FOOD & DRINK PROCESSING & PACKAGING Issue 30 2020
Grading facility puts its eggs in the Rotamec basket Proseal solutions meet quality pet food packing requirements HARTING launch a connector solution for the food and beverage industry Sustainable wheat ingredients for functional concepts
If you have rotating machinery on your production & packing lines, and need to keep them running, then you should be looking at the affordable, easy to use, Vibration Analyser range from
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Contents
The Team Editor Amanda Buckingham editor@fdpp.co.uk Business Manager Josh Holmes josh@mhmagazine.co.uk
Digital Sales Manager Jessica Bennett T: 01227 392571
Sales Manager Benjamin Dubois benjamin@fddp.co.uk Tel: 01227 392529
Digital Manager Jamie Bullock jamie@fdpp.co.uk Tel: 01227 392571
Publishing Director Martin Holmes martin@fdpp.co.uk
Studio Designer Richard Bland richard@mhmagazine.co.uk
M H Media Global Ltd.
Features PROSEAL HRS CAN MAKERS BRILLOPAK SUMITOMO FOOD SAFETY GOUNDSMIT
Office 15, Second Floor, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, CT13 9FD
KG GROUP
Tel 01304 806039
ROMATEC
www.fdpp.co.uk All web addresses are interactive, simply click the web address of your choice to view the company website. There is also a useful tool bar where you can search for a specific product. Please mention FDPP when responding to items in this issue.
Every effort is made to ensure the accuracy and reliability of material published in Food & Drink Process & Packaging however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers. No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.
FORTRESS TECHNOLOGY KAWASAKI ISHIDA LORYMA RITTAL SEEPEX UNIPAKER STAUBLI
< 04 < 10 <12 < 14 < 16 < 20 < 22 < 23 < 24 < 26 < 28 < 32 < 36 < 40 < 44 < 48 < 50
FDPP - www.fdpp.co.uk 3
Proseal solutions meet quality pet food packing requirements Proseal tray sealing technology is
techniques and processes, with the
The tray sealers also include several
enabling pet food manufacturers to
corresponding need for appropriate
Proseal-developed features that help
meet growing demand for high quality
quality packaging to reflect this
to maximise performance, reliability
products and packaging, as well as
premium image.
and efficiency, such as the company’s
providing mass customisation solutions
pioneering Eseal® energy saving The comprehensive Proseal tray sealer
technology, ifilm™ intelligent film
range has the flexibility to perform in a
monitoring, and ProTect™ RFID access
ordering for home delivery services.
wide range of disciplines, including Gas
login system that provides full audit
Flush Modified Atmosphere Packaging
trail visibility and layered security.
A recent report from Transparency
(MAP), Vacuum MAP with lid control
Market Research has predicted a CAGR
and Skin Packaging. In particular, the
of 6% in the global pet food market
company’s advanced sealing systems
in the ten years from 2019, reaching
ensure absolute control and integrity of
an expected value of US$168.3 bn by
the seal between the lid and the tray, a
autumn 2029. Increasing consumer
vital requirement for applications that
demand for premium quality products
incorporate a substantial controlled-
has led manufacturers to use high
retortion-process or other High
quality materials and ingredients
Pressure sterilisation processes after
while streamlining their production
sealing.
that can help businesses in the sector to diversify and introduce online
4 FDPP - www.fdpp.co.uk
In addition, Proseal’s AP60 linear conveyor tray sealing system is able to provide bespoke automated solutions for high speed applications and demanding production conditions, based around individual customer production processes and requirements.
Among the system’s many features,
“As the pet food market continues
We are delighted that our expertise can
the length and width of the indexing
to expand, we were keen to provide
help companies to achieve a point of
conveyor can be customised to
solutions for companies requiring a
differentiation in the competitive pet
accommodate particular de-nesting
significant upscale in their production
food sector.”
and filling requirements. Full or partial
of core products in new packaging
vacuum systems can be incorporated
formats, which could be met on one
to enable post seal processes such
machinery platform,” said Tony Burgess,
as retort or High Pressure Processing
Head of Sales and Control Systems,
(HPP), and X-ray inspection systems
Proseal.
sealing tools for food industry markets
“The flexibility of our technology and
part of the US-based JBT Corporation
the wide variety of machines available,
in 2019. JBT is a complete solutions
including fully integrated conveyor
provider to the growing pet food sector,
systems, mean we can offer a full
committed to exceeding customer
turnkey production line solution which
expectations.
and checkweighers can be included after sealing for enhanced quality control. The AP60 also offers seamless integration with third party process equipment including depositors, multihead weighing applications and CIP systems with sealing speeds of up to 240 packs per minute.
is key for this particular market.
Founded in 1998, Proseal designs and manufactures high quality tray sealing machines, conveyor systems and worldwide. The company became
www.proseal.com
Furthermore, Proseal’s AP60 benefits from shared technology across the Proseal machinery range. Options can be specified and retro-engineered at the customer request, allowing a more flexible approach to each distinct application. All Proseal machines offer a userfriendly interface and easy to maintain design, with a rugged and hygienic food industry approved construction geared to full washdown protection.
FDPP - www.fdpp.co.uk 5
The Delta Speed Air: A Game Changer, Inside & Out ENERCO is pleased to launch the Delta
for your people (and equipment) to
Speed Air, an innovative high-speed
move efficiently around your premises,
door that pairs proven self-repairing
wish to increase privacy or need a
technology with an adjustable air
quality door to deliver a superior seal
curtain which significantly enhances the
around the full perimeter of your
doors efficiency.
opening, ENERCO’s Delta Speed Air is a fine choice. It also comes with a
Designed to intelligently separate areas
24-month warranty (subject to a service
where the traffic is high, the Delta
contract being taken out at the time
Speed Air is a perfect match for internal
of installation based on their intended
and external applications. It makes easy
operational usage). Whilst standard
work of confined spaces with different
sizes will meet most operational
temperature and humidity levels,
requirements, ENERCO recognises that
making it suitable for warehouses,
in certain situations a bespoke solution
factories, food processing facilities,
is best. Their team can provide a truly
car washes and many other industrial
tailored service to ensure your Delta
environments.
Speed Air exceeds your operational requirements, utilising proven high-
Made for minimum maintenance to maximise reliability and reduce the need for costly maintenance, the Delta Speed Air is simplistic in its design, and available in standard sizes up to 4.5m wide x 8.0m high. The galvanised side columns ensure high resistance and exceptional durability, whilst they are self-lubricated with directional air vanes for a smooth and fast action.
VISION PANELS ELEVATE SAFETY The 1300g curtain includes vision panels (available as standard), allowing workers to see the other side clearly, minimising potential dangers from approaching traffic. Multiple vision panels manufactured using clear PVC or mesh for air flow can be included if required. Boost speed, manage traffic flows and prevent temperature fluctuations with a rapid operating speed and
speed and self-repairing technology. hygiene, improve safety and maintain optimum room temperatures. The
With over 25 years of experience,
vertical air curtain is fitted to both
ENERCO has developed longstanding
columns maximising the barrier effect
partnerships across a diverse range of
across the full width of the door.
industries including construction, food, retail, manufacturing and logistics.
EXTREMELY EASY TO OPERATE The motors can be front or sidemounted and the standard 3PH inverter controls are simple to use. The door can be equipped with a single-phase 230V supply, available up to 9m2. The door is 100% fail safe with its light grid and soft edge bottom rail technology and will accept all forms of activations devices as well as traffic light and interlocks.
ENERGY SAVING The Delta Speed Air reflects the company’s commitment to helping businesses boost energy efficiency, improve goods flow and minimise
excellent seal, the Delta Speed Air
energy costs in industrial and
facilitates efficient traffic flow while
commercial environments.
minimising temperature variations. This applications, guaranteeing a strong,
HOW CAN THE DELTA SPEED AIR IMPROVE YOUR OPERATIONS?
secure and robust barrier to maximise
Whether you want to make it easier
makes it ideal for a broad spectrum of
6 FDPP - www.fdpp.co.uk
The Delta Speed Air is an exciting addition to the collection because it delivers on speed, energy-efficiency and flexibility, whilst it’s also very versatile, being suited for internal and external applications. The door can help organisations reduce heat loss, save money, keep the temperature constant, control hygiene, enhance the work environment, reduce noise and maintain security. If you’d like to learn more about its features or wish to discover ENERCO’s full range of high speed, self-repairing doors, other industrial doors and loading bay solutions, please visit WWW.ENERCO.co.uk.
ENERCO launch the Delta Speed Air ENERCO is pleased to launch the Delta Speed Air, an
innovative high-speed door that pairs proven self-repairing technology with an adjustable air curtain which significantly enhances the doors efficiency.
A GAME
CHANGER
INSIDE & OUT
www.enerco.co.uk/air 01525 289322
Significant energy saving
Air
Vermin and insect contaminant protection Self-repairing with rapid opening and closing Helps prevent ice build up Ideal for high traffic areas Colour, finish and size options
Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.
K
ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste. Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm. Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications. Typical applications in the food industry include transferring tomato
The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste
8 FDPP - www.fdpp.co.uk
puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables. Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.
Kecol’s articulated pump systems
Kecol’s articulated pump systems
The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean
Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.
Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@kecol.co.uk www.kecol.co.uk
See us a
t
Stand N
o. 4E 02
THE HOME OF VISCOUS PUMPING SOLUTIONS
Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.
A sample of products we already pump… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax
T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk
✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax
Increase the pressure with annular space heat exchangers Annular space heat exchangers, such
treatment (sometimes as many as 20 or
as the HRS AS Series, work by passing
30 elements), the product needs to be
the product through the gap between
pumped at considerable pressure. The
the inner and outer tubes (the annular
physical properties of such fruit purees
space), which makes them suitable for
mean that this high-pressure handling
thick, highly viscous products such as
does not adversely affect the quality of
fruit purees, thick sauces, honey and
the product.
syrups. For such applications, HRS offers The advantage of such a design is
a high-pressure version of the AS
that it ensures even heating or cooling
Series. This includes thicker tube walls
of the product, while the use of HRS
around the product, while the service
corrugated tube technology increases
fluid (usually water or steam) remains
heat transfer and energy efficiency, as
be achieved as standard on the product
at standard pressures of around 10
well as reducing product fouling on the
side, but for some applications even
bar. The design means that process
tube surfaces.
higher pressures are required.
pressures of up to 150 bar can be
HRS produces both a three- and
One common example is the
of the heat exchanger, making it ideal
four-tube version of the AS Series (the
sterilisation of tomato puree using
for applications such as pasteurising
AS 3 and AS 4) to facilitate different
multiple heat exchanger modules.
and sterilising tomato and strawberry
arrangements and couplings of service
Because of its viscous nature and the
purees.
fluid. The thicker wall on the AS 4 series
number of heat exchanger modules
means that up to 25 bar of pressure can
that may be involved in large-scale
accommodated on the product side
10 FDPP - www.fdpp.co.uk
www.hrs-heatexchangers.com
Erca, the inventor of the form, fill and seal technology, enlarges itsâ&#x20AC;&#x2DC; machine portfolio and offers now also FS machines The first machine in the enlarged portfolio is the EFS-L, the recently developed new format flexible indexing platform for preformed cups. Utilising new technology enhances the available options and ease of operation and maintenance procedures. Modular in design with stainless steel construction and servo-operations it allows for flexibility with filling stations, pre-fill and post fill for wet or dry ingredients. The chainless solution for the cup transportation enables format flexibility and precision index positioning throughout the machine. Capable of filling cups up to a diameter of 130 mm, the FS machine is suitable for products such as yoghurt, fresh cheese, white cheese, single and multilayer desserts, aerated mousse products, deli salads, dips, hot filled sauces, soups, jams, fruit purees, sweet spread, pet food, etc. Key benefits of the EFS are the format flexibility (quick release, tool free), the chainless drive (no chain stretch, no regular adjustment, less cup cassettes),
the modular design and construction, the recipe functionality, and itsâ&#x20AC;&#x2122; improved hygiene options (UVC, Pulse light, H2O2). The machine will be available in the hygiene levels: clean or ultra-clean. For more information please contact p +44 740 884 06 02 www.imadairyfood.com
FDPP - www.fdpp.co.uk 11
Can Makers confirms appointment of new chairman The Can Makers, the industry trade body
promote the beverage can as the preferred
address the challenges that initiatives such
representing drinks can manufacturers in
format for drinks packaging.
as DRS will bring.
“I would like to thank Marcel for his
“The beverage can is already the most
enthusiasm, hard work and commitment
recycled drinks pack in the world and it is
its new chairman.
during the last two years. His work has
critical that any DRS implemented follows
been instrumental in helping the Can
best practice and that all packaging formats
Simon has taken over from Marcel Arsand,
Makers to raise the profile of the beverage
are included as well as a variable deposit
Head of Sustainability at Ball Beverage
can as a sustainable packaging format and
Packaging EMEA who was held the role
there are now a greater number and variety
fee based on size.”
since July 2018. Simon brings more
of drinks commonly packaged in cans than
Previously General Manager at Ball Trading
than three decades of experience in the
ever before. The rise of craft beers for
UK and Director at Ball Packaging Europe,
packaging industry to the role and was
instance has been phenomenal and all the
Simon has held commercial and latterly
previously chairman of The Can Makers
signs are that wine in cans will see similar
general management positions in the
from 2006 to 2008.
growth.
industry including overseas assignments in
Simon said: “This is an exciting and
“At the same time, we have seen the UK
challenging time for industry and the Can
recycling rate for aluminium beverage cans
Makers. We have yet to see many of the
increasing year on year to a new high of
Simon has held his current role at Ardagh
effects that we know the pandemic will
76%. We will continue to showcase the
have, although the industry has already
environmental and sustainability credentials
for five years. He completed the Ashridge
demonstrated its innovative spirit and
of the beverage can and as chairman, I will
resilience, while the Can Makers are
continue to work in partnership with the
progressing a number of new initiatives to
Can Makers members and stakeholders, to
the UK, has confirmed the appointment of Simon Gresty, General Manager Metal – Beverage UK & Ireland, Ardagh Group, as
12 FDPP - www.fdpp.co.uk
Russia, Africa and more recently four years in Zurich.
Business School Directors Programme in 2007. www.canmakers.co.uk
HARTING launch a connector solution for the food and beverage industry The newest addition to the Han® portfolio is the Han® F+B, a range of connectors which have been specially designed for the requirements of the food processing, bottling and packaging industries. Within these sectors, hygiene and safety are key considerations, meaning machines and equipment must be both easy to clean and designed so dirt pockets and bacteria cannot accumulate. The Han® F+B has been specifically developed as a suitable product for the food zone and primarily the splash zone and there are several innovations which make it the ideal solution. Firstly, all hoods, housings and seals are IP69K rated, so the connections are fully protected and resistant to the water jets used to clean equipment. They also have large nooks and surfaces in accordance with the guidelines of the European Hygienic Engineering & Design Group (EHEDG), which allows cleaning and disinfecting agents to flow unhindered. For secure identification and easy traceability, the connectors are blue, although a black version is available. The range is Ecolab approved, which means it is resistant to the highly
aggressive cleaning agents used in the
power, a versatile connector concept
food and splash zones. As the housings
which makes it possible to configure
are constructed from polypropylene,
future-proof machine design for
they conform to the directives of FDA 21.
processing units, including Ethernet.
All surfaces also have a smooth finish, which prevents impurities and bacteria from accumulating, whilst the portfolio can function in a wide temperature range
To learn more about the Han® F+B and download our FREE whitepaper, which gives more detailed information about
from -40 to +125° C.
using connectors in food and beverage
As well as hygiene and safety concerns,
UK/en-gb/connectors-food-industry or
HARTING have also considered the
email salesUK@HARTING.com.
facilities, please visit www.harting.com/
impact of machine downtimes, designing in features which keep disruptions on the production line down to a minimum. With the Han® F+B, operators do not need to open any cable glands on the control cabinet in order to decouple field devices, eliminating the complex disconnecting and reconfiguring of fixed wiring. This solution also allows for faster replacement of defective components and a more efficient method of changing equipment, allowing businesses in the food industry to shorten set-up times and reduce production stoppages. The housings can be used with hybrid contact inserts for all types of industrial transmission, including data, signal and
FDPP - www.fdpp.co.uk 13
Rather than picking up the entire stack and relying on gravity to despatch the bottom crate, the Crate DESTAKer clamps the bottom crate down, lifts the rest of the stack up, and then despatches the bottom crate
Case stacks up for new dual crate destacker Brillopak has launched a new Dual
to a game-changing operating principle;
UNIQUE OPERATING PRINCIPLE
Crate DESTAKer for feeding empty retail
rather than picking up the entire stack
The Crate DESTAKer uses pneumatic
crates to food packing lines at high
and relying on gravity to despatch the
clamps to grip both the bottom crate
speed with maximum flexibility. Based
bottom crate, the Crate DESTAKers
and the upper (remaining) section of
on the same proven operating principle
clamps the bottom crate down, lifts
the stack. The upper clamp is powered
as the original Crate DESTAKer system,
the rest of the stack up, and then
by two servo motors, which lift the
the new Dual Crate DESTAKer destacks
despatches the bottom crate.
crates up to enable the bottom crate to
two stacks simultaneously, enabling
be moved out of the stack and indexed
handling of 18 crates per minute and
In a typical packing hall set-up, crates
into the downstream automated crate
servicing of multiple packing lines.
are transported to the line via forklift by
packing system. The use of servo
the pallet load (usually around 30 to 40
motors makes the destacking system
Brillopak’s Crate DESTAKers are
crates high). The pallet load is pushed
infinitely adjustable – the operator can
employed in packing facilities for food
onto an accumulation conveyor that
change between crate sizes, change the
products ranging from fresh fruit and
feeds stacks (usually five crates) into
speed at which the system accelerates
veg to meat, baked goods and pizzas.
the crate destacker, leaving operators
and decelerates and alter the height
The innovative system is prized for the
free to focus on other tasks while the
to which the stack is lifted – all via the
unrivalled flexibility and reliability it
machine continues to destack onto the
system’s user-friendly HMI.
offers versus the competition, thanks
line.
14 FDPP - www.fdpp.co.uk
CRATES NEVER GET STUCK
lines; rather than conveying crates
of 8-9 crates per minute. By lifting two
Brillopak’s innovative approach to crate
individually around the hall at very high
stacks simultaneously, the new Dual
destacking has several advantages; one
speeds, crates can be sent in stacks of
Crate DESTAKer is capable of handling
problem encountered with conventional
two or three at much lower speeds, then
16-18 crates per minute, giving food
systems is that when releasing the
destacked at the entrance to the packing
producers and packers a high output
bottom crate sometimes the one above
system, via a second ‘mini’ destacking
option.
comes with it because the two are stuck
module. The Crate DESTAKer range of crate
together. On the Crate DESTAKer this is never an issue as they are automatically
“Food packing operations rarely give
destackers can be supplied as a stand-
separated when the bottom crate is
much consideration to the crate
alone system, to integrate with a
clamped. In addition, the clamps on the
destacking operation, but the design
factory’s existing packing automation
Crate DESTAKer have PU (polyurethane)
of this system can have an important
system, or in conjunction with
faces to prevent damage to the crates.
bearing on overall line efficiency. If crates
Brillopak’s award-winning UniPAKer
This is in contrast to the metal teeth that
get stuck together, the line might have
robot packer, which has revolutionised
some rival systems use.
to be halted and operators will have to
the packing of bagged fresh produce
intervene to manually separate them
into crates. In this configuration, crates
Servo-motion for unmatched flexibility
before packing can continue. Large
leave the Crate DESTAKer and are
This design also means the process
packing halls with multiple lines in
indexed into the UniPAKer cell. The
is inherently more flexible; whereas
particular will reap the efficiency rewards
UniPAKer checks the bale arms are fully
most crate destackers can only handle
of a more flexible crate destacking
open before placing bags into the crate
individual crates, the bottom clamping
operation,” explains Peter Newman,
(it can happen that the bale arms move
unit on the Crate DESTAKer is adjustable,
Technical Director at Brillopak.
out of position and impede the crate packing operation).
so factories can easily switch to dispensing two or three crates at a time,
DUAL STACKS, DOUBLE SPEED
if required. This can be desirable for high
In its original single stack configuration,
Check out the new Dual Crate DESTAKer
speed packing halls operating multiple
the Crate DESTAKer operates at speeds
here: https://youtu.be/CxE1ZpX5K4I
Brillopak’s new dual Crate DESTAKer which feeds empty retail crates to food packing lines at high speed with maximum flexibility
FDPP - www.fdpp.co.uk 15
Balancing packaging safety, security and sustainability post COVID-19 Comment from Nigel Flowers, Managing Director, Sumitomo (SHI) Demag UK Around the world, health has taken priority over sustainability. As we begin to cautiously emerge from the pandemic, Nigel Flowers, Managing Director of Sumitomo (SHI) Demag examines how brands can move forward with their sustainable packaging initiatives and discusses the consumer behaviours and attitudes towards single use packaging that may stick around in the foreseeable future. In the early days of the COVID-19, sentiments towards sustainability diminished. Although this was anticipated to be a short-term shift, concerns around hygiene, sanitation, crossinfection and the protection of health took priority. Initiatives like bring your own containers and resusable coffee cups were suspended. Substrate choices veered back to the ‘perceived’ enemy plastic. The big question facing packaging producers now is how much consumers in the future will be prepared to trade off product safety, security and hygiene against sustainability and whether there
the market has been moving more
machine and tooling give the optimum
towards novelty solutions that improve
blend of speed, quality and consistency.
performance, functionality and shelf impact.
NEW EXPECTATIONS Until March, eschewing plastic was
is a middle ground. Most companies operating in this
the campaign of the day. The tide was
For several decades now light-weighting
competitive arena produce millions of
turning. And I’m in no doubt that public
and consumer convenience have given
packaging containers, caps and closures
rallying for circular packaging will resume
packaging manufacturers the strong
every year. Volume, raw material waste
in the next six months. Attitudes and
commercial incentive to do more with
and precision are fundamental to each
actions will inevitably shift again.
less. No strangers to responding to
packaging manufacturers’ financial
demographic and lifestyle changes and
viability, with many facilities operating
What this pandemic has clearly illustrated
balancing a wide range of variables,
20+ machines to meet supplier demand.
however, is the context in which decisions about packaging need to be made.
including cost, increased strength, recycle rates and functional requirements,
To successfully succeed in the thin
Exploiting people’s fears about reinfection
lightweight formats have become the
walling arena, injection moulders need
and sanitation should not be used as an
industry norm. Especially in food and
to examine every potential application to
argument to revert or redefine legislation.
medical packaging. More recently,
ensure that the selection of materials,
Understandably, the UK’s ban on plastic
16 FDPP - www.fdpp.co.uk
straws, cotton buds and stirrers has
need to be factored into the mould,
is aimed squarely at high volume
been delayed for six months by DEFRA
machinery, and packaging component
manufacturers of polymer products,
until October 2020. This is a temporary
design.
including caps and closures, thin wall
measure, but concurrently must not
containers and lids.
threaten progress towards more
Even when using less raw material,
sustainable packaging.
packaging forms the protective layer so
With the introduction of a new control
still needs to be engineered to provide
valve regulating the hydraulic pressure
MANUFACTURING CONSIDERATIONS
strength. Choosing the best machine
during the loading of the accumulator,
for your packaging application is critical.
the range consumes up to 15% less
As a material, plastic is inextricably
Understanding the melt stability and how
energy that previous generations
linked with energy and resource savings.
the plastic will perform as an end product
of El-Exis machines. These savings
Its low weight makes it both cost
should form the basis of all decisions.
are dependent upon the packaging
effective and flexible to use, adding to
application, moulding cycle time and
the sustainability score when measuring
To support these efforts, Sumitomo
environmental, social and governance
(SHI) Demag continues to pioneer the
(ESG) performance. If anything, this
development of packaging machines. The
Additionally, all-electric drives set a
pandemic has presented retailers, brand
companyâ&#x20AC;&#x2122;s El-Exis SP range, available
new benchmark for achieving absolute
owners and packaging manufacturers
globally, now comprises 10 machines,
processing precision, accuracy and
with the opportunity to review, realign
with a clamp force range of between
dynamics. These are essential criteria
and reinforce the value of their packaging.
150 and 1,000 tons.
in the quest to achieve the highest
process parameters.
process consistency, as well as reducing From a machinery performance
Capable of delivering dry cycle times
scrap to a minimum during start-up and
viewpoint, thinner wall sections bring
of less than two seconds, the latest
during ongoing production. The fast and
changes in processing requirements.
generation of EL-Exis SPâ&#x20AC;&#x2122;s are specifically
precise response of these direct drives
Among them, higher pressures and
designed to withstand the higher
also enables special processes to be
speeds, faster cooling times, and
stresses and injection pressures that
implemented with pinpoint accuracy,
modifications to part-ejection and gating
are so critical in achieving repeatability,
opening up new possibilities for
arrangements. These process changes
particularly in thin walling. This range
packaging moulders.
FDPP - www.fdpp.co.uk 17
AHEAD OF OUR TIME Like any other business, economic viability is just as important a consideration for packaging moulders. Low unit costs, high output coupled with energy savings all need to be factored in. Thatâ&#x20AC;&#x2122;s why so many packaging manufacturers today are prepared to invest in new high-performance plant. Increasingly, packaging moulders are looking to injection machinery suppliers to provide turnkey solutions, including robotic product handling, advice with tooling, training and testing and all the know-how and support that underpins efficient manufacturing. Automated vision quality control is one area where significant advances have been made. At K-2019, we showcased our fastest closure turnkey exhibit to-date featuring the inspection Capwatcher Q Line from Intravis. Comprising eight highresolution cameras, this technology collects, visualises and provides up to 144,000 cavity-based measurements per minute. It also sources a unique
has probably superseded sustainability
packaging. While food and medical
inline temperature measurement for
as an immediate priority. Attracting new
packaging saw rises in demand, other
each closure, which allows moulders
people with the appetite for innovation
categories softened.
to determine the shrinkage behaviour
is as critical as ever.
of each and every closure. From a
Responding to a pandemic of this scale
quality control perspective, this is
Workforce and skill shortages can have
will always be a series of educated
groundbreaking stuff and significantly
a profound impact on cost, overruns
guesses. Iâ&#x20AC;&#x2122;m personally encouraged
reduces production waste.
and quality. Demands to create smaller,
to hear how packaging moulders are
lighter parts have made thin-wall
flexing to this unknown landscape and
Another way to achieve thinner yet
moulding one of the most sought after
acknowledging the fragility as well as
stronger packaging containers is to
capabilities in the injection moulding
the resilience of their product portfolios.
apply injection compression techniques
community.
Equally, the climate emergency has not
to stack moulds. With this, packaging
been forgotten.
moulders can increase output while
In mid-June the company reopened its
reducing the wall thickness of
training facility doors. To further assist
As public health concerns gradually
containers and lids from 0.45mm to
moulders of all sizes and sectors, this
ease, I suspect demand for reusable
0.35mm. This saves around 25% in raw
July Sumitomo (SHI) Demag will also
and sustainable solutions will swiftly
polypropylene materials compared
host a free series of Webinars covering
resume. However, the exact timings
to the standard injection moulding
some of the basic principles of injection
will be very much determined by
process, while maintaining comparable
moulding. The first discusses how to
consumers. Understanding how
mechanical properties.
calculate a correct clamping force
people interact with packaging and the channels they purchase through will
COMPLETING THE CHAIN OF CUSTODY
Packaging businesses we are in daily
be a clear driver, ensuring consumer
contact with are very much back to
safety, product security and future
Sustainability and production efficiency
business. Nevertheless, the pandemic
sustainability are evenly balanced.
is also intrinsically linked to skills. As we
has forced another re-think to our
reopen our society, resource efficiency
way of living and future reliance on
18 FDPP - www.fdpp.co.uk
http://uk.sumitomo-shi-demag.eu/
How leasing can support business development when cashflow is tight How do you invest in the equipment your business needs during uncertain times? Finance leasing from AJ Products can provide the answer. Even when cashflow is tight, businesses need to be able to invest in the future by having the right equipment to maintain safe and efficient work practices throughout the company. With affordable fixed monthly payments and no deposit, finance leasing allows any business to improve cashflow, complete projects with immediate effect and provide high-quality modern equipment for your staff when you cannot afford to make the
won’t change throughout the duration of
business improve workplace productivity,
effective way to spread costs over
the lease, allowing you to manage your
boost employee wellbeing and support
a period of up to five years to ease
budget effectively. In the meantime, you
social distancing. We can lend to
the financial burden and drive your
will have the cash available to invest in
businesses of all types including start-
business forward. Furthermore, as all
other key areas of your business and
ups and sole traders for projects from
leasing payments are tax deductible, it
safeguard essential outgoings, such as
£1000 to £1,000,000. For your peace of
is a solution that will save the business
staff costs and rental payments.
mind, security is levied on the equipment
full investment upfront. Leasing is an
money and is beneficial no matter your
rather than your property, minimising
financial circumstances.
Launched in January 2020, AJ Products
By maintaining your cashflow, you
workplace furniture and equipment
don’t have to make a choice between
requirements. From pallet racking,
the short- and long-term goals of your
lifting equipment and materials handling
business. You can spread the cost of
solutions to office furniture, cafeteria
Contact AJ Products to find out how you
your development project across your
spaces and changing room facilities, AJ
can arrange to lease the furniture or
chosen term as a fixed payment that
Products has the solutions to help your
equipment your business needs.
now offers a leasing solution for all your
the risk to your business if your circumstances change. At the end of the lease, you can keep, return or upgrade the products as suits your needs.
AJ Products is a full-service supplier of furniture and interior solutions for offices, warehouses and industrial facilities, offering everything from design suggestions and planning to quick delivery and installation. www.ajproducts.co.uk Email: info@ajproducts.co.uk Tel: 01252 359760
FDPP - www.fdpp.co.uk 19
Cerberus guards the food safety gates Automation of inspection processes is on the rise, particularly in High Care food production environments where COP compliance and food safety assurance are integral to productivity. Driving down production costs while ensuring an accurate and reliable inspection process results in time and cost savings. With the Cerberus combination machine from Sparc Systems, automated metal detection and checkweighing, with the option to integrate label verification, are delivered in one space-saving unit. The inspection machines market is projected to rise at a CAGR of 5.5% between now and 2024, with combination systems estimated to grow the most during the forecast period.1 A number of factors are attributed to the increasing adoption of integrated technologies, from demand for inline product inspection to growing need to comply with GMP requirements. However, the efficiency of integrated inspection lines is yet to be realised by many UK
To address the unique challenges posed
ensures fast and accurate rejection of up
by the food manufacturing sector, Sparc
to 200 out-of-tolerance or contaminated
is one of the few global inspection
packs per minute. An integrated metal
suppliers that offers cohesive reporting,
detector identifies ferrous and non-
data capture and COP testing in a combination system. Rather than slotting two systems together, the Cerberus provides complete mechanical and electronic integration with single point controls and trend feedback.
food manufacturers who continue to monitor performance manually or by a
Specifically designed for High Care food
machine-by-machine basis.
production environments, the Cerberus
ferrous particles down to 1.5mm, and stainless steel down to 2.0mm in bags weighing up to 60kg. Sparc’s European Sales Manager Charlie Graham explains: “Designed, engineered and constructed to the highest High Care, Food Grade engineering standards, no other system in the world comes close to this performance and sensitivity.”
DRIVING DOWN PRODUCTION COSTS Despite projected market growth, UK food suppliers are facing increasing pressure from all directions. With volatile market fluctuations and input costs squeezing already fragile margins, increasing output and installing reliable machinery are essential to drive down manufacturing costs and ensure productivity. The impact of machinery downtime alone costs Britain’s manufacturers more than £180bn every year.2 For checkweighing systems, reliability and accuracy is paramount to minimise downtime, false readings and food waste.
20 FDPP - www.fdpp.co.uk
Sparc addressed these issues by
which typically use pusher or air blast
market in the years to come.3 Every
designing the Cerberus with a heavy,
reject systems, the Cerberus uses an
retailer COP requires food manufacturers
stainless steel frame. Whereas other
all-electric direct drive which dips 90
to test their metal detectors and
suppliers are reducing weight, Sparc
degrees and 45 degrees to segregates
checkweighers regularly and document
engineers maintain that a heavier
metal contaminated products from
the results. But for staff completing
framework reduces vibrations from
weight rejects.
the tests by hand, the costs in time and
the factory environment to eliminate
money can be vast and the process is
the potential for false readings. Charlie
BRC-approved reject bins are located
comments: “In addition to its smart
beneath the conveyor framework
design, the high-spec checkweighing
rather than to the side, keeping the
To ensure absolute traceability and
station offsets the potential for both
machine footprint as compact and
compliance, Sparc designed the Cerberus
costly product giveaway and incomplete
slimline as possible. By containing these
with a single swipe touchscreen HMI and
packages reaching the market. In some
components within the body of the
paperless audit software with unlimited
cases, our customers have reported a
machine, plant flexibility and factory
pre-programmed COP. Believed to be
55% reduction in product giveaway.”
footprint are enhanced.
the most transparent system of its type,
subject to human error.
contract packers and manufacturers Keeping quality control front of mind,
“As a high-end combination metal
supplying multiple retailers can select
the system utilises a precision metal
detector and checkweigher, the Cerberus
from an unlimited list of retailer COP by
detector to inspect packaged food
was designed to eliminate emergency
product type. When a routine Quality
products. Identifying metal contaminants
product recalls with minimal operator
Assurance machine test is due - typically
with high sensitivity drives increased
intervention at inspection set up or
hourly - , a visual alert is issued to
security and reduces the risk of costly
product changeover. Furthermore, the
operatives. Steps cannot be skipped.
recalls. Food items involving numerous
in-line, electric-powered reject system
And if not performed to the set retailer
production steps where the potential for
removes the need for compressed air,
parameters, this is also flagged by the
metal contaminants to enter the supply
which has been proven to save some
machine and in the data reported that’s
chain is higher (sliced meat and cheese,
manufacturers up to £4,000 a year on
transmitted to the factory’s Quality
frozen products and convenience meals
running costs.
Assurance manager.
consistent inspection process.
COP COMPLIANCE WITH PAPERLESS AUDITS
When upgrades are issued, Sparc simply
UNIQUE CONVEYOR CONCEPT
Regulatory mandates in the food
which operatives can insert and upload
As a single unit, the Cerberus has two
industry to maintain compliance with
to the machine via the built-in USB.
reject bins to separate contaminant
retailer Codes of Practices and HACCP
and weight rejects situated beneath a
principles mean that the fully automated
Food factories are also able to select
three-position dipper conveyor. Notably,
machines segment is expected to
and bring to the HMI foreground their
unlike most other combination systems
dominate the inspection equipment
preferred operational parameters.
etc.) benefit from this repeatable and sends the new retailer COP parameters,
Charlie adds: “By generating constant feedback on operational statistics such as volume, weight and speed, downtime is reduced. And, the data capture element is fully integrated, making it simple to send information direct to the server or wireless devices. “With the Cerberus, nothing gets passed these food safety gates. No other combi system can accurately inspect 200 food packs a minute without compromising on any other aspect of performance. It is literally the most transparent and integrated combi system on the market today.” sparc-systems.com
FDPP - www.fdpp.co.uk 21
Magnetic separator for chocolate flakes We received a request from a producer
and carries away the metal-containing
of chocolate garnish for cakes, biscuits
product. The clean product falls directly
and yoghurt. The garnish is in the form
into the packaging machine.
of chips and granules that could possibly contain tiny pieces of metal less than
CLEANING
<1 mm in diameter. This is a common
Hygiene is of the utmost importance,
problem in the production of chocolate.
especially in the food industry. This
We were asked if we could filter the
is something we considered carefully
pieces containing metal out of the product flow, without loss of product.
while designing the HG separator. A separator, because with the latter you
quick release system makes removal
have to slow down the metal particle
and replacement of the conveyor
HIGH GRADIENT MAGNETIC SEPARATOR
before you can capture it. In addition
belt quick and easy. The special open
to chocolate, the magnetic separator
construction and covers that easily
To achieve this, we developed a high
is also suitable for other dry, granular
swing out of the way make the system
gradient separator with a strong
products, such as herbs and spices.
easy to clean.
the food industry. With this system we
HOW IT WORKS
For more information, please contact:
achieve exceptionally high separation
The process itself is simple. A vibrating
Arthur Jonkman â&#x20AC;&#x201C; Sales Engineer
efficiency, not just for iron particles,
chute feeds the chocolate flakes and
Goudsmit Magnetic Systems BV Tel.:
but also for weakly magnetic stainless
pellets onto the conveyor belt and
+31 (0)40-2213283 mail:
steel particles, such as AISI 304 and
distributes the products in a single layer
magnetic conveyor roller, specifically for
AISI 316. The high gradient separator is more effective than a free-fall magnetic
22 FDPP - www.fdpp.co.uk
over the belt. The conveyor belt turns around the magnetic roller that captures
AJ@goudsmit.eu Or send an e-mail to: pe@goudsmit.eu) /www.goudsmit.co.uk
KG Group Invests 20M EUR in New Plant in Lithuania European demand for instant noodles,
the existing production capacity and at
an Asian food staple, is increasing,
the same time allows to maintain the
while the Covid-19 pandemic is
same level of quality control.
leaving many supply chains broken. As
The 6.5 thousand square meter
European instant food buyers, such
production facility houses state-of-
as supermarket chains, are looking
the-art equipment, which the company
for local producers, Lithuanian instant food company invests 20M in a new
acquired from leading German, French,
local production facility. This is the
Swiss, and other manufacturers in
second company’s production facility in
today will be increased up to 180 million
Europe, complying with the latest
Lithuania.
units per year.
quality standards (the highest AA
September 7, 2020. Global Instant
KG Group is already operating in the
Noodles market, according to a new
UK, producing noodles, pasta, oatmeal
report, is growing despite the Covid-19
porridges and rice for this market. In
The commercial range of instant foods
crisis, and is estimated to reach USD
2019 more than 34 million units were
produced by KG Group includes instant
32.1 Billion by 2027. Up till now, most of
sold in the UK, while in 2020 this number
noodles and porridges in cups and
this instant food has been produced and
rose to 56 million units (sold until July,
pouches labeled with brands well-known
bought from different Asian countries.
2020). The products of KG Group may be
in Lithuania and abroad, such as Sun Yan,
found in most large supermarket chains
Activus, Dorea, and Just Inn. More than
of the UK. The new production facility is
forty major foreign companies, including
expected to fill a significant portion of
large supermarket chains trust their
demand for instant noodles in the UK
private label production with KG Group.
grade according to BRC Global
However, the coronavirus pandemic is affecting the market of this Asian staple food, among many others. As many companies are looking to alter their supply chains to be less dependent on
and to decrease the country’s reliance on
Standards Version 8).
Asian suppliers.
The technological features of the
Covid-19 crisis, they are exploring the
“We are glad we will be able to meet the
competencies and knowledge of the
options of local production. Exclusive
increased demand of local buyers, many
R&D Department even more effectively
reliance on Asian suppliers has shown its
of whom are European supermarket
introducing new products. KG Group
drawbacks as supply chains were cut or
chains. A new production plant in Alytus
produces new categories of instant
unreliable during the pandemic.
city is our response to the rapid growth
products in cups such as pasta, cereal
of consumer demand, and changes in
mixes, granola mixes, and couscous.
In order to satisfy the need for instant
global supply chains,” said Tautvydas
Private label services are available as
noodles and porridges in the European
Barštys, Chairman of the Board of KG
well.
FMCG retail market, including the
Group. He added that Alytus city is
UK, KG Group - one of the biggest
strategically favourable from a logistical
KG Group started the instant product
agriculture and food groups in the Baltic
point of view, as KG Group exports 95
business eight years ago, when the
States - is launching a modern instant
percent of instant food production.
first production facility, operating
Asia, especially China, in the wake of the
noodles production facility in Alytus city, Lithuania, after having attracted 20M
The new facility is an important addition
EUR investment.
to the KG Group chain of production.
The newly introduced technologies
quality the group exerts control over and
will not only increase the production
takes responsibility for all processes of
capacity, but they will also enable a
production from field to table. KG Group
greater variety of products and speed up
buys grain from Lithuanian farmers,
the production process by 4-5 times. The
selects it with care and uses the group-
capacity of forty million units of instant
owned mill to ensure the highest quality
food in cups that KG Group produces
of flour. The new local facility expands
To ensure the highest standards of
production facility help to embrace the
to date, was opened in Kėdainiai city. Further plans of the company include the development of products and the range of items, an increase of sales volumes, a supply of new products to consumers, development of export volumes. The main focus is on exports to Western Europe, Spain, Great Britain, and Scandinavian countries. www.kggroup.eu/en
FDPP - www.fdpp.co.uk 23
Grading facility puts its eggs in the Rotamec basket When shopping at the supermarket or eating at a restaurant, you want to be assured that your food has undergone proper quality checks. These checks can be quite the challenge for a foodstuff as delicate as eggs. Grading eggs is a specialty of grading facilities, which quality check eggs from nearby prior to distribution. One such facility operates a wide array of specialist equipment on-site and trusts Rotamec, an electromechanical engineering service provider,
“We have to react quickly to minimise
This customer does present specific
to deliver repairs and source spares.
downtime. For example, the customer
challenges though, as Darryl reiterates:
required a double-sided open length
“One repair job required us to source
Eggs are a staple food for many of us,
timing belt to keep a conveyor operational
which means that there is a high level
specialist foam material that cushions
after a failure of the OE part. The cost
of demand for the produce irrespective
the eggs during grading. The egg comes
of downtime on this machine is around
of season. Consumers will only settle
£3,000 an hour, so lead time was all
through to a sensor, where it taps
for quality produce, so grading facilities
important. In this case the maintenance
assesses each egg that reaches its
team decided to order two parts, one from
processing lines from partnered farms
us and one from the OEM, to maximise
before packaging. By checking for any
their chances of getting the machine back
imperfection with specialist equipment,
up and running the same day.
grading ensures every egg is in optimum condition before it is packaged and
“We were able to deliver the belt in 2
delivered to customers. With millions of
hours, while the OEM took 6 hours. Ours
eggs passing through grading facilities
was installed and the OEM item added
each year, keeping specialised equipment
to spares. All in all, we managed to save
running is especially important in helping
them roughly £12,000 in downtime costs.”
shops meet the demand. However, the more specialised your equipment, the harder it is to repair or replace parts in the event of a failure. Lead times from OEM’s are often unforgiving, which in the pressurised world of food
The egg grading facility operates varied motors and gearboxes, reliable supply of a wide range of standard parts from a single supplier is important in keeping equipment running. Thanks to existing warehouse stock and in-house distribution
against the foam, which detects any hairline cracks as part of the quality control process. Improper foam will crack the egg, so only an exact solution will do. Th grading facility required replacement foam for the machine, but the OEM lead time was going to take too long, so we were approached. It was a bit different from the mechanical issues we typically deal with, but we managed to source the foam within the required timeframe.” Both the grading facility and Rotamec understand that reducing downtime is one thing, but preventing it is another. This is why engineers from both businesses are building redundancy
capabilities, Rotamec is able to deliver
into maintenance and repair operations.
standard parts quickly – typically same
By undertaking asset inspections and
day if required. Further, its in-house
identifying ‘showstoppers’ - equipment
machining capabilities mean that bespoke
that risks overall uptime if it fails – the
items such as shafts in various bore sizes
engineers are prioritising maintenance
can be easily produced too. Specialising in
to focus on the most critical assets.
motor repair and refurbishment helps as
Rotamec has also enacted a policy
well, with Rotamec able to offer 24-hour
of ordering spares from relevant
Reducing downtime via responsive
turnarounds on motors and gearboxes.
OEMs during each repair, ensuring
maintenance is very important to this
So, despite different configurations and
facility, as Darryl Beecham, Business
equipment throughout the site, Rotamec
maintenance work is backed by a
Development Executive at Rotamec
can still offer reduced repair and sourcing
explains:
lead times.
supply adds further stress to operators. For one grading facility, keeping the machines running and eggs moving demands the assurance of a dynamic service provider, which is where Rotamec - a leading service provider for engineered equipment - comes in.
24 FDPP - www.fdpp.co.uk
growing spares inventory. www.rotamec.com
An industry leader in the supply of environmentally responsible & HACCP compliant preventative controls & detection systems to the regulated food industries
MAGNERSCAN Chemical free surface integrity & crack detection testing
GAPPSCAN Heat exchanger integrity quantification for multiple PHE plates reducing downtime
PASFLO Non-intrusive pasteurisation residence & flow validation for the liquid dairy, brewery & juice industries
BACTISCAN Isolating BioFilms, bacteria, mould & contaminants using wave alternating UV to reduce product recalls or worse
To discover more, contact us today: enquiries@eit-international.com or visit:
www.eit-international.comFDPP - www.fdpp.co.uk
25
Compact inspection systems become the ‘new normal’ When it comes to buying criteria
However, producers have a duty of care
systems on the same conveyor results
for inspection equipment, whilst
to operators to ensure they are working
in a far smaller footprint than stand-
commercial viability will always make
in a safe environment. Rather than
alone units would occupy.
or break decisions, the COVID-19 crisis
reconfiguring production line layouts,
is pushing space-optimised design and
companies are looking at how they can
Combi metal detector/checkweighers
remote diagnostics to the fore.
redeploy and organise operators in a
are not a new concept, but last month
safer way, for example, by altering shift
[May], saw Fortress unveil its first ever
patterns. In other words, the focus is on
offering in the space under the Raptor
moving people rather than machinery.
marque. Developed in collaboration with
Footprint has long been a consideration when choosing packaging and processing equipment – factory space is at a premium and the ever-increasing
As factories adapt to these new ways
cost of real estate means each cubic
of working, Phil Brown, Managing
metre has to be maximised.
Director of Fortress Technology, expects
In production and packaging facilities where every inch counts, establishing
equipment compactness to become even more important.
new practices that will enable factory
“From a factory floor perspective,
personnel to work safely during
adapting to COVID-19 is all about
the COVID-19 pandemic is a huge
creating space. Smaller footprint
challenge. Preventing the spread of the
equipment creates more space for
virus within the workplace is all about
people to move around without being
creating distance and physical barriers
restricted to certain pathways,” he says.
between workers, but space is in short supply in most facilities.
COMBI SYSTEMS COME INTO THEIR OWN
MOVING PEOPLE, NOT MACHINERY
One of the ways in which companies
Redesigning factory layouts is not easy,
combined checkweighing and metal
requiring considerable investment.
detection system – mounting these
26 FDPP - www.fdpp.co.uk
Sparc Systems, the integrated system delivers hygienic and user-friendly operation on a compact footprint. The machine’s footprint has been minimised via several design features. Clever configuration of the reject mechanisms, for example, means that they occupy 50% less space than a conventional design. “You can’t get away from the fact you need separate rejects for weighing and metal as the rework required for rejected products is very different. However, we have designed the system
can save line space is to opt for a
with opposing rather than end to end rejects, reducing the length of the reject system from one metre to 500mm,” explains Brown.
“500mm might not sound like a lot
lines, where multiple components are
and supermarkets have grappled with
of space, but it can be the difference
added manually. Here, where individual
unpredictable purchasing behaviour and
between a safe working space and one
working space can’t be maintained,
patterns. Issues with equipment have had
that doesn’t meet requirements. Also,
factories have had to install physical
to be resolved as quickly as possible, with
if you equate it to the amount you are
screens to separate operators. Either
minimal disruption and person-to-person
paying per sq ft, it translates to a tangible
solution increases the line space required
contact. In these circumstances, remote
cost saving,” he adds.
to safely perform this operation, so
troubleshooting is the ideal solution,
downstream equipment space savings are
and even if the issue cannot be resolved
needed to free up space.
remotely, it can serve as a first line
Another way in which the Raptor Combi system can offer space-saving advantages over rival systems is through
DISTANCED DIAGNOSTICS
the flexibility this platform offers. Whilst
approach, arming engineers with valuable information so that site visits can be as brief as possible.
Fortress manufactures a standard Raptor
As well as creating a further driver for
system for customers wanting a short
more compact systems, the COVID-19
Now that companies have started to
lead-time system for handling products
pandemic is accelerating adoption of
realise the benefits of remote assistance,
up to 400mm in size and up to 8kg in
remote access functionality on inspection
Brown believes it is unlikely that the
weight, it will also manufacture custom
equipment.
industry will revert to a more traditional
systems for smaller products and space-
face-to-face approach and that it will be a
restricted areas.
“Most modern metal detectors and
“A lot of our competitors will just produce
diagnostics but until now this function
Likewise, the food industry will continue
a standard system that can accommodate
has been under-utilised. However, recent
to demand inspection systems with
any product up to 500mm. However, if
months have seen it taking on increasing
ever more compact dimensions. Whilst
you are running a 250mm product, you
importance as companies seek to protect
technological progress will continue to
don’t need such a long system. In that
staff and reduce travel and face-to-face
forge ahead in this area, there comes a
situation, we can engineer the system
contact,” notes Brown.
point when both physics and the need
down to 1.2m instead of supplying a standard system that is 2m in length,”
checkweighers have in-built remote
There are several reasons for this shift
says Brown.
in behaviour. Some areas of the food
One scenario where space-optimised
demand in recent months as consumer
combi systems can really come into their
spending has shifted from the out of
own is on labour-intensive ready meal
home hospitality sector to retail grocery,
industry have faced unprecedented
focus for innovation in years to come.
to guarantee product quality place limitations on reducing system size. It is about finding that sweet spot, where footprint, reliability and cost of ownership can all be balanced. www.fortresstechnology.com
FDPP - www.fdpp.co.uk 27
Food for thought: Robot stacks sandwiches in 800 milliseconds Although simple automation can
frequent shortage of labour. Their
give some manufacturers the boost
production lines were understaffed,
needed to increase production and
and they were always missing people
product consistency, more complex
from their optimum shift capacity,”
applications often require intelligent,
says Kyran Findlater, Mechatronics
flexible robotic solutions that can
Designer at TechBrew. Obviously
adapt to variable products and picking
TechBrew had to consider national
locations. In the case of a large-scale
food safety regulations when designing
sandwich producer, growing production
this solution, and in this case the
demands coupled with a major labour
integrator used the cleanroom version
shortage provided motivation for
of Kawasaki’s 5 kg payload RS005L
them to robotically automate a high-
general purpose robot. As standard it
speed sandwich stacking application.
offers a pressurized cavity, ISO Class
To resolve the challenge, TechBrew Robotics, a Kawasaki Robotics Preferred Integrator based in British Columbia, Canada, designed a custom solution using Kawasaki’s R series robots and F60 controller. The robots’ task may seem simple: after the sandwiches are halved in the cutting machine, the robots need to pick up and rotate to stack one half on top of the other, making them easier for human workers to package manually further down the line. However, this application was tricky to automate for a number of reasons. The sandwich halves vary in their position as they come out of the cutting machine, so the robot would need some sort of vision intelligence to recognise and understand the location of each half on the conveyor. They also needed to be able to stack the sandwiches in practically the blink of an
the sandwich cutting machine itself. To maximise throughput, the robots face outward, stacking sandwiches on two different conveyors which are running simultaneously. There are many variables in this application, so TechBrew used a laser range finding system coupled with conveyor tracking to detect the shape and location of the sandwich halves as they emerge from the cutting machine. Once the sandwich halves have been stacked, they travel down the conveyor to a place where human workers are waiting to place the product into triangular cardboard boxes. TechBrew designed a custom gripper specifically for this application. The pneumatic end effector is controlled directly by the F60 Controller, allowing for quick movements. A controllable pressure plate comes down to hold the
5 cleanroom specification, and comes with an aluminium arm cover, rubber outer seals and a chemical resistant epoxy paint finish for easy wash down. The patent-pending end effector’s tool-less design makes it easy to disassemble for cleaning purposes, and it is constructed with stainless steel and food-grade plastic. The combination of Kawasaki’s AS programming language and its F60 controller easily handled the complexities of this project. Findlater was able to program this application directly on the robot, without a coprocessor, which reduced costs and simplified the installation. The Kawasaki F60 Controller’s high processing speed handled real-time scanning and data analysis on the sandwich halves, and output the robot coordinates in under 200 milliseconds, while processing a
eye.
product in place as two stainless steel
Because TechBrew needed to integrate
lift it. Once lifted, the actuator spins the
its solution into the customer’s
sandwich half through 180°, and force
existing production line, it meant
The entire sandwich stacking process
dampers at the end of the rotation keep
making creative use of limited space.
takes just 800 milliseconds and
the sandwich and its ingredients intact.
according to TechBrew, it didn’t take
paddles slide under the sandwich half to
To this end, the R series robots were inversely mounted on a cantilever
Like many other manufacturers, the
beam attached to the cutting machine,
customer struggled, sometimes daily,
and the F60 controllers’ compact
to keep up with production goals
size made it possible to save further
due to absent workers. “The main
space by stacking them on top of
driver for the end user here was the
28 FDPP - www.fdpp.co.uk
queue of sandwiches at a rate of 60 per minute.
the customers’ line managers long to adjust to their new robotic co-workers. Throughput has increased significantly as a result of the robot’s consistency. https://robotics.kawasaki.com/en1/
Hassia’s form-fill-seal machine F600 for sachets produces four-sided sealed sachets at a pace of up to 80 cycles/min Among other differentiators, the F600 offers single-roll functionality, an improvement over two-roll formats. The units run a single wide roll, which is located at floor level for easy changeover and front-and-back sachet
registration – an option offering more printing choices than traditional two-roll machines. The F600 can handle rolls as wide as 1.200 mm with a diameter of 800 mm, which can yield up to 16 hours of run
time between roll changes; the result is significantly reduced downtime and boosted productivity. The F600’s careful product handling places a premium on quality assurance, and its CIP and SIP-suitable dosing units can be adjusted per specific product requirements. Exemplary filling accuracy and hygiene standards are assured, and the hermetic pack seal produced by the F600 is secure yet easy to open for consumer convenience. The F600 is also flexible: A range of pack designs are possible, and sizes can be configured to align with production capacity. The machine’s control concepts are highly versatile and include opportunities for integration with customer-specific systems. The unit can handle all common packaging materials suitable for heat-sealing. For more information please contact p +44 740 884 06 02 www.imadairyfood.com
FDPP - www.fdpp.co.uk 29
The New SRP Cobot by Phoenix Handling Solutions The new SRP Cobot from PHS is an
scanning system to the front. Should
• 6 bar air pressure
extremely compact, versatile and fully
a person be detected by the radar, we
• Lease purchase, hire purchase, lease
automatic, low-cost modular robot
automatically slow down the Robot into
only or outright purchase options
palletizing system, based on a Hanwha
Cobot mode, ie it runs at a lower speed
available
HCR-12 industrial collaborative robot.
for safety reasons.
Designed for easy, low-capacity palletizing on a very small footprint. The system is available in two versions. Given the vast experience of PHS in end of line automation, Cobots were a natural progression for our business for existing and new customers alike.
Should your business be considering Advantages
a low cost palletizing solution, then
• Low investment, fast ROI
please contact Phoenix Handling
• Standardized system - fast delivery
Solutions Limited:
and installation • Very compact footprint, easy to re- locate by pallet trolley or forklift • Collaborative industrial robot -
They are simple to install and do not
safety fencing and safety radar
require masses of conveyors to feed
scanner included – CE certified
them. Hence they can be easily placed at
• Easy product change-over
the end of a production line picking and
• Can handle Euro 1200 x 800 or
placing product 24/7 if required.
Chep style 1200 x 1000mm pallets x 2 positions
Safety plays a huge part of the PHS
• Optional layer sheet inserter
solution, as we provide a fully guarded
• Up to 6 cycles per minute, either
cell to follow the strict guidelines for CE
single or multi picking according to
T: 0845 265 7570
marking Cobots, with safety guarding
gripper type and dimensions
E: admin@phs-uk.com.
at each side of the machine and a radar
30 FDPP - www.fdpp.co.uk
• Single phase power supply
www.phs-uk.com
Ishida Solutions support Danish Crown’s China expansion Ishida Europe has designed and installed a series of bespoke packing lines for specialist meat producer Danish Crown’s new greenfield factory in China. Working in close partnership with the customer, Ishida has supplied its own and ancillary equipment for the four lines, which are handling a variety of products including minced and diced pork, ribs and steaks, as well as quality control for thermoformed packs of pork. The factory is now in operation and will have a capacity for 14,000 tonnes of meat to be processed and packed each year when it is up to full speed. Ishida’s ability to devise complete solutions in line with customer requirements and efficiency and throughput targets, along with the excellent performance and reliability of its equipment, were key reasons for the company’s selection by Danish Crown.
32 FDPP - www.fdpp.co.uk
“We felt that Ishida offered the most
variety of products and pack types. For
inspection systems and DACS-G-015
relevant experience and the best
example, the multihead weigher is able
checkweighers are also providing
solutions,” explains Nicolai Linde,
to discharge diced meat directly into
quality control and weight checks on
Senior Manager Projects, Production
trays, or transfer ribs to a batching
two separate thermoforming lines.
and Supply Chain. “Having a single
table for styling in the trays. Similarly,
point of contact helped to speed up the
the QX-1100 tray sealers which
Danish Crown is one of the world’s
process. In particular, the close working
currently seal MAP trays are also
largest exporters and one of Europe’s
relationship established between our
able to handle skin packs, which will
largest producers of pork. The new
two teams and the continuing dialogue
enable Danish Crown to meet growing
China factory in Shanghai was
between them ensured that any issues
demand in the Chinese market for
established to meet growing consumer
or problems could be discussed and
bone-in products.
demand in the Chinese market for high
quickly dealt with to keep the project on
quality meat products, supplied via
time and budget and enable us to meet
“Although we were not previously
our performance targets.
familiar with Ishida’s tray sealers, they
“In addition, the company has an office in China which ensures a fast response in terms of service support and spare parts.” The Ishida models installed at the factory include the company’s
supermarkets and e-commerce.
have proved to be very reliable and
“Our objective was to build the new
deliver consistently high-quality seals,”
factory to Danish standards,” explains
comments Nicolai Linde.
Nicolai Linde. “For this reason, we focused on sourcing the very best
As another example of the excellent
European equipment throughout.”
performance of the Ishida machines, the company’s IX-GN 4044 x-ray
www.ishidaeurope.com
advanced RV-214 multihead weigher, QX-1100 Twin tray sealers, DACS-G checkweighers, IX-GN x-ray inspection systems and its weigh-price-labellers. Additional equipment integrated into the lines includes dicers, slicers, batching tables, labellers and cartoners. Ishida also gave factory personnel comprehensive training on all its machines and provided a technician onsite permanently during the first months of operation to ensure a trouble-free start up. A key requirement of the overall design was to ensure maximum flexibility in the lines’ ability to handle a wide
FDPP - www.fdpp.co.uk 33
The Benefits of Automatic Metal Detector Testing By Mike Bradley, Global Head of Sales (Metal
the metal detector. This is because they
ATS is suitable for use in vertical food
Detection) Mettler-Toledo Product Inspection
do not confirm centerline testing – the
inspection applications such as snacks,
least sensitive part of the metal detector
crisps, confectionery, infant formula,
– as the placement of test samples
bulk flour and nutraceutical powders,
passing through is generally random. In
plus granulates such as sugar and food
Traditional methods of testing gravity fed metal detectors and those installed on Vertical Form Fill and Seal (VFFS) packing lines typically involve frequent and timeconsuming stoppages, potential risks to operator safety and often generate inconsistent results. In many cases, the test methods used do not confirm that the operational specification of the metal detector is being achieved. Automatic metal detector testing systems overcome these issues and can aid food manufacturing quality, efficiency and productivity.
addition, manual testing processes can carry cross-contamination risks and can potentially compromise food product quality, as the test samples come into direct contact with the product. Mettler-Toledo has delivered a solution to all these problems, while also helping to improve Overall Equipment Effectiveness (OEE) and productivity: its Automatic Test System (ATS) on Safeline metal detection systems, won
The “Drop-Through”, “Fishing Line”
the CFIA Innovation Award for Quality,
and “Test Rod” methods are all routine
Hygiene, Security and Environment in
performance monitoring test processes
France in 2019 and has been recognised
for vertical metal detection inspection
as accepted best practise by a major UK
systems. Manual testing often requires
high street retailer.
teams of operators to put their safety at risk by climbing ladders and reaching over machinery so that they can drop or insert test samples into a throat or gravity-fall metal detector. These test processes are unable to accurately verify the operational specification of
additives. Test samples are transported, by pneumatic control, up discreet nonmetallic tubes inside the metal detector’s aperture to a defined position within the sensing coils. The test samples are then released, simulating the presence of a contaminant in free-fall under gravity. A software algorithm correlates centerline sensitivity with edge of aperture sensitivity, eliminating the random nature of vertical metal detector testing. Reduced Test (RT) Mode is an additional feature available on some throat and gravity-fall metal detection systems. When RT Mode is active, the metal detector monitors its online sensitivity performance and provides an alarm should the sensitivity drop below the specified level allowing companies to reduce the frequency of testing by up to 80%, without increasing their risk. This directly, and in some cases dramatically, improves productivity as production is now stopped less frequently for testing allowing productivity gains to be realised. Major Italian savoury snack producer PATA S.p.A has 30 throat-style metal detectors on its production line, of which five have ATS installed. RT Mode is included as standard on the MettlerToledo Profile metal detectors that it uses. ATS and RT Mode have provided several benefits for PATA and for other food manufacturers that use them:
#1 ENSURE COMPLIANCE ATS is the only method of testing that confirms centerline (worst-case) sensitivity performance. As such, it delivers test results of ongoing working performance that can be trusted.
34 FDPP - www.fdpp.co.uk
#3 ENHANCE OPERATOR SAFETY Not only will operators be safer with ATS, but fewer of them will be needed to conduct testing. For example, instead of one operator having to climb high to drop a sample through the aperture, and one to record the result and remove the sample from the production line, ATS testing can be completed by a single operator. It virtually eliminates the need to work at height to conduct routine testing and removes the need for operators to reach across installed equipment to insert a test sample.
#4 IMPROVE PRODUCT QUALITY AND FOOD SAFETY
When connected to centralised data
a single operator in under 40 seconds,
collection and management systems,
compared to an average three to four
ATS is a non-invasive method of testing,
such as Mettler-Toledo’s ProdX software,
minutes and two operators using
so test samples do not come into
ATS provides electronic records that
traditional, manual methods.
contact with food, removing the danger
are easily stored for future reference, for audit compliance or proof of due diligence. Having electronically stored data reduces the risk of errors or loss associated with paper records. This also supports rigorous quality control regimes, production optimisation and simplified production line operation.
#2 INCREASE PRODUCTIVITY
By using RT Mode to reduce testing frequency from every two hours to every 12 hours, a typical snack food manufacturer with 24 weigher-bagger lines running at an average of 100 bags per minute could save more than 4000 man-hours and produce 25 million more packs per year. Mettler Toledo’s online calculators
ATS tests are much faster than
www.mt.com/md-roi-rt enable food
traditional testing methods. An end-to-
manufacturers to work out how much
end 3-metal test (ferrous, non-ferrous
they could benefit from using ATS and
and stainless steel) can be completed by
RT Mode.
of cross-contamination. The higher sensitivity levels of RT Mode mean that smaller, irregularly shaped metal contaminants can be detected. RT Mode also continuously checks the performance of the metal detector to ensure it is always working to a level as good as, or better than, the food manufacturer’s specifications.
#5 ADDITIONAL FEATURE TO FACILITATE SOCIAL DISTANCING REQUIREMENTS Additional to ATS and RT Mode is an ‘Emulation’ feature which allows operators to remotely control the metal detectors by mirroring their interfaces on remote networked devices. This is ideal for testing of systems installed in inaccessible locations plus also supports COIVD-19 social distancing requirements and enhances operator safety. Food manufacturers can try out Mettler-Toledo’s ATS ROI Calculator here: www.mt.com/md-roi-rt
For more information, download MettlerToledo’s “Five Reasons to Invest in Automatic Test System”: www.mt.com/md-ats
FDPP - www.fdpp.co.uk 35
Future ready: Sustainable wheat ingredients for functional concepts How the corona crisis has led
trends through innovative technology.
consumers to rethink their attitude to
As a result, manufacturers benefit from
food â&#x20AC;&#x201C; a statement by Henrik Hetzer,
higher quality end products using the
Managing Director of Loryma
same or optimised production processes.
The post-corona era calls for innovation
There are three megatrends at the
and more global responsibility in the
epicentre of the corona disaster that
food industry. Consumers increasingly
will prove to be true innovation drivers
demand sustainable, safe and
in years to come. The crisis has led to
uncomplicated products. Market research
a reorganization of the way we work,
institutes such as Mintel1 are forecasting
greater respect for the older generation
a long-term trend reversal in the food
and a desire to take more responsibility
market after the crisis: towards higher
for our environment. These experiences
expectations in terms of quality, as well
will have a lasting impact on peopleâ&#x20AC;&#x2122;s
as increased awareness of added health
living and consumption habits. Key
benefits and environmental compatibility.
learnings are a daily diet with less meat,
As experts in ingredients made from
easy preparation of food at home and a
the natural raw material wheat, we at
need for healthy and ethically justifiable
Loryma can respond to current consumer
nutrition.
36 FDPP - www.fdpp.co.uk
This is where the natural raw material wheat offers great potential: using extrusion technology, it is versatile and combines nutritional and technological advantages. Wheat proteins optimise the consistency of products such as meat alternatives, cereals, baked goods and convenience food. They provide high-quality amino acids and help to reduce global meat consumption, contributing to a better ecological balance. Wheat
Our great asset is the flexibility of wheat
joint production, i.e. the creation of
starches improve stability, texture
combined with the expertise we have
different products from the same raw
and flavour, while extending shelf
acquired over several decades. Loryma
material, the wheat can be utilised
life and positively influencing the
is a brand of the Crespel & Deiters
almost entirely with a yield of 99 per
nutritional profile of food products,
Group, which processes 330,000 tonnes
cent. This guarantees efficient and
for example through sugar reduction.
of wheat annually, which equates to an
resource-friendly handling. Lorymaâ&#x20AC;&#x2DC;s
The use of functional blends enables
area the size of 57,500 football pitches.
products are crisis-proof and pioneering
individualised visually and texturally
100% of the guaranteed GMO-free
convincing applications that are quick
raw material comes from the EU, 75%
and easy to prepare. This holds true
of which is harvested and processed
for a virtually unlimited number of
in Germany. The regionality of this
solutions, from breadings and vegan
renewable natural product ensures
meat substitutes to confectionery,
a reliable supply, short transport
snacks and ready meals.
routes and low emissions. Thanks to
for use in globally significant markets of the future. This also benefits the manufacturers who work with our ingredients. For further information, please visit: www.loryma.de/en/
FDPP - www.fdpp.co.uk 37
CUSTOMISE YOUR PPE … PROTECT YOUR STAFF WITH PRINTED VISORS … We have e l b Tilta Visor GIVE YOUR EMPLOYEES A certification CUSTOMISED FACE VISOR … ADD YOUR NAME TO YOUR PPE MINIMUM ORDER – 250 VISORS LOW COST FROM UNDER £4.00
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DESIGNED & MANUFACTURED
IN GREAT BRITAIN
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DESIGNED & MANUFACTURED
IN GREAT BRITAIN
The Specialists for Retail and Promotional Packaging using Recycled PET and Folding Box Board BELL Packaging One of Europe’s leading suppliers of Retail packaging opened a PPE division in March supplying a range of Face Visors which are widely used by the NHS – As companies welcome back their staff from Furlough we must protect them and Visors provide excellent protection from harmful COVID droplets. In July BELL introduced a Tiltable visor which is CE Certified – this is very popular
+44 (0) 1582 459292
with people working in Hotels, Bars and the Entertainment sector but is also used in shops, department stores, beauty and hair salons. For October we are launching Printed Visors … Yes your LOGO or MESSAGE printed onto the Visor … Minimum Order quantity is 250 Pieces with print in 1 or 2 Colours – Cost is under £4.00 / Visor for a 1 colour print plus Printing Die @ £100 & Delivery
www.bellpackaging.com
i.bennett@bellpackaging.com
Price subject to MOQ & approval of final artwork. Delivery time is really fast as we hold over 10,000 Visors in stock. Coming soon BELL have Protective screens which are 100% Recyclable and costing under £15.00 each – for more information visit our dedicated website www.faceguards.co.uk or call +44 (0) 1582 459292 and ask for a free sample
www@faceguards.co.uk
Barratt Industrial Park, Airport Way, Luton LU2 9NH
in
What does the future hold for food & beverage manufacturing? By Emma Ryde, Rittal’s Product Manager
As digital technologies continue to
advancements. Europe has long been at
Industrial & Outdoor Enclosures
transform global markets, no industry
the forefront of these legislative changes
remains untouched, and food and
and successful companies will likely be
beverage manufacturing is certainly no
those who stay ahead of the curve by
exception.
implementing changes sooner rather
Food and beverage manufacturers of all sizes are facing huge operational challenges right now. Sudden increases in consumer demand, shifting expectations, changes in
Let’s consider how each of these three factors can impact day-to-day operations
than later. These companies will avoid both production downtime, and the potential for higher costs associated with
on the production floor, and how leading
refits, when new legislation eventually
manufacturers are adapting to win.
passes.
be responsive, agile and flexible. There
STANDARDS AND LEGISLATION
Even in our current outcomes-based
is also the matter of ensuring seamless
In recent years, food and beverage
regulatory framework, reducing cleaning
production continuity, to ensure
manufacturing regulations have
time and ensuring impeccable hygiene
consumer confidence around maintaining
changed significantly across the globe
standards continue to be key areas of
food and beverage supplies.
due to technological and scientific
focus.
food safety legislation, and emerging technologies, all require companies to
40 FDPP - www.fdpp.co.uk
As the physical landscape of
their way to support companies who
to clean them will lower both water and
manufacturing shifts to accommodate
follow environmentally friendly practices.
energy usage.
Manufacturers that want to reach this
In order to offset the cost increases
cleanliness.
audience will need to implement changes
associated with making these transitions,
that reflect this shift in consumer
industry leaders are continuing to refine
This leads us to our next topic: the
priorities and effectively communicate
efficiency-boosting practices like CIP to
presence and proliferation of technology
the changes that have been made. To do this, you’ll need to streamline every
make production facilities greener.
in food production spaces.
the increased presence of technology, so too will our approaches to safety and
FOOD SUSTAINABILITY AND CORPORATE RESPONSIBILITY
aspect of your business with a new focus on environmental sustainability.
There’s no denying that we all have a
Whether it’s recycling production
responsibility to implement sustainable
materials to close the loop on waste
environmental practices. But from a
outputs, or reducing the energy
commercial perspective, it’s also worth
consumed during cleaning, every part of
TECHNOLOGY AND DIGITAL TRANSFORMATION At this point, we can consider the massive impact that the Internet of Things (IoT) will have on manufacturing is a sure thing.
your process should be moving towards
Telstra puts it very clearly when they
a more sustainable future, either directly
state that “In an increasingly automated
the consumer market.
or indirectly. For example, Rittal’s HD
manufacturing environment, having
The consumers of the future will
to make them quicker and easier to
place huge value on environmental
clean. HD enclosures are typically power
sustainability, and they’ll also go out of
washed, so reducing the time it takes
your time to embrace sustainability as millennials and Gen Z begin to dominate
enclosures are specifically designed
multiple machines communicating with each other and being managed and diagnosed remotely offers benefits that are self-evident.” These smart machines pose a unique challenge to the food and beverage industry; their delicate circuitry and sensors must be on the production floor but must also be protected from contaminating or being contaminated by the manufacturing process. Additionally, these complex computer systems need to be compliant with current and future food safety regulations and be well-suited to withstand increasingly ambitious CIP procedures. Now is the time to consider how you can update your existing manufacturing systems to try and account for the changes that are taking place in the industry. Whether it’s investigating new, sustainable production methods, or investing in physical infrastructure that supports new technologies, now is the time to move confidently forward or get left behind. Optimising every piece of the manufacturing puzzle is essential to maintain a competitive advantage. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.
FDPP - www.fdpp.co.uk 41
How to Reduce Cleaning Downtime and Ensure Precision Weighing Day after day, food manufacturers
the cleaning process can be improved
WITH EASILY DISMANTLED AND
operating in harsh production
and the time it takes can be reduced by
REASSEMBLED CONVEYORS
environments face an essential but
following these 3 tips. Food manufacturers can benefit
laborious task - to clean all production machinery. Production line equipment, including
#1: UNDERSTAND THE HYGIENIC
from considerable time savings if
DESIGN PRINCIPLES OF PRODUCTION
conveyor belts can be easily dismantled
EQUIPMENT
and reassembled for cleaning and
checkweighers, must regularly complete
maintenance. Conveyor belts and parts
mandatory, rigorous cleaning regimes
Having a hygienically designed inspection
that can be removed intuitively and
to avoid bacterial contamination. But
machine helps to avoid bacterial
without requiring tools, dramatically
cleaning time equals downtime resulting
contamination. Hygienic design features,
reduce downtime and having parts
in a reduction of production output and
such as easily accessible machines, an
designed following the poka-yoke
profits.
open frame design with only four feet on
principle assures error free and fast
the floor, sloped surfaces and an IP69
reassembly. This further reduces
On top of this, the operator must ensure
rating help in withstanding thorough
production downtime as the equipment
that the machinery is fully operational
cleaning routines.
is put back together correctly – and
when the production line restarts. Rigorous cleaning procedures are essential; however, the effectiveness of
42 FDPP - www.fdpp.co.uk
Download the free eGuide: “7 Points to Understand Hygienic Principles” #2: SELECT INSPECTION EQUIPMENT
quickly – for the line to resume.
Manufacturers aiming for zero
production immediately after harsh
downtime during cleaning can deploy a
washdown, without affecting
second set of conveyor belts to resume
accuracy and weighing results.
production immediately after a product change over by switching the belts whilst the first set is being cleaned. Check out: C33 PlusLine Washdown Checkweigher and C35 AdvancedLine
To find out more How Washdown Resistant Checkweighers can Reduce Cleaning Downtime, request your free eDemo now!
Washdown Checkweigher #3: UPHOLD PRECISION WEIGHING IRRESPECTIVE OF ENVIRONMENTAL CONDITIONS A loadcell is the heart of a checkweigher, however, excessive fluctuations in temperature caused by, for example, high pressure cleaning with hot water can affect its performance. Manufacturers looking to uphold precision weighing irrespective of environmental conditions should consider Electromagnetic Force Restoration (EMFR) loadcells. These are more accurate, measure at a faster rate, and are temperature-stabilised compared to other loadcell types. This enables the manufacturer to resume
FDPP - www.fdpp.co.uk 43
Accurate dispensing of ab mauri bakery ingredients: Concept Controls Ltd and Seepex UK Ltd provide a perfect solution A significant factor in baked goods
Flow meter, Concept Controls Ltd, in
manufacturing is the need to reduce the
conjunction with their partner company
cost of raw material delivery into dough
PVSL Ltd. (Brierley Hill), are able to
mixes. Modern research and process
meet the challenging specification
techniques have been used by AB Mauri,
requirements for A.B. Mauri. The
a major manufacturer and supplier of
detailed design phase started with 3D
bakery ingredients, to produce a range
Models of the proposed equipment
of Enzymes, Bread Improvers and
generated by PVSL Ltd.
Enhancers in a highly concentrated form. These ingredients are highly effective, requiring very small amounts to be added to each batch. To maximise the benefit of these concentrated products accurate dispensing of the ingredients is critical, both to ensure optimal ingredient performance, and to minimise overdosing (which can add to material usage and cost). Traditional weighing and Diaphragm Pump dispensing, even with the best of metering control, can lead to significant variations in the actual additive level to each batch of dough.
SOLUTION
peristaltic, lobe and double diaphragm pumps a higher performance pump was sought to ensure accurate repeatable dispensing of concentrated ingredients
The result is an easy to apply Dosing System, that includes bulk frame storage for IBC containers (normally in
from bulk containers.
Stores area), with buffer tanks to allow a
During the research process the SEEPEX
stock. The Seepex PC pumps are more
Progressive Cavity (PC) Pump, became a clear leader. The main benefit of the PC pump is that there is a sooth pulsation free delivery of material delivering repeatable accuracy of +/-1%. The flow rate is linear, proportional to motor speed and regulated by a simple speed
practical regime for maintaining product than capable of delivering the various products to a dosing frame mounted close to the Mixers, and hence through the associated mixer lids and into each batch of Dough. The Dosing Frame is a small matrix of
controller over a very wide range. This
fast acting Ball Valves which allow the
was specifically useful as there is a
product to be fed either directly to the
limited time (Less than 25 Secs) for
Mixer, or via the flow limiting orifice plate.
dosing of the A.B. Mauri products when
Although A.B. Mauri has considerable
operating on a standard Bread Mixer,
The net result is a system that can deliver
in house experience at developing the
hence a high rate of delivery is needed for
as low as 50g into a batch of product, and
products, the related processes, and
rapid dispense, but a low rate of delivery
also extend to several kilogrammes, all
even the engineering of equipment, they
for accuracy of dispense.
within the 25 second window, and every
wished to use an external engineering
batch can be metered to the nearest
company with experience in Bakery and
The pressure capability of these pumps is
other process equipment to develop a
also very wide, and the Concept Controls
solution that met demands for accurate
Ltd system uses this to deliver a high
The overall benefit to the end customer,
dispensing.
pressure and high accuracy phase at the
is that they can rely on a very consistent
end of the dosing cycle. The pumps can
product, with the advantages of the most
Concept Controls Ltd (Waltham on the
also accurately dispense products with a
modern process innovations, without
Wolds) were approached, and shown
wide range of viscosities.
the potential of overdosing (i.e. wasted
some of the original systems, a number of which had performance limitations with the latest developments in ingredients. After technical analysis of
44 FDPP - www.fdpp.co.uk
By coupling this high performance PC pump, orifice plates, and a very high accuracy Endress and Hauser Coriolis
gram.
product), overall enhanced quality and reduced overall scrap. www.seepex.com
GET EVERY LAST DROP FROM YOUR EXISTING EQUIPMENT. Inefficient processes and wasteful operations can put a drain on the bottom line; but transforming your operation into a Smart Factory doesn’t always mean costly capital investment.
FlexEdge™ Edge Automation Platform All-In-One: •
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Innovation at high-speed: container filling machines Newtec’s High-Speed Container Filler
can streamline your applications and
(HSCF) has been designed for speed and
increase your bottom line.
versatility, in response to client requests
“It’s highly flexible and it offers high-
for a solution capable of achieving higher
capacity and high-speed,” he says. “That’s
capacity across a variety of products and packaging materials.
the main advantage of this machine. The
The HSCF can be easily adjusted to pack
of having a basic machine where you add
a diverse range of products, from harder
a set of unique tools depending on your
high flexibility comes from the concept
items such as nuts and candies to softer
The cost-effective system is operated
and more fragile foods such as cherry
by an intuitive interface, which is an
tomatoes and blueberries. The solution
important factor, as well as the easy
is capable of filling containers in various
access for cleaning and servicing if you
dimensions with or without lids. Newtec has designed a tool for each
are changing your production many times a day.
preferred container types”. “This means that you don’t need to buy a completely new machine if you get a new packaging material. That’s a big advantage.” However, the machine has been designed
DESIGNED WITH SPEED IN MIND
specifically to deliver higher levels of
from running e.g. clamshell trays to
Newtec mechanical engineer, Mathias
machine,” adds Mr Eilertsen. “That was the
buckets. It has achieved this by using the
Theil Eilertsen, worked on the solution’s
main goal. With other machines, we are
following three units: the denester, the
development. The solution represents a
doing about 70 or 80 packs a minute. We
filling chute and the closing unit, which are
fully automatic system from start to finish
can do up to 100 packs a minute with this
all exchangeable.
and is just one example of how Newtec
one”.
container type and while covering complex functions each tool is very easy to change
46 FDPP - www.fdpp.co.uk
speed. “Speed was quite a big thing for this
primarily for the fruit and vegetable industry. With more than 20,000 successful installations over the last 40 years, they have maintained their position as a reputable worldwide company. Newtec is represented in more than 50 countries with subsidiaries in Copenhagen and the UK and a joint venture in China. Newtec has formed many strong partnerships throughout the industry, ensuring the right solutions are delivered. They deliver cutting-edge machinery, integrated into one solution and supported by local, qualified representatives to ensure each solution continues to meet the needs of their customers. “Customers will experience a higher
visit the customer after the installation
speed and they will notice a lot more
for the final fine-tuning and see how
production than normal.”
their vision has been realised.”
KEEPING UP WITH NEW ORDERS
Despite being able to operate at higher
“We always develop new machines
isn’t any higher than current machines
based on request and interest from
on the market. Mr Eilertsen says the
customers,” Mr Eilertsen says. “Of
feedback has been highly positive and
course, they have an interest in getting
there are more orders to follow. This adds
the machines as quickly as possible
to Newtec’s total of installing more than
when they get in touch with us.
20,000 machines during the last 40 years.
Often, our customers are taking a big automation step forward and can’t wait to start optimising their production”.
speeds, the HSCF’s energy consumption
NEWTEC Odense (UK) Ltd. 22 Fleet Road Industrial Estate, Fleet Road, PE12 8LY Holbeach, Spalding United Kingdom Ph: 01406 426 526 Mobile: 07827 973 238 Mail: dean@newtecuk.com www.newtec.com
Newtec is a leading manufacturer of weighing, packing and sorting machinery
“So there’s a bit of pressure when we are in the innovation phase aiming for the best quality on the market and working hard to exceed the expectations of our customers. For me, it is so rewarding to
FDPP - www.fdpp.co.uk 47
Unipaker variations make robotic crate packing as easy as 123 Brillopak has developed its award-
can only be achieved in real life on very
dual and triple robot configurations for
winning UniPAKer robotic crate packing
straightforward crate/case packing
our UniPAKer packing system – to help
platform with the introduction of single
applications such as packs of biscuits.
our customers meet their performance
and triple-head versions of the system,
It is very unlikely that any packaging
and payback objectives without making
following the success of its dual robot
automation supplier who is handling
false promises.”
cells in fresh produce applications. The
delicate or awkward products like
ability to incorporate one, two or three
flow-wrapped apples, bags of carrots
Working on the premise that most
parallel arm delta robots into a single
or tray-sealed meat would be able to
fresh produce packs – whether punnets
crate packing cell enables the design of
achieve anything close to those kinds of
of soft fruit, bags of sprouts or flow-
flexible systems that strike the optimum
speeds without damaging the product
wrapped packs of peppers – can be
balance between speed and gentle
in the process, it simply isn’t possible,”
packed into crates using a single
handling.
says Peter Newman, Technical Director
robot head at speeds of 30-40 packs
at Brillopak.
per minute, the UniPAKer can double
“Whilst delta robot heads might boast
or triple those speeds to achieve
mechanical speeds in excess of 120
He continues: “That is precisely the
a customer’s target by adding a
picks per minute, such high speeds
reason why we have developed single,
second or third robot.
48 FDPP - www.fdpp.co.uk
Each robot takes it in turn to take
carrots at speeds of 37 ppm per head.
this configuration, the robot performs
a pack off the infeed conveyor and
A triple-head system can achieve over
two picks, then places the packs in the
position it precisely in the crate, so the
100 ppm, which should enable the
crate, two at a time. This design works
desired crate presentation is achieved
customer to meet its two-year payback
well for tray-sealed meat packs, which
twice or three times more quickly
target.
are uniform packs with flat surfaces, but cannot be handled at very high
than with a single robot. To maintain a compact footprint, simplify operation
Another potential application for the
speeds as the film lid may tear. Speeds
and minimise capital outlay, the entire
triple-head UniPAKer is for placing
of 60-70 ppm can comfortably be
system is centrally controlled and the
products such as peppers into the
achieved on this application.
robots share a vision system, infeed
pocket of the flow wrapper. Using three
and outfeed, regardless of whether it is
robots operating at 60 picks per minute,
Brillopakâ&#x20AC;&#x2122;s UniPAKer robotic pick and
a dual or triple configuration.
the UniPAKer would be able to match
place cell was originally engineered
typical flow wrapper speeds.
for packing bags of potatoes and
The 70-80 ppm speed capabilities of
apples into crates. Designed to handle
match for flow wrapping lines handling
MULTI-PICK SPEEDS UP SINGLE ROBOT SYSTEM
fruit and veg such as apples, sprouts,
However, adding another robot is not
tomatoes, peppers and pears, with or
always the best approach for increasing
without a supporting tray.
packing speeds. In applications where
the dual-head UniPAKer are the perfect
the product is fairly straightforward to When three heads are better than two
pick, a single robot with a multi-pick
The triple-head system has been
head might be a more cost-effective
conceived with difficult-to-handle or
and space-efficient option. In
VFFS, tray-sealed or flow-wrapped packs up to 1kg, the UniPAKer has been proven over-and-over again to improve productivity and improve pack presentation on shelf. www.brillopak.co.uk
bulky products in mind. Brillopak is currently building its first triple-head UniPAKer cell for a supermarket customer with the goal of packing bags of carrots into plastic retailer crates at speeds of 100 ppm. Carrots are a difficult product to handle as each bag of the same weight is a different shape and size, therefore the robot has to slow down to perform the pick and position the pack in the crate; too much speed will result in the bag falling out of the gripper or an untidy crate presentation. Using a single robot head in conjunction with a flexible finger gripper, the UniPAKer can handle
FDPP - www.fdpp.co.uk 49
Now is the time to unleash the potential for robotics in UK food manufacture There are few who would argue that 2020 has been an extremely challenging year as the COVID-19 pandemic has changed the way in which businesses of all types operate and more importantly, the environment within which we work, as we strive to contain the virus and remain safe. As businesses adapt to what is likely to be the new “normal” for the forseeable future at least, and with the ongoing uncertainty surrounding the effects that Brexit may have as we near the end of the transition period, the debate surrounding robotics and automation, especially within the food manufacturing and processing sector, is reaching a new peak. It is becoming clear that robotics and automation will hold the key to achieving the efficiency and productivity levels required for cost effective food
a growing shortage of manual resource,
surrounding COVID-19 and future
processing, especially in high-care
have been the drivers for increased
areas, and those which traditionally
uncertainty around the UK outside
levels of robotics and automation within
have been labour intensive. This article
of the European Union next year.
the food sector in recent times.
Although many of the potential benefits
by Simon Jenkins of Stäubli explains why now is the perfect time for the UK
The COVID-19 pandemic has also raised
food manufacturing sector to unleash
the stakes for the adoption of robotics
the potential that robotics holds, and
and automation as a means of removing
how companies will benefit, not only in
people from what are now being seen
addressing the short term issues within
as the high risk environments within a
the sector, but in securing their future.
range of manufacturing environments,
There is no doubt that historically people have been the highly flexible resource which has sustained manufacturing in many sectors, including food and beverage. The ability of humans to adapt to changes
including meat processing facilities. Large numbers of people working within a chilled and sometimes confined environment have proven to be a catalyst for rapid transmission of this deadly virus.
of robotics and automation, when applied to food manufacturing, have been understood for some time, there has still been a reluctance overall to fully embrace the technology. The often perceived barriers to automating food manufacturing processes, those of limited flexibility, complexity and unsuitability for high care areas, are no longer valid with the latest generation robot systems. Many of the challenges now being realised in high care areas, such as meat processing, can be
in products and processes is, even
Stäubli’s Simon Jenkins explains further:
addressed successfully using the HE
today, unparalleled in some cases.
“The food and beverage sector is
series robots, specifically designed
However, the demands for greater
currently facing serious issues brought
in conjunction with (EHEDG) - The
quality, consistency and predictable
about by difficulty in recruitment and
European Hygienic Engineering &
high productivity levels, combined with
retention, the significant challenges
Design Group and their guidelines.”
50 FDPP - www.fdpp.co.uk
ROBOTS AS MASTER BUTCHERS An innovative solution for processing pork and removing bones from pork legs can be seen in this Japanese system, which incorporates three Stäubli sixaxis RX160 HE robots operating as master butchers. The specifications for robotics in a meat factory could not be more onerous. Chief among them are the strict hygiene requirements that apply to the handling of fresh meat. In addition, expectations in terms of speed, precision and flexibility are set high, as no fewer than 500 pork
the latest generation technologies
the traditional short term view on
are capable of and therefore what
payback on capital projects is often
can be achieved here in the UK. In this
cited as a reason to avoid investing in
application, an X-ray system is used
new equipment or technology such
to detect the position of the bones
as robotics or automation. Taking
within the meat, and the exact incision
an alternative view, either on the
line for the robots is then calculated.
duration of the payback period and
A perfect solution, but one that is also
/ or considering flexible financing
subject to the vagaries of the meat
options such as hire or leasing, may
processing industry. The fact that
open the door to the introduction of
the meat hanging on its hook is liable
the technology which could potentially
to shift its position on the overhead
transform productivity levels.
conveyor within certain limits means that the robots must operate in a highly coordinated way to achieve the correct
Improvements as a result of this investment may actually contribute
cut and avoid the bones.”
to the security of contracts with
operating within this system are at
The de-boning system represents a
future of the business. The flexibility of
the highest levels possible, given the
high level application of robots within
robots, for example, allows them to be
special conditions prevailing in the meat
the food sector, however there are also
used for new products or new contracts
processing industry. Also, because
many other less complex applications,
and their inherent reliability means
no one piece of pork is the same as
such as handling and packing products,
that they will provide years of service.
another, flexibility is required to allow
where robots can be used to address
Having this type of technology in place
high-speed processing
the numerous issues facing the UK’s
when bidding for new contracts can also
food manufacturers.
differentiate suppliers and provide a
legs enter and leave the line each hour. The functionality of the robots
Simon Jenkins expands on the capabilities of this system: “This
Of course, this will require investment
system clearly demonstrates what
by manufacturers, and historically
customers and ultimately the long term
competitive advantage. www.staubli.com
FDPP - www.fdpp.co.uk 51
â&#x20AC;&#x201D; A plant of infinite possibilities. Talk to us. Are you constantly striving for increased efficiency? Working to integrate processes? Seeking to optimize every aspect of production? Our comprehensive portfolio and consultative approach runs from power to palletizing. So whether you need total traceability or simply higher efficiency, we have the answer. Discover the infinite possibilities at our stand F80 at the PPMA show, 25-27th September or visit new.abb.com/food-beverage
