capacity by 40% and automated dispatch. £1.7 Million Expansion Prepared salad producer Hazeldene Foods is literally reaping the benefit of a £1.7 million expansion to its factory in Wigan. Operating from a purpose built high care facility, Hazeldene supplies varieties of leafy and baby leaf salad, sliced product including tomatoes and cucumbers, and vegetable ingredients including freshly prepared onions and carrots, to some of the leading names in the retail, food service and food manufacturing sectors. All products are washed, ready to eat and packed in a variety of bag sizes. The expansion programme has entailed the installation of two new bagging lines, in time for the summer salad season, to take the total at the factory to ten. Over 62% of all the company’s leaf is sourced within 25 FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

Frozen Foods Business Aunt Bessie’s is the UK market leader in frozen Yorkshire Puddings and has a strong portfolio of frozen accompaniments, meal centres, vegetables and desserts. Aunt Bessie’s currently produces over 20 million Yorkshire Puddings per week at its factory in Hull. Launched in 1995, Aunt Bessie’s was initially focused on Yorkshire Puddings but the brand has been successfully extended into other traditional sectors of the frozen foods market and the portfolio currently encompasses products such as roast potatoes, stuffing balls, meat pies and ready meals. To complement its savoury foods offering, Aunt Bessie’s is also a key player within the UK frozen desserts market, specialising in traditional dishes. Prepared Vegetables Parripak specialises in supplying freshly prepared vegetables in a variety of cuts from root crops through to peppers and broccoli, with exotic lines and bespoke products to leading food manufacturers, food service and catering markets. The company was established in 1987 by the Parrish family. Located on 700 acres of prime farmland in rural Bedfordshire with a second location in the Scottish Borders, Parripak is strategically placed to supply anywhere in the UK. J

Aunt Bessie’s is the UK market leader in frozen Yorkshire Puddings and has a strong portfolio of frozen accompaniments, meal centres, vegetables and desserts.



Seven Generations of Excellence anaged by seven generations of the same family, Norwegian meat procesM sor Grilstad is investing in the latest robotic slicing technology from Marel. Based in Trondheim, Grilstad is a private company managed by the seventh generation of the Jenssen family with the same pride and dedication to quality established by their ancestors in 1790. Today, the company has eight factories in Norway – employing some 700 people operating 20 lines to produce salami, burgers, fresh meat and air dried ham. Cooked meat and ham production is also being planned for the future. Thanks to high quality and an enviable reputation, the company supplies around 50% of the salami consumed in Norway and their other products enjoy equal, if not greater, success in the home market. To cope with increasing demand, the Trondheim plant has been extended no fewer than 24 times since 1957 and now operates 6 slicing lines that produce 65 tonnes every week. Grilstad has also recently invested in a Marel IBS2000 Vision bacon line in their Gjovik plant, the success of which inspired Head of Technical Development, Georg Mattingsdal, to look at how Marel could help reduce high labour costs and improve profitability at his Trondheim plant. Robot Technology Georg was attracted to the idea of applying robot technology to automate the slicing and packing operation and, safe in the knowledge that Marel are without doubt, market leaders in intelligent portion loading, he carefully researched and subsequently ordered, a PolyLine comprising


The PolyLine installed at Grilstad’s Gjovik plant comprising PolySlicer 3000, G2300 Checkweigher, VBS Vertical Buffer, Pack Desynchroniser and a triple head IPL Robot.

PolySlicer 3000, G2300 Checkweigher, VBS Vertical Buffer, Pack Desynchroniser and a triple head IPL Robot. The new line was installed with a Marel engineer appointed to oversee and optimise the performance of the system. The PolySlicer 3000 high speed slicer automatically loads and slices up to 4 logs of high quality salami at a time. The sliced groups are then dynamically weighed by the G2300 Checkweigher which is connected in closed loop feedback with the PolySlicer in order to maintain on-weights in excess of 98%. After the checkweigher a VBS Vertical Buffer System is programmed to buffer a certain percentage of the sliced groups so that they can be released into the product flow when the PolySlicer is being reloaded. This delivers a more consistent flow of product to the IPL Robot and thermoformer and, in turn, achieves higher throughput. Georg says the VBS plays a valuable role in the line with its compact footprint and substantial contribution to higher throughputs. The IPL Robot is equipped with 3 heads which share the work of loading the sliced groups into the thermoformer at, typically,180 picks/min. FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

PolyLine PolyLine produces both shingled packs and overlapped shingle packs which, Georg says, have been welcomed by customers who have commented on the improved presentation of the product. IPL Robot has a great deal to do with this because it can place the sliced groups in the pack more quickly, more gently and more precisely than any operator and the relatively few transfer points on the PolyLine also contributes to maintaining good presentation and hygiene - a vital safety issue with ready to eat products. Georg is delighted with the new PolyLine, commenting: “It has made a big difference to the output, quality and presentation of Grilstad's products and Trondheim's profitability. I am also pleased about being able to manage the system on line and, in partnership with Marel, he looks forward to even higher levels of efficiency and productivity in the future.” For more information about the Marel’s Hish Speed Slicing range, contact:Tony Ambrose or Terry Starkey, Marel UK, on Tel 01603 700755, Fax 01603 700844, E-mails, J


UK Consumers Hit Hard by Rising Cost of Food ising food prices are forcing UK R consumers to make changes to their shopping habits, according to Which? A new national survey from the consumer champion found that 84% of people are worried about the rising cost of food - and yet, as figures reveal that the rate of inflation has fallen slightly, food prices continue to climb. Nine in 10 people have noticed an increase in food prices over the last year, and a third told Which? they had already reduced their spending on groceries this year. 39% are now using discount supermarkets more than they had previously People have also changed which foods they are buying to cope with higher food prices, switching to cheaper brands, bigger 'value' packs and more economy supermarket own-brands. Shoppers are also putting less organic food in their baskets, with 38% now less likely to buy organic meat, and

43% cutting back on organic fruit and vegetables. Which? looked at over 200 everyday items from the big four supermarkets and found that consumers can make some simple savings without compromising on taste by swapping some premium products for cheaper foods. Budget versions of fish,

cheese, butter, natural yoghurt and dried spaghetti were all recommended to try for everyday use in place of more expensive alternatives “Our research shows that despite inflation falling slightly in June, people are still feeling the squeeze from soaring food prices,” says Which? executive director, Richard Lloyd. “People are changing their behaviour and becoming more savvy shoppers when it comes to groceries, but there’s only so much they can do to cut back on the basics. We’ll be investigating supermarket pricing over the coming months, and doing everything we can to give people the advice they need to make those crucial savings.” Which? is talking to economists, the food industry and government to find out what is really driving the increasing cost of food, and what can be done to address rising prices. J


Food and Beverage Manufacturing Sector Under Real Pressure he UK food and beverage manufacT turing sector faces an increase in the number of companies facing ‘critical‘ financial problems for the first time. The latest Red Flag Alert issued by Begbies Traynor, the UK’s leading business recovery specialist, shows that the number of food and beverage manufacturers suffering from ‘critical’ financial problems has increased markedly by 24% since this time last year – the first increase evidenced in this sector. In addition, Begbies Traynor found that the number of UK companies facing ‘critical’ financial problems across all sectors has risen by 12% to 5,179 as more businesses make the transition from ‘significant’ to ‘critical’ problems.

Julie Palmer, Partner at Begbies Traynor, comments: “This is the first time that we have witnessed a rise in the level of critical distress in the food and drink manufacturing industry. The rise can be attributed to the impact of reduced margins within supermarket supply chains and higher input prices that are being absorbed by the manufacturers.” She adds: “It is a real concern that reduced levels of consumer spending are impacting on businesses across the supply chain for very basic products such as food and beverages – anxieties about low consumer confidence are not limited to retailers and manufacturers of high end or luxury goods anymore.” J FOOD & DRINK BUSINESS EUROPE, AUGUST 2011



Temperature Controlled Storage & Distribution Exhibition 2011 – September 14-15, Exec, Peterborough he Temperature Controlled Storage & Distribution Show 2011 is an exciting T new exhibition designed to showcase products and services from the industry’s leading suppliers. Promoting innovation and technology in temperature controlled storage and distribution, the exhibition will run between September 14th and 15th 2011 at EXEC in Peterborough. The temperature controlled storage and distribution industry is becoming ever more sophisticated with the progression of current technology. End users are looking to suppliers to reduce running costs while increasing operational efficiency. This new exhibition is designed to address buyers’ needs by bringing the whole of the supply chain together under one roof for the first time in the UK. The new event is supported by both the Food Storage & Distribution Federation and the British Frozen Food Federation. These two influential trade associations will each present seminars in the morning during the show – the FSDF on Wednesday 14th and the BFFF on Thursday 15th – while a variety of other speakers are lined up for the afternoon sessions. Exhibitors Over 80 of the industry’s major players will exhibit a very broad range of products and services designed to reduce costs and increase efficiency in the chilled and frozen supply chain. The highly focused event will help visitors to evaluate their temperature controlled distribution and storage needs.

SSI Schaefer’s Orbiter represents the latest technology in automated deep pallet storage and retrieval and is ideal for the demands of the food and drink market.


Visitors planning to upgrade their fork lift truck fleets will have a number of options to consider. Doosan Industrial Vehicle (stand B3) will promote its range of over 100 models including counterbalanced forklifts from 1.5 to 16.0 tonnes for IC models and from 1.3 to 5.0 tonnes for electric models, plus the new warehouse range of pallet trucks, stackers, order pickers and reach trucks. Visitors to the Jungheinrich UK stand (D27) will be able to see products from the company’s extensive portfolio of materials handling equipment, racking and storage systems. Crown Lift Trucks (stand D21) will be demonstrating its award-winning ESR 5000 reach truck in full cold-store specification, able to work in temperatures down to -30 C. Also on show will be Crown’s WP 2300 walkie and WT 3000 ride-on pallet trucks, along with continuous live demonstrations of the latest version of Crown’s InfoLink fleet management system. Translift Bendi (stand D9) will show off its new cold store ‘Arctic’ cab, allowing cold storage companies to benefit from superior performance in aisles just 1.6m wide. Toyota Material Handling UK will showcase its latest range of warehouse trucks including a BT Reflex reach truck fitted with a cold store cabin, a BT Levio ride-on powered pallet truck and a selection of BT Lifter hand pallet trucks. On stand E15, Toyota will also demonstrate the latest BT Radioshuttle, a high-density solution based on electrically powered load carriers that transport goods in storage tunnels within specially designed racking via wireless remote control. SSI Schaefer will be promoting a fully automated alternative on its stand (C16). The company’s Orbiter represents the latest technology in automated deep pallet storage and retrieval and is ideal for the demands of today’s food and drink market. Long-life power capacitors ensure that this intelligent storage system is suitable for deep freeze environments without loss of power or operational efficiency. FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

High-tech monitoring and control systems will be promoted by a number of suppliers at the show. On stand D2, Blue Tree Systems will demonstrate the benefits of its R:COM fleet management system, which takes care of the management of temperature, fuel, driving style, tachograph, in-cab communication, satellite navigation and vehicle tracking. Several exhibitors will show solutions for product protection and cargo security. SCA Packaging Industrial Division (stand A14) will demonstrate its expertise in the design of bulk packing solutions, produced from heavy-duty corrugated board, for the frozen food sector. Cost Savings Many exhibitors will be focusing on potential cost savings in the cold supply chain. Luxonic Lighting, for instance, will show how its energy-efficient light fittings and controls help clients to reduce their power consumption and hence their electricity bills. Located on stand D12, the firm will be launching its new, LED cold store luminaire, which is suitable for mounting at low levels and in high racking areas. Specialist cleaning company Distribution Hygiene Services (stand G9) provides deepcleaning services for chilled and frozen environments, including evaporators and coolers. Research shows that the cost of regular cleaning is far outweighed by the subsequent savings in energy costs. Meanwhile, The Rack Group (stand G10) will be demonstrating how to reduce pallet racking maintenance costs through safety inspections, planned maintenance, training and Rack Armour protective guards. Visitors interested in software will have a number of stands to visit. Mobile computing specialist Belgravium will be promoting its range of rugged mobile devices and its sophisticated software for a variety of supply chain applications on stand B4. Minster Logistics – which lists Marks & Spencer, Wincanton and Brakes among its clients – will showcase its bespoke software solutions, including end-to-end, voiceenabled modules, on stand G7. Chillers When it comes to chillers, visitors can talk to Eberspacher and Cool Energy. Eberspacher UK (stand E7) is distributor for Euroengel, a

STORAGE compressor-driven, insulated container that is ideal for transporting small quantities of chilled goods amongst ambient goods, or a small amount of frozen goods amongst chilled loads. For those wishing to rent, Cool Energy will be exhibiting its wide selection of rental chillers and fan coils on stand E2, all of which are in stock and available for next-day hire. The company will also be showcasing for the first time its award-winning, walk-in modular cold stores that can achieve temperatures between -30 C and +30 C. Other exhibitors include refrigerated vehicle manufacturers, bodybuilders and converters such as Schmitz Cargobull (C9), Krone Trailers UK (C21), Gray & Adams (C17), Montracon (A20), Thermo King (E9), Paneltex (D17) and The Cold Consortium (A21). Leading suppliers showcasing temperature control solutions will include Euroscan Technology (C13), Testo (H27) and Seven Refrigeration & Telematics (B6). Cold chain transport providers and contractors at the event will include Star Refrigeration (G1), Chiltern Cold Storage (D6), Dawsonrentals (A19A) and Peter Staines Refrigeration (C13), while ISD Cold Stores (F15) and Chalcroft Construction (G18) will share

their expertise in cold store development projects. Also present will be packaging specialists, Automated Packaging Systems (H9); industrial door suppliers, Hörmann (F15) and Lincs Doors (G1A); cargo control special-

Toyota’s latest BT Radioshuttle is a highperformance solution for efficient handling of goods in high-density racking.

ists, Loadlok (A18); distributor of replacement parts for transport refrigeration applications, Myriad (B5); providers of temperature-controlled storage, blast-freezing, tempering and distribution services, Rick Bestwick (A12); supplier of customised, promotional model vehicles, Search Impex (B10); and supplier of specialist gases and fully certified disposal services to both wholesalers and the end-users, Blended


Products (G17) – to name but a few. Live Demonstration Area Adding to the visitor experience will be a live demonstration area, where exhibitors will be able to show solutions and benefits in action for a variety of products, including a number of forklift truck. Visitors will also be able to enjoy networking in a special cafe area. Networking Dinner Taking place at the end of the first day of the show, the TCS&D Dinner will make a welcome return after a break of some 15 years. Exhibitors and visitors are invited to enjoy a three-course meal with entertainment and the opportunity for some valuable networking. The Venue Exec in Peterborough is easily accessible by train, plane or car, so it is convenient to get to from anywhere in the UK and beyond. Exec is just 15 minutes from Peterborough's mainline railway station with King's Cross just a 45-minute ride. The region’s airports are within easy reach with East Midlands, Birmingham, London Luton and London Stansted just one hour away by car. Exec has access to the adjacent A1. For more information visit J


• UK Temperature Controlled Pallet Network • Temperature Controlled Storage 24 hours a Day

• Sites across Manchester and London Heathrow • European Dedicated and timed deliveries • Air Freight, Import and Export • 20ft and 40ft Reefer Containers for Ocean, Full loads and Groupage

• Dry Ice, Chill Packs and packaging • HMRC Bonded, ERTS and ICD Tel: +44 161 491 8673

Tel: 00353 1 8666660


We specialize in the transportation of • Foodstuffs & Wine

• Pasta & Pastas Sauces

• Cheeses

• Fruit & Vegetables

• Ham & Salami

• Olive Oil and Balsamic Vinegar

• Desserts & Diary Products

• Fresh Meat & Poultry

Tel 00353 857 154 061 E-mail:

Provide the following services

• Warehousing services for frozen /chilled and ambient product in Ireland /Belgium and China • Provide a full logistic solution for wine importers from managing the inbound freight to the provision of bonded warehosing solution in the UK ,Ireland and China markets respectively. • A Irish nationwide delivery service for Frozen/Chilled and ambient product within Ireland • Provision of a groupage and full load service for frozen/chilled and ambient products to and from Ireland for the European /UK /American and Asian market.We also provide groupage services from the USA and China for the European market • International sample delivery service for frozen and chilled product. • International parcel delivery service • Seafreight services to/from ASIA • A 24 hour next day pallet service to/ from UK to Ireland


Worldwide Perishable Logistics Solutions from Direct Food Express, Monterey Solutions and Arcese Cosulich Ireland irect Food Express specialises in D the transportation of frozen, chilled and ambient foodstuffs throughout the UK, Europe and across the globe. The company handles consignments of all sizes. Whether it is a small sample that needs shipping from Europe, or a huge consignment that needs exporting worldwide, Direct Food Express has both the capacity and the capability to handle it. Working together and in partnership with Monterey Solutions and Arcese Cosulich Ireland, the three companies can now offer a viable alternative to Temperature Controlled Consolidation Services out of Ireland. To be able to provide a true service led, cost effective consolidation service is something the industry has Direct Food Express has developed an extensive required for many years. With a 24 temperature controlled pallet network. hour Ireland to UK service via daily departures the level has now been achieved. With Arcese and Monterey hantion in the UK, Ireland and China mardling all Irish export bookings and DFE’s kets respectively. UK temperature controlled pallet network • A nationwide delivery service for now in full swing the three companies are Frozen/Chilled and ambient product pleased to confirm the service as a reality. within Ireland. Arcese Cosulich Ireland is a joint venture • A groupage and full load service for between Gruppo Arcese and Fratelli frozen/chilled and ambient products to Cosulich Group, two major Italian players and from Ireland for the in the transportation and shipping industry. European/UK/American and Asian marThe Dublin office was set up in 2007 by a kets. Also a groupage services from the team of very experienced Italian freight-forUSA and China for the European market. warders whose extensive knowledge of both • International sample delivery service for the Italian and Irish market ensures that frozen and chilled product. each shipment coming from Italy is handled • International parcel delivery service. in a highly competent, professional and effi- • Seafreight services to/from Asia. cient manner. Because it is part of Gruppo • A 24 hour next day pallet service to/from Arcese, Italy’s biggest logistics and transUK to Ireland. portation provider with a fleet of over 1500 trucks and 2600 trailers, it can avail of the Unique Service best transportation network locally as well “Our company is unique in collecting and as state-of-the-art warehouses for the safe delivering, door to door, any type of perishable product - frozen, chilled or ambient and efficient handling of goods. Monterey Solutions provides the follow- without any restrictions to the size or weight. We have a worldwide customer ing services • Warehousing services for frozen /chilled base and operate a 24/7 service across all and ambient product in Ireland /Belgium international time zones,” explains Adam McKenna of Direct Foods Express. and China. The company’s LCL (less than full con• A full logistic solution for wine importers from managing the inbound freight to tainer load) service offers customers the the provision of bonded warehosing solu- flexibility of transporting their products by



a single pallet load if needs be and the Direct Food Express guaranteed 12day door-to-door delivery service by ocean makes its service both fast and highly cost effective. In addition, Direct Food Express offers a full hand in hand service, advising on Health Certificates and other necessary official documentation to ensure that all duties, variable charges (VCs) and taxes are correct; this also ensures shipments are delivered on time without any costly delays. Product evaluation by port health and trading standards approval can also be arranged. All products are shipped at a temperature specified by customers and can either be delivered straight to its final destination or stored at one of the company’s distribution centres until required.

Nationwide Delivery Direct Food Express operates a nationwide delivery network that can deliver either express same day or reduce costs by consolidating a shipment and delivering over a two day period. The drivers distribute from local shops and delis to supermarket distribution centres. This, combined with the company’s 5 Class A bonded storage depots located thought the UK, which hold both ambient and temperature controlled products, means that Direct Food Express can service virtually every customer need. Historically, those wishing to transport small quantities of perishable products have been forced to pay a premium for the privilege. By consolidating numerous pallets from other shippers Direct Food Express can drive prices down and pass on these reductions to customers “With Direct Food Express, our customers can send even the smallest and most delicate samples, safe in the knowledge that it will arrive within the given time and still in perfect condition. What's more, the cost of shipment will not break the bank, as the large quantities we handle mean that we can offer highly cost-effective rates, even on the notoriously expensive transatlantic routes,” says Adam McKenna. J 41

3 BANK VIEW • BAILDON • BD17 7PA • (M): +44 (0)7966 202131 • ( F ) : +44 (0)1274 414008 ( E ) : • ( W ) :


Star Treatment for Arla Foods Dairy tar Refrigeration has installed a high effiS ciency multi-temperature cooling plant at Arla Foods in West Yorkshire. The project by industrial cooling and heating specialist Star formed part of Arla’s third phase of investment in additional production facilities at its flagship dairy in Stourton, Leeds. Having been involved in refrigeration works in the previous construction phases, Star was responsible for designing a high efficiency cooling system to allow Arla to manufacture cottage cheese for the first time in the UK. With an overriding commitment to reduce energy consumption and CO2 emissions, Arla was looking for an environmentally con-

scious cooling solution. Star designed, supplied and installed a state-of-the-art central ammonia refrigeration plant, with energy sav-

ing equipment and control. The plant has a 5MW total cooling demand and operates at three separate temperature levels. A chilled water circuit provides cooling for the building’s heating, ventilation and air conditioning (HVAC) systems. Ice water is circulated to meet various process cooling demands within the production facility. Sub-zero glycol also provides cooling for a 2 C cold store and a blast chilling tunnel. Star’s Telstar computerised control system constantly monitors and adjusts operating conditions to optimise efficiency. Star also provides an online 24-hour a day fault monitoring service. J

Chips are Stacked in Eurotek’s Favour worldwide appetite for French Iledncreased fries and other fried potato products has to a bumper serving of order wins for chilling and freezing system specialist GEA Eurotek (part of the GEA Freezing group that includes the Aerofreeze and Intec brands). With a number of made-to-measure potato product freezers already installed around the world, designers and engineers have most recently been working on bespoke IQF and spiral systems for customers as far afield as Australia, China and India - where the latest installation was a four tonne/hour system to handle French fries at a new factory in Agra.

Many of these large-scale projects have been undertaken in partnership with potato processing equipment specialist Kiremko, which is known world-wide for its high quality turnkey solutions: Most recently, Eurotek has just completed its first installation for Pomcobel, a subsidiary of Belgian potato giant Mydibel. The sequential defrost spiral is designed to handle up to five tonnes of piping hot, freshly fried potato product an hour achieving an output temperature of -18 C. A leading manufacturer of chilling and freezing systems, the GEA Freezing range includes spiral freezers, IQF and single/multi band freezers as well as carton

freezers, handling products ranging from seafood to baked goods, poultry and ready meals. J

Starfrost Showcases Freezing Technology in India K-based equipment manufacturer U Starfrost is supplying an innovative quick freezing system for mango to a pio-

neering food processing facility in India. Over the next decade India is predicted to continue its significant year-on-year growth in the food and drink processing sector. Located in South East India, the Mega Food Park will provide local farmers and food producers with a state-of-the-art processing plant. As one of India’s largest integrated food parks, the 141-acre facility will bring vital post harvest infrastructure to a region renowned for fruit and vegetable production. Starfrost secured the prestigious contract from client Srini Food Park. The new venture is being supported by India’s Ministry of Food Processing Industries to showcase the world’s latest equipment and technology in one location. In time, further food parks will be developed across India based FOOD & DRINK BUSINESS EUROPE, AUGUST 2011

on Srini Food Park with similar facilities and equipment. Starfrost is custom designing a new MS (Modular Series) Turbo Freezing Tunnel for the individual quick freezing (IQF) of 1,000 kg/hr of diced fresh mango. The rapidly frozen mango product will then be sold on to the domestic retail market and packaged for export. Starfrost’s Turbo Freezing Tunnel is an enclosed freezing system that can be custom designed for product capacities from 500kg/hr to over 16,000kg/hr. Suitable IQF product applications include French fries, frozen herbs, bean sprouts, cooked rice and pasta, minced meat and a wide range of fruit and vegetables such as mushrooms, onions, peas, tomato diced mango and peach. J 43


Oakland Distribution to Support Muller Dairy Wholesale Supply Chain akland Distribution, a subsidiary of O Oakland International, a multi temperature supply chain specialist in warehousing, distribution and logistics, has been selected by Müller Dairy to create and implement a new bespoke distribution scheme designed with the small wholesale client market in mind. “The wholesale market is made up of businesses which generally represent a diverse section of the market, coping with challenges not usually experienced in the major retail sector,” explains Oakland International strategic development manager, Pete Vaughan. “Oakland's scheme with Muller Dairy will provide wholesale clients

with the ability to continue to access Muller products, whilst allowing Muller Dairy the opportunity of working with a wider base of potential smaller clients than before due to

our ability to offer a more flexible distribution offer. Initially the scheme will service twenty wholesale clients, covering all areas of the UK, with the option to add more and extend the scheme providing they have similar business profiles. Muller Dairy national account manager and wholesale hub project leader, Keith Langley, comments: “Oakland's progressive and flexible approach has enabled Müller Dairy to find the optimum solution for a seamless transition of supply and logistics to our valued regional wholesale customer base, whilst providing a solid platform for future business development.” J

Thermo King Launches V700 Max Spectrum hermo King, the leading manufacturer of transport and logistics refrigeration units T has unveiled its latest multi-temperature unit, the V700 Max Spectrum. The V700 Max Spectrum is the latest addition to the V-Series and is the most powerful multi-temperature unit in the vehicle powered range market place. The V700 delivers increased capacity compared to the Thermo King V500 Max multitemperature unit and in fact has a total nominal capacity 30 per cent higher than its direct

competitors. In addition, the V700 Max Spectrum is a unit powered by the vehicle not a diesel engine. This technological advance ensures the V700 Max Spectrum is the most environmentally friendly unit on the market. An additional bonus is that the V700 Max Spectrum refrigeration unit is a low noise unit, allowing for inner city delivery at any time. Transport companies are no longer restricted to delivering goods at particular times, enhancing the time and cost effectiveness of each delivery and in turn increasing the fuel effi-

ciency and environmentally-friendliness of each delivery. Suitable for trucks up to seven metres long, the Thermo King V700 Max Spectrum refrigeration unit meets requirements for both transversal and longitudinal two-compartment configurations. J

Chalcroft at Frozen & Chilled Foods 2011 halcroft will be showcasing its work at C the first Frozen and Chilled Foods Show 2011 in September. Representatives from Chalcroft will be on hand at stand G18, to discuss how its services could be of benefit to food producers and distributors wanting to either refurbish their premises or construct new facilities. Chalcroft operates across the UK from its bases in East Anglia and the West Midlands and can list well-known names such as Ardo, Bakkavor, Brakes, Branston, CocaCola Enterprises, Hazeldene Foods and Zorba Delicacies among its client base. With an established reputation, Chalcroft

understands the exacting demands of the food industry, while wide experience of working in high and low-care environments enables Chalcroft to carry out its work with


minimum disruption to production and in compliance with all food regulations. One of Chalcroft’s most recent completions was for Wingland Foods, owned by Icelandic frozen and convenience food company Bakkavor. A growth in demand for its products saw Wingland Foods embark on an expansion programme at its Sutton Bridge site. The project saw Chalcroft working on a high-care facility, complete with insulated white walls, kerbs and resin floor, and alterations to a blast freezer, upgrades to existing plant and the installation of an innovative air-handling system.J 45


Taste the Future at Anuga – 8th to 12th October 2011, Cologne he 31st Anuga, which will be held in Cologne from 8th to 12th October 2011, will feature around 6,500 suppliers from about 100 countries. The estimated 150,000 international trade buyers will be treated to a superlative supermarket that is clearly organised into ten trade shows that focus on key themes and enable visitors to directly and easily access the entire range of products on the world market. The ten specialised trade shows clearly structure the world's largest and most important trade fair for the food industry according to themes and focal points, and in their respective areas they bring together suppliers from Germany and abroad - ranging from small and medium-size companies to market leaders.

the international forum for buyers from the trade and catering sectors, with participants including Andros/Bonne Mamman, Bahlsen, Darbo, DEK, Dilmah, Guschlbauer, Harry Brot, Hyson, Intercookies, Kronenbrot, Lantmannen Unibake, Mabroc, Mestemacher, Vandemoortele and Zentis.


Anuga Fine Food Featuring gourmet and delicatessen products and general provisions, Anuga Fine Food is the biggest and most international of the Anuga trade shows. Companies exhibiting here include A Viani, Develey, Di Gennaro, Fuchs, Herbert Kluth, Carl Kuhne¸ Schamel, BIP Holland, Del Monte International, Fazlani Exports, Monari Federzoni, Monini, Scana Noliko, Scandic Food, Sea Value, Struik, Thai Union and Unaprol Consorzio Olivicolo Italiano Scarl. Anuga Drinks Anuga Drinks will feature a wide range of non-alcoholic beverages, a special platform for trend and bar drinks and - in combination with Anuga FoodService - the Wine Special. Exhibiting companies include Beijing Huiyuan, Bitburger, Bosch Boden Spies with Chiquita, Citrosuco Fias , Dohler, FW Langguth Erben, Gerolsteiner Brunnen, Glockengold Fruchtsaft, Harboes Bryggeri and Nestle Waters. Within Anuga Drinks, the Drinks Trend Forum will focus on the latest drinks trends in an attractive setting - served by professional bartenders who will demonstrate their expertise with alcoholic and

non-alcoholic beverages to the trade visitors. Anuga Chilled & Fresh Food Anuga Chilled & Fresh Food incorporates fresh convenience products, fresh delicatessen products, fish, fruit and vegetables and is now even more clearly positioned within Anuga and expanded to include all fresh convenience products. Companies exhibiting include Edmund Merl, Feinfischräucherei Noll, Heinrich Kuhlmann, King Cuisine, Larsen - Danish Seafood, Mosna, Rugen Fisch, Stuhrk Delikatessen, Wewalka and Estonia Fisheries. Anuga Meat Featuring meat, sausage, game and poultry, Anuga Meat is the trade show for the meat industry. Participants include Alcisa & Pick, Brasil Foods, Citterio, JBS, Mafrig, Reinert, Tonnies, Vion, Wiesenhof and the zur Mühlen Group. Anuga Meat is the second largest trade show within Anuga, after Anuga Fine Food. Anuga Frozen Food Anuga Frozen Food is the international platform for the marketing of frozen food products, with exhibiting companies including Ardo, Aviko, Champimer Scelta Mushrooms, Crop’s, Lamb Weston, Neuhauser, Pickenpack - Hussmann & Hahn, PinguinLutosa, Surgital, Wagner and Wernsing. Anuga Dairy Anuga Dairy provides a comprehensive overview of the international milk products market. The exhibitors include Alpro, Bauer, Conaprole, Ehrmann, Emmi, FrieslandCampina, Goldsteig, Hochwald, Hoogwegt, Humana Nordmilch, Milchunion Hocheifel, Milkpol, Saputo, Uhrenholt, Valio and Zott. Anuga Bread & Bakery, Hot Beverages Anuga Bread & Bakery, Hot Beverages is



Anuga Organic Anuga Organic will feature exhibitors such as Alb-Gold, Bioland, Bio-Zentrale, Lauretana, Naturland, Roggenkamp, Schedel, Sonnentor, Bernhard Zabler, as well as national presentations from Denmark, Italy, the Netherlands, Romania and the USA. Anuga RetailTec Anuga RetailTec will showcase technology and services for the retail trade. Companies exhibiting include AHT Cooling and Baro. Anuga FoodService Anuga FoodService is a new improvement on the previous trade show Anuga CateringTec. The range of exhibited products and services has been expanded to include the offerings of food and beverage suppliers. The aim is to provide a focused ordering and information platform for buyers from the food service and catering market. Exhibiting companies include Cimbali/Faema, Christian Seltmann, JJ Darboven, Evian, Firma, Fripan, Hupfer, Kahla, LMC Eurocold, Meiko, MKN, Rational, Salomon, Ugur Sogutma, Unilever, Wiesheu and WMF. The new Anuga FoodService will be enhanced through the integration of catering sector-oriented special shows. These shows will include the ‘Catering Marketplace’, which is specially oriented to the German catering scene, as well as ‘Creative Kitchen’ and ‘Visions of Cooking’. The new Anuga FoodService will be complemented by a programme of presentations featuring renowned experts in the field. For further information visit J

Cargill’s Cocoa Farmer Training Introduced in Cameroon armer co-operatives in Cote d’Ivoire F are benefiting from average yield improvements of nearly 50%, a 30% reduction in major pest problems and quality improvements in bean fermentation as a result of Cargill’s farmer training to support sustainable cocoa production and certification. Following on from the success of these pilot co-operatives, the training programme is being expanded to include Cameroon, the world’s fourth largest cocoa producer. Harold Poelma managing director cocoa, Cargill Cocoa & Chocolate, explains: “After the first year of UTZ certification, our pilot co-operatives in Cote d’Ivoire have seen on average a 47% increase in yields, rising from 559 to 882 kilograms per hectare. “As a result of the adoption of good agricultural practices around pruning and weeding, there also has been, on average, a 30% reduction in major pests along with major improvement in the fermentation level of the beans and a decrease in humidity, due to improved dry-

ing and storage after harvest. These results convince us that we are following the right strategy in Cote d’Ivoire, and we will now adopt this successful policy in other cocoa growing countries where we feel we can make a real difference.” Cargill, which is the largest exporter of cocoa beans from both Cote d’Ivoire and Cameroon, has built up an extensive network and presence on the ground in Cameroon, comparable to that in Cote d’Ivoire, including rural buying stations

and warehouse facilities. This extensive network, and the close relationship with farmers it brings, benefits farmers in Cameroon and their communities. The programme of farmer training in Cameroon will be delivered in partnership with Telcar, Cargill’s joint venture partner in Cameroon. It is being launched in conjunction with the World Cocoa Foundation and Socodevi, a Canada-based network of co-operative businesses that supports farmers organisations’ initiatives in the developing world. The programme will support the creation of a sustainable cocoa supply chain in the country, with the aim of achieving UTZ certification for co-operatives in 2012. This latest expansion of farmer training, which complements that previously announced in Vietnam, underlines Cargill’s belief that training farmers successfully is key to building a sustainable supply chain as well as helping increase farmers’ incomes and supporting the future growth of cocoa farming. J

Nestle’s Cocoa Plan Extends to Indonesia estle is gaining momentum in its comN mitment to sustainable cocoa production with the launch of The Cocoa Plan in Indonesia. Aiming to impact on the lives of 10,000 Indonesian cocoa farmers and their communities by 2015, the Plan also seeks to increase cocoa productivity at farmer level by 30%. As the third largest cocoa producing country in the world after Cote d’Ivoire and Ghana, Indonesia will benefit from the Plan’s investment of over SFr3.4 million ($4 million) over four years to train farmers, provide plant expertise, and support supply chain transparency. In addition, it aims to improve livelihoods by focusing on pro-

jects related to nutrition education, water, and rural development, while also supporting Nestle’s commitment to the environment. Led by Nestle Indonesia and supported


by the Nestle Research and Development Center in Tours, France, the launch is in collaboration with the provincial Government of West Sulawesi and South Sulawesi in Indonesia, Armajaro, Petra Foods, and the Indonesian Coffee and Cocoa Research Institute (ICCRI). Nestlé’s Cocoa Plan – launched in 2009 – aims to create a sustainable supply chain for the cocoa industry. By improving the quality and quantity of yields, this will provide better quality cocoa and, in turn, also benefit cocoa farmers and their communities by providing them with long-term security and training expertise. J 47

National Flexible Engages In Germ Warfare ational Flexible, the film packaging N specialists, has expanded its portfolio of films to include a new material that directly addresses recent health-scare problems facing the food industry. The new anti-bacterial film makes use of silver ion technology as a way of inhibiting bacterial and microbial activity on the surface of the film. Just like the ‘well known brand of bleach’ the film is effective in eliminating 99.9% of bacteria on packed product in contact with the film. This includes effectively attacking the Staphylococcus bacteria as well as Escherichia Coli (E.coli) which was at the source of recent food poisoning outbreaks and has potentially cost the food industry millions through lost confidence as end consumers seek assurances about food safety. The film’s performance has been inde-

pendently tested under ISO:22196 and meets approval for direct food contact. It can be applied in a variety of packaging formats for products such as fresh and prepared produce where its unique properties potentially offer extended shelf life. Extra anti-fog properties can be added to the film if required. The film is identical in performance and appearance to standard BOPP films and can be used on existing packing lines without any modification to the machinery. National Flexible is the UK’s largest distributor of polypropylene, laminates and special films. Its custom factory is purpose built to be compliant with the latest BRC standards for food-grade packaging, and the company has become well known as an innovator in the field of packaging films for the food, bakery, snack, confec-

tionery and contract packing industries. For any further information contact National Flexible on Tel +44 (0)1274 685566 or visit www.national J

Nesting’ Drums See Customers Flock to FDL s FDL Packaging Group, of St Helens, A Merseyside embarks upon its fourth year as the official UK distributor for the range of steel drums and premium bespoke litho-printed drums from Mauser, one of the world’s leading packaging manufacturers, one Mauser product in particular is making serious waves in the marketplace. While FDL has, of course, been offering tapered steel drums of up to 120-litre capacity for a number of years, the new Mauser range offers drums in anything up

to 218-litre capacity. Not only that but, crucially, because of equivalent diameters, the drums are designed to ‘nest’ inside one another regardless of filling volume, making significant reductions on transport costs and the valuable warehouse space required for empty drums. While, to save even more space, the drums can also be neatly palletised. For more information contact FDL Packaging Group on Tel +44 (0)1942 722299 or visit J

Spooner Employee Clocks Up Half Century pooner employee Richard Garnett has S just celebrated the 50th anniversary of his employment with the company. Having started his career with Spooner as a 16 year old apprentice in July 1961, today Richard acts as a technical consultant, having officially retired from full time employment in May last year. Richard began work in the old factory on the Railway Road site in Ilkley and took home £2.50 a week. Over the years he has worked his way from the shop floor through research and development, the 48

drawing office, sales and eventually to the applications department of which he became manager in 1989. The company, which is now based in purpose built new premises in Ilkley and is one of the town’s biggest employers with over 150 staff, has come a long way from its beginnings in 1932 with founder William Wycliffe Spooner and his three employees. Richard is one of a few remaining members of staff who remembers life working for Mr Spooner. Today Spooner supplies forced convecFOOD & DRINK BUSINESS EUROPE, AUGUST 2011

tion baking, proving, cooling and drying process equipment for the industrial manufacture of bread, cereal, biscuits, pies, pastries, pet foods and other savories. Spooner is continuously developing new and innovative technologies and solutions in its inhouse testing and R&D facilities to remain at the forefront of the food industry. J




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