F&D Business February 2012

February 2012

Arla Foods invests for sustainable growth

Food & Drink Business Website:

www.fdbusiness.com

C o n t e n t s

- 3 M ERGERS & A CQUISITIONS

- 25 D EVELOPMENT S TRATEGY

Coverage of British and international deals.

Nestle to invest £500 million in UK manufacturing facilities.

P AGE 11

Paul Walsh, ceo, Diageo.

PAGE 3

John Bryant, ceo, Kellogg Company.

- 7 C OVER S TORY

- 45 E XHIBITION Foodex 2012 – The UK show for processing, packaging and logistics.

Arla Foods invests for sustainable growth.

PAGE 13

R EGULARS

Ian Curle, ceo, Edrington Group.

Processing & Manufacturing 19-23, 35-38, 46 PAGE 3

Jorgen Buhl Rasmussen, ceo, Carlsberg.

- 11 B REWING Diageo trims investment plans for historic stout brewery.

Bottling & Packaging . . . . . . . . 28-33 & 47 Control & Automation . . . . . . . . . . . . 39-43 Materials & Handling . . . . . . . . . . . . . . . 47 Materials & Ingredients . . . . . . . . . . . . . 48

PAGE 25

Paul Grimwood, ceo, Nestle UK & Ireland.

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

- 13 D ISTILLING

PAGE 4

Cees ‘t Hart, ceo, Royal FrieslandCampina.

Thirst for Scotch fuels Edrington expansion.

Advertising: Susan Doyle, Neela Desai, Kieran Kenny. Senior Sales Executive: Paul Lees Production Manager: Susan Doyle

Food & Drink Business Europe is published by Premier Publishing Limited, 51 Parkwest Enterprise Centre, Nangor Road, Dublin 12.

Tel: + 353 1 612 0880 Fax: + 353 1 612 0881 E-Mail: info@prempub.com Website: www.fdbusiness.com London Office: Premier Publishing Limited, CTS, 34 Leadenhall Street, London, EC3A 1AT Tel: 0171 247 3238 Fax: 0171 247 3239 Premier Publishing Limited can accept no responsibility for the accuracy of contributors’ articles or statements appearing in this magazine. Any views or opinions expressed are not necessarily those of Premier Publishing and its Directors. No responsibility for loss or distress occasioned to any person acting or refraining from acting as a result of the material in this publication can be accepted by the authors, contributors, editor and publisher. A reader should access separate advice when acting on specific editorial in this publication!

- 17-29 & 9 T RADE FAIR Anuga FoodTec - 27th-30th March 2012 – Cologne.

PAGE 7

Design, Origination and Separations by Fullpoint Design (057) 8680873 Printed by GPS Colour Graphics

AnugaFoodTec 2012 Previews

Peder Tuborgh, ceo, Arla Foods.

Annual Subscription (UK and Ireland) £95 Overseas Subscription £115

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

1

M E E R R G G E E R R S S M Kellogg Company to Acquire Pringles For $2.7 Billion Kellogg Company has agreed to acquire Procter & Gamble's Pringles business for $2.67 billion. Pringles is an excellent strategic fit for Kellogg and significantly advances the company’s goal of building a global snacks business on par with its global cereal business. Pringles is the world's second largest player in savoury snacks, with $1.5 billion in sales across more than 140 countries and manufacturing operations in the US, Europe and Asia.

Kellogg has established a strong US-based snacks business since its successful acquisition of Keebler more than a decade ago.

With the acquisition of Pringles, the company will build a truly global snacks platform and organisation for further growth.

Internationally, Pringles provides a strong brand and an established platform from which Kellogg can more aggressively leverage its brands in the international snacks category.

Kellogg and P&G expect to complete the transaction in the summer of 2012, pending necessary regulatory approvals.

“Pringles has an extensive global footprint that catapults Kellogg to the number two position in the worldwide savory snacks category, helping us achieve our objective of becoming a truly global cereal and snacks company,” says John Bryant, president and chief executive of Kellogg Company.

US-based snack foods group Diamond Foods had agreed to acquire Pringles from Procter & Gamble in April 2011.

However, the $2.35 billion deal, which was expected to close in December 2011, was deferred following the decision to investigate an accounting irregularity at Diamond Foods. This investigation recently resulted in Diamond Foods announcing that its financial statements for 2010 and 2011 could not be relied on and would need to be restated. It also placed its president and chief executive, Michael Mendes, and chief

& &

A C C Q Q U U II S S II T T II O O N N S S A

financial officer, Steven Neil, on administrative leave and commenced a search for their permanent replacements.

John Bryant, president and chief executive of Kellogg Company.

Carlsberg to Acquire Full Control of Baltika Carlsberg Group intends acquiring the remaining 15% stake in its Russian subsidiary, Baltika, for up to DKr6.5 billion (Eur870 million). The move will involve a delisting of Baltika.

Russia is the world’s 4th largest beer market and Carlsberg firmly believes in the long-term market and profit pool growth opportunities. The transaction is in line with the Carlsberg’s strategy of having 100% ownership of its most important subsidiaries to achieve greater operational flexibility.

By having 100% ownership of Baltika, the company can be fully integrated into the Carlsberg Group which will speed up the implementation of decisions and also make Baltika a vital part of the back-end integration which Carlsberg has accelerated recently.

Jorgen Buhl Rasmussen, chief executive of Carlsberg.

SABMiller and Molson Coors Move into Fast Growing US Cider Market SABMiller and Molson Coors, through their MillerCoors brewing joint venture in the US, have moved into the cider market, the American beer industry’s fastest-growing category. Tenth and Blake Beer Company, MillerCoors’ craftand-import division, has acquired Crispin Cider Company, the third largest producer of cider in the US. Crispin Cider Company produces European-style natural hard apple ciders using fermented unpasteurized fresh-pressed apple juice. The company also imports a classic English Dry Cider, Crispin Browns Lane.

SABMiller and Molson Coors formed their US joint venture, MillerCoors, in 2008.

MillerCoors created Tenth and Blake Beer Company in 2010 to be a leader in the crafts and import segment.

and produce packing factories, enabling it to have a greater control over the quality, cost and the supply of fresh food into its 476 stores nationwide.

This acquisition is the latest in a number of transactions to strengthen Morrisons’ manufacturing capabilities. Morrisons has pledged to invest £200 million over a three year period to support the growth of the business.

“Owning the manufacturing sites that produce our fresh food is crucial to Morrisons because it ensures we can control quality and keep down costs for our customers,” explains Martyn Fletcher, group manufacturing director of Morrisons.

Muller’s Recommended Cash Offer For Wiseman Declared Unconditional

Morrisons Expands Food Manufacturing Capacity UK grocery chain Morrisons has expanded its meat processing operations with the acquisition of a 105,000 sq ft facility in Winsford, Cheshire from Vion UK. The site is a centralised fresh pork and lamb retail packing plant which has the capacity to expand into beef products and increase its overall existing production. The acquisition will give Morrisons even greater capacity as it continues to grow and exert greater control over the quality of the meat products sold in store.

Morrisons is the second largest fresh food manufacturer in the country, employing over 7,000 people, and a central part of its differentiation from its competitors is this vertically integrated model. The food retailer owns a number of bakeries, meat processing facilities

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Having purchased or received valid acceptances for 93.9% of the ordinary share capital of Robert Wiseman Dairies, the UK liquid milk processor, German dairy group Muller has declared its recommended cash offer unconditional. Wiseman has now applied for the cancellation of its listing on the London Stock Exchange, a process which should be completed by early March.

Wiseman will then be re-registered as a private company.

Muller’s UK subsidiary, Muller Dairy (UK), made its £279.5 million recommended cash offer for Robert Wiseman Dairies on January 16th 2012.

Operating from six major processing dairies in Aberdeen, East Kilbride, Glasgow, Manchester, Droitwich Spa and Bridgwater,

3

M E E R R G G E E R R S S M Robert Wiseman Dairies processes and delivers more than 30% of the fresh milk consumed in Britain, every day.

Muller Dairy (UK) is the overall market leader in chilled yoghurts and potted desserts in the UK.

Senoble and Agrial Joint Venture Approved The European Commission has cleared the proposed creation of Senegral, a joint venture between French dairy companies Senoble and Agrial. The new joint venture will operate in the production and sale of private label fresh dairy products in France, Germany and Benelux. The Commission concluded that the proposed transaction would not raise competition concerns, in particular because the new entity will have numerous competitors in the markets concerned.

Senoble manufactures and sells fresh dairy products such as yoghurt, fresh cheese, fresh cream. It operates in France, Spain, the UK, Italy and Slovakia in the production and sale of milk, dairy products and fruit-based beverages. Agrial is a French agricultural co-operative group operating in particular in the milk collection sector.

FrieslandCampina to Acquire Two Dairy Companies in Western Balkans FrieslandCampina is strengthening its position in South-East Europe with the acquisition of dairy companies Imlek and Mlekara Subotica, which both have operations in the Western Balkans. This is the Dutch dairy co-operative’s first substantial acquisition since the merger between Friesland Foods and Campina in 2008.

FrieslandCampina is purchasing majority stakes in the two dairy companies of approximately 79% in Imlek and 82% in Mlekara Subotica from Salford Capital Partners.

FrieslandCampina intends to acquire the remaining shares, which are traded on the Belgrade Stock Exchange.

FrieslandCampina’s route-

4

& &

A C C Q Q U U II S S II T T II O O N N S S A

2020 strategy is designed to increase worldwide its position in dairy-based beverages, infant nutrition and branded cheese and to generate maximum value for the milk produced by the cooperative’s member farmers.

Imlek has activities under various brand names in Serbia, Montenegro, Bosnia and Herzegovina, and the Former Yugoslav Republic of Macedonia, while Mlekara Subotica has activities in Serbia.

Together the companies have around 1,470 employees at six production plants. The total turnover of the two companies is about Eur270 million.

Cees ‘t Hart, chief executive of Royal FrieslandCampina.

The Greenery UK Acquires John Baarda The Greenery UK, one of the leading suppliers of fruit, vegetables and mushrooms to supermarkets and wholesalers across Britain, has acquired John Baarda, the second largest tomato producer in the UK. The move follows several years of poor financial performance and operational challenges at John Baarda.

The Greenery UK is part of The Netherlands-based business The Greenery BV, which is a subsidiary of the grower owned co-operative Corforta.

Fuller Smith & Turner Expands Pub Estate UK regional brewer and pub company Fuller, Smith &

Turner has agreed to acquire 15 freehold, tied, tenanted pubs from Enterprise Inns for £22.9 million. Fuller will fund the transaction from existing bank facilities. Under Enterprise’s ownership, these pubs generated operating profits of £1.7 million in the year to 30 September and had a balance sheet value of £18.4 million as of that date.

The pubs are all freehold and will allow Fuller to bring its Fuller’s brand into areas of the west and south east of England where it has previously been under-represented.

Simon Emeny, group managing director of Fuller, Smith & Turner, comments: “The transaction demonstrates the continuation of our strategy to selectively purchase only the highest quality pubs, where the Fuller’s name and operating style can add real value. This deal will take the total number of pubs acquired by Fuller’s in the last 12 months to 29, giving the business tremendous momentum as we head towards the summer of 2012.”

Barry Callebaut to Acquire American Chocolate Decorations Manufacturer Barry Callebaut, the world’s leading manufacturer of highquality cocoa and chocolate products, is acquiring Mona Lisa Food Products, a leader in chocolate decorations products in the US. The currently privately owned company will be integrated into Barry Callebaut’s North American Gourmet & Specialties Products business.

The acquisition of Mona Lisa confirms Barry Callebaut’s intention to further accelerate the growth of its Gourmet & Specialties Products business and to add more adjacent products to the company’s offerings for professional users of chocolate such as chocolatiers, pastry chefs, bakers and the HORECA business (hotels, restaurants, catering). With the acquisition of Mona Lisa Food Products, Barry Callebaut will also strengthen its global footprint and establish a dedicated

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

foothold for decorations products in the US. The newly acquired company complements the business activities of Barry Callebaut’s center of competence for chocolate decorations located in Zundert (The Netherlands).

UK Poultry Industry Must Increase Consolidation Despite operating in one of the highest value-add markets in the EU, the UK poultry industry is suffering as a result of high feed prices, limited volume growth and oversupply, according to Rabobank.

Increases in domestic demand merely reflect population growth, whilst the UK's export industry still underperforms by failing to capitalise on a strengthened competitive position, for example depreciation of sterling and new marketing standards for fresh poultry.

Oversupply has placed retailers in the driving seat of the value chain, points out Rabobank. Players without a preferred supplier relationship find themselves having to fight for retail tenders based on price alone (or supplying ingredients to companies with retail access), exacerbating the high levels of competition that arise from feed costs.

Rabobank further suggests that in order to thrive, the UK poultry industry must increase consolidation levels to more closely match that of the retail poultry market; increase efficiency in the supply chain and the rate of structural change; and improve supply discipline.

COVER STORY

Arla Foods Invests For Sustainable Growth Arla Foods will invest DKr1.8 billion (Eur242 million) in 2012 to improve efficiency, expand capacity and strengthen its international competitiveness as the dairy cooperative focuses on growth markets.

A

rla Foods’ investment plan for 2012 marks a slight increase on the DKr1.7 billion in 2011. Having been forced by the severe economic environment to make cuts across its business during 2009, Arla Foods substantially increased its investment budget for 2010 to DKr1.84 billion as it focused on expansion and has maintained this level of expenditure since, despite the continuing economic crisis and slowing of consumer spending in the US and Europe.

“In times of crisis, it’s vital that we maintain our competitiveness. We believe that these investments in increased efficiency and rationalisation will support our long-term competitiveness and growth ambitions,” explains Peder Tuborgh, chief executive of Arla Foods.

Planned Investment Approximately half of the planned investment of DKr1.8 billion for 2012 has been earmarked for capacity and rationalisation projects, explains Povl Krogsgaard, vice chief executive officer of Arla Foods, who oversees the group’s overall investment plan.

“We have prioritised Peder Tuborgh, chief executive of Arla Foods. investments aimed at simplifying our dairy structure and increasing capacity as well as investments with a quick pay-back. Our aim is efficiency and lower production costs.”

The investment priorities for 2012 include improving the group’s dairy structure to significantly enhance efficiency, increasing resources for growth markets and accelerating growth and added value in Arla Foods whey ingredients processing business. Many of the investment projects will also generate CO2 and energy savings.

Food Ingredients One of the biggest single investment areas in 2012 will be at Arla Foods Ingredients (AFI) where DKr246 million will be invested in various projects, including a new drying tower at Denmark Protein in Videbaek. The tower, which is currently under construction, is

an essential component in Arla’s joint-venture with the German dairy company, DMK. “We’ve never invested so much in AFI before, but we’re doing so now because the subsidiary is performing extremely well and its results are helping to fund strategic initiatives in other areas. AFI is a world leader in its field and our investments will help us build on this,” says Povl Krogsgaard.

The 50/50 joint venture between Arla Foods and DMK will process whey for the global food manufacturing industry. The two partners are investing a total of Eur44 million, of which Eur35 million will be used to build a whey processing plant at DMK’s cheese plant at Nordhackstedt in Northern Germany, and Eur9 million will be spent at Arla Foods’ Danmark Protein plant in Denmark.

The joint venture, called ArNoCO, will buy whey from DMK estimated at more than 700,000 tonnes annually and convert it into whey protein concentrate and lactose at the new plant. The Whey Protein Concentrate will then be dried at Arla Foods’ Danmark Protein plant, which is scheduled to beoperational by the end of 2012.

“We have identified the whey business as an important part of Arla Foods’ 2015 strategy and we are set to double the turnover of our whey business. This is an important step forward in achieving that goal,” says Peder Tuborgh. Arla Foods is a leader in the global market for whey protein and has other whey partnerships in Argentina, Germany, France, Norway and Sweden.

Strategy 2015 Arla Foods’ growth ambitions are identified in its Strategy 2015 development plan, which aims to increase annual revenue to DKr75 billion by 2015. Arla Foods intends to be the best dairy company for the more than 250 million consumers in Northern Europe/UK through its three global brands - Arla, Lurpak and Castello. It also has ambitions to become the world’s leading supplier of whey pro-

During 2011, Arla Foods achieved a significant breakthrough in Germany resulting from its merger with Hansa-Milch followed by the acquisition of Allgauland-Käsereien.

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

7

teins through innovation, research and acquisitions.

Arla Foods has divided its various markets into three categories – core markets, growth markets and value markets. Its objectives in its core markets of the UK, Denmark, Sweden, Finland, Germany and the Netherlands is to build strong positions within liquid milk as well as a full range of dairy products for the retail sector.

In its growth markets of Russia, Poland, US, China and Middle East and North Africa, the focus is on investing in a sustainable platform for growth, the full roll-out of category leadership positions and boosting growth through mergers and acquisitions.

Arla Foods’ value markets are Canada, Spain, Greece, Brazil, Norway and export markets, where the emphasis is on maximising profits and moving milk from bulk to value added products.

A key part of Strategy 2015 is maintaining the focus on improvement and efficiency throughout the company as it expands.

Growth in Russia Arla Foods has recently formed a joint venture in Russia for the production of yellow cheese. The partnership with Molvest Group, Russia’s third largest dairy company, will see Arla Foods establishing local production in Russia for the first time, following years of growing export sales.

Arla Foods’ Russian subsidiary, Arla Foods Artis, in partnership with the Molvest Group will convert one of Molvest’s existing dairies in south-west Russia to yellow cheese production. Arla Foods will buy processed milk Approximately half of the planned investment of from Molvest and will DKr1.8 billion for 2012 has been earmarked for be responsible for the capacity and rationalisation projects. production of yellow cheese at the dairy as well as the distribution of the finished product. The conversion of the dairy represents an investment of DKr25 million for Arla Foods. The joint production is expected to commence in early 2013 with the aim of producing about 6,000 tons in 2014, with a subsequent annual volume increase of 10%. ”As Russia is one of our strategic growth markets this agreement is important because it provides us with the opportunity to combine our export business to Russia with local production,” says Peder Tuborgh. “This is unlikely to be our final expansion into the Russian market but this agreement alone is expected to double our turnover in Russia before the end of 2015.”

Arla Foods’ Russian business grew by about 30% to generate sales of DKr500 million in 2011, driven chiefly by exports of Lurpak butter, Castello speciality cheese and cream cheese under the Arla Natura brand. These brands are expected to benefit further from Arla Foods’ new production presence in Russia.

Arla Foods has just started work on the construction of a new £150 million fresh milk dairy in the UK.

Construction of £150 Million UK Dairy Arla Foods is also planning major expansion in another core market – the UK. The dairy co-operative has just commenced work on the construction of a £150 million fresh milk dairy in Aylesbury in England. Once completed, the dairy will process and pack up to one billion litres of milk per year. The project is being 100% funded by Arla Foods and will create 700 new jobs.

“We are delighted to be underway with the development of this new dairy. We have ambitions for it to be the world’s first zero carbon fresh milk dairy, which will help Arla achieve its growth ambitions in the UK,” says Peter Lauritzen, chief executive of Arla Foods UK. “The new facility will create a platform for the company to grow its fresh milk business, allowing us to deliver our UK growth strategy.”

Financial Performance Despite continuing weak consumer confidence in Europe, where 80% of its business is based, Arla Foods achieved double digit growth in both revenue and earnings in 2011. Revenue rose by 12% to almost DKr55 billion and Arla Foods increased the earnings for its 8,200 co-operative owners in Denmark, Sweden and Germany by 11%. During 2011, Arla Foods also paid DKr1.6 billion more to its co-operative owners than in the previous year. The retained profit of DKr1.311 billion was up from DKr1.268 billion in 2010.

Half of Arla’s revenue growth was through organic growth, in part driven by Arla’s three global brands. AFI had a strong year and was one of Arla’s most profitable business areas. Arla Foods enjoyed success in new markets, particularly in MENA (Middle East and North Africa) and Russia

Outlook Although Arla Foods expects to maintain growth in 2012, the year ahead will be challenging. “While 2011 was a good year for Arla, the last quarter showed slight pressure on performance, reflecting a deteriorating business environment in Europe, which has continued into 2012. We expect significant revenue growth and for profits to be on par with 2011 albeit with fluctuations in the milk price for our co-operative Expansion in Germany owners over the year,” says Peder Tuborgh.

Building a core market in Germany is a central element of Arla The investment plan for 2012 will help Arla Foods to furFoods’ Strategy 2015. During 2011, Arla ther improve competitiveness. ”To secure Foods achieved a significant breakthrough the top-line expansion effectively conin Germany resulting from its merger with verts to the bottom-line, we’re working Hansa-Milch followed by the acquisition of on all fronts to improve our internal effiAllgauland-Käsereien. The two deals have ciency. For the group as a whole, we’re expanded Arla Foods’ co-operative ownerfocusing on growing revenues considership to include milk producers in Germany. ably faster than costs. We’re making progress in this direction, but there’s still Germany has been transformed from an some way to go. We’re focusing, thereexport market to one where Arla Foods now fore, on creating a more structured and operates five dairies and has high expectaless complex way of working, and we tions of further growth. Arla Foods is now expect to launch some specific initiatives the seventh largest dairy company in in 2012,” the Arla Foods chief executive Germany, with ambitions to be one of the Lurpak is one of Arla Foods’ three global brands. concludes. J top three.

8

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

I ANUGAFOODTECH 2012 PREVIEW

SPX Showcasing Robust Portfolio of Innovative Process Technologies at Anuga FoodTec 2012 PX’s portfolio of products and services for the food and beverS age industries is helping manufacturers around the globe increase process yields, enhance sustainability and receive rapid return on investment. The company’s highly engineered solutions are playing an important role in helping to meet rising global demand for innovative and sustainable products and processes.

Considered to be a major process systems and components supplier, SPX has brought together a collection of world class brands to serve the food and beverage marketplace including Anhydro, APV, Bran+Luebbe, Gerstenberg Schroder, Johnson Pump, Lightnin, Plenty, Waukesha Cherry-Burrell and e&e. All of these brands will be represented at SPX’s stand A11/B28 and A31/B38 in hall 5.1 at Anuga FoodTec 2012.

SPX will present several new, cost and energy-saving solutions for food and beverage processing. SafeWater, for example, is a new eco-friendly technology that revolutionises cleaning procedures. Also on display will be the new APV Cavitator which harnesses the power of cavitation for heating liquids without scaled build up and/or the mixing of liquids with other liquids, gasses or solids at the microscopic level to imp-rove product quality and functional performance.

The SPX Gersten-berg Schroder brand Nexus scraped surface heat exchanger is another innovative technology that uses CO2 as a cooling medium. SPX will also showcase their new FX

APV FX Systems™ SafeWater.

Systems™ (Factory Xpress) pre-engineered, self-contained skidded proc-ess plant units that make a wide range of process technologies and applications av-ailable on ultra-short delivery times for fast time to production, all with comprehensive auto-mation options.

A team of process engineering experts from around the world, including scientists from our Innovation Centres will be on the stand to share ideas with visitors and help them find solutions quickly and effectively.

Come and learn about the latest addition to the SPX family e&e and see how the company's many years of experience in extraction, evaporation, vacuum and freeze drying for the food, pharmaceutical, cosmetics and coffee industry can be the key to your success Best in Class Solutions

With a strong synergy between brands as well as a solid process knowledge and innovation platform, SPX offers customers in the food, beverage and pharmaceutical industries a broad range of best-in-class products, turnkey systems and innovative solutions.

One of the company’s main objectives is to give customers maximum value for their money with innovative products and solutions.

SPX Innovation Centres

The SPX Gerstenberg Schroder brand Nexus scraped surface heat exchanger.

SPX Flow Technology Innovation Centres are well equipped with test facilities. The company’s dairy and food specialists are working closely with customers’ food designers to develop new systems and solutions that meet the demands of the industry and the consumers. For more information on SPX, please visit www.spx.com. J

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

9

I BREWING

Diageo Trims Investment Plans For Historic Stout Brewery Having finally completed a major review of the long term sustainability of its brewing operations in Ireland, Diageo has decided to invest €153 million in a centre of excellence at its historic St James’s Gate site in Dublin, where all beer production will subsequently be consolidated. iageo’s Irish brewing operations are central to supplying its home markets of Ireland and Great Britain but also export to international destinations. About a third of Diageo’s global brewing volumes are produced in Ireland.

Diageo’s principal brewing facilities in Ireland are located at St James’s Gate, which is the centre for Guinness Draught production, and in Kilkenny and Dundalk.

Indeed, every pint of Guinness sold throughout Europe and the United States is currently brewed in Dublin. The two smaller breweries in Kilkenny and Dundalk produce other beers including Irish brands Smithwicks ale and Harp lager.

The rejuvenation of the St. James’s Gate Brewery will entail the construction of a new brewhouse, with building due to commence, subject to planning permission, in the first half of this year. To support the new brewhouse facility on the Northlands of St James’s Gate (Victoria Quay), the proposed brewery development plan also includes (subject to planning permission) the construction of a new grain intake building and associated silos, an extension of the existing fermentation plant to the southwest of the new brewery and the associated expansion of utilities generation and distribution.

The new brewhouse will have an annual capacity of approximately 7 million hectoliters, representing an increase of 40% on the current maximum capacity.

D

An artist’s impression of the new brewing centre of excellence at St James’s Gate in Dublin.

Long Term Competitiveness According to David Gosnell, president of Diageo Global Supply, the plans for remodelling St James’s Gate over the next two years will be an important part of securing the long term competitiveness of Diageo’s beer business and by concentrating all brewing activity on the St James’s Gate site will underpin the company’s commitment to Ireland. “The decision to consolidate to the St James’s Gate site is fundamental to delivering the competitiveness necessary for the long term sustainability of our brewing in Ireland,” he explains. “This is a significant investment and an expression of confidence by Diageo in our Irish operations.”

St James’s Gate is the centre for Guinness Draught production.

Scaled Down The planned Eur153 million capital investment is only about a quarter of the spend envisaged under an earlier plan to modernise and restructure Diageo’s Irish brewing business. In 2008, Diageo announced that it was to invest Eur650 million in its Irish brewing operations to support the growth and development of its global beer business and its flagship Guinness stout brand.

Diageo proposed building a new brewery on the outskirts of Dublin as part of a planned streamlining of the group’s Irish brewing operations which would also have entailed the rejuvenation of the brewery site at St James’s Gate and the closure of the two breweries in Dundalk and Kilkenny.

The plan was for the new brewery to have an annual capacity of 5 million hectoliters and to produce Guinness to meet growing export demand and also brew ales and lagers. With an annual capacity of 3 million hectolites, the remodelled St James’s Gate was to continue to brew Guinness beer primarily for the Irish and British markets. A large part of the St James’s Gate site was to be sold for redevelopment.

However, the subsequent global econom-

ic recession, which has hit beer sales in many key markets, particularly in Ireland and Britain, and the collapse of the property market in Dublin forced Diageo to review its plans for its Irish brewing operations. The revised plan has substantially the same scope as the original proposal, namely the restructuring of all three Diageo breweries in Ireland and is expected to yield similar cost savings.

The centralisation of brewing activity at St James’s Gate will still entail the closure of the sites at Kilkenny and Dundalk.

Subject to planning and construction timelines at St James’s Gate, the Dundalk site is now scheduled for closure in July 2013 with the Kilkenny brewery following in December 2013, resulting in the loss of about 100 jobs. Diageo has already consolidated all its keg operations onto the St James’s Gate site to streamline operations in Kilkenny and Dundalk.

When the consolidation process is finally completed at the end of 2013, Diageo’s only Irish brewing facility outside Dublin will be a small plant in Waterford producing Guinness ‘essence’, which is shipped to almost 50 breweries worldwide for production of the famous stout brand. J

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

11

Quality Italian Engineering From Di Zio Costruzioni Meccaniche i Zio Costruzioni Meccaniche is an D Italian contractor for stainless steel plant construction. The company has a current turnover of about Eur20 million and operates from a factory in Spoltore, located on the Adriatic Sea Coast, two hours drive from Rome.

Di Zio Costruzioni Meccaniche specializes in stainless steel tanks and plants for the food liquids (fruit juices, beer, milk, edible oils, wine, spirits), chemical and biofuel industries. In the area of aseptic juice production, pasteurization, storage, mixing and handling, Di Zio Costruzioni Meccaniche has sound process design capabilities.

The company’s last project reference involved an aseptic bulk storage/mixing

12

plant for orange juice (capacity 11,000 cu m approximately), inclusive of pasteurization unit, CIP unit, truck loading station, process control and instrumentation in Spain.

On the spirits production side, Di Zio Costruzioni Meccaniche recently completed two main projects in Scotland, relating to a complete distillery tankage system and to an impressive set of stainless steel whisky fermenters (1400 hl capacity each).

For the beverage industry, the company has supplied a full stainless steel process plant to a famous whisky cream producer in Northern Ireland, and the biggest storage and handling plant ever built for apple cider fermentation and storage, consisting of 354 fully insulated stainless steel tanks,

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

with a capacity 300 cu m each, on site in Clonmel, Ireland.

For the wine industry the Di Zio brand is a by-word for top quality wines, as the company’s wine fermenters are used in most of the world’s top wineries.

Within the edible oil industry a great number of plants built by Di Zio Costruzioni Meccaniche are successfully operating in Tunisia, Italy, Morocco, Spain and Libya.

Di Zio Costruzioni Meccaniche is able to design, fabricate, forward, install and commission its products and plants worldwide.

Its after-sale service provides assistance to customers everywhere within 24–48 hours with skilled technicians and always available spare parts. J

I DISTILLING

Thirst For Scotch Fuels Edrington Expansion To support the continued growth of its export sales, Scotch whisky producer Edrington Group has recently invested £48 million to expand distilling, bottling and warehousing capacity and improve efficiency. drington Group, which celebrated its 150th anniversary in 2011, employs more than 2,300 people worldwide.

In its last financial year, ended 31st March 2011, Edrington Group increased profit before tax (excluding exceptional items) by 19.3% to £141.5 million on turnover up 18.2% to £553.4 million.

The company has five core brands – The Macallan and Highland Park single malt whiskies, The Famous Grouse and Cutty Sark blended whiskies and Brugal rum. The group owns several malt whisky distilleries, including The Macallan, Highland Park, Glenrothes and Glenturret.

It also owns 50% of The North British Distillery, which is Scotland's largest grain distillery. This facility supplies grain whisky to Edrington Group as well as a large number of other companies in the Scotch whisky industry.

Edrington Group produces over 60 different whisky products, all of which are blended at the same site as the group’s bottling operation - the Great Western Road site in the west end of Glasgow. The site handles over 85 million bottles of Scotch whisky every year using 10 lines, including its flagship Line 1, the fastest whisky bottling line in the world, capable of filling, labeling and packaging up to 10 bottles every second.

The company’s products are exported to more than 100 international markets worldwide.

E

Expansion Programme Edrington Group has now completed a £40

million expansion programme at The Macallan Distillery along with constructing a new £8 million tank farm at the Drumchapel Distillery, Glasgow.

Commencing in 2008, the expansion programme at The Macallan Distillery site has provided extra capacity in the distillery and additional warehousing for maturing casks.

The additional production capacity will support the continuing growth of The Macallan brand. A rain water harvesting system has also been incorporated into The Macallan warehouses for use in the distillery.

The tank farm (known as the Solera vats) at Drumchapel is used to mix the various whiskies that are used in Edrington Group’s blended products, primarily The Famous Grouse and Cutty Sark brands. The investment programme at the Drumchapel, which started in 2010, has increased capacity and also improved the efficiency of marrying and blending whisky prior to bottling.

Edrington is now planning further expansion of warehousing capacity at The Macallan Distillery.

Development Strategy Edington Group’s strategy for long term development is based on continued investment in three areas - its premium spirits portfolio, development of its routes to market, and in its people and resources to support brand growth.

Edrington Group has continued to invest behind its premium brands despite the difficult trading conditions in mature markets in recent years. This investment is now paying off as some stability returns to many western markets. The group’s Asian business has continued to grow steadily and Edrington Group is experiencing positive developments in Russia and a number of emerging territories.

Brand Investment “Investment is targeted on brand equity growth and is focused in the markets where we anticipate the greatest opportunity for long term growth,” explains Ian FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Ian Curle, chief executive of Edrington Group.

Curle, chief executive of Edrington Group.

“Brand initiatives are focused strongly on the consumer and sustained with programmes that innovate within our categories.”

The premium spirits portfolio has been enhanced recently with the acquisitions of a majority stake in Brugal Company, a rum producer in the Dominican Republic, in 2008 and the Cutty Sark brand in 2010.

The Brugal purchase allowed Edrington Group to diversify into rum, while the acquisition of Cutty Sark added a one million case brand to its premium spirits portfolio and strengthened its distribution presence in southern Europe and the USA. Route to Market Ian Curle continues: “We operate a number of ‘route to market’ models, depending on the best fit for our brands in each marketplace. In recent years, we have increased the number of markets where we have full ownership, however, joint ventures and third party arrangements still play an important part of our ‘route to market’ model.” In 2009, Edrington Group joined forces with Beam, the US-based global spirits group, to establish a new sales and distribution alliance in 24 key international growth markets. Also in 2009.

Edrington took direct control of six international distribution companies in Norway, Sweden, Denmark, Finland, Taiwan and South Korea.

Last year, Edrington Group assumed ownership of the Maxxium distribution companies in China and Hong Kong. Asia has been an area of significant growth for Edrington Group over the last number of years and it now owns distribution companies in Taiwan, China, Hong Kong and South Korea. J 13

I TRADE FAIR

Anuga FoodTec – 27th-30th March 2012 – Cologne he international food technology sector will meet for Anuga T FoodTec 2012 in Cologne between March 27th and March 30th. Anuga FoodTec offers an information and purchasing platform that covers the entire spectrum of technology and investment requirements for production in all segments of the food industry.

With almost 1,300 exhibitors from 35 countries, Anuga FoodTec 2012 will set a new record in terms of exhibitor turnout.

The trade fair is also set to expand in terms of exhibition space.

Anuga FoodTec is jointly organised by Koelnmesse and the German Agricultural Society (DLG).

The sixth Anuga FoodTec will present all the relevant themes of food production on the basis of the three pillars - Food Processing, Food Packaging and Food Safety. The 1,300 exhibitors will present their technical innovations and cutting-edge solutions in Cologne.

Compared to the previous event, the trade fair is set to expand its participation figures by more than 16% this year.

Exhibitors Over half of the exhibiting companies come from abroad. The majority of these participants come from Italy, the Netherlands, Denmark, France, Great Britain and Sweden, followed by Spain, Austria, Turkey and the United States. In addition to the world market leader TetraPak, numerous key players will participate, including Albert Handtmann, Alco-Food-Machines, Alpma, Baader Nordischer Maschinenbau, Bizerba, Ecolab, Fuji Packaging, GEA, Grundfos, Grundwald, Heinen Freezing, Henckert Engineering, Inauen, Indag, IMA Industries Unipersonale, Ishida, Kawasaki Robotics, Kiremko, Komet Maschinenfabrik, Kronen Nahrungsmittel-technik, Krones, Linde Gas, Maja Maschinenfabrik, Maschinenfabrik Seydel-mann, Mespack, Mettler Toledo, Meypack Verpackungstechnik, Multivac,

Provisur Technologies Formax, Reepack, Robert Bosch, SACMI, Schwarte Jansky, Sidel, Siemens Industry Sector, SPX Flow Technology, Tipper Tie Alpina, Treif, Trepko, Vemag Maschinenbau and Weber Maschinenbau.

Also taking part will be many new companies from Germany and abroad that are exhibiting at Anuga FoodTec for the first time in 2012. More than 400 new exhibitors have registered for Anuga FoodTec so far.

This growth in exhibitor turnout is also reflected in the size of the exhibition area. In addition to the large number of new exhibitors, many regular exhibitors have signed up for significantly larger stand areas. As a result, Anuga FoodTec will not only occupy Halls 4.1, 5.1, 6, 7, 8, 9 and 10.1, as in 2009, but will also integrate Hall 5.2 for the first time, thus creating a gross exhibition space of 127,000 square metres - a gross increase of 10,000 square metres.

Technological Edge Visitors to Anuga FoodTec can expect integrated and flexibly usable technology concepts covering all stages of food and beverage production. The following sectors will be represented: process technology, packaging technology (including filling technology), automation, data processing, control and regulation technology, food safety and quality management, environmental technology, bio-engineering, operating materials, air conditioning and cooling technology, conveying, transport and storage installations, logistics, technological process materials, ingredients, components, assemblies, surface technology, equipment and services.

Supporting Programme In addition to the exhibitor presentations, Anuga FoodTec will also feature a diverse, top-quality supporting programme that will provide answers to specific questions and include special shows of innovative concepts.

Under the direction of the DLG, 27 specialist forums will address topics and questions of current interest to the sector, with presentations by leading research institutes and associations. The programme will consist of the following elements: emulsifying technology, process-structure-function-relations in food, the use of ultrasound in food technology, energy efficiency, coating and capsules, sensor technology, nanotechnology, controlled-temperature logistics, meat technology, cooling and freezing, KIN forum on

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

15

the subject of ‘Successful Strategies for Chilled Ready Meals’, the HighTech Europe Innovation & Technology Transfer Workshop, dosing and weighing technology, seals, nozzles and pumps, IT solutions for the food industry, the future of food technology, the use of robots in baked goods production, packaging technology, extruder technology, modified atmosphere packaging, ‘Inside Food’, maintaining the global food supply, the High Tech Europe Stakeholder event ‘Future of Food Processing’, foreign object detection, halal food production, fresh convenience, clean room technology and allergy management.

Conferences Anuga FoodTec 2012 will also be accompanied by top-class conferences. The congress organized by the European Federation of Food Science and Technology (EFFoST) will show the latest developments in the production of chilled food, with a particular focus on fresh-cut products. The symposium by the European Hygienic Engineering & Design Group (EHEDG) will share comprehensive know-how on the role of hygiene technology in the production of undamaged and healthy food. A particular focus will be on hygienic design and guidelines for hygienic processing.

Once again Anuga FoodTec will be hosting International Fruit World (IFW). Under the title ‘An Opportunity for Fruit Juice?’, the congress will focus on several cutting-edge topics, including markets and trends, quality assurance, process technology and the raw materials procurement market. Experts from the worlds of business, industry, science and research will give a series of talks underlining the strategic importance of sustainable management.

the finished pieces of primary packaging in the cleaned E2 boxes, which are then automatically placed onto the pallet.

Another section of the Robotic Pack Line will demonstrate a highperformance secondary packaging process. Here, the trays are automatically removed, checked, labelled and put into boxes. The trays are then labelled as well and placed onto pallets.

Careers Day For the first time, Anuga FoodTec will stage a Careers Day this year.

This initiative will enable closer contact between the exhibitors at Anuga FoodTec and students and graduates of related subjects, thus strengthening the sector's recruitment strategies. Careers Day will take place on Friday, 30th March 2012, from 9.00 am to 6.00 pm.

An overview of the entire supporting programme, including detailed information on the topics, speakers, places and times, can be found on the Anuga FoodTec website at www.anugafoodtec.de or www.anugafoodtec.com.

Anuga FoodTec is open to trade visitors only. Anuga FoodTec will be open daily from 9.00 am to 6.00 pm. The Anuga FoodTec website www.anugafoodtec.com offers online visitor registration and provides affordable and time-saving assistance with travel and hotel arrangements. The ‘Matchmaking’ online tool also enables trade visitors to research various exhibitors and product segments before the trade fair and to contact exhibitors directly. J

Sustainable Packaging The Nova Institute will organise a conference on ‘Sustainable Packaging – SusPac’k at Anuga FoodTec. Over the course of two conference days, presentations and discussions will analyse the current challenges and solutions in the field of sustainable packaging.

One focus will be on organically based packaging and the questions it raises: Where and how has organically based packaging already been successfully established? What advantages does it offer, and what do we need to know about its use? And finally, which innovations, trends and potentials can be predicted?

At a joint event with Anuga FoodTec, nova-Institut will for the first time issue the ‘SusPack-Award’ for the most innovative and most sustainable packaging solution introduced on the market in 2011/2012. Following a pre-selection round, a panel of judges will choose the overall winner on the first day of the conference. The prize will be awarded in a special evening event on 29th March 2012.

Meat Industry New international challenges, guidelines and procedures as well as packaging trends for the meat industry will be the subject of the half-day conference, which will take place on 28th March 2012.

This year's trade fair will host a world-premiere live presentation of the Robotic Pack Line, which cannot be seen in this form anywhere else and will demonstrate new possibilities for the sector.

This time, the show will demonstrate the hygienic handling of real fresh meat. In a complete production line, robots will automatically take E2 boxes from pallets and check the fresh meat contained in the boxes. A robot equipped with a hygienic gripper will take the pieces of meat out of the boxes and place them in a piece of primary packaging (a tray), which it then seals. After the seams of the seal have been checked and the product labelled, a Scara robot will lay

Constructie Bruynooghe NV Bruggestraat 74 B – 8840 Staden

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Tel: 32 (0) 51 70 50 88 Fax: 32 (0) 51 70 51 40 btw be 429.254.692

17

I ANUGAFOODTECH 2012 PREVIEW

Argelith Bodenkeramik – The Specialist in Hygienic Floors roducers of food and beverages expect their P industrial floors to remain permanently hygienic over years despite chemical and

one can create any kind of slopes. In the past, wide joints and overlippings on high and low points caused tile chippings. Furthermore, sewage stayed in the wide joints so that chemicals damaged the joints on a sustained basis.

Wide joints are a paradise for bacteria.

Exact calibration of Argelith’s hexagonal tiles reduces the joints down to a necessary minimum of approximately 2.5mm.

mechanical influences. The German manufacturer Argelith Bodenkeramik has specialized in this niche market and has proved able to match these requirements over several decades.

With the right planning in construction, difficult and cost-intensive repairs of floors can be avoided. A hexagonal tile floor is the perfect solution in order to meet the above mentioned requirements in the following three production areas:

Driveways

Hygienic Areas

Especially hygienic requirements after HACCP are a challenge for industrial floors.

Argelith tiles are up to 18mm thick and resistant to acids and caustics. Tiles from Argelith are unglazed and slip resistant, but at the same time permanently stain resistant and easy to clean, thanks to very low water absorption. At this level no other manufacturer can compete with the high quality from Argelith.

Wet Areas

The Hexalith® tile has proven to be useful in wet areas. Thanks to its almost round shape

In areas with daily fork lift traffic a thick tile and narrow joints are essential to guarantee a durable, heavy duty floor. Argelith tiles of 18mm thickness are very size accurate and can be laid butt-jointed. They withstand the highest mechanical point loads.

The Hexagonal shape offers an optimal protection for the floor as dynamic loads occur in pointed angles towards tile edges and so tile edge impacts are reduced to a minimum.

For further information contact Argelith Bodenkeramik on Tel +49 5472 402 112 or visit www.argelith.com. J

Au2mate Performs Successful Upgrading of Control System at Arla Foods Holstebro rla Foods Holstebro annually produces A 58,000 tons of cream cheese in various flavours. Approximately 3,500 plant com-

Arla Foods IT reporting system and SAP.

ponents are connected to the control system. Success criteria for the technical solution were to achieve an open system that Holstebro itself could maintain/enlarge, a future-proof investment, plus encapsulating the knowledge and experience in the dairy.

Furthermore, it was constructed in accordance with Arla Foods’ Standards ISA S88/ISA S95, and built for data collection and traceability through integration to the

• 8 Siemens S7-414 PLC’s; • 1 Wonderware Intouch station with big screen in the control room; • 14 Wonderware Intouch stations distributed in the respective control rooms and process area; • 3 redundant Wonderware IAS servers; • 1 Siemens programming station; • ISA S88 structured Siemens software application; • Wonderware Intouch SCADA application; • Data collection for the ISA S95 structured database.

Scope of Supply

Project Process

The project was initiated in early 2009 and extended over three years. It was carried out as a step by step upgrade/development, in order that the commissioning was implemented with minimum interruptions. The project was implemented in close co-operation with Holstebro’s technical personnel FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

and operators.

Benefits For Arla Foods

As result of the upgrade Holstebro has since 2008 reduced its costs for electricity, steam and ice water by over 20%, and for water and chemicals by over 30%. Additionally, the maintenance costs for the control system have been reduced and its flexibility and integration possibilities have increased.

As a natural part of the upgrade Holstebro has implemented a good deal of optimization and expansions of the process plant.

Today there is better traceability and far better reporting capabilities than before.

For further information contact Au2mate on Tel + 45 87205050 or visit www. au2mate.dk. J 19

I ANUGAFOODTECH 2012 PREVIEW

Food Quality Testing With Brabender Instruments ased at Duisburg in Germany, B Brabender specialises in the development, manufacture, and distribution of instruments and equipment for testing material quality and physical characteristics in all fields of research, development, and industrial production in the chemical and food industries worldwide.

At the core of Brabender business is the adaptation of measuring principles into easy to use, highly accurate, reliable and competitively-priced laboratory instruments for use within the food and drink industry.

Brabender instruments for the quality control of raw materials help customers to optimise their production processes. Indeed, some Brabender instruments are used not only in the laboratory but also at the production line to test the quality of products (like dough) as they are being processed.

The company’s laboratory instruments are used extensively in the milling, baking, starch, brewing, animal feed, chocolate and sugar confectionery, meat, cheese and snacks sectors of the food and drink industry.

“Our instruments provide customer with a good overview of the quality of the raw materials they are using, giving them with the information necessary to improve efficiency and to reduce costs,” says Markus Loens, senior sales director food of Brabender.

Founded in 1923 by Carl Wilhelm Brabender, the company developed the Farinograph system, which since being first introduced in 1928 has become the worldwide standard for testing flour.

The Farinograph

The Farinograph’s easy handling, reliability

The Brabender MT-C provides a quick method for moisture determination on all types of material.

and the objectivity and reproducibility of its results have made it the instrument most frequently used all over the world for determining the water absorption and mixing characteristics of wheat and rye flour.

The determination of the flour quality and its processing characteristics are a basic demand in the milling and baking industries for ensuring optimum and uniform flour qualities for the production of bakery products and noodles. The Farinograph can measure the water absorption of flours; determine the rheological properties of the dough; check production and flour blends in the mill; test rye flour, sponge batters, egg foam, etc; and test full formula doughs.

The latest generation of Farinograph offers a number of advantages including an automatic water dosing system; extended software applications; variable speed (0-200 min-1); higher torque (20 Nm); coloured display to show temperatures; recording of two temperatures (dosing water and dough); and the calculation of mixing energy. A variety of mixing tools for the Farinograph are also available.

While well known for its use within the milling and baking industry, the Farinograph is also suitable for other applications such as chocolate, chewing gum, fish, cheese and meat.

Heavy Investment in R&D

Brabender invests heavily in R&D, which is reflected in its impressive track-record of innovation. “Our major strength is the excellent service that we offer customers along with our capacity for innovation.

Every year we allocate a high percentage of our turnover to invest in research and development,” says Markus Loens. “We produce high quality instruments with exacting standards of accuracy and reproducibility. We are constantly looking for new developments.”

The percentage of the company’s turnover invested in R&D is in the high single-digits.

Annual turnover is in excess of Eur20 million and Brabender currently employs 170 people. It can also draw upon the resources of its parent group, which employs 450 people.

Moisture Tester MT-C

Another major development by Brabender is the Moisture Tester MT-C. Used extensively in the brewing industry globally for the FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

The Farinograph is the instrument most frequently used all over the world for determining the water absorption and mixing characteristics of wheat and rye flour.

testing of barley and malt, Brabender’s Moisture Tester MT-C is also used in all sectors of the food industry where the accurate testing of moisture content is required.

The Brabender MT-C provides a quick method for moisture determination on all types of material, such as grain, flour and feedstuffs. The Brabender MT-C is an electronic moisture tester using the drying oven principle with moving air. Due to the continuous air flow within the drying chamber, the drying process takes considerably less time than in a conventional drying chamber without ventilation. The integrated software allows fully automatic measurement and saving of the results.

The MT-C offers numerous advantages over other instruments/methods for moisture determination (NIR, drying balances, dielectric instruments). No special calibration for different samples is required, it can measure up to ten samples at a time, determine the water content with an accuracy of < 0.1% and incorporates fully automatic reweighing in the drying chamber after drying. It has a drying temperature up to 200 C and a measuring range (water content) of 0.1-99.9%.

The MT-C is also approved under German law in a special version, the MTC/Z. The reason for this is the high accuracy and reproducibility of results and special software.

Support Services

Brabender’s modern application laboratory is at the disposal of all customers and interested parties for trials with their own material. All Brabender’s measuring systems can be tested under practical conditions. An experienced expert team is available to assist with the tests and to answer any questions. J 21

I ANUGAFOODTECH 2012 PREVIEW

BEST Innovations in Sorting Technology EST (Belgian Electronic Sorting Technology) is an innovative company B specialized in manufacturing sorting machinery for the food and non-food industry. BEST is using the latest and most innovative optical technologies (laser, camera, Fluo™, LED and x-ray or a combination of them) to achieve highest efficiency in the detection and removal of unwanted materials.

At the Anuga fair, BEST will show, besides the well-known and proven Genius belt sorter, also the new state-of-the-art Nimbus.

The Nimbus

The Nimbus is a laser/camera sorting solution that combines the efficiency of laser detection on foreign material, together with the accuracy of the camera detecting discolorations and shape differences in free-fall.

The sorter detects all color, structure, size and shape defects from a stream of good products. Besides these conventional sorting methods, the Nimbus is also able to sort based on biological characteristics, such as chlorophyll (Fluo™), mycotoxins (Detox™), and water (SWIR).

To sort out shape characteristics, the machine is equipped with an additional module with a general shape sorting toolbox that adds complementary sorting capabilities by applying object oriented features like length, width, diameter, area, broken piece recognition, etc.

The sorter also features 3-way sorting, designed for the removal of unwanted products with high accuracy, very low false reject and an optimal yield. 3-way sorting capabilities on the BEST sorters feature two ejector

modules, allowing processors to separate different reject streams that before ended up in the same stream.

The new revolutionary sorter has a new and more powerful hardware processing platform, allowing the implementation of new modules, like the BEST Smart Sort and BEST Flex Sort.

By analyzing intelligently the incoming products, the Smart Sort module helps the operator in setting parameters. This new feature ensures a faster and easy configuration of the machine. Also the operator has the possibility to adjust the sensitivity set by the Smart Sort module, according to the changing sorting circumstances.

The digital Flex Sort allows the operator to quickly switch from sorting one product to another without having to make any mechanical adjustments. It is a revolutionary technology that also ensures an improved contrast between good products and defects. By using this module, customers can maximize the ease of operation and uptime, optimize the sorting performance and minimize the investments.

Visit BEST at Hall 10.1 booth F010 to learn more about this new revolutionary sorter.

number, type and position of the cameras, lasers and lighting depend on the product and type of defects. State-of-the-art air guns reject any defects within milliseconds thus allowing the good product to proceed its way in the processing line. By doing so, the Genius™ achieves unequalled sorting performance and detects the slightest shades of discolorations, foreign material or other product related defects.

BEST will show other sorting solutions during the fair. Visit our booth F010 in Hall 10.1 to discuss with the company’s experts how BEST can find a customized solution for your sorting challenge.

To book an appointment at the booth contact info@bestsorting.com or visit www.bestsorting.com for more information. J

The Genius Belt Sorter

BEST will also show the Genius™ belt sorter, which offers different inspection technologies located in several inspection zones, to provide enhanced detection efficiency. High resolution cameras (color or monochromatic), lasers and Fluo™ lasers can be combined with different types of illumination for each area. Products can be inspected from all sides (full surround view), on or off belt, allowing an optimal inspection on color, structure, shape and biological characteristics. The FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

The Nimbus.

23

I DEVELOPMENT STRATEGY

Nestle to Invest £500 Million in UK Manufacturing Facilities Nestle UK & Ireland is investing £200 million to extend its Nescafe factory in Tutbury, Derbyshire, as part of a £500 million programme, running over the next three years, to modernise its British manufacturing facilities. he investment at Tutbury is in addition to the £110 million extension to the Nescafe Dolce Gusto facility at the site announced in November 2011. When completed, the latest expansion at Tutbury will mean that for the first time in the UK all forms of coffee production, including freeze dried, spray dried and pod technology, will be assembled on one site.

However, production at Nestle’s coffee factory in Hayes will transfer to Tutbury, leading to the eventual closure of the Hayes site, where 230 people are employed, in 2014. Although the Hayes factory plays a key role in Nescafe production, it is not feasible to redevelop the site to create the manufacturing facility Nestle UK & Ireland needs for the future.

Some 125 new jobs will be created in Tutbury through the transfer of production. This is in addition to the 300 new jobs at the Dolce Gusto facility in Tutbury announced in November 2011 The £110 million investment will equip the Dolce Gusto plant with 12 new high speed production lines to triple its coffee capsule production from its current level of about four million capsules a day. More than 90% of the capsules will be exported to more than 38 countries around the world. They will also be sold in the UK. Nestle has invested more than £100 million in the factory over the past five years to strengthen its position as a leading Nescafe production site. The factory in Tutbury is one of only two production

T

Paul Grimwood, chairman and chief executive of Nestle UK & Ireland.

sites for Nescafe Dolce Gusto coffee capsules in the world. The other is located in Girona, Spain.

Nestle UK is investing £200 million to extend its factory in Tutbury.

£500 Million Investment Programme The expansion of the Tutbury site is part of much bigger investment programme

by Nestle UK & Ireland across its manufacturing assets. “Over the next three years, we are investing £500 million to establish our next generation of world class manufacturing facilities in the UK,” says Paul Grimwood, chairman and chief executive of Nestle UK & Ireland. “The proposed restructuring, which will bring all our coffee manufacturing together at Tutbury, is a key part of this overall investment programme.”

Employing approximately 7,000 people across 19 sites, Nestle UK & Ireland comprises a number of businesses Nestle UK (Food & Beverage, Confectionery and Food Services), Nestle Ireland, Nestle Purina Petcare, Nestle Waters, Nestle Nutrition, Jenny Craig, Nespresso, Cereal Partners UK (a joint venture with General Mills) and LactalisNestle Chilled Dairy (a joint venture with Lactalis).

Nestle manufactures a variety of iconic brands in the UK. These include: Kit Kat, the country’s number one selling biscuit, Quality Street confectionery, Nescafe soluble coffee, and Shredded Wheat cereal. The company had sales of SFr3.7 billion (£2.6 billion) in the UK in 2010. Nestle is one of the UK’s major food exporters, selling products worth more than £260 million each year to 50 countries around the world.

UK Market Leader In the last year Nescafe Dolce Gusto, which provides coffee-shop quality coffee at home, for a fraction of the price of coffee on the high street, has increased machine sales by over 77% and increased value share of the UK pods market by 4.2% points to 44.1%.

Nescafe continues to retain its position as the UK’s leading soluble coffee brand producing the category’s two best selling brands - Nescafe Original and Nescafe Gold Blend. During 2011, Nescafe grew particularly well in the cafe menu segment and in a The £110 million investment will equip the Dolce Gusto plant Nescafe new mixes segment, with the with 12 new high speed production lines to triple its coffee capsule production. launch of Nescafe 3 in 1.

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

25

Strong Year 2011 was a strong year for Nestle UK & Ireland despite the difficult economic climate, according to Paul Grimwood. “UK shoppers are adapting to challenging times, they still want to provide their families with good quality food and drink, and the occasional luxury - they’re just looking for value in the way that they do it. We are helping them by offering brands they can trust, great quality products, value for money, and the occasional affordable luxury,” he comments.

“Listening to shoppers and providing them with the quality products they want that deliver real value for money has never been more important.”

For instance, in confectionery, the ultimate affordable treat, chocolate multipacks (+17.20%), blocks (+20.7%) and confectionery share bags (+30%) all saw significant increases last year. Nestle Confectionery continued to grow during 2011, driven by the core brands with exceptional performances from Aero and Rowntrees up 17.6% and 16.8% respectively with Rolo up 31.5%. Innovations in confectionery included Kit Kat Pop Chocs, Rolo and Aero biscuits, Aero Caramel, and the expansion of the Rowntrees offering including Sour Pastilles, Jelly Aliens and Very Berry Jellies.

Nestle has also created a £40 million European centre of excellence for Nescafe Cappuccino in Dalston, Cumbria.

“We need to continue to innovate to remain ahead of the market and are committed to the ongoing modernisation of our UK manufacturing capabilities,” says Paul Grimwood.

Nescafe continues to retain its position as the UK’s leading soluble coffee brand producing the categories two best selling brands - Nescafe Original and Nescafe Gold Blend.

on developing new products to meet changing demand to drive growth. If we continue to invest in our business and our brands during challenging times we will be in a much stronger position when the economic climate improves.”

He characterises the newly announced £500 million three year investment programme as a real sign of Nestle’s “confidence and commitment in the UK in the long term.”

In the last year Nescafe Dolce Gusto, which provides coffee-shop quality coffee at home, has increased machine sales by over 77% and increased value share of the UK pods market to 44.1%.

Maggi gained 11.3% value share of the cooking sauce category and 47.0% share of the cooking bag segment in 2011 through the launch of Maggi So Juicy, which provides a quick and easy family meal. This contributed to the delivery of an increase of 14.6% growth to the sales value of the total cooking sauce category in 2011. One of Nestle’s billionaire brands, Maggi is a global powerhouse, with products including everything from stock cubes, to soups, table sauces and noodles.

Paul Grimwood adds: “2012 will continue to be tough but our focus remains

£35 Million Investment at Nestle Waters On the bottled water side of its business, Nestle is currently building a new £35 million bottling plant in Buxton, Derbyshire, which will be one of the most environmentally sustainable operations of its kind in the world when it opens later this year. The new factory will, for the first time, combine the Nestle Waters UK bottling facility with a warehousing capability. The new bottling lines will significantly reduce the site’s total energy output, as well as producing the lightest weight bottled water bottles made in the UK. The innovative new bottle design will use an average of 25% less PET plastic than the current design, and will be used across the entire still range of Buxton Natural Mineral Water and Nestle Pure Life. Furthermore, by the end of 2012 the site aims to be certified zero waste to landfill.

Paolo Sangiorgi, managing director of Nestle Waters UK, remarks: “Demand for our bottled water brands has seen double digit growth over the last three years. This major investment in a state-of-the-art factory in Buxton clearly demonstrates our commitment to our market leading portfolio of bottled water.”

Nestle Waters finished 2011 strongly with a total value market share of 20.5% (Share of Total Plain Water) up from 19.3% a year ago, making Nestle Waters the fastest growing branded player in the category. Nestle Pure Life consolidated its role as the fastest growing bottled water brand, with value growth of 140 bps, and Buxton maintained its position as the UK’s top local mineral water with a value share of 11.9%. J

Competitive Edge Nestle invests heavily to maintain a competitive edge in manufacturing technology and efficiency. Indeed, over the past five years Nestle has undertaken a multi-million pound investment programme in the UK. For example, Nestle has spent £200 million transforming its major confectionery factory in York to create a best in class manufacturing facility plus £7 million to expand the group’s global Research & Development centre for confectionery, also based in York.

Also within its confectionery business, Nestle has invested £20 million establishing a sea- Nestle is currently building a new £35 million bottling plant in sonal confectionery manufac- Buxton, Derbyshire, which will be one of the most environmentally turing centre in Halifax, sustainable operations of its kind in the world when it opens later this year.

Yorkshire.

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

27

Cama - Excellence in Cups Technology side loading solutions, equipped with its legendary range of high-speed cartoning machines. The cartoning machines make light work of many different complex product configurations in a flexible and reliable way, with added reduced footprint and easy maintenance.

he markets of coffee, tea and herbal tea T in cups are experiencing strong growth in the beverage market, with increasing investment in technological high-speed systems. Cama, a private company based in Lecco, Italy, is a leading supplier in cartoning technology and one of the early pioneers in the cup sector, continuously investing in innovative solutions to meet the growing demand in superior technology for high-speed packaging systems.

Cama has gained further trust from leaders in the international market for coffee/tea cups and has increased its experience over the years in high-speed cup packaging solutions. In 2003, the company provided a large and reputable ‘multinational’ company with the one of the first robotic lines in the world that was able to package up to 1,400 cups per minute; arguably the fastest in the world. The ongoing success is due to Cama’s continuous attention to detail and commitment to constant improvement of its packaging systems that is driven by the customer.

Global Consultant Today Cama continues to innovate offering its customers comprehensive technical

28

advice on the best cardboard packaging solutions in relation to project specifications. The company presents itself as a ‘global consultant’, providing customized technical solutions, combining both skills in packaging and robotics, materials, packing styles resulting in pay-back on investments. Cama also offers multiple combinations that are made possible for secondary packaging.

Annalisa Bellante, marketing manager of Cama, explains: "Our customers often tell us that we are the ‘ideal partner’. Our experience in coffee packaging does not only concern cups though. We provide multiple applications for pods, bags, doy-packs and instant coffee stick-packs. Stick-packs now at run production speeds of 960 per minute, thanks to special hopper loaders used to handle high speeds."

For state-of-the-art top loading solutions, Cama can pack at more than 780 cups per minute with special packaging configurations. The line, consisting of a box forming machine, a double-loading robot, a box closing machine and a case packer, has proven to be extremely flexible and reliable.

Cups are loaded into a special configuration to optimize the size of final packaging.

They are then placed in cartons containing 8 to 48 pieces, gathered together and packed in an American case. The increase in sales, combined with the high-level relationship between technology and reliability of the production system, has led some customers investing again and subsequently doubling the number of production machines.

For the primary packaging of coffee cups using flowpack or bags, Cama usually offers FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Custom-made Packaging Solutions Depending on requirements and a wide range of project specifications, Cama is able to offer its clients custom-made packaging systems from the company’s diverse portfolio including: robotic solutions (top loading), cartoning (side loading) and case packing with wrap-around display stands or display-boxes.

Cama produces machines with what it describes as Italianita (the Italian spirit)

which lives right through the company philosophy today. It is still a privately owned company and headed up by the Bellante family.

Annalisa Bellante adds: “The development of cups is always intrinsically linked to the machine, they are like hand and glove. We have a strong cultural bond to coffee too here in Italy! This, together with our family spirit and creative technology offers, is what I would say ‘an unrivalled package’ in the exciting beverage market and we are very proud to be at the forefront.” J

I RETAIL READY PACKAGING

Corrugated Innovation – Helping Packaging Users Succeed Retail ready packaging, the most significant development in ‘on-shelf ’ packaging for many years, has changed the way consumer goods are distributed and displayed forever. ow that retail ready presents products N and brands to shoppers every day, marketers are becoming very aware of new opportunity. Well printed, well designed packs can help drive impulse sales, enable shoppers to navigate the category or reinforce brand messaging.

By listening carefully to customer briefs, and by enlisting and combining the skills of experts across its network of businesses, DS Smith Packaging gets to the heart of a brand’s strategy to deliver tailor made solutions. Tony Foster, Sector Director, comments: “There is nothing ‘off the shelf’ about DS Smith Packaging’s approach to retail ready.”

Spectacular Results The results come through in spectacular fashion. Take, for example, the retail ready packaging for Seabrook Crisps.

Seabrook wanted a corrugated pack that perfectly reflected the qualities of its new range called “Goodbye salt Hello flavour”. The message to the shopper stands out loud and clear; it highlights the reduction in salt but not flavour.

A superb product shot is featured with a background texture depicting a traditional potato sack. DS Smith Packaging recommended its R-Flute®, a significant breakthrough in corrugated fluting. When

Retail ready packaging for Seabrook Crisps.

compared to the commonly used b-flute, R- Flute® offers a flatter, better surface for printing and presentation, a crucial advantage for more and more customers who seek brand appeal and sales success with shoppers.

ImageRight A major component in the success of DS Smith Packaging’s printing is the use of ImageRight, part of a unique set of business tools called PackRight. ImageRight is used to protect a brand’s identity at the point of sale by ensuring consistent colour.

The successful ‘TiltMaster’ pack is an innovative retail-ready concept produced for Roach Bros.

and present them as shoppers expect, in the right context. Put simply, good RRP helps drive sales.”

DS Smith designed new, high quality retail ready packaging for the Seven Seas range of Liquid Pure Cod Liver Oil.

DS Smith designed new, high quality retail ready packaging for the Seven Seas range of Liquid Pure Cod Liver Oil. ImageRight matched brand colours in different elements of the packaging, so that the primary and secondary packs work together in perfect harmony. High quality flexo print has been applied on both the outside and inside liners to create greater impact on shelf.

Terry Morgan, Market Development Director, confirms that: “There’s a growing recognition that RRP is a valuable tool in shopper marketing. Designing RRP, with the right look and feel to complement the primary and secondary pack, enables brands to position their products FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Innovative ‘TiltMaster’ Pack The successful ‘TiltMaster’ pack is an innovative retail-ready concept produced for valued customer Roach Bros. The corrugated concept, which has recently won a WorldStar Packaging award, allows the product to be displayed on a backwards tilt, so that it does not fall over, is always clearly visible to shoppers and thus generates optimum shelf impact. The tilting function only operates when the lid is removed, therefore taking up 18% less storage and distribution resource compared to a pre-formed construction. As always with corrugated packaging, the Tiltmaster is 100% recyclable.

Tony Foster sums up: “Customers are increasingly turning to DS Smith Packaging to make ideas happen. We are continuously raising the bar to help customers succeed at the point of sale, whilst reducing cost and carbon in their supply chains. We heartily welcome the challenge to help brands stand out positively from their competition.’’ J 29

I PRODUCT INTEGRITY

New Solution For Glassware Traceability Provided by MSC & SGCC While glass manufacturers have to continuously improve the quality of the delivered products, they also need to ensure the best possible traceability of the produced articles. nce empty glassware is manufactured O and delivered, new challenges related to counterfeiting and distribution management also arise. A new opportunity is now available to improve production management in the glass plant and to offer better product tracing all along the distribution channels. MSC & SGCC is introducing the Total Tracer solution to the market, enabling a 100% individual article lifetime identification.

Innovative Technology The total tracer, a laser engraving solution, has been developed to ensure an individual marking of each produced article. The laser beam engraves a Datamatrix on the articles directly after the forming machine. This code contains: manufacturer identification information, date and time labels and additional data related to the manufacturing process.

Datamatrix is a redundant, secure and resistant encoded marking allowing very high decoding performances. Hot end laser technology leads to a high quality compact and precise code. Using laser technology on hot articles provides way better results than conventional systems based on cold sidewall engraving.

As the laser operates on glass with a temperature above 450° Celsius, it

Datamatrix code engraved in glass surface.

Example of a Total Tracer hot-end marking.

avoids the creation of micro cracks in the glass structure. Once engraved, the code cannot be erased or modified as the laser beam operated modification inside the glass sidewall on hot articles. The position of the code can be adjusted in order to match the article shape and characteristics. Different dedicated reading devices have been developed to provide reading capability either online or offline.

Product Range Total Tracer: Laser engraving system.

This device engraves the Datamatrix code while grabbing process information from the forming machine. It is positioned just after the IS forming machine.

Engraving can be done either on neck or body of the article.

CDR: The Carousel Datamatrix Reader is suited be integrated into carousel cold end quality inspection machine.

Integration into any machine that puts the article into rotation is also possible. It is able to read the neck engraved codes on round or not round articles.

LDR: The Line Datamatrix Reader is dedicated to online non-contact code reading. Itâ&#x20AC;&#x2122;s a standalone device able to read codes on the body of non-round articles.

MDR: The Manual Datamatrix Reader is a standalone portable reading tool FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

Example of a cold-end datamatrix marking showing micro-cracks.

designed to ensure offline reading capability.

Benefits This product range brings unique features and solutions.

Beside the productivity and process control benefit that can be achieved inside the glass plant, the provided solutions also

Total Tracer.

31

MDR – Manual Datamatrix Reader.

enable quality issues management down to the final customer. In fact, each article will

keep this unique and individual identification all along its product lifetime, it becomes then possible to recover the manufacturing data at any step of the filling process or even after the product has reached stores ‘shelves. At this final stage of the product’s life, the standalone MDR reading device provides information such as the plant origin, the production date and one can even access process information like the cavity number of the forming machine.

Considering that glass manufacturer data are enclosed in the code and keeping in mind that this Datamatrix code is unal-

terable once engraved, this product range provides a real solution for 100% counterfeiting, guarding all along the production and distribution stages. The MSC & SGCC traceability product range is the most advanced operational solution available on the market against counterfeiting problems. J

I TRACEABILITY

Glanbia Implements New Labeling System to Comply With Customer Requirements lanbia, one of Ireland’s largest food G manufacturers, has implemented a print and apply solution from Zetes. The solution developed enables Glanbia to comply with a new customer requirement for full product traceability and the highest possible quality standards.

Currently all butter manufacturers in Ireland are required to assign every pallet of butter produced with a unique label combining information including the manufacturer, weight, lot number, pallet number and best before date.

Zetes is internationally recognized as a leading expert in the field of print and apply and was a natural choice of supplier. The company currently works with manufacturers from all sectors of industry to provide effective printing and labeling solutions, including advanced serialized labeling solutions for the pharmaceutical sector to combat counterfeiting. It was as a result of this expertise that Glanbia decided Zetes had the right skills to implement a unique labeling solution for its butter division.

“We were concerned that this new customer requirement would have an impact on our production costs and so looked for a solution that required minimal levels of human intervention. Our IT department initially recommended we work with Zetes as local specialists in automated identification and data capture,” says Gerry Warren, Butter Store manager at Glanbia.

The Solution Glanbia’s application has been installed at 32

the end of each butter production line and works in conjunction with its existing pallet wrapping system. Pre-loaded pallets of butter are placed onto a wrapping turntable ready for shrink-wrapping and a traceability label is affixed after this stage once the correct pallet is automatically identified. The

print and apply solution developed by Zetes uses wireless technology and MCLNet as its communication and dispatching programme. This directs the Motorola wireless handheld scanner, Datamax A Class printer hardware and a Zetes dedicated print and apply applicator unit.

Using the MCL programming language, Zetes has effectively turned an ordinary industrial printer into an intelligent device able to capture information from a variety of different databases and combine the results to create a unique number for each pallet, without the need for additional PCs. FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

The unique pallet number is produced by combining both the lot and best before date information.

After loading, the pallet’s existing barcode label is scanned and a new label combining any additional production and traceability information required is generated automatically. To complete this stage, the printer effectively recognizes individual pallets before they are shrink-wrapped on the production line and is able to generate the correct label for application after wrapping.

By integrating the label printer with Glanbia’s product database, details relating to lot number and expiry date can be captured and combined with manufacturer information in a single label. The label is then transferred to the applicator pad ready to be affixed to the pallet following shrinkwrapping.

Glanbia estimated that without the print and apply solution from Zetes, they would require extra staff to manually produce labels and apply them to the finished pallets “The solution is completely automated and our only involvement is to replace label rolls when they run out,” says Gerry Warren. “It has eliminated the need for additional staff to manually produce labels and there has been no impact to the volumes of finished goods we can dispatch each day. We are delighted with Zetes’ solution, it does exactly what we require and always runs smoothly.” J

I PACKAGING DESIGN

A Tasty Alternative From DS Smith Packaging S Smith Packaging Livingston, were D delighted to support customer Paterson Arran in designing a new innovative pack that reduces the amount of material needed, speeds up packing time and provides a great promotional unit in store.

The Bronte Giants range, cookies and creams had previously been packed into solid board cartons, and then into a brown corrugated box for shipping. The new pack which is specified in R-Flute®, a DS Smith material that provides great supply chain and print benefits, results in the cookies being packed into a single corrugated display unit which removes the need for an estimated 400,000 cartons. The

pack is stronger than the original so no shipper box is required, and the print looks great too.

Amy Coles, Marketing Manager from Paterson Arran, reports: “The new pack means we receive more boxes per pallet inbound and have reduced the amount of items we have to order, store and pack.

We even improved the impact at the point of sale by incorporating a display feature.

We are truly delighted with the overall result.”

Demonstrating corrugated innovation at its best; this single material, fully recyclable pack provides protection and promotion.

It just goes to show how packaging users can improve sales and reduce cost and waste by working with DS Smith Packaging - they make ideas happen. J

DS Smith Packaging Win Worldstar Award For Innovation S Smith Packaging Belper, are very D proud to have won an award in the prestigious Worldstar competition, competing with entries from 33 countries. The successful ‘TiltMaster’ pack is an innovative retail-ready concept produced for valued customer Roach Bros. It fulfils a market need for a self-merchandising pack and it is 100% recyclable.

The corrugated concept, which has already won a Starpack Award, allows the product to be displayed on a backwards tilt

thus keeping it upright and maximising shelf impact. The tilting function only operates when the lid is removed, therefore taking up 18% less storage and distribution resource compared to a pre-formed construction.

Tony Foster, Sector Director for DS Smith Packaging, comments; “we are delighted to receive this global award on behalf of our customer and their brand. Awards demonstrate our wide ranging capabilities and are testament to the hard work and skill of our

people, the success of our business tools PackRight, and clever innovations such as ‘TiltMaster’. We aim to help customers succeed at the point of sale whilst reducing cost and carbon in their supply chains”. J

New app For Everards Beers S Smith Packaging has produced a new D corrugated carry-pack for well-known family owned Everards Brewery, featuring QR codes and a striking seven-colour print.

Everards turned to DS Smith Packaging Belper to upgrade their 2-colour pack into one with a flexible structural design, attractive graphics and Quick Response (QR)

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

codes. The print required careful testing to ensure the quality and integrity of the QR codes that appear on the side of the carrypack, for those customers wishing to learn more about their favourite tipple. The unit also promotes Everards’ use of social media platforms such as Facebook and Twitter.

The packs, which are engineered to carry either three bottles of beer or two plus a glass, have been designed with integrated inserts and a carry handle. Packs are available to buy through Everards Brewery shops and via its online store. Graham Tattam, MD of the Belper site, confirms that ”it is great to see that corrugated developments and innovation from DS Smith Packaging are not only protecting precious goods, but also creating impact in-store whilst helping with advertising too!” J 33

I CHOCOLATE TEMPERING

In Line or Near Line Tempering Check?

By Samuel Bize of CCMS he tempering process in the chocolate T industry is performed to enable the chocolate to transform from liquid to solid.

It is a common name given to the technique of generating a definite amount of cocoa butter crystal seeds in a chocolate mass, with the objective of the multiplication of the crystals during the solidification process. A better name for tempering would be pre-crystallisation.

There are several ways to check the tempering rate, in order to adjust the tempering process on the tempering machines.

The most common method uses a tempermeter. The principle is based on the simple thermal analysis. A chocolate sample is placed in an aluminium cup and placed in a cooling bloc in order to cool the chocolate and enable the crystallisation (solidification) to occur. In fact, we reproduce what happen to the chocolate products in the cooling tunnel, but with a precise control of the cooling rate and very precise temperature monitoring. A temperature probe is placed into the chocolate in order to monitor the evolution of the temperature versus the time.

The heat released during the solidification showed by the tempering curve of the chocolate mass gives an indication of the relative amount of crystal nuclei formed during the pre-crystallisation process. The slopes of the curves at the inflection point (a cross on the diagram) are linked to the amount of cocoa butter crystals that have been formed during the tempering process.

Some instruments use an index, but all these indexes lie at a point (very high and very low amount) because they are not proportional to the slope all through the tempering grade range. I would use the slope and the temperature of the inflection point, as these figures describe exactly the curve and the related crystallisation heat release.

There are several models of tempermeter

on the market, most of them are portable and allow determining near line measurement, which means you have to sample (fill up your cups) and place it in your tempermeter placed not to far from the sampling.

The sampling is performed usually very close to the last step of the chocolate processing (chocolate curtain, depositor, noz-

zles, etc).

There are other tempermeter models that are designed to be built in line, which means the sampling is done automatically within the pipe delivering the chocolate masses to the enrober, to the moulding line, to the extruder. Some models are placed right out of the tempering machines.

The benefit of such an in line measurement is that you do not need to sample.

However, there are important risks of a misuse of such an in line measurement.

In the chocolate crystallisation process from liquid to solid, we have to continually consider two inseparable parameters TIME and TEMPERATURE, versus the cocoa butter crystal growth, and the polymorphic transition.

Different lines have different configurations due to the design of the factory. Some manufacturers want to have the tempering machines out of the production line, so it means that the chocolate masses will take a long time to be conveyed to the moulding or enrobing line, consequently, especially if the temperature is not well adjusted for the double jacketed pipe, a lot can happen.

(Crystal growth, or the opposite).

Most of the tempering machines are

The 3 different steps of chocolate crystallisation

Solidification curves or so called tempering curves performed with a tempermeter.

Step

Process

1 Pre-crystallisation 2 Crystallisation

Tempering Solidification

3 Post-crystallisation

Maturation

Where

Amount of solid cocoa butter crystals Tempering machine From 0.1 to 0.8 % Cooling Tunnel About 95 % of cocoa butter crystals *

Storage

A few percent

* this is the percentage of the cocoa butter part that usually crystallises at room temperature, as we know that stable CB at 20 C still contains 20% of liquid fat.

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

35

I CHOCOLATE TEMPERING

STATICE Develops Tempermeters and Specific Measuring Systems For the Chocolate Industry he French company STATICE designs T and produces customised systems for industries wanting to monitor their processes, especially the food processing industry. Confectionery companies pay close attention to process quality and repeatability. In order to improve the quality of their chocolate, the supervision of the pre-crystallization of chocolate is essential.

STATICE has been developing tempering measurement systems for the chocolate industry for five years. Two types of tempermeters are offered.

The EXOTHERM SMART, which is a manual tempermeter, provides easier moni-

working as Swiss watches and deliver a very constant rate of tempering (steady amount of cocoa butter crystals), as long as all the manufacturing constraints are respected (throughput, inlet and outlet temperatures, deseeding, etc). Consequently, a regular or frequent tempering check right out of the tempering machine is of little importance.

If you check the tempering grade right out the tempering machine, and just before using, you should have the same grade, this is rarely the case, and I have observed important discrepancies in some cases.

Even if you check the tempering grade at both ends of a hopper, you may find in some cases some differences!

What is the Good Tempering Curve?

During the tempering course CCMS offers all over the world, the following question arises all the time: which is the best curve to temper? To respond to this legitimate question in detail would take to much time here, but we can mention what we call a golden rule:

toring of chocolate tempering by sampling the chocolate in an aluminium cup, which possesses good thermal transmission. The temperature sensor is heated before and after the sample measurement, thus keeping the same temperature and increasing repeatability while avoiding false negatives.

Data that is collected provides slope, temperature, time and RSI. The user can follow the curve in time on the colour screen, and results are printed to assure traceability.

The machine can be configured to the production parameters of each user. It is portable, weighs 5.5 kg and is very easier to handle.

The EXOTHERM IN-LINE tempermeter assures an automatic monitoring of chocolate. It incorporates a PC user unit, 1 to 4 measuring heads, and 1 to 5 sensors for the tunnels. Installed directly in the production line on the up going flow, the measuring head takes samples every 15 minutes. The sample is cooled down for the measure, re-heated and pulled back into the flow. This automatic control of the production gives traceability and continuous improvement with storage of the data and statistic tools.

There is no good or bad curve looking at the shape or at the related figures. We cannot use the slope of the curve as an absolute value for all chocolate. The curve should be referenced with the finished product, under defined processing conditions.

In other words, for each product, each recipe, and even the same product and recipes made on an other line, a reference curve has to be established. Do not overlook that during the storage, and depending on the storage temperature, the crystallisation is not finished ( especially on the polymorphic transition point of view), and the reference curve has also to take into account the storage condition, especially the few hours right after the cooling tunnel.

In Conclusion

• The tempering is a difficult technique to master in some cases.

• The habit of checking the tempering grade contributes to the quality and to diminishing the non productivity figures, FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

The PRALINE SMART controls the cooking of pralines with an infrared sensor.

The temperature is supervised on a colour screen, big bright signs allow a control at distance and an alarm indicates the end of the cooking to the user. Data is printed on the integrated printer. J as long as we understand what to do with the results given by the tempermeter (how to react to the inseparable processing conditions which are the pre-crystallisation and the cooling regime).

• I would recommend factories to start with a portable tempermeter, if possible, one computerized with the ability to monitor tempering curves versus a reference curve created previously, according to the best criteria that you have defined for your product to be said to be well tempered chocolate products (gloss, snap, texture, resistance to blooming, etc).

• An inline tempermeter could bee useful for a large line where the instrument could be dedicated, as long as the sample head could be placed close to the final use of the chocolate mass before solidification. The best place to sample is at the last place it is used before solidification, for example in the pipe just before the hopper.

For further information visit www.ccmschocolate.com. J 37

N

I W D N A DAY O T E B I SUBSCR

R O F D N E K E E A W N DUBLIN I O W T

is read by more senior management than any other magazine

• 24,700 copies distributed every month • Read in-depth analysis of key industry trends • Understand how the top chief executives are thinking • Be informed about the latest legislation • Discover how your competition are doing business • Daily updated news and features • Weekly newsletters covering: Business Ingredients Processing Packaging Logistics Materials Handling IT Food Safety Environment

Arla Foods play

s to its stre

April/May

ngths

2011

Food & Drin k Business Website:

.foodanddr

inkbusiness

Still top of the world af ter 125 year s

June 201 1

.foodanddr

inkbusi

TOP 100

2011 Food and Drink Manufac turers in the UK and Ireland Food & Drink Business Web site:

www.foodan ddr

inkbusiness

.com

£95

Call the subscription hotline +353 1 6120880 To receive or email susan@prempub.com 10% discount www.fdbusiness.com mention TOP 100

I ROBOTICS & AUTOMATION

Growing Appetite for Robotics & Automation by Food and Drink Manufacturers he adoption of robotics and automation T technology by food and beverage manufacturers is growing rapidly. Key to this has

ducers working in bakery, prepared foods and meat processing and packaging opting for a free automation review.

been the efforts by suppliers to develop robots and automation systems to meet the special requirements of the food and drink Barbers has implemented an automatic manufacturing industry, and the realisation weighing and cutting system to reduce giveby food and drink businesses of the benefits away. that this type of technology can bring.

An increasing number of food and bever- BARA’s Automating Manufacturing age manufacturers are turning to robot and Programme automation technology as they seek to Mike Wilson, chairman of BARA, comimprove productivity, efficiency and flexi- ments: “The Government is putting considbility. Indeed, robotics and automation is erable money behind the promotion of playing an increasingly important role as robotics in UK manufacturing in recognimanufacturers strive to keep production tion that robots actually create more jobs costs down, in the knowledge that cheap through growth. Currently over 100 comlabour is not a long term option. The panies, including many food producers, are smarter food and drink companies are look- making use BARA’s Automating ing to grow out of the recession using the Manufacturing Programme which offers latest technologies and equipment. any UK manufacturer a free automation Robot sales to the food and drink sector, review. This in turn should also enhance which has traditionally been slow to adopt growth in robotics over the next couple of this type of technology compared to other years.” industries, have grown by 56% since the Food manufacturers have shown great year 2000, according to the latest statistics interest in BARA’s Automating compiled by the British Robot and Manufacturing Programme with many proAutomation Association (BARA).

Food manufacturers of all sizes have been turning to robotics and automation technology. For instance, one of the largest investments in recent times was by Northern Foods. The UK convenience food group, which is now part of 2 Sisters Food Group, invested £26.5 million in automation across its Fox’s Biscuits business to support higher margins and to generate greater operational efficiencies.

Smaller companies have also been embracing this type of technology.

Scottish biscuit manufacturer Tunnock’s has spent £4 million in state-of the-art robotics and automation systems, while Barnsley-based Fosters Bakery has automated an oven loading application to increase capacity and improve energy use. Within the FANUC food grade robots picking chocolate confectionery. dairy sector, traditional cheesemaker

Competitive Edge The Programme, which runs until 31st March 2013, has been developed by BARA and offers independent, impartial advice to assist manufacturers in their implementation of automation solutions. The primary objective of the Programme is to help UK manufacturers increase their competitive edge and gain from the benefits that automation offers including increased productivity, reduced waste and greater profitability.

Although the Programme primarily looks to assist SMEs throughout all manufacturing sectors within the UK, larger companies with limited knowledge of and expertise in automation are also eligible. The government funded program provides a rare opportunity for UK companies to take what is a risk-free plunge into the automation arena Judged on its knowledge and expertise, BARA has carefully selected independent automation advisers who will offer support to the enrolled manufacturers in two stages. The first is a strategic review of their manufacturing operation, commencing with an audit aiming to identify opportunities to improve production through automation, followed by a recommendation report, which is presented at a review meeting. The second stage will provide a more detailed intervention to develop the outcomes from the audit, which will provide the client manufacturer with the knowledge and information required to plan and successfully implement the automation solution.

Any company wishing to make use of the free automation review should contact Grant Collier on Tel 0208 773 8111 or E-mail grant.collier@ppma.co.uk or visit the website www.automating manufacturing.-co.uk. J

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

39

I ROBOTICS & AUTOMATION

Pacepacker’s Multi-tasking Blu-Robot Takes Centre Stage at New Fresh Produce Plant obot systems integrator and FANUC R strategic partner, Pacepacker has installed a packing solution, which includes a versatile robot that can easily switch between bag and box palletising, at Preva Produce’s new highly efficient multi-million pound premium potato packing plant in Snetterton in Norfolk, England. Potato grower Preva Produce, which farms 700 acres and packs 15,000 tons of salad potatoes per annum, built the new plant to address its capacity and quality needs.

The recent turnkey installation designed

by Pacepacker, which bags and palletises salad potatoes in 10-25 kg sacks for the wholesale food market, includes a C21 sack placer which places up to 10 sacks per minute onto a filling spout, a Total Bag Control (TBC) sack closing system which supports and guides a bag throughout the closing process, and a pre-owned BluRobot which is capable of palletising either boxes or bags of potatoes at the new site.

The Blu-Robot has been fitted with suction cups as well as gripper arms so that it can easily switch between stacking sacks and boxes dependant on the product option selected from a pre-programmed list of recipes. “Within our budget constraints, we wanted a versatile robotic palletising system that would sit between a bagging line and a box packing line, which with little human intervention, would quickly switch between the two types of packing style dependent on current market demands,” explains Ian Anderson, managing director of Preva Produce. “At half the cost of a new system, Pacepacker’s preowned Blu-Robot provided us with an affordable solution; we should see a return on our investment in just over three years.”

Pacepacker's weighing, bagging and palletising line at potato grower and packer Preva Produce.

Pacepacker's Blu-Robot is a versatile and economical robotic palletising system.

The Blu-Robot, which typically incorporates a high quality ABB robotic arm originating from the automotive industry and is approximately 35% of the way through its expected 100,000 operational hour lifespan, has been successfully installed by numerous seasonal fresh produce packers.

Pick and Place Strategic Partnership With FANUC Leading robotics manufacturer FANUC recently extended its strategic partnership with Pacepacker to include pick and place systems for primary and secondary products

including confectionery. The two companies have a long standing relationship, which began in 1997, when FANUC first appointed Pacepacker as its strategic partner in the field of robotic palletising.

The move enhances Pacepacker’s current pick and place equipment offering, which includes a range of DeltaPac pick and place machines and mechanical bespoke pick and place systems, as it enables the company to provide a complete range of solutions, both mechanical and robotic, pre-owned or new, for any type of confectionary application.

“Operating as FANUC’s strategic partner for pick and place systems, we can select from over 30 robots to suit all budgets and individual project needs dependent on the speed, payload and reach requirements for both primary and secondary product packing,” says Paul Wilkinson, Pacepacker’s business development manager. “With our ‘try before you buy’ facility where customers can run tests of their products to derisk the procurement and equipment selection process, there’s never been a better time to look at automation projects.” For further information visit www.pacepacker. com. J

New Fast Stacking Robots From KUKA peed and accuracy are the hallmarks of a new range of KUKA S palletising robots, which are specially designed for use in the food processing and logistics industries. The new palletising robots, part of KUKA’s new QUANTEC series, not only offer a choice of payloads of 120, 180 and 240 kg, but also have a reach of 3,200 mm. They can achieve fast stacking times meticulously thanks to a new compact design and use of lighter components.

In addition, the robot arm features a hollow wrist with a 60mm aperture so that all common types of dress packages can be safely routed within the arm’s casing. The hollow wrist design also allows easy access for quick changeovers, making offline programming much simpler and prolonging the service life of the dress package.

“These new QUANTEC models successfully address the major challenge of delivering a rapid, robotic palletising operation without compromising on accuracy,” explains Ian Walker, general sales manager at KUKA Robotics UK. “They are designed to boost productivity and transform cumbersome, time-consuming tasks into nimble, high-performance processes.”

As well as the new palletising robot range, KUKA Robotics UK is also unveiling other products such as the new KR C4 all-in-one system, which integrates robot, motion, sequence and process control, and its touch screen smartPAD operator panel. J FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

43

I EXHIBITION

Foodex 2012 – March 25-27 – The UK Show For Processing, Packaging and Logistics Live Events Foodex Live offers insight, advice and expertise, including lively debates, plenary sessions and interactive master classes - all featuring the latest news and trends from around the industry. Developed specifically to meet the needs of food and drink producers, manufacturers and retailers, the theatre hosts leading speakers from across all sectors of the indus-

rom 25-27 March 2012, Foodex will F open its doors once again at the NEC in Birmingham. Bigger and better than ever before, Foodex 2012 will incorporate dedicated elements of bakery and logistics, making it the only event truly covering the entire food and drink supply chain.

Foodex works closely with highly respected trade associations across all markets to create a show which offers unmissable content and a valuable, time-efficient experience for all visitors.

Foodex 2012 covers every area of the food and drink supply chain including: * Bakery * Beverage * Dairy * Fresh * Ingredients * Logistics * Meat * Seafood.

Bakery@Foodex showcases the latest innovations, products and services from more than 190 exhibitors operating in the sector. It not only attracts established suppliers but also smaller scale businesses looking for one of the best-attended events to introduce their new products into the industry. A complementary live events programme runs alongside the exhibitor offering.

Foodex will showcase more than 110 exhibitors operating in the beverage sector.

From water and soft drinks to nsbonded warehousing solutions, Beverage@Foodex attracts some of the biggest players in the industry promoting the latest products and services.

The dairy supply chain will be well represented at Foodex 2012, with a wide variety of new and innovative products

on show.

Supported by the Fresh Produce Consortium, Fresh@Foodex will showcase a wide variety of products and services to meet the unique needs of the fresh produce sector.

From functional ingredients to herbs and spices, the latest innovations will be on show in Ingredients@Foodex.

Logistics@Foodex will provide visitors with everything they need to improve efficiency and cut costs in their supply chains.

The meat processing industry remains at the heart of Foodex with more than 170 exhibitors showcasing products and services from across the sector. A full pro-

gramme of competitions, demonstrations and masterclasses runs alongside the exhibitor offerings. Coinciding with National Butchers’ Week, Foodex attracts established suppliers as well as smaller scale businesses looking for one of the most popular events to introduce their products into the industry.

Seafood@Foodex will showcase a wide range of produts and services.

Foodex is co-located with a number of other key trade shows including Food & Drink Expo featuring Farmshop & Deli, National Convenience Show and the Forecourt & Fuel Equipment Show, to provide you with a highly time-efficient visit.

try, including Campden BRI, The National Association of Master Bakers, The National Federation of Meat and Food Traders, British Soft Drinks Association and The Anaerobic Digestion & Biogas Association.

Industry Competitions at Foodex include The National Meat Product Competition brought to you by the NFMFT and the Q Guild of Butchers’ Ready Steady Cut competition. Product competitions for both butchers and bakers will take place as well as master classes and business briefings covering both the latest trends and techniques as well as legislation and best practice.

The British Society of Bakers (BSB) Foodex Exhibition Dinner will bring together exhibitors and visitors from all aspects of the baking and general food industry on the second night of the Show, Monday 26th March.

The 2012 Meat & Poultry Processing Awards will be announced at a glittering awards ceremony on Monday 26th March 2012 at the National Motorcycle Museum, Birmingham. J

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

45

I FOODEX PREVIEW

Dedicated Divisions the Focus For Interfood at Foodex nterfood Technology will be introducing Icessing a number of new developments in proequipment and ingredients at Foodex 2012, with the latest technological advances from many of the world’s leading manufacturers. Exhibiting on stand P291 in Hall 19, Interfood has the largest stand at the biennial food and meat processing exhibition and will have a wide range of equipment on show. From functional ingredients through to slicing, Interfood will have products from each of its six dedicated divisions: Ingredients & Product Development, Fresh Meat Slicing/Portioning, Preparation, Curing to Clipping, Cooking & Cooling/Pasteurisation, and Slicing.

Mark Bishop, Group Joint Managing Director of Interfood, comments: “Foodex is one of the most important dates in the food processing calendar and we see it as a prime opportunity for both existing and potential customers to see technology that can make a real difference to their busi-

ness. However, we appreciate that the equipment is only half the story so we will have on hand our experts from all areas in which we operate to ensure the visitor makes the most of their time on our stand.

Plus we’ll have details of all the services that we have to offer to ensure a customer maximises the potential of their investment.”

This will be the first showing for a number of manufacturers for whom Interfood has become the sole representative in the UK and Ireland since the last Foodex two years ago. This includes Carnitech (meat grinding and mixing), K&G Wetter (bowl cutters, mixers and grinders), Pujolas (automatic whole muscle stuffing), and Henneken (vacuum tumbling).

Jim Sydenham, Interfood’s other Group Joint Managing Director, says: “We are continually working with our customers to find even better processing solutions, which means we have complemented our range in line with customer requirements.

Interfood Technology will be introducing a number of new developments in processing equipment and ingredients on stand P291 in Hall 19 at Foodex 2012 (25-27 March 2012, NEC, Birmingham).

Recognising the breadth of areas that we now operate in, we established the six divisions to ensure that we provide dedicated and focused expertise in each of those areas. This is the first Foodex since we introduced the divisions and we are looking forward to what I’m sure will be a busy three days at the NEC.” Ë

Interfood Launches New Website ood equipment and ingredients specialF ist Interfood Technology has launched a new website which not only offers information on the company’s wide range of products and services, but also provides the latest news from the meat and food processing industry.

The new site - www.interfoodtechnology.com - is a significant step forward from Interfood’s previous site and illustrates the development of the company into one of the major suppliers to the UK and Ireland

Interfood Technology has launched a new website - www.interfoodtechnology.com.

46

food industry. Jim Sydenham, Group Joint Managing Director of Interfood, comments: “We have made a number of changes to the business as we have grown and we realised that our existing website was no longer really a true representation.

A good example of this is that we set up specific divisions to deal with the different areas of the food production process in which we now operate. This was key to the brief for the new website and we feel that the design, with its colour coding for the six divisions which now make up the Interfood Group, enables visitors to find the information they are looking for much easier.”

To further aid the ease of navigation, searches can be made using three different criteria: by brand, by process or by keyword, with a Process Flow menu also a central feature to enable a quick drill down into a specific process. News feeds are included on the home page to encourage visitors to return to the site on a regular basis.

Mark Bishop, Interfood’s other Group Joint Managing Director, says of the website: “We have built it over a number of FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

months to ensure that it does exactly what we set out to achieve. It is not simply a spring-clean of our existing site but a complete rethink of how we position ourselves on the web. Naturally it is a shop window for our own equipment, ingredients and services but we think it is also a useful resource for other information too, with the news feeds as well as features such as a dedicated section for upcoming industry events.”

Like many businesses, Interfood is increasingly communicating with customers electronically. Visitors can sign up to receive regular communications on company developments, download the latest brochures directly from the site or see what Interfood customers think through various testimonials from leading food processors.

The website includes a user-friendly contact form, allowing the site visitor to specify the nature of their enquiry based on a simple ‘tick box’ based menu, from the request for an engineer callout to details of Interfood’s finance packages.

The site is available on www.interfoodtechnology.com. J

Faerch Plast Packaging Helps to Keep Chantenay Carrot Snacks Fresh For Lunchboxes pecialist manufacturer of qualS ity plastic packaging for the food industry, Faerch Plast is supplying a four-compartment tray to fresh produce company, Fresh Growers, for its new Chantenay Carrot Snack Packs. Produced from APET (Amorphous Polyethylene Terephthalate) with 50% recycled content and perforated to allow each of the four compartments to be separated and popped into a lunch box, the containers are currently on sale in the fresh produce section of Morrison’s supermarkets.

Comments Alan Hunt, commercial manager at Freshgro, a growers’ co-operative based near Nottingham: “We were looking for a new concept to provide a top quality alternative to baton carrots. A sample punnet produced by Færch Plast was just what we needed for the packaging.”

The snack packs of Chantenay carrots are available in two designs, one for children featuring cartoon character, Tiny C, and one for adults, with each of the four

snacks, and ambient food sectors with a wide range of containers and trays produced from PS, CPET, APET, PP, PLA, MAPET® and AMPET®.

Danish parent company Faerch Plast has just announced plans to open a state-of-the-art manufacturing facility in the North East of England. A large part of its production for the UK market will be moved to the new Durham-based plant as part of an on-going strategy to secure costs, improve efficiencies and minimise its environmental snap packs containing 60gms of sweet, sliced carrots.

The packs are currently filled by hand with the lids sealed on a PA automation machine, but as the product develops there are plans to fully automate the process.

Since it was established in 1989, Faerch Plast has built an excellent reputation for high quality plastics packaging products, supplying major blue chip customers in the ready meal, fresh meat, cold foods and

impact.

The company has acquired 14,000 square metres of factory buildings with a view to starting production in the summer of 2012. This key move will help improve operating efficiencies, shorten lead times and further strengthen the overall service provided to its rapidly expanding UK customer base. For further information contact Faerch Plast on Tel +44 (0)20 8254 2300 or visit www.faerchplast.co.uk. J

UPM Celebrates 35 Years at NPE PM claims to be the longest servU ing supplier of ancillary equipment to the world’s plastic industry having participated in the NPE show for the past 35 years. The emphasis this year is on exhibiting Dynacon Belt Conveyors at booth 1873 with Dynamic Conveyor highlighting the modular conveyor system that lengthens; shortens; adapts and changes as your need requires.

UPM has a global agreement with Global Closure Systems (GCS), which incorporates Zeller Plastik, Massmould and UCP, who have taken delivery of their 700th Dynacon Belt Conveyor in the UK, based on the versatility available from using standard bolt together injection moulded filled polycarbonate compo-

nents to allow any shape to be produced in any configuration plus zero maintenance as the belt is guided in channels either side eliminating the need to track or tension.

UPM Conveyors has extended the Dynacon principle to their own Syscon range, which is machined from High Molecular Weight Polyethylene (HMWPE) and for which UPM was awarded the Queens Award for Innovation, being FDA approved for food contact and high care/hygiene applications plus being robust for heavy duty systems. UPM has inhouse facilities for all aspects of manufacture including programming and control build allowing complete control of quality/inspection and maintaining delivery promises. J FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012

47

New Range of Gerkens Cocoa Powders From Cargill he new Dutch Dark cocoa powders T range is one of the results of a substantial investment by Cargill’s cocoa & choco-

um dark colour, which is particularly suited for use in luxurious desserts and ice cream.

The smooth taste of Dutch Dark powders also means there is no need to use sugar to mask the bitterness that can be associated with dark powders, which is a great benefit for those wishing to develop recipes with less sugar.

The investment to develop the company’s Wormer facility has been part of the Dutch Dark innovation story. “The investment includes the creation of new laboratory facilities, which will further strengthen our innovation capabilities,” explains Harold Poelma, managing director of cocoa, Cargill Cocoa & Chocolate. These new laboratory facilities consist of a microbiological and technical lab dedicated to product and quality control, and an application lab to provide product development and recipe formulation expertise for customers.

Cargill’s expert taste panel has also been expanded to focus on cocoa liquor and powder, and is constantly looking to optimise products and processes and encourage innovation. “The result of all these efforts will be a great new Centre of Expertise for cocoa,” he adds.

The launch of the Dutch Dark range comes alongside a large increase in butter and powder production capacity at the Wormer plant. Further development of Dutch Dark powders is planned, which will expand the availability of Cargill’s premium

late business in its Wormer facility in the Netherlands – home of the renowned Gerkens® cocoa powders.

The Dutch Dark range of powders combines an intense dark colour with a smooth chocolaty taste and is available in a variety of high and low fat versions. The range provides a real opportunity to innovate and

The Dutch Dark range of powders combines an intense dark colour with a smooth chocolaty taste and is available in a variety of high and low fat versions.

develop new recipes in different applications. An example of the range is high fat Gerkens® Holland DS150 with a premi-

The launch of the Dutch Dark range comes alongside a large increase in butter and powder production capacity at the Wormer plant.

Gerkens® powder range for customers.

Cargill Cocoa & Chocolate offers the food industry a wide range of both standard and customised cocoa and chocolate ingredients to be used in bakery, confectionery, and dairy applications all over the world. For more information visit: www.cargillcocoachocolate.com. J

New Natural Red Colour Line For Fruit Preparation ycoRed of Israel has launched a new range L of natural, vegetarian red and orange colors with non-migrating properties for fruit preparation. The new line is based on both tomato lycopene and natural beta-carotene and covers a full- spectrum of color possibilities ranging from red to yellow. The colors are extracted from carotenoids, which are widely recognized as healthful alternatives to synthetic colorants due to their natural antioxidants benefits.

Many popular dairy products contain colored fruit-based layers or stripes. For these formulations, it is critical that the colorful appearance of the fruit preparation base remains stable and does not bleed color into the white dairy phase. Colored fruit preparation using LycoRed's colors can create appealing color effects in yoghurts, smoothies and desserts.

“Stability during processing and throughout 48

shelflife is one of the main issues the food industry faces when using natural colors,” explains Roee Nir, Color and Flavor Global Commercial Manager for LycoRed. “Formulation challenges can relate to: stability to pH, light, temperature and oxidative degradation, as well as to interactions with other ingredients. LycoRed has overcome these problems to produce natural carotenoids

based formulations delivering vibrant, stable natural food colors. The colors are created using a patented technology that is fully compliant with kosher and halal laws.”

Tomat-O-Red formulations are based on tomato lycopene and offer a completely stable, natural color, with processing parameters of prolonged high temperature, light exposure and pH and with no adverse reaction to Vitamin C, making it an ideal colorant for red fruit preparations.

Lyc-O-Beta formulations from Natural Beta Carotene are produced by the same patented technology applied to tomato lycopene. The line provides complementary orange to yellow shades to support a full range of fruit preparations used in the dairy industry.

For more information contact: Karina Bedrack, Sales Manager, at info@lycored.com or visit www.lycored. com. J

FOOD & DRINK BUSINESS EUROPE, FEBRUARY 2012