Food & Beverage Industry News - Dec 2017

DEC 2017/ JAN 2018

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DEC 2017/ JAN 2018

Satisfying & safe the hygiene imperative

PLUS: Country of Origin labelling | Design & Construction tips | Paddock to Plate

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WELCOME

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Copyright Food & Beverage Industry News is owned by Prime Creative Media and published by John Murphy. All material in Food & Beverage Industry News is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy of information, Prime Creative Media will not accept responsibility for errors or omissions or for any consequences arising from reliance on information published.

The opinions expressed in Food & Beverage Industry News are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2016 Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.

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ere at Food & Beverage Industry News, we aim to provide businesses with the information they need to grow in these fast-changing times.

With this in mind, it makes sense to hear from important industry organisations about what matters to them and their members. This issue, both the Australian Food & Grocery Council (AFGC) and the Australian Institute of Packaging (AIP) join us as regular contributors.

In this issue Chris Preston, AFGC’s Director of Legal and Regulatory offers tips about how businesses can best handle the upcoming introduction of Country of Origin Labelling, while AIP’s Dr Carol-Kilcullen Lawrence provides her take on the issue of plastic bags and recycling.

We are delighted to have these experts on board and are confident their contributions will prove invaluable to our readers.

After some delay, Amazon has launched in Australia. We examine the arrival of this retail giant and ask what affect it will have on the local food and beverage industry.

Also this issue, Comet Line Consulting continue their regular column on market

activity in the sector and we launch Total Tips, a regular column by Total Construction which provides advice on design and building for food and beverage manufacturers.

Elsewhere we examine the Q-ton, an air-to-water hot water solution by Mitsubishi Heavy Industries Air-Conditioners Australia.

This unit, which uses CO2 gas as a refrigerant, promises to address two of the biggest issues facing food manufacturers − sustainability and energy costs.

Then we profile Adelaide-based HMPS, a developer and manufacture of packaging machinery, which has tasted export success overseas. The company argues looking overseas is the best way to ensure local success.

Finally, our promotional feature this issue is Food Safety & Recalls. We feature GS1 Australia, Inoxpa, Roxset Australia, Tork Professional Hygiene and CRC Industries; all of whom contribute to improving the hygiene standards of the industry.

Matthew McDonald, Editor

INSIDE 14

25

32

Average Net Distribution Period ending Sept ’15

5,316

Printed by: Manark Printing 28 Dingley Ave Dandenong VIC 3175

8 MARKET WATCH

26 TRADE & EXPORTS

31 TOTAL TIPS

10 COMMENT

28 RETAIL RELATIONSHIPS

32 FOOD SAFETY

14 EFFICIENCY & DOWNTIME

29 FOOD & BEVERAGE INDUSTRY AWARDS

40 NEW PRODUCTS

24 FOOD TRENDS

Ph: (03) 9794 8337

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 5

THE GLOBAL LOGISTICS REVOLUTION 10-12 MAY 2018 MELBOURNE CONVENTION & EXHIBITION CENTRE

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MARKET WATCH

MG sale marks busy Q4 D eal making momentum has continued in the fourth quarter with nine acquisitions announced. A feature of transactions in the quarter is the large proportion of transactions (67 per cent) in the dairy and related sectors.

Date

29-Sep-17

Target Name

Pyengana Dairy

Acquirer

Sector

Deal Value

Tasfoods Ltd

Dairy

$1.6 million

3-Oct-17

Everest Foods

Allegro Funds

Ice cream

Undisclosed

12-Oct-17

Udder Delights (90 per cent)

Megmilk Snow Brand Group

Dairy

$14 million

19-Oct-17

Cerebos branded foods & instant coffee

Kraft Heinz

Processed food

$290 million

24-Oct-17

Real Pet Food Company

New Hope Group and Temasek

Pet food

$1 billion

27-Oct-17

Murray Goulburn

Saputo

Dairy

$1.31 billion

10-Nov-17

Peanut Company of Australia

Bega Cheese

Processed foods

$12 million

11-Nov-17

NuLac Foods

Bubs Australia

Dairy

$38 million

Brownes Dairy

Shanghai Ground Food Tech Company

Dairy

Undisclosed

14-Nov-17

Capital and New Hope Group and Singaporean investor, Temasek. The transaction values Real Pet Food Company at $1 billion which is significant considering Real Pet Food Company was valued at $410 million when Quadrant invested in the business in June 2015.

Allegro Funds acquired Everest Foods, a leading manufacturer of premium ice cream, gelato and sorbet with distribution primarily into the foodservice channel.

Comet Line Consulting advised the owners of Everest Foods on the sale of the business to Allegro Funds.

Kraft Heinz acquired the food and instant coffee business of Cerebos for $290 million. The brands sold by Cerebos include iconic food brands such as Fountain, Gravox and Saxa.

The disposal of WA-based Brownes Dairy by Archer Capital to Chinese dairy company, Shanghai Ground Food Tech, is also significant.

In the final quarter of 2017, four offshore investors made significant inward investments in the Australian food and beverage industry. This underlines the attractiveness of the food industry to overseas investors. The Australian food and beverage industry remains highly attractive to domestic and offshore investors and we expect the high level of deal activity to continue for the remainder of 2017 and into 2018.

Acquisitions announced

Listings on the ASX

The transaction that stood out in the quarter was the acquisition of Murray Goulburn by Saputo for $1.3 billion. The transaction is subject to approval by Murray Goulburn shareholders. If approved, Saputo will become the largest processor of milk in Australia with approximately 2.9 billion litres of milk. The acquisition of Murray Goulburn by Saputo is the largest transaction in the food and beverage industry in 2017.

Another standout transaction is the disposal of Real Pet Food Company by Quadrant Private Equity to a consortium made up of Chinese investors, Hosen

There were no listings of food and beverage businesses on the ASX in the months of September and October 2017.

Ben van der Westhuizen (left) and David Baveystock are directors of Comet Line Consulting, an advisory business that specialises in acquisitions and divestments within the Australian food and beverage industry.

For more information visit www.cometlineconsulting.com.au.

Commodity Outlook WHEAT – Wheat price to increase but remain low, reflecting a fall in high-quality wheat supply.

COARSE GRAINS – World barley prices to increase but remain low due to abundant supplies.

OILSEEDS – World canola prices to remain unchanged due to tight canola supplies and falling soybean prices..

SUGAR – World sugar prices to fall as a result of increased world supply.

COTTON - World cotton prices to fall as a result of supply growing faster than demand.

BEEF AND VEAL – Saleyard prices to fall due to weaker export returns and increased beef production

8 Food&Beverage Industry News | Dec 2017/ Jan 2018 | www.foodmag.com.au

SHEEP MEAT – Firm export demand and restocker demand to support lamb prices DAIRY – Milk prices to rise, reflecting firmer global demand and competition for milk supply Source: Department of Agriculture and Water Resources (ABARES), Agricultural commodities September quarter, 2017.

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COMMENT

Country of Origin Labelling Australia’s much talked about new labelling laws are now just around the corner. Chris Preston offers some tips on how food and beverage makers can best deal with the changes.

Product of Australia

W

e are now more than half way through the lead in time before the new origin labelling rules for food become mandatory on 30 June 2018, so with just a few months to go it is time to take stock and see what pitfalls and tricks the experience so far has thrown our way. Here’s my top six.

ONE. Data is king. You don’t just need to label your food, you need to hold data to back up the percentage and origin claims on the label.

If you do not have origin data on each ingredient, you really have to count that ingredient as being not Australian.

TWO. Be very, very sure of your ingredient sourcing. Your product may be 80 per cent Australian today, but if some weather calamity happens, there goes your origin claim as well as your source of

ingredients. There is no allowance in the new rules for natural disasters or similar events, nor is there any allowance if the Australian supplier’s prices go up to the point you need to swap to imported product.

THREE. Don’t be scared of under-declaring. The rules require declaration of minimum Australian content, not actual content. Only over-declaring will get you into strife. What this means in practice is that most products will actually have more Australian content than their labels declare. The rules do allow averaging of Australian content which may be a way forward in some cases, but again data is king – you will need to hold and maintain, on a rolling basis, data proving your average content labelling as well as provide consumers with some off-label means to find out the actual Australian content in the product.

FOUR. There will be a lot more products labelled as being “Made in Australia”. Products currently labelled as being “Product of

10 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

Australia” but which contain some minor imported ingredient, even if it is a food additive used at tiny levels, will no longer be eligible for the “Product of” claim.

At the other end of the spectrum, manufacturers who didn’t want especially to sell their products based on origin would often use a “Packed in” claim, but with the hierarchical nature of the new rules this may not be possible if the product is substantially transformed in Australia – the product will be required to use the “Made in” claim.

So both ends are being squeezed into the middle by the new laws.

FIVE. Water is tricky, especially if it serves more than one purpose.

The first point is that water used to reconstitute or rehydrate a dehydrated or concentrated ingredient takes on the origin of the ingredient. You would need data (told you data was king) showing how much water was taken out of the ingredient so you know how to treat water put back in.

Secondly, when calculating your percentages, ignore any liquid packaging material (i.e. that is typically discarded prior to consumption). You may need data showing why you treated a

packaging liquid one way or another.

Finally, any other water is an ingredient in its own right and should be treated as having its own origin – even if some or all of it is cooked off during manufacture, because the calculation is based on ingoing ingredients by weight and no adjustment is allowed for volatiles. To this, I would add one more – water used to boil a product is not an ingredient unless it is absorbed into the product itself.

It is a cooking medium, not an ingredient.

SIX. The key date may be earlier than 30 June 2018. That is the date by which the law requires products to be packed with the new labels attached. Product packed prior to that date can, at least according to the law, still be sold. However, you must also check your customer requirements, as they may insist on compliant labels sooner than that. The commercial effective date may be earlier than the legal effective date.

Chris Preston is the Australian Food and Grocery Council Director of Legal and Regulatory.

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COMMENT

In search of environmentally friendly shopping bags Free plastic carrier bags will disappear from Australia’s two largest supermarkets in 2018. There are many arguments for and against this change, as it is important to look at the all environmental impacts of their alternatives. Dr Carol Kilcullen-Lawrence writes.

F

ree plastic carrier bags are often referred to as single use; however, this doesn’t take into account their downstream use as bin liners for example. Studies show that, in South Australia when this change occurred, sales of bags for refuse massively increased. In many cases, these bin liners are heavier than carrier bags, so more plastic reaches landfill. Additionally, if light-weight supermarket bags are replaced with thicker bags that customers pay a small fee for, while these are designed to be reusable for a while, if they eventually end up as bin liners the negative environmental impact is even greater.

In Europe they have taken some steps to avoid this use of the sturdier bags for refuse, by describing them as a ‘Bag for Life’ so when they are no longer suitable for carrying groceries, they can be returned to the supermarket for recycling and replaced with a new one free of charge. It’s important to point out however that the colourful branding with supermarket logos etc. provides another negative environmental impact compared to plain lightweight bags.

Many would be surprised at the findings when sustainability of different carrier bags is assessed throughout their full lifecycle. A common reaction is to assume paper bags have the lowest environmental impact. In fact, although studies vary, all agree that paper bags have higher or equal environmental impact (depending upon which specific impact is being measured) as lightweight plastic bags and fabric reusable bags. Paper is only more favourable if measuring eutrophication, as manufacturing and recycling paper carrier bags has a lower impact on our waterways in terms of release of nutrients. In considering other types of environmental impact, resource use, energy and greenhouse gas

Many would be surprised at the findings when the sustainability of different carrier bags is assessed throughout their full lifecycle. production, the most favourable carrier bags are light-weight plastic and reusable fabric bags.

Looking more closely at reusable fabric bags, focus clearly needs to shift to how many times they are actually reused. To ensure their impact remains the most favourable they must be reused at least 100 times, with some analysis claiming this can be as high as 175 times. This varies depending on their actual composition, be it PP, PET, cotton or hemp and the like.

Many are not sturdy enough to last the distance, in terms of stitching etc.

Some customers also raise concerns about hygiene and no studies have taken into account the impacts of regularly washing bags.

While not as numerous as supermarket bags, it would be good to see investigations into other types of free shopping bags at retail outlets. The formats of these are wide and variable – high quality, heavyweight, paper and plastic - many with

12 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

elaborate ribbon and cord handles so that when customers recycle them, they are unlikely to deconstruct them into separate components that are compatible with recycling together.

Many DIY stores are giving customers access to cardboard packaging that their goods have been delivered to the store in. This was popular for groceries in many parts of the world years ago. While this could be acceptable to many customers, space is premium in supermarkets and this may not fit with the in-store image large chains want to portray.

Once light-weight carrier bags are gone, will the focus shift to the smaller light-weight grocery bags used for customers to select their own loose produce? Increasingly, there are options emerging to buy fabric reusable versions of these and in reality they could themselves be reused several times as they are not subject to the stresses put on carrier bags.

There are so many factors that

come into play when assessing which carrier bags are truly best for the environment. An Australia-wide approach is more likely to achieve the best outcome, rather than individual states and supermarket chains making random decisions. Light-weight plastic carrier bags are not necessarily the worst environmental option, so perhaps the focus needs to move to offering customers effective ways to recycle them. Essentially, their composition is almost identical to many soft plastics used to package all types of products used in the home, and courier bags from online shopping. We shouldn’t accept that these are destined for landfill. Light-weight plastic carrier bags can be diverted into schemes that are emerging for such household waste.

Dr Carol Kilcullen-Lawrence FAIP PhD is National President of the Australian Institute of Packaging (AIP). educate@aipack.com.au

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EFFICIENCY & DOWNTIME

Environmentally friendly, cost saving hot water solutions Mitsubishi Heavy Industries Air-Conditioners Australia has released an innovative sanitary hot water solution that addresses two of the biggest issues facing manufacturers, sustainability and energy costs.

G

iven its use in everything from plant wash downs to pasteurisation, access to a reliable hot water supply is a musthave for many food and beverage manufacturers. The problem is, the traditional means of producing readily available water has been both expensive and environmentally unfriendly.

In response to this, Mitsubishi Heavy Industries Air-Conditioners Australia (MHIAA) has released the Q-ton - a highly efficient, air-to-water hot water solution which utilises CO2 gas as a refrigerant. According to the company, the unit uses a safe, natural and environmentally responsible refrigerant. This has natural accruing properties that give the Q-ton advantages over conventional refrigerant heat pumps.

MHIAA describes it as a breakthrough in terms of both sustainability and reduced running costs.

Suitable for use by food processors, distillers and other manufacturers, the unit features a coil of cold refrigerant that absorbs heat from the outside air, as well as the world’s first two-stage compressor (combining state-of-theart rotary and scroll technology).

A hot water solution with high efficiency rates and low carbon emissions, the Q-ton delivers outstanding performance as a solution based product. The product recovers heat energy from the air and can perform in extremely cold temperatures (down to -25°C).

“Q-ton supplies hot water from 60°C to 90°C at 100 per cent capacity at an outdoor temperature down to -7°C and will continue to produce hot water down to -25°C,” Trent Miller, Air-to-Water Manager for Mitsubishi Heavy Industries Air-Conditioners Australia, told Food & Beverage Industry News.

Essentially, the pump forces air

through an evaporator that contains CO2. The heat in the air is then passed through the evaporator before being absorbed by the CO2. The refrigerant is circulated in the system via the compressor causing its temperature to rise as it passes through the compressor and a heat exchanger. This heat is then transferred to the passing water before being delivered into the storage tank.

The Q-ton produces hot water at off peak electricity times and stores it in a tank for daytime use, offering a large cost saving for operators and is considered a direct replacement for boiler systems as it controls the water supply and storage temperature as well as the output capacity.

According to Miller, it offers a number of important advantages compared to the conventional alternatives.

“When you use a normal hot water solution, the conventional refrigerant can’t achieve the high temperatures of hot water. Furthermore the conventional alternatives cannot perform in lower temperatures and require the use of an electric element in heating,” he said.

Miller explained that, before the arrival of the Q-ton, there was no way for such units to manage highly compressed gasses. “The CO2 in the Q-ton has a resting temperature of about 5500 kPa while a conventional refrigerant may only have a couple of hundred. As soon as the compressor starts up, we will be getting pressures of up to 12000 kPa which is a lot of energy,” he said.

Heat pumps are rated by their Coefficient of Performance (COP), which is the ratio of the energy output over the energy input. The higher the COP ratio, the more efficient the unit.

The Q-ton boasts an industry-leading COP of 4.3. According to Miller, depending on the application, that figure can be even higher.

14 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

"The Q-ton produces hot water at off peak electricity times and stores it in a tank for daytime use."

The Q-ton uses the environmentally refrigerant CO2.

“In a distillery in Tasmania, the Q-ton was installed instead of their originally planned electric line heater because of the projected energy savings and proven COP that the Q-ton gives. The 4.3 COP is actually a conservative estimate that is based on the standards in Japan where the ambient temperature of the water is much lower,” he said.

“In warmer climates like say Cairns, depending on the incoming water’s ambient temperature, it could

require a lot less energy to heat and the COP could be a 5 or 6.”

Improved sustainability The innovative hot water solution also offers significant environmental benefits.

“Because we are not using conventional refrigerants, we are eliminating the emission of hydrocarbons which can damage the atmosphere. This is the main reason why we should be using natural

EFFICIENCY & DOWNTIME

refrigerants,” said Miller. The Q-ton has been rated as having Ozone Depletion Potential (ODP) of zero.

Miller explained that, as a by-product of the refrigeration process, the unit simultaneously produces cool air. Manufacturers can take further advantage by using both to their benefit.

“If you had an abattoir you could mount the units in the cool rooms.

Each unit has 20kW of cooled air. So if you had five units there’s 100kW of cold air coming off the top of it,” he said.

For example, you can produce hot water to perform plant wash downs while, at the same time, using the cooled air to refrigerate your cool areas and keep product fresh.

Safety and predictive maintenance Miller pointed out that safety is another key selling point for the system. “The refrigerant charge is only 8.5kPa per unit which is roughly what’s in a fire extinguisher. It’s a very small charge. Safety wise, it gives businesses a lot of control over their hot water,” he said.

For example, where businesses

want to reduce the chances of Legionella they need to heat water to 90°C. “Rather than keeping everything heated to 90 degrees all the time, they can elevate the cycle, run it to that heat, and then come back down to something that’s safer to work with.

Unlike a gas boiler it ramps up then ramps down. Normally people set it and forget it,” said Miller.

“We’ve got a touch screen remote or you can do it remotely through your computer and change the temperature to within 0.5 of a degree so that’s really going to change how people work with hot water.”

This remote monitoring capability, combined with inbuilt sensors within the unit, allows operators to oversee the operation of the unit system as well gather a lot of useful data such as the amount of hot water produced and energy used on a per day basis.

“With this information, customers can then have more visibility on how efficiently they are running their manufacturing processes in, let’s say, an abattoir or a dairy plant,” said Miller.

The fact they can use the data to deliver predictive maintenance

programs is another reason the unit represents a step forward in heat pump technology and can help businesses looking to increase operation efficiency and improve their bottom lines.

While Miller conceded there is a competitor in this space, he pointed out that those are larger units than the Q-ton.

“We have a unit that can be modulated together. The versatility of our unit and our ability to increase the capacity size required for the job means that users have more control over the system. Other systems tend to have larger size units which do not allow for modulated flexibility within the product,” said Miller.

He explained that this, in combination with the company’s rich history in variable flow refrigerant technology (air-to-water) found in the VRF systems, gives the Q-ton system the edge in the market in providing a sanitary hot water solution to commercial spaces.

“With the Q-ton it’s not a split system, it’s all self-contained.

You’ve got no one welding in the system. It’s all water in, and water out. That means we’ll get a lot longer run hours and a lot longer design life out of ours just because there’s no interaction with the refrigerant circuit from the tradesmen. It comes pre-set,” said Miller.

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 15

EFFICIENCY & DOWNTIME

Vision inspection solution breaks rejection issue An egg packer was having its products rejected by retailers because of poor quality control. The solution, a vision inspection system supplied by Matthews Australasia, not only solved the problem but also won the company the PACE Zenith Award for Manufacturing Control.

P

acking eggs has several challenges: the fresh produce is both fragile and perishable, thus has a limited shelf-life. This means it is imperative that eggs are handled correctly the first time, without extra processes and time in re-work due to incorrect packing or labelling.

In its fast-paced environment with 18 different production lanes, an Australian egg packer was packing more than 30 SKUs for several customers. Every individual consumer-unit egg carton (or “inner”) is packed into a specific shipper outer for transportation, after which the 18 production lanes finally merge into one.

The packer had two main issues.

Firstly, its outdated, unreliable coding equipment was causing downtime and, secondly, a lack of quality control meant the incorrect consumer-unit egg cartons were sometimes packed into shippers. This was resulting in an increasing number of retailer rejections, which was wasting

resources and had the potential to waste produce and damage the brands The business wanted to eliminate date coder-related downtime, ensure the correct consumer units were packed into shippers, and verify the date-code format printed onto the outer carton matched the SKUs it contained and change this QC check from manual to automatic.

Having worked with Matthews in other areas of its business over several years, the egg packer asked the product identification and inspection specialist for guidance. Matthews recommended a date coder that allows flexibility in code styles and formats, and an integrated inspection solution to verify the correct SKUs are packed into shippers.

Counting eggs The date coder’s capability has given the egg packer more versatility, allowing it to print both different dates and formats on different products going down the same

Because of their fragile nature, it is best for eggs to be handled correctly the first time.

16 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

conveyor line. This means each of the 18 production lanes can run a different brand and egg size simultaneously.

It also allows the business to run any one of the 30-plus SKUs in any production lane, without the need for dedicated lanes for certain SKUs. Additionally, the packer can get counts of cartons for each SKU in real time, giving highly accurate production output data that it did not previously have.

The camera-based vision inspection solution looks into the shippers before they are closed, checking that the barcode on the inner units matches the barcode on the shipper, thus verifying that the correct consumer-unit egg cartons are in the right shipping boxes. As well as verifying the date code is correct, this automated process also checks the legally required date code is present to begin with.

To make the solution even more cost effective for the egg packer, Matthews implemented it after the

production lines merged. This meant the packer only needed one system in total, instead of one for each of its 18 production lanes.

Initially, this made the application itself more challenging because any one of the multiple SKUs could come down the line, and the inspection solution needed to verify if the shipper matched the inner. A second challenge was the fact that the barcode for the inner has to be read after it’s stacked inside the shipper; this is not a common practice.

However, using the latest vision technologies, Matthews designed a highly reliable, repeatable solution that gives peace of mind with its accuracy. Retail rejections due to incorrect date coding and product mismatching is now virtually zero, giving significant brand confidence.

This solution has also brought other issues to light that the egg packer wasn’t aware of, having the bonus outcome of allowing it to address overall business efficiency.

EFFICIENCY & DOWNTIME

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www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 17

EFFICIENCY & DOWNTIME

Single and multipoint lubricators Alemlube offers a range of single and multipoint lubricators that are suitable for use with the conveyor systems and remote greasing points used by food and beverage manufacturers.

L

ubrication is an important consideration for operations wishing to optimise machinery life and minimise downtime. A good lubrication strategy can translate into a better functioning operation and, ultimately, growth.

Unfortunately, in reality, maintenance budgets are often not high enough to accommodate such strategies. Despite the fact that more than half of bearing failures in the field are caused by either inadequate lubrication or improper lubrication and contamination, too often not enough attention is paid to high-quality, wellfunctioning lubricators.

The good news is that unlike overload, installation errors, storage and handling errors, in most cases bearing failures due to inadequate lubrication and contamination are preventable.

Bearings are high precision components that need lubrication to prevent metal-to-metal contact, which results in wear and failure. They also need to be protected to keep water and contamination out, which also leads to wear and failure. The best way to achieve both of these essential

operating goals is to regularly grease all the bearings.

It can be difficult to find the right way, the right time, and the right amount to lubricate while determining what the best lubrication solution is for your machinery because optimum lubrication practices require skill, time, manpower and money.

Alemlube automatic greasing systems take the guess work and worry out of the equation in determining a solution. The result is a combination of precise lubrication, systematic lubrication management, safety in potentially hazardous environments and long-term cost benefits.

In particular, the Pulsarlube range, solely distributed by Alemlube in Australia, utilises patented cuttingedge microprocessor technology resulting in one of the most innovative and reliable automatic single and multipoint grease (and oil) lubricators on the market.

Pulsarlube M series The Pulsarlube M series is available in four models, with capacities of 60, 125, 250, and 500cc.

The units are primarily designed

The Pulsarlube M series offers advantages in terms of cost competitiveness and user friendliness.

18 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

to compensate the performance of conventional gas type automatic grease lubricators. They also offer advantages in terms of cost competitiveness and user friendliness.

They consist of a vertical selfpriming pump, microprocessor control system, and large LCD display. They are ideal for applications where considerable back pressure in lube line exists, a precise lubrication is required, or a disposable gas type lubricator is not economical.

They feature pump grease up to 60 bar and are not affected by temperature or bearing back pressure.

These lubricators are reusable and refillable via service packs (bladders and batteries). They can be mounted up to 6m away from the bearing and can supply up to 8pts via a progressive divider block. In addition, they feature an easy-to-read LCD display with bearing blockage alarm time remaining till empty.

Simply, by installing the unique M Series electro-mechanical type lubricators, the user will not only benefit by long term cost savings but also by having precise and

The Pulsarlube E series of lubricators are highly cost effective and simple to operate.

systematic machinery lubrication management throughout the entire plant running cycle.

Pulsarlube E series The Pulsarlube E Series of lubricators are highly cost effective and simple to operate. They are resistant to temperature variation due to Nitrogen gas generation compared to a Hydrogen gas type lubricator, which means the volume and amount of gas remain constant. Easy to install without the use of tools, they feature an instant on and off function. Adjusting of the dispensing period while in operation is not only possible, but simple.

The circuits and parts of the E series lubricators are designed based on the energy limitation concept by adopting a non-sparking, explosion-proof structure that keeps an electrical device from sparking an explosive gas whether it is working under normal or certain abnormal condition.

The E Series lubricators are highly reliable and can be relied upon to deliver the required and set volume of grease to machinery.

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EFFICIENCY & DOWNTIME

Smart, connected, collaborative factories As attendees at a recent seminar held by global automation leader Omron heard, smart factories with efficient and fully connected supply chains are critical to manufacturing innovation.

M

anufacturing is undergoing a digital transformation.

Industry 4.0 has opened new market possibilities and enabled businesses in the sector to be more responsive to customer driven trends.

Significant advances in technology, including big data and analytics, the Internet of Things (IoT), robotics and additive manufacturing, are changing manufacturing operations globally.

“It’s all about collecting and analysing data to improve efficiency,” said Chris Probst, Omron’s automation technology product manager. “The amount of data doesn’t matter – it’s what you do with the data that counts.”

This was one of the key messages from Omron’s Food & Packaging Seminar, Smart Factory Solutions

with IoT Technology held recently in Sydney, Melbourne and Brisbane.

Smart factory solutions At the events, the company unveiled smart factory solutions encompassing IoT technology. These included the latest applications in robotics, machine vision, safety, big data, traceability, PackML and IO link.

As Omron’s team of experts explained, these products are set to increase productivity and improve profitability in the food and packaging sectors.

Probst pointed out that, while many Australian companies are now talking about the IoT technical revolution, not many are prepared for it.

Those which do become prepared, he said, stand to benefit greatly

Omron AIV mobile robots use laser scanners and other advanced technologies that allow them to determine their own path.

20 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

from the effort. They will be better positioned to adapt to changing marketing conditions and customer needs; and stand to boost productivity by up to 30 per cent.

“This is the next generation of manufacturing where people and machines work together,” said Probst, adding that he has no doubt collecting data, and then using it to measure and improve performance, holds the key to the future for Australian manufacturers.

Data collection & analysis According to Wei-Jian Ong, Singapore-based product manager for Omron’s Sysmac controllers, data collection and analysis can help manufacturers streamline their operations.

“The collection of data is now vital for industry,” he told guests at the Sydney seminar. “The IoT is basically a network of devices with network connectivity for the collection and exchange of data. With IoT you can monitor, analyse and act – you can coordinate and monitor your production line. All machines work together to perform at optimum level.”

An estimated 13.5 billion devices will be connected by 2020 worldwide and right now, according to Ong, programs such as Packaging Machine Language (PackML) are being widely adopted by industry globally.

PackML is a universal programming standard defined by the Organization for Machine Automation and Control (OMAC) and by the International Society of Automation’s

EFFICIENCY & DOWNTIME

Technical Report 88 which defines a common approach, or machine language, for automated machines.

The primary goals of the standard are to encourage a common “look and feel” across a plant floor and to enable and encourage industry innovation.

Omron PLCs can work seamlessly with databases such as SQL, which is the standard language allowing manufacturers to communicate with a database. The SQL database can collect huge amounts of data (Big Data), that can be used to measure the performance of each machine and increase yield.

With Omron’s NJ SQL version controllers, it is possible to send the Overall Equipment Efficiency (OEE) data from machine to database and then use that data with MES and ERP systems.

“Smart factories need to be more efficient and fully connected to their supply chains,” said Probst.

“Omron offers the industry’s first complete and fully integrated robotic automation solution.”

Omron's unified concept According to Probst, all of the components within this solution are designed to work together.

And all solutions are developed with Omron’s unified concept – to develop connected, smart, collaborative factories – in mind.

According to the company, this concept works to boost productivity.

In this context, The Connected Factory involves seamlessly integrating machine automation and corporate IT to generate, collect and exchange relevant data.

The Smart Factory is where intelligent data analysis and evaluation to predict maintenance issues and implement improvements to reduce resources, energy and waste; and The Collaborative Factory involves enhancing the interaction between humans and machines.

Omron’s automation solution oversees the entire packaging line, with horizontal and vertical integration, ensuring line coordination and monitoring.

To improve efficiency and productivity, more factories are now turning to robotics. More and more, they are using fixed (articulated, SCARA and parallel) robots as well mobile robots or autonomous intelligent vehicles (AIV).

Omron AIV mobile robots use laser scanners and other advanced

"The amount of data doesn't matter - it's what you do with the data that counts.." technologies that allow them to determine their own path, avoid obstacles and be re-tasked quickly.

These are being used in a wide variety of applications across warehouses, distribution centres, manufacturing, automotive, food and beverage, hospitality, logistics, health and medical and other challenging environments.

“AIVs not only save on labour costs, they can increase operational efficiency,” said Probst. “Mobile robots are easy to deploy, with no facility modifications required. They work safely around people and can operate 24/7.”

He added that smart factories were also helping to significantly improve workplace safety.

With improved safety, employers can minimise worker injuries, machinery downtime and loss of production. They can also save on workers’ compensation payouts, compliance fines, court costs and legal and insurance fees.

“The smart factory of the future will improve workplace safety, improve yield and traceability, drive down production costs and eliminate errors,” said Probst. “This will enable a flexible manufacturing revolution.”

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Call Us NZ 0800 55 77 33 / AU 1800 318 019 | sales@aurora-nz.com | www.aurora-nz.com www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 21

EFFICIENCY & DOWNTIME

PFD Food Services expands distributions With the help of Vaughan Constructions, Australian-owned PFD Food Services recently expanded operations with a new 25,484 sqm warehouse and distribution centre in Melbourne’s east.

R

anked 14 on the Australian Financial Review’s Top 500 Private Companies list for 2017, PFD Food Service can trace their company lineage back to the 1940s, proving themselves a commanding force in Australia’s $21.6 billion wholesale grocery market.

The company’s new automated facility is set to see the $1.86 billion food service distributor continue to dominate local markets.

Positioned on the prominent corner

of Ferntree Gully and Henderson Roads in Knoxfield, the facility boasts a hefty 8,500 sqm of freezer space, a 5,500 sqm cool room, 25 loading docks and a 1.5 million litre recycled rainwater system.

Located next to the company’s existing site, the new centre includes a dedicated seafood processing space, refrigerated food storage and dry food store areas.

Staff amenities include ample breakout space, a wellness room and outdoor areas, setting the standard

The new PFD Food Services facility is located in the Melbourne suburb of Knoxfield. (Image: Nick Billings Photography)

22 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

of employer of choice environments within commercial and industrial grade facilities.

Appointed under a Design and Construct contract, Vaughan Constructions began work on the project in late November 2016, and handed over the site in October this year.

Partnering with PFD’s appointed project manager TM Insight, Vaughan Constructions internal design team scoped the detailed distribution needs of PFD to develop

a comprehensive design which now holds a commanding place in the local landscape.

“To facilitate an integrated base build and fit-out, Vaughan programmed early accessed dates to allow for fit-out works to be completed simultaneously with the base build,” explained Vaughan Constructions managing director, Andrew Noble.

With a large portion of the build delivered during the winter months, Vaughan’s project delivery program

EFFICIENCY & DOWNTIME

was unorthodox in that external works were prioritised and completed early.

“This included laying the freezer base slabs while the structure was being prefabricated, effectively mitigating potential time delays due to heavy rainfall saturating the site,” said Noble. “Further precautions were taken to avoid inclement weather delays, with the entire site stabilised with cement and lime to improve subgrade performance.”

Key areas of the project build were strategically prioritised as part of this detailed program to allow subcontractors early access to facilitate the install of fit-out equipment. Vaughan further coordinated building services and racking too, as part of the fast tracked program.

Harnessing the power of the environment, the now completed building includes impressive sustainable water saving initiatives.

Tanks on site have the capacity to collect and store over one and a half

million litres of rainwater, which can be re-used for refrigeration, irrigation and bathroom facilities.

“The project’s quality is to the highest standard in every aspect, excellent execution and finishes, cementing Vaughan’s reputation as the leading Design and Construct contractor for the food and beverage sector,” noted Noble.

He said Vaughan were recently recognised by the Master Builders Association of NSW for construction excellence on similar distribution facilities for Torino Food Services in Ingleburn, NSW. “Other leading food and beverage customers include Coca Cola Amatil, Diageo, Pepsico, Woolworths, Coles and Aldi,” he added.

With this portfolio of experience, Vaughan focused on functionality to be at the core of PFD’s new distribution centre design, but the completed project really sets the standard in the industrial design aesthetic, accurately reflecting the

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The facility includes 25 loading docks.

(Image: Nick Billings Photography)

strength of the food giant’s brand.

PFD’s strong corporate governance and a strategic approach to business growth has seen the company approach the development of their new Knoxfield facility with the same careful planning. With expansion in mind, the new build’s refrigeration design has allowed for current ambient storage to be adapted to create additional cold storage should anticipated business growth occur.

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At project inception, PFD Food Services CEO Kerry Smith outlined the importance of appointing a builder with a like-for-like business structure.

“Partnering with a contractor who had similar business synergies to our own was important. Vaughan Construction’s wholly Australianowned business model, supported by a strong family ownership framework appealed to PFD Food Services,” said Smith.

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Industrial Water Analysers and Liquid Analytical Products (pH, Conductivity, ORP, Dissolved Oxygen, etc) www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 23

FOOD TRENDS

Keeping energised through the night shift It is especially important for people who have to deal with irregular sleep patterns, to eat well.

Christian Philippsen, managing director for Beneo in Asia-Pacific, explores how food manufacturers can deliver them healthier snack options, which provide sustained energy release without the subsequent crash.

W

orking the graveyard shift or even pulling an all-nighter is an everyday reality for many employees in industries like entertainment, healthcare, security or transportation.

This can be challenging for anyone. It is also hard to feel revitalised or rested enough to head back to work the next day – not to mention doing it again and again in shift work. So it is no wonder some describe the feeling like “a zombie chasing a caffeine drip”.

Although many shift workers say that they are used to working overnight, staying awake and inverting sleep patterns can lead to a number of negative consequences in the long run. In fact, it is common for shift workers to get shift work

sleep disorder (SWSD) , which is characterised by insomnia. SWSD sufferers may constantly feel tired even when they have had enough time to rest. They are also more prone to making mistakes and causing accidents Furthermore, night shift workers tend to turn to convenient food options (e.g. chocolate bars, sugary cupcakes) when they need an energy boost to stay alert and get them through the wee hours of the morning. However, such snacks may not provide enough nutrition or the healthy energy that someone staying up late often would need.

Yes, reaching for a night snack, especially a sweetened one, can help to offer a quick energy boost but it

"Night shift workers tend to turn to convenient food options like chocolate bars when they need an energy boost." may also be bringing on precisely the kind of lethargic feeling that the night shift workers are trying to avoid. This is because sweet confectionary products, including cakes, chocolates and cookies, tend to contain a high ratio of conventional sugars and thus high glycaemic carbohydrates – the main culprits of the energy spikes and crashes.

Crashing from a sugar high Many confectionery products are sugar-laden and highly processed.

They also often carry a large amount of high glycaemic carbohydrates that are digested very quickly, resulting in a fast and high release of glucose – the body’s main energy supply – into the bloodstream, thus causing an energy “spike”.

For night shift workers, these sugar spikes cause their blood glucose and insulin levels to rise, leading to an initial energy “boost”. However, these glucose stores are quickly depleted, causing a drop in blood glucose levels even below baseline, which translates to an energy ‘crash’, which is the sluggish feeling that people often feel after a meal.

The benefits of all things healthy is impacting the consumer market in ways that could only be imagined a decade ago. Consumers these days are making an effort to eat healthier, either to look or feel better or for health reasons.

According to a Nielsen study, 60 per cent of consumers in Asia-Pacific are choosing to eat less sugar and 54 percent are opting for more fresh or natural food.

Avoiding the sugar crash

Christian Philippsen, managing director at BENEO Asia Pacific.

24 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

Successful food manufacturers in tune with the market are offering consumers healthier options in view of demand trends. They are designing products that are suitable for low glycaemic dietary plans by incorporating functional carbohydrates such as Beneo’s Palatinose (generic name: isomaltulose), which can be used to fully or partially replace sucrose or other high glycaemic carbohydrates, for slower energy release.

Palatinose has a unique physiological profile that helps support healthy nutrition – especially with regards to blood glucose management.

Although Palatinose is classified as

FOOD TRENDS

a sugar, it has a special molecular structure that enables it to be seen as a “good” sugar. Its uniqueness lies in the fact that it is hydrolysed four to five times more slowly by the enzymes in our small intestine as compared to high glycaemic sugars, yet it provides the body with the full amount of energy (4kcal/g). This results in a low glycaemic sugar that is fully digestible – thus making it ideal for providing sustained energy with gentler blood sugar levels that provide long-term benefits for glucose control, body composition and weight management.

Palatinose can be easily incorporated into various types of food and drinks. Derived from natural beet sugar, it has a sugar-like, mildly sweet taste and can be used in the development of a wide range of great tasting and healthy snack products, from cereals and baked goods, to dairy products and sports and energy drinks.

Palatinose can be used in healthy snack products, from cereals and baked goods, to dairy products and sports and energy drinks.

Getting through the graveyard shift Working the night shift is definitely not an easy task, and it can be one of the most challenging experiences when people have to do it for a long period of time. Nevertheless, we will continue to need shift workers, especially in today’s urbanising

society and having cities that never sleep.

Shift workers need to get enough rest in the off hours, and watch what they eat. Food products that allow for slow, sustained energy release – such

as those made with Palatinose and low in high glycaemic carbohydrates – are ideal. This way they help avoid the consequences of the extreme blood sugar peaks and dips, and can provide access to sustained energy release

mechanisms and improved metabolic balance. Palatinose equips food manufacturers with the opportunity to formulate innovative snacks that not only taste good, but provide consumers with a healthier energy source.

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 25

TRADE & EXPORTS

Think local, act global HMPS, a designer, developer and manufacturer of packaging machinery, realises that looking to the world is an important part of becoming a successful local business. Matthew McDonald writes.

Mark Emmett, executive chairman of HMPS.

I

n September, Adelaide-based HMPS was named winner at the Impact Awards 2017, an event that recognises companies that assist with the globalisation of the South Australian economy.

The judges said the company has the capability to have a significant impact on global markets and generate high value opportunities for South Australia’s economy. They were impressed by the year-on-year growth, advancement and ambition of HMPS. They said that, as a business, it is an exceptionally well run and managed, with a leadership team who understand the market and how to add value to customers.

The win makes this a stellar year for the company, which also took home the prize for Innovative Technology of the Year (for its

HMPS5000 Wraparound Case Packer) at our own Food & Beverage Industry Awards in July.

As Mark Emmett, executive chairman of HMPS told Food & Beverage News, the company was established back in 1980.

“Our company started when we developed the first bag-in-box machine for the local wine industry.

From there, we have grown into various other markets and types of machines such as case packers, palletisers, wraparound case packers and sleevers, carton erectors and specialised robotic packaging machinery,” he said.

“Today, we are also part of the Aerosol Association and have packed many specialised aerosol products as well. We pack anything from dry goods and ready-made meals,

26 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

"Australia is perhaps one of the most interesting examples of adapting and surviving." to baby wipes and coffee pods. You name it, we pack it.”

Looking to the world There have also been other changes for the company since 1980. It now exports to South Africa, Europe and Asia; and has agents in New Zealand and the US. Emmett explained that the company has had installations in Thailand and one of its projects engineers recently returned from an installation in the Philippines. “Pretty much we export to anywhere and we offer the customers in those areas installation, commission and service,” he said.

“We also have preferred value partner agreements with various global component suppliers and this gives

us the assurance that our customers anywhere in the world will have access to spare parts and technical expertise from these providers. Mostly we like dealing with our customer directly.

“Our service is mostly bespoke machinery so therefore we like to be involved in coming up with the solution which will ultimately give the customer the best bang for buck and future expansion options for their business. Our engineering team is also very heavily involved in the process. I suppose you could say we like solving problems.”

For Emmett, this successful global integration goes to show that businesses do not need to be based around their locality.

TRADE & EXPORTS

“I think HMPS is testament to the fact that you don’t have to live and work where you sell. You can in fact work anywhere in the world,” he said.

According to Emmett, Australia’s small population can sometimes be an advantage.

“Australia is perhaps one of the most interesting examples of adapting and surviving. We build machines which will pack in various configurations – sometimes up to as many as 20 variations. And this is because we know one machine has to do all of it. Australian manufacturing doesn’t have the luxury of specialisation,” he said.

He said that this is very attractive to economies [such as many in Asia] where automation is on the rise but companies don’t have the capital to buy many different machines. Being able to buy one machine that packs various configurations is an advantage for organisations that are just starting to introduce automation technologies.

HMPS designs, develops and manufactures bespoke packaging machinery.

Bringing success back home When he received the Impact Award on behalf of HMPS back in September, Emmett praised his own team and said that his vision for the company was always to provide jobs and a future for the young people of South Australia. Today, the company employs 55 people from its head office and main production facility in Adelaide.

He also pointed out that HMPS provides customised packaging solutions that are based on highly

advanced robotic systems for manufacturing companies who must compete globally.

“The technology also recognises that to be truly compete against lower cost manufacturers, product quality and production line efficiency must also feature strongly. Our mission is to help manufacturing companies in high-cost economies remain competitive and indeed thrive against low-cost economies,” he said.

Pointing to an economy that is still coming to terms with – but yet to feel the full effect of – the death of the car industry, Emmett said South Australia needs to use its ingenuity and tenacious spirit to ensure its manufacturing industry survives.

“We have space. We have lower costs – when it comes to labour, property, and so on – than other states and we need to use this to our advantage. It can make us more

competitive and we must leverage off this,” he said.

“South Australia is home to some of the top universities. We need to harness the talent that is coming into the market. We need to ensure the survival and future of our economy for our children. As a father to two teenage children, I feel very passionate about doing my bit to make South Australia a manufacturing hub.”

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 27

RETAILER RELATIONSHIPS

Amazon makes its way to Australia Australia has officially become the 13th country in which Amazon operates.

What affect is this likely to have on the local food and beverage industry?

A

fter much anticipation, and some delay, internet retail giant finally landed on our shores in late November.

With the company’s new 24,000 sqm fulfilment centre in Dandenong now in operation, local retailers now have a big, new, (non-traditional) competitor to deal with.

According to research by UBS, groceries aren’t at the top of the list of products that Australians are expected to purchase online through Amazon (that honour goes to the likes of electrical appliances and clothing).

However, dry and fresh foods definitely are part of the mix.

Exactly how much food consumers are likely to start buying online is not clear. Predications vary greatly and, while some commentators point to medium-sized markets such as Canada (where Amazon has done reasonably well without setting the house on fire) as an indication of what is likely to happen here, it looks like we will just have to wait and see what happens.

For their part, the major retailers have noticed what is happening.

Woolworths seems to be preparing itself for its new competitor. At the company’s general meeting in October, Chairman Gordon Cairns said Woolworths plans to open four “dark stores” (or premises with no customers but only packing and despatch facilities for fulfilment of online order) by the end of next year.

The attractions for suppliers But what’s in it for suppliers. Why should local businesses sell their products on Amazon?

Amazon’s Australian country manager, Rocco Braeuniger told a gathering of sellers in Sydney in November that the size of the market that Amazon brings to sellers is a key attraction.

“We held the Seller Summit to encourage and educate Australian businesses on how they can use

Amazon recently held a sellers' summit in Sydney.

Amazon Marketplace to take their products to a global audience. With more than half of units sold globally coming from Marketplace sellers, we know that customers love the unique selection that they bring,” he said.

“We are excited to work with many thousands of Australian businesses to help them reach more than 300 million customers around the world and to grow their business.”

At the Sydney event, several successful Australian businesses including Bondi-based baby brand, Hip Cub took to the stage to provide firsthand insights on their own experiences selling on Amazon globally. The consensus from these businesses was that selling on Amazon simplifies the despatch and fulfilment process and opens up sellers to hugely expanded markets.

The event was organised in partnership with the Australian Retailers Association (ARA) and

28 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

the SME Association of Australia (SMEA) and was intended to explain how businesses, big and small, can use Amazon Marketplace to grow.

Executive Director of the ARA, Russell Zimmerman pointed out that Amazon’s presence represents a significant opportunity for local businesses.

Amazon's Australian country manager, Rocco Braeuniger at the Sydney event.

“Amazon’s entry into Australia provides a great opportunity for local retailers to grow their customer base and increase sales. I personally am excited to see how Australian businesses respond and succeed on the platform. It’s time to embrace change and get excited about the future,” he said.

FOOD & BEVERAGE INDUSTRY AWARDS

From the boardroom to the farm This year the Food & Beverage Industry Awards introduced a number of new categories. One of these was the Paddock to Plate award, won this year by El Cielo.

Cesar Duran, managing director of El Cielo at this year's Food & Beverage Industry Awards.

T

he Food & Beverage Industry Awards’ Paddock to Plate category celebrates companies that source their product direct from the producer and maintain freshness while meeting a consumer demand, such as longer shelf life and/or ease of preparation and cooking.

The winner of the award this year, sponsored by Chr. Hansen, was El Cielo for its White Corn Tortillas, Totopos and Tostaditas.

As Cesar Duran, managing director of El Cielo told Food & Beverage Industry News, putting the Paddock to Plate philosophy into practice was no easy task.

“It’s a continuing work in progress. You’re bringing together two worlds which are very different.

The language is very different; the expectations are very different,” he said. “It took a lot of communication, a lot of understanding and a lot of time to get everybody [farmers, manufacturers and retailers] on the same page.”

Despite the difficulties, the Paddock to Plate dream started to

"You're bringing together two worlds which are very different. The language is very different; the expectations are very different." come to fruition in 2016 when the company started to grow and use its own white corn in northern NSW. In conjunction with the farm, extensive research and planning was undertaken in order to establish the best location for growing high-quality white corn in Australia. This also required extensive planning with regards to logistics and ensuring the white corn would reach the production facility fresh.

Upgrades and development of processing machinery were required in order to facilitate the production of the products, while providing the fresh products to restaurants (including El Sabor) meant the dream was realised. In order to maintain freshness, the grain is harvested in NSW, then immediately transported to a production facility in Port Melbourne for processing. The products are then delivered directly to restaurants and

independent retailers for sale.

The end result impressed the judges of the aforementioned awards.

“El Cielo has taken the concept of paddock to plate one step further deciding to grow the corn themselves to ensure the best quality for the product. Their impressive supply chain sees them grow the corn, process it in their Port Melbourne facility and then deliver direct to restaurants as a fresh product,” they commented.

Does El Cielo have any advice for businesses hoping to follow in its footsteps?

“The hardest bit is to develop trust and understanding. The advice I would give them would be to come down from the boardroom and be closer to where ingredients come from,” said Duran. “It’s about relationships and getting off our high horses in the cities to actually

go to the farms and see where food comes from.”

Founded in 2012, El Cielo (which translates as ‘The Heaven’) employs over 20 people. The company was established with the aim of promoting ‘The True Taste of Mexico’, offering the flavours of traditional Mexican cuisine.

According to Duran, the company plans to grow into 2018. “Soon we’re launching a range of full-flavoured tortillas. Also we’ll continue to develop our Mexican range next year. We have new salsas and new products coming,” he said.

While at this stage only the company’s corn products (White Corn Tortillas, White Corn Totopos - corn chips, and Tostaditas) are ‘Paddock to Plate’, all other products use elements of the philosophy.

According to Duran, the company intends to maintain close relationships with those on the land. “We need to be more grateful to farmers. We should probably be more grateful to farmers than doctors.” he said.

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 29

Automation & efficient production Do you have a product or service that can help food and beverage makers improve their factory practices? Let us know and be featured in the next edition of this magazine.

Automation can help food makers improve quality control, cut costs, and generally become more efficient. In fact, as competition increases and innovation continues, food makers increasingly have no choice but to automate. In the February/March issue of Food & Beverage Industry News, we are featuring companies that can help you automate your operations and improve your bottom line.

FEB/MAR 2018 DEC 2017/ JAN 2017

Satisfying & safe the hygiene imperative

PLUS: Country of Origin labelling | Design & Construction tips | Paddock to Plate

To book in Food & Beverage Contact Sonia Bonner now SONIA.BONNER@PRIMECREATIVE.COM.AU | 0432 574 669

TOTAL TIPS

Total Tips - design and building advice Welcome to Total Tips, a new regular column by plant building and design provider, Total Construction.

Over the coming issues, we will hear from this industry leader about how to ensure businesses have welldesigned, well-functioning manufacturing facilities that give them the best chance to prosper.

TIP 1

WHEN SELECTING NEW PREMISES, ENSURE YOU CHOOSE SOMEWHERE WITH SUFFICIENT UTILITY SERVICES

Selecting new premises is a big step for any food manufacturer. Think about the last time you moved house and (depending on the size of your business) multiply the effort involved several times over.

If the physical logistics involved in uprooting plant, machinery, furniture, IT equipment (plus employees) is enormous; the amount of planning involved can be even more daunting.

Price is the obvious consideration. There is no point in relocating to a facility your business can’t afford. Digging a financial hole that you have no chance of getting out of is never a good move.

Also, as in the residential market, “Location, Location” is a good philosophy to follow. Food and beverage manufacturers need to locate their plants in the right place. The right place, that is, in terms of transport (be it by road, rail or air); as well as easy access to supply chains and logistics.

And, of course, they need to be easily accessible by the people who actually keep the business going, employees.

The importance of utilities However, when choosing new premises, there is one important consideration businesses often overlook. It is important to find somewhere that includes a sufficient, reliable supply of basic utilities (electricity, gas, water), not just for today but for the future.

Far too often, Total Construction sees examples of businesses who neglect to include this in their relocation check list. Then, sure enough, when they move they find they don’t have the utilities they need to run their operations. After the move is made is too late to realise you need more power or gas.

Increasing energy supply is not always an easy thing to do. The task of upping the power supply may involve the creation of a new substation. Even in industrial areas, this does not happen overnight.

We have seen cases where the installation takes as long as eight months. On top of the high costs and planning involved, this is bad news for any business.

Planning & estimating future utility needs When planning a move, businesses should study past gas and electricity bills to establish average

usage. However, we recommend adding a further 20 per cent to this figure to allow for future growth. Any figure beyond that mark will likely be years down the track and can be addressed at that later date.

In our experience, many businesses who don’t factor in their energy requirements actually find that their “dream facilities” don’t have sufficient utilities to support them into the future.

In many cases, this comes down to who were the

previous tenants. It’s important to keep in mind that, even though they are located in industrial areas, many buildings have never housed manufacturing businesses. Many were used as warehouses and therefore didn’t require anything like the amount of electricity or gas that manufacturers need.

While they may tick all the boxes in terms of price, location and size, they may not actually have what it takes to get your business running today, let alone grow into the future.

Location, size and price are important, but they are not the whole story when choosing a new facility. www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 31

PROMOTIONAL FEATURE Safety & Recalls

Setting the standard in traceability Food safety scares and product recalls are unfortunate facts of life in the food sector. GS1 Australia provides the standards to enable organisations to effectively keep track of where our food comes from and help implement recalls quickly and efficiently. Matthew McDonald writes.

I

n China back in 2008, six babies died and thousands more became seriously ill after consuming infant formula tainted with melamine, a chemical used to make dinnerware, laminates, flooring and the like.

On top of the horrendous human cost, the scandal significantly damaged China’s food industry.

Imports of Chinese dairy products were banned in many countries and, as the huge demand for Australian infant formula in China illustrates, the reputation of Chinese formula

producers has yet to fully recover.

The lessons here are obvious. Food safety is the top priority for food and beverage manufacturers and recalls are to be avoided. When they do occur, they need to be implemented and resolved as quickly as possible.

In large part, this comes down to traceability.

As Peter Chambers, head of supply chain improvement services at GS1 Australia told Food & Beverage Industry News, increased consumer awareness coupled with “an ever

Increased consumer awareness means that traceability has become flavour of the month.

32 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

increasing channel called the Internet” mean that traceability has become flavour of the month.

“The time is right to talk about traceability, not just in food but in all areas. Anywhere where people can get injured, get sick or die, traceability is very important,” said Chambers.

Supply chain complexity Chambers explained that true traceability is the ultimate goal.

“This involves the ability to exchange information with all the actors up and

down your supply chain community.

Once this occurs, information of the whereabouts of affected product can be interrogated at any time,” he said.

In the real world, however, the complexity of the food supply chain makes this difficult.

“The supply chain comprises many different stages or types of organisations (or actors) who often either distribute or manufacture product that is sold to consumers,” said Chambers.

So, when food safety issues do

arise, recalls can be complicated because the products involved have been widely dispersed.

On top of that, he said, different actors use a range of processes and systems to record production information. Data capture is typically manual and either stored in private ERP systems, in spreadsheets or paperbased recording systems.

“While traceability exists, it is mostly very disjointed and requires manual intervention and interpretation of data. In the case of a recall, the process of notification, product identification and so on can take days, if not weeks,” said Chambers. “The opportunity exists to improve both the notification and recall process and reduce times and accuracy of recalled products significantly.”

Chambers also pointed out that, traditionally, there has only been limited information available from each step in the supply chain.

“We now have the ability to add event data – information starting with the transformation of raw materials and produce into commercial product and the aggregation and de-aggregation, as well as the physical whereabouts as it moves though the supply chain to point of sale,” he said.

This data includes the what, where, when and how of supply chain events.

It provides visibility at each point up and down the chain.

Standards are important “GS1 is a global standards organisation. Our role is to help companies and industries collaborate in areas where a common standard, language or solution would help every participant achieve a better outcome,” said Chambers.

“Having quality traceability and product recall capabilities are critical areas that can assist any organisation deliver product safely to consumers.”

GS1 Australia provides a range of training and education services to organisations in areas such as item identification, data capture, traceability, to name a few. The company’s GS1 system of standards provides global unique identification keys for products, locations, shipments, assets, documents and so on.

"Anywhere where people can get injured, get sick or die, traceability is very important."

On top of that, the organisation recently released a new updated version of its Global Traceability Framework to help industries and businesses implement traceability solutions across supply chains.

“Because there are major capability and even requirement differences between sectors, we are now preparing additional sector based guidelines on how to apply the framework. For example, the fruit and vegetable sector is vastly different to beef which, in turn, is different to consumer packaged food,” said Chambers.

Recall portal One of the key benefits of having a strong traceability system involves a company’s preparedness to conduct a product recall or withdrawal.

Identification of the affected product is only one part of this process.

Food Standards Australia New Zealand’s (FSANZ) Food Industry Recall Protocol outlines the legal requirements and responsibilities of food businesses with regard to product recalls and also offers advice and assistance in this area.

In 2011, GS1 Australia launched GS1 Recall (formerly GS1 Recallnet), a portal developed in collaboration with FSANZ, as well as the Australian Food and Grocery Council, (AFGC), the Australian Competition and Consumer Commission (ACCC), national retailers and a number of local and international food and grocery manufacturers.

According to Chambers, the portal is a community based mechanism intended to improve the communication between the two main stakeholders in recalls, namely the initiator or sponsor of a recall or withdrawal notice and recipient organisations (wholesalers/distributors, retailers, hospital networks, etc.).

The aim of the portal is to facilitate the identification and potential quarantine of affected goods as quickly as possible. It’s the link between identifying the affected product and removing it accurately.

“We are quite excited about the growth of ‘Recall’. We have well

over 600 subscribers across food and beverages, general merchandise and healthcare and that is growing at 25 per cent per annum.

“This involves many major recipients including the supermarket giants, smaller grocery providers, and hospital networks, as well as many food production and distribution companies,” said Chambers, adding that food relief organisation, Foodbank is one interesting recent addition to the portal.

New technologies Blockchain (the technology used in the crypto-currency, Bitcoin) has been much discussed of late. Because it allows users in a network to share information without it first passing through a server, it has potential for implementation in the food supply chain.

The hope is that it will help overcome the problem of data fragmentation and provide the data integrity needed to not only carry out recalls, but also prevent fraud.

Blockchain purely addresses the security of exchange of information, particularly between anonymous parties, while GS1 is more concerned with the standardisation of information within the blockchain.

Nevertheless, recognising the importance of the technology within this space, the organisation recently announced a collaboration with IBM and Microsoft to leverage GS1 standards in their enterprise blockchain applications for supply chain clients.

There are also other new technologies on the way. For example, GS1 Australia has developed a Visibility Sandpit solution that makes it possible to trial a communitybased network solution that captures traceability event data at each point in the nominated supply chain using the GS1 EPCIS standards. EPCIS (Electronic Product Code Information Services) is a GS1 standard that enables trading partners to share information about the physical movement and status of products as they travel throughout the supply

chain – from business to business and ultimately to consumers. According to John Szabo, manager – consulting at GS1 Australia, this will enable communities to cost effectively evaluate what does and doesn’t work in proposed traceability solutions.

He added that the organisation also provided standards for Radio Frequency ID (RFID) technology that can help capture product IDs at each point in the supply chain without direct line of sight.

“There are developments for more commercial use of RFID in food and grocery, particularly with meat which is a high end item. The higher the value and the higher level of packaging, the more cost effective the RFID solution becomes. Active tags also enable additional data to be captured such as the temperature variances suffered en route. RFID will also help traceability solutions which tie into visibility and event data.

It is much better to track and trace a product,” said Szabo.

“There are a number of ‘newer’ data carriers (bar codes) that have been introduced that allow these data carriers to include additional information such as batch numbers, expiry dates and so on. One of these barcodes, GS1 DataBar, will allow the capture of batch information at point of sale in the near future. Being trialed by major supermarket chains for use with loose fruit, this has demonstrated significant benefits over the current identification,” added Szabo.

Chambers pointed out that coordinating complex supply chains is difficult and stressed that true and effective traceability requires the full participation of everybody in the chain.

“Use of global standards facilitates that adoption but at the end of the day it comes down to the preparedness of each stakeholder to understand the change, see the benefits both for them and for the greater good, and want to participate,” he said.

Still, where this is achieved, it is now possible to cut recall notification times from days or weeks down to minutes, and more importantly, the safety of the end consumer or patient is enhanced.

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 33

PROMOTIONAL FEATURE Safety & Recalls

Control, accuracy & hygiene For food and beverage manufacturers, efficiency isn’t the only priority. Inoxpa Australia offers a range of seat valves that that deliver not only reliability and accuracy, but also hygiene.

W

hile valves, pumps, agitators, vessels and so forth are essential to food processing operations, they can also pose a hygiene threat. Such machinery with its various surfaces, cracks and crevices can provide an ideal home for microbes to thrive.

It is critically important, therefore, for food and beverage manufacturers to only use hygienically engineered components in all their processing operations.

All components should be made of a suitable hygienic material, such as stainless steel and also be easy to clean. They should not offer a place for micro-organisms to survive.

Ensuring that all machinery and components meet these crucial standards is best addressed during the design stage. As a rule, upgrading machinery to meet hygiene requirements is difficult and costly. The best components are those that have been designed with food safety standards in mind.

chamber, situated between the two “seats”, which is under atmospheric pressure. As the seats are moved they open or close flow, ensuring a safe interface between the two liquids, one of which is usually a cleaning in place (CIP) solution. The leakage chamber can be cleaned by independent lifting of the seats during the CIP cleaning of the line.

Also produced according to EHEDG recommendations, the Innova K-type valve has a gasket designed to facilitate cleaning and also ensure reliability under adverse working conditions. Its valve can be changed to normally open by simply reversing the position of the single-acting pneumatic actuator.

Both valves feature a single-acting pneumatic actuator as well as a 360° adjustable body. Assembly/disassembly of internal parts involves loosening of a clamp fastener; and an open lantern allows for the easy visual inspection of the shaft sealing.

Within the food and beverage sector there can sometimes be a trade-off

"A commitment to innovation and continuous improvement has allowed Inoxpa to enter the global market without compromising its product quality or customer relations."

High performance seat valves Seat valves, pneumatically-controlled devices that are used to precisely control high flows of liquid, are found in various food processing and dairy applications and elsewhere.

Within this space, Inoxpa Australia offers the Innova range of valves, which not only meet the strict hygiene requirements of the food and beverage sector, but are also designed to guarantee no leakage or mixing of fluids during operation.

The Innova P-type valve is a pneumatic shut-off double seat valve that is designed according to the recommendations of the European Hygienic Engineering and Design Group (EHEDG), a European-based organisation dedicated to hygienic design for the food sector.

The valve features a leakage

between performance and food safety.

The Innova range strikes the right balance between these two imperatives, delivering reliable operation and hygiene.

Founded in Spain, Inoxpa is a long-standing business group. Apart from valves, the company also specialises in the manufacture and trade of a range of other stainless steel components, including pumps, agitators and blenders; as well as the management of processes and services for various industries.

A commitment to innovation and continuous improvement has allowed Inoxpa to enter the global market without compromising its product quality or customer relations. The company counts many prominent food and dairy processors, both in Australia and overseas, as clients.

34 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

The Innova K has a maximum working pressure of 10 bar.

Recall

Food safety is more than just compliance Regulation

Technology

Supply chain complexity

Reduce your risk today!

!

Find out more:

1300 BARCODE

www.gs1au.org/recall

PROMOTIONAL FEATURE Safety & Recalls

FZP classification means a product is food contact safe Not all items are suitable for use in the food manufacturing industry. However, businesses can rest assured that Tork Professional Hygiene offers a number of products that are.

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hile there can be vast differences between the regulations, expectations and auditing of food manufacturers and producers across the country, one thing remains constant – risk

management is a key to success.

One way that companies can help to reduce their risk is to seek-out third-party food safety certifications.

The requirements for certified food safety management systems are

Some Tork Wipers are HACCP certified Food Zone Primary.

36 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

based on the principles of HACCP. HACCP International operates an assessment and certification scheme for equipment, materials and services used within the food industry that make a contribution to food safety.

But there is even more to the story, with HACCP International working to make certification more transparent and to help food businesses identify appropriate use of products with Food Zone classifications. Karen Constable, technical manager of HACCP International explained, “Evaluation of products and services is strictly confined to characteristics which could have an impact on food safety or on the proper operation of a HACCP based food safety program.”

Certified products are classified as suitable for use in various applications or areas of a food facility. FZP (Food Zone Primary) items are suitable for use in the food zone and are suitable for contact with food. FZS (Food Zone Secondary) items are suitable for touching food contact surfaces but are not expected to touch food during normal conditions of use.

For example, wipers and cloths that are marketed with claims that they are suitable for direct contact with food must be verified as being suitable for such to be eligible for certification. If they are found to be suitable for certification they will be classified FZP. Wipers that are marketed for use as aids to cleaning and for use on food contact surfaces are certified with the food zone classification FZS if they are found to be suitable for such.

There are also SSZ (Splash or Spill Zone) items that are suitable for use in food zones, but are not suitable for coming directly into contact with food or items that will touch food. And NFZ (Non Food Zone)

items make a contribution to food safety, but are not suitable for use in areas where open (unpackaged) food is handled.

Global leading brands like Tork Professional Hygiene recognise the importance of HACCP certification and have a large number of wipers, hand towels, soaps and dispensers that have passed the strict certification criteria. When a business buys a Tork product with HACCP certification they can be confident and assured that it has been assessed as safe for use in the food industry.

There are very few brands of wipers and woven cloths that are classified FZP and HACCP certified.

However, a number of Tork wipers and cloths have been HACCP certified FZP, including Tork Basic Papers, Wiping Papers and popular Tork Heavy Duty Cleaning Cloths, often used as a tea towel replacement in the hospitality industry.

“Verification of suitability for direct food contact can be done in a number of ways. Commonly, HACCP International will review and verify laboratory reports of testing for compliance to EU10/2011 and the requirements of EC1935/2004. The tests are used to check that the wiper (for example) does not let dangerous chemicals leach or migrate into food during contact,” said Constable.

So while many wipers and cloths may be used in kitchens wiping down meat and fish, straining oils and sauces, their job in food manufacturing is less likely to be in contact with food. But knowing that the risks have been assessed should that occur, is reassuring to the quality control manager who may be facing weekly audits and assessments. If it’s in the food zone, being food contact safe simply reduces the risk.

GUILL - ENGINEERING DEPARTMENT SONIA - SPARE PARTS SALES DEPARTMENT

In food and pharmaceuticals, you need more than just good pumps.

This is where INOXPA comes in. With four decades of specialisation in the food and pharmaceuticals industry, our team of experts take the time to meet with you, and truly understand your production needs. As you use our products, we are there to support you with strong service, support, and ongoing engineering advice.

Find out more today, visit www.inoxpa.com.au or call us on 613 5976 8881

Unit 1/4 Fuji Crescent Morning ton, Australia inoxpa.au@inoxpa.com

PROMOTIONAL FEATURE Safety & Recalls

Food safety, from the ground up Food safety isn’t only about supply chain transparency, temperature control and handling procedures. As Roxset Australia can attest, other factors like hygienic flooring are also critical.

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or food and beverage manufacturers, the hygiene imperative extends far beyond the actual products being made.

In order to maintain hygiene, food businesses must adhere to a set of wide-ranging regulations set out by Food Standards Australia New Zealand (FSANZ). These cover the design and construction of their premises, fixtures, fittings, equipment and food transport vehicles.

The flooring in these facilities, for example, should not only drain well and be easy to clean, but also be resistant to grease. It must be non-corrosive and able to handle regular spills (of blood, milk and so forth). And it must not provide an environment where pests can survive.

In other words, it needs to be hygienic and minimise the risk of contamination. It needs to help ensure that what consumers eat doesn’t end up making them sick.

Roxset SE epoxy flooring Australian-owned company Roxset Australia has developed SE epoxy flooring, an AQIS and HACCP certified flooring solution that meets these requirements.

The product is one of a number of flooring products made by

the company. Apart from epoxy surfaces, Roxset also offers Polyurethane concrete (PU), Methyl methacrylate (MMA) and polyester flooring options.

SE flooring is particularly recommended for wet and dry food processing facilities because, unlike PU and MMA products, it is non-toxic and therefore does not, itself, represent a food safety risk.

SE Flooring delivers a seamless, impervious, durable surface. And, importantly, it is also non-slip and suitable for use in high traffic areas. It has a long service life and represents a good return on investment.

Ruby & Roy Yoghurt Sydney-based business Ruby & Roy produces hand-made natural yoghurts which have received numerous industry accolades including being named Australia’s Champion Flavoured Yogurt at the 2015 Australian Grand Dairy Awards.

Recently, after experiencing some problems with its original flooring, the business decided to install Roxset SE 3 flooring in their production areas and Roxset SE 1 in their warehouse and bulk storage areas.

The result was a non-slip, high abrasion and chemical resistant

SE Flooring delivers a seamless, impervious, durable surface. surface that is also HACCP BRC FSANZ certified. In addition, the yoghurt maker received an antimicrobial infusion that protects against a number of bacteria, including E-coli and salmonella.

Management was delighted with the result. “Roxset delivered a fantastic high quality, food grade flooring solution for each area of our factory, which we are confident will meet all the demands of our growing business well into the future,” said Ruby & Roy director, Karen Neil.

Preparation & installation

SE flooring is particularly recommended for wet and dry food processing facilities 38 Food&Beverage Industry News | Dec 2017/Jan 2018 | www.foodmag.com.au

Roxset Australia can provide audits of manufacturing facilities in order to identify issues such as a potential weight distribution of vehicles or equipment which could cause deterioration of floors, or underlying joint weakness or chipping which can cause a contaminant build up and effect hygiene in the long term.

They can offer advice concerning additional technology and products that can help preserve the life and durability of existing floors.

In terms of installation, the company carries out all elements of construction and preparation. They can remove existing vinyl, ceramic or existing painted or trowelled coatings; and perform all other necessary tasks such as slab levelling, joint repair and concrete replacement.

They carry out necessary grading, diamond grinding, shot blasting and scabbling tasks, as well as saw cutting and caulking of construction joints and seams; and line marking.

Roxset recognises that no single floor solution is suitable for every environment and tailors each project to individual customer requirements.

The company spends time covering all the critical production requirements to ensure the quickest turnaround time possible.

Keep your cool this summer with CRC’s food grade range According to CRC Industries – a leading supplier of accredited lubricants, aerosols and chemical maintenance products to the food and beverage industries for more than 50 years – summer is a crucial time to audit food production processes for the safest outcomes.

T

he Australian summer brings with it a heightened risk of potentially fatal contaminants entering our food due to careless food handling practises and poorly maintained equipment.

CRC Industries Australia Managing Director, Shona Fitzgerald, said warmer temperatures leave zero margin for error for food safety.

“Industrial kitchens and food manufacturing plants are well aware of the importance of proper refrigeration, sterilizing equipment, removing waste and avoiding cross contamination when it comes to preventing food poisoning,’’ Fitzgerald said.

“It is equally as important to focus on the procedures, products and equipment used to maintain machinery in the food manufacturing and processing sectors to ensure the highest standards for reliability and safety are being met.”

Farm to fork food safety is a primary concern across the entire supply chain. Food processors and packaging manufacturers have an obligation to keep their plants running efficiently, while preventing contamination of their goods.

To help minimise the risk of maintenance, repair and operations (MRO) chemicals across all food processing and non-production areas, CRC developed the HACCP Certified Greenlight Food Safety Program – a visual identification labelling program that ensures maintenance employees use and store MRO chemicals in the proper locations and in accordance with audit requirements “At CRC we understand the food industry, whether growing, producing, processing or packaging, requires the most stringent conformity of compliance,’’ Fitzgerald said.

“Well maintained equipment is one of the golden rules to keeping safety standards high in food-processing facilities.

Poorly maintained equipment, or equipment serviced with substandard maintenance products will inevitably lead to machinery breakdowns, compromising production processes and jeopardising food safety.’’

Since the 1960s, CRC has been providing innovative solutions to the ever-changing food and beverage industry through revolutionary technology and quality products.

As an ISO certified manufacturer, CRC is committed to continue leading the evolution of maintenance chemicals as they relate to regulatory compliance within the food industry.

In addition to food grade lubricant products, the company offers a wide variety of aqueous cleaners, heavy duty degreasers and precision cleaners that meet Australian compliance standards for foodprocessing and handling plants.

Scientifically formulated to maintain food safety behind the scenes and accepted for incidental food contact, CRC’s comprehensive food grade range includes water based silicone, white grease, di-electric grease, Parcel Glide, chain lube, belt dressing, machine oil, penetrating oil, sealants, anti-seize compounds and more.

Starting with one product, the multi-purpose lubricant CRC Corrosion Inhibitor, CRC Industries began in a Pennsylvania garage in 1958 as Corrosion Reaction Consultants.

Today, the company has evolved into a global supplier of speciality chemical solutions, manufacturing in excess of 1,300 products to meet the unique needs of the industrial and electrical, automotive, marine, food and beverage, mining and

manufacturing sectors.

CRC Industries services a vast international client base with the manufacture and distribution of its specialty products throughout Australia and the Asia Pacific, the Americas, Europe and the Middle East.

The company operates 26 facilities around the world, producing more than 80 million

aerosol products each year and is a leader in product quality, performance and regulatory compliance.

CRC places strict controls on its product development and manufacturing processes, starting with the finest raw materials and continuing with consistent, high quality manufacturing techniques and rigorous testing.

Food grade Di-Electric grease aerosol.

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 39

NEW PRODUCTS

Automatic cleaning magnets INTEGRATING cleaning magnets into process lines to work hand-in-hand with inspection equipment is rapidly becoming a preferred food safety solution.

Force10 high-performance automatic cleaning magnets are designed to ensure that product lines in the food and dairy sectors are free from metal contamination.

Fully customisable and able to suit different product types and flow conditions, the units are used by many leading global brands, covering products found in most kitchens and supermarkets.

The self-cleaning magnets target metals including work-hardened stainless steel and ferrous wear particles. One of their main benefits is that, because operators do not have to stop the processes to clean them, they save time and resources.

Unlike the case with manual clean units, these magnets do not require operators to "break the line". This means that the product line can stay closed to atmosphere and its associated microbial risks. As such, hygiene can be maintained.

The magnets boast high efficiency levels and, due to the ease and economy of automatic cleaning, regular cleans can be scheduled which increase foreign matter extraction performance.

The units are suitable for a range of applications, including in gravity fed chutes pre-packing to purify final product; mid-process locations such as post sifters and blending to protect equipment; and intakes or at the start of the process to prevent metal entering the process.

They can also be used prior to metal detectors, in order to reduce product reject rates and line downtime and also remove contamination that metal detectors miss.

Increased consumer awareness and the associated increased demand for product integrity mean that brands cannot afford the damage associated with product recalls.

Aurora Process Solutions aurora-nz.com 1800 318 019 / 0800 55 77 33

Innovative label press INSIGNIA recently released the state-of-the-art OMET XFlex X4 label press -Raphael-. The unit is the latest addition to the company's national fleet of label presses, and has been installed in its Brisbane manufacturing facility.

Raphael received its name as part of a long-running tradition at insignia. Each label press in its national fleet is named after a renowned artist, as they believe custom labels are a piece of art, designed to identify, distinguish and bring their customers' brands to life. Raphael joins notable artists in insignia's production facilities, including Da Vinci, Matisse, Rembrandt, Michelangelo, and others.

The label press combines traditional flexographic printing with the latest technology to deliver an industry leading press, delivering excellence in label manufacturing. Inspired by careful analysis of customers' needs, Raphael is equipped with pre-register and autoregister technology, enabling insignia to deliver the highest print quality. Specifically, the pre-register device is designed to reduce machine set-up time, resulting in a shorter turnaround time to complete label jobs and a reduction in material waste. Increased precision and label quality is delivered through the auto-register device, which automatically positions the label image and maintains this position throughout the entire press run providing high-speed accuracy.

The label press enhances insignia's label capabilities for a broad range of market applications including self-adhesive labels, flexible packaging and niche market unsupported filmic tags. A range of premium-labelling embellishments are also available, including cold foiling (designed to deliver high quality and cost-effective metallic printing effects), two side printing, UV Flexo and UV lamination. insignia continues to experience strong growth, and recently, their Brisbane and Melbourne label manufacturing facilities achieved

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 40

record production output converting raw material into custom labels. This significant investment in the new label press reinforces insignia's commitment to supporting their business growth and is recognition of their ongoing commitment to their customers.

Raphael provides an opportunity for insignia to increase their current technical capabilities, while continuing to offer market competitive lead times and support large and short run orders.

Meaning they can better support Australian businesses in building their market competitiveness.

This investment also extends to their people - their experienced team members are passionate about sharing their knowledge and skills, and providing a first-rate customer service experience at every stage of the label making process.

Insignia 1300 467 446 www.insignia.com.au

NEW PRODUCTS

Magnetic gripper SMC has added to its gripper range with the launch of the MHM-X6400, which uses a magnet for the handling of steel plate, without the need for vacuum.

Ideal for workpieces with uneven or irregular surfaces or featuring holes, this magnetic gripper provides reliable and safe handling at reduced cycle times for improved productivity. It's also ideal for many varied sheet metal handling applications including robotic systems.

In developing this product, SMC has looked to improve its handling flexibility by using magnetic grippers where vacuum was never an option due to the limitations of a vacuum system.

With a holding force of up to 120 N, the MHM-X6400 continues to hold a workpiece even when air supply is lost completely or pressure drops are experienced, offering peace of mind when it comes to reliable and safe movement of workpieces. Furthermore, with a residual holding force of only 0.3 N or less, cycle times are reduced and productivity output is improved.

Suitable for a range of transfer applications, the holding force of the MHM-X6400 can be adjusted by simply changing the height of the of bumper being used.

Made from Fluororubber, the bumper also prevents the workpiece from slipping and damaging during operations, improving safety.

Featuring three mountable surfaces and the option to mount auto switches, the MHM-X6400 offers flexibility and greater process control.

Logistics drives In plants with many drive units, the total cost of ownership can be reduced by up to 70 per cent through intelligent management of variants.

Therefore, Nord Drivesystems has established three preferred sizes for efficient variable-frequency drives in materials handling and conveyor applications. These cover the typical functional and performance requirements in postal hubs, intralogistics applications, and baggage handling systems.

The standardised drive systems greatly simplify purchasing, engineering, commissioning, and spare parts stocking. Moreover, they are particularly easy to install, operate, and maintain.

The LogiDrive line is the solution for conveyor systems spanning many hundred meters. The variable-frequency drives (VFDs) allow for simple daisy-chaining; short power lines can be connected from one drive to the next. NORD has tailored this line to intralogistics and airport technology.

Three geared motor variants meet all typical performance requirements. IE4 permanent-magnet synchronous motors with power ratings of 1.1 kW, 1.5 kW, or 2.2 kW are combined with efficient two-stage helical-bevel gearboxes in two sizes for torques up to 260 Nm. Robust frequency inverters from the NORDAC LINK series enable a wide range of speeds. The systems feature a high overload capacity and offer a uniquely versatile range of functions.

Interfaces for all commercially available communication protocols are available, including PROFINET, Ethernet POWERLINK, EtherCAT, and EtherNet/IP. Nord Drivesystems 03 9394 0500 www.nord.com

SMC Australia 1800 763 862 www.smcworld.com

Knife edge rollers Knife edge rollers from igus deliver optimum results in high speed conveying applications through precise and quick movement of goods, especially in constrained spaces.

Gentle and speedy transport of goods is critical in the materials handling and packaging industry. When conveyor belts have to be deflected with precision in narrow spaces with narrow radii, these rollers offer a cost-effective, lubrication-free and maintenance-free solution.

Developed from the high performance plastic iglidur H1 material especially for belt deflections in applications involving high transport speeds, the new knife edge rollers not only deliver better performance at higher conveying speeds but also have a very long service life even at high temperatures.

Since the rollers are exposed to aggressive cleaning media, the use of the chemically resistant iglidur H1 material delivers an important advantage to the application. These rollers are, therefore, particularly suitable for the packaging, materials handling, automation and food technology sectors.

The use of iglidur H1 in the latest knife edge rollers expands the range to a total of four materials. To implement exact deflection of conveyor belts, the company has developed a standard range

for different application areas.

In addition to the new iglidur H1 for high transport speeds, the company offers the universally applicable iglidur P210, as well as the FDA-compliant material iglidur A180 for temperatures up to 90 degrees C, and iglidur A350 for application environments with temperatures of up to 180 degrees C, both of which are particularly suitable for use in the food industry.

All the rollers are characterised by a compact design and long service life, thus contributing to the high efficiency of the machines.

Treotham Automation 02 9907 1788 www.treotham.com.au

www.foodmag.com.au | Dec 2017/ Jan 2018 | Food&Beverage Industry News 41

NEW PRODUCTS

Vibratory chip sizer tna has announced the launch of the tna roflo VMCS 3, the world's first chip sizer that uses vibratory motion to separate large from small chips to maximise packaging efficiencies and speeds.

According to the company, the unit is ideal for a range of fried snack products, such as potato chips, but also fruit and other root vegetable chips. The system's unique pan design ensures that each chip is sized, sorted and gently transported along the line for a continuous product flow with minimum breakage.

Unlike conventional systems that employ rotary motion to separate the chips, the chip sizer uses vibratory motion to limit maintenance requirements and gently convey product across a cascading chip-sizing screen, mounted on a shallow conveying pan.

Smaller chips pass through the screen to the lower level and larger chips will continue on the higher level, each one continuing on separate conveyors towards their designated bagging station. The removable screen is designed in such a way that it maintains product quality and ensures no product blockages during sizing. Integrated productdivert gates can act as an effective bypass feature when sorting is not required.

The unit's interchangeable chip-sizing screens can be customised for various sizes to accommodate a range of ratios between small and large chips. Each screen can be easily removed within just a couple of minutes thanks to tna's unique quick-release mechanism, offering snack manufacturers maximum flexibility over product sizing.

The system's simple, yet highly effective design further ensures that all parts are accessible to facilitate cleaning and maintenance procedures, reducing downtime and delivering equipment reliability.

The chip sizer is available in standard (600mm width) and larger pan sizes (750mm width) and can be integrated with the company's range of flexible conveying solutions, including horizontal and vibratory motion distribution systems like the tna roflo HM 3 and the tna roflo VM 3.

Enhanced vibratory conveyors Key Technology has introduced new features to the vibratory conveyors - Iso-Flo, Impulse, Horizon and Marathon - for food processing and packaging lines.

Together with established features that promote food safety and equipment durability, the innovative new grounding arm, label stand-offs, sanitary drives and Vector-Lock Gen 2 ease use, reduce maintenance and maximise sanitation.

The new patented grounding arm is made of a single stainless steel structure. Unlike braided wire rope with crevasses, which can harbor bacteria and a crimped ferrule that can fail, the single structure, smooth texture and open design of the new grounding arm enhance sanitation and improve durability.

Mounted to Key's StrongArm spring arms to dissipate static between the conveyor bed and frame, this grounding arm presents no horizontal surfaces where liquid, product or particulates can pool. It comes standard on new conveyors and can be retrofitted to existing systems in the field.

Label stand-offs are superior to traditional riveted plaques, which can trap bacteria, and adhesive stickers, which can peel off after repeated exposure to washdowns. Each conveyor's identification, specifications and stroke indicator are laseretched or stamped onto stainless steel and the colorful ISO safety pictogram labels utilise epoxy-based baked finish over stainless steel. All these new labels consume less surface area and are attached to the conveyor with stand-offs to reduce laminations, which eases cleaning and improves sanitation.

Key Technology 03 8710 8200 www.key.net

tna 02 9714 2300 www.tnasolutions.com

Walk-behind floor scrubbers TENNANT Company has introduced its newest family of automatic scrubbers - the Tennant T500, and T500e - adding to its broad portfolio of commercial floor scrubbers and cleaning solutions.

The scrubbers enable professional cleaners to improve cleaning performance and address the hassle of manual battery maintenance.

The units are available with the company's newly enhanced IRIS asset manager, a web-based fleet management system that provides customers more thorough information regarding equipment use to help clean more intelligently and efficiently.

The scrubbers offer versatility, productivity and also tackle one of the biggest customer complaint points - batteries - with the new Smart-Fill automatic battery watering system.

The T500 walk-behind scrubber offers innovative technologies to drive performance and increase versatility. Equipped with the exclusive Smart-Fill automatic battery watering system, customers can focus on cleaning without the hassle of manually watering batteries.

Key benefits include easier maintenance, improved performance, automated service notification, and simplified operation.

42 Food&Beverage Industry News | Dec 2017/ Jan 2018 | www.foodmag.com.au

In addition, the scrubbers are designed to minimise environmental impact. The ec-H2O NanoClean technology electrically converts water into an innovative cleaning solution that is detergent free.

This next generation technology cleans effectively to save money, improve safety, and reduce environmental impact compared to daily cleaning with floor chemicals.

It is ideally suited to food manufacturing and food preparation areas because it ensures no cross contamination and lingering smells of detergents.

Tennant Australia 1800 226 843 au.tennantco.com

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