May 2013
Haribo and the bear essentials
Food & Drink Business Website:
www.fdbusiness.com
C o n t e n t s
- 46 E XHIBITION
- 2 M ERGERS & A CQUISITIONS
UK’s largest processing and packaging exhibition.
Coverage of British and international deals.
P AGE 13
- 7 C OVER S TORY Haribo and the bear essentials.
Martin Thatcher, MD, Thatchers Cider Company.
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Hans Christensen, VP, Arla Foods.
R EGULARS Processing & Manufacturing. . . . . . . 16 & 20
- 13 B EER & C IDER Materials & Ingredients . . . . . . . . . . . . 28-33
Over £220 million capital investment in UK brewing and cider production.
Salt & Sodium Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-33
Bottling & Packaging. . . . . . . . . . . . . . 34-43
- 17 F RUIT & V EGETABLES Green growth at Ardo
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Simon Cox, MD, Molson Coors UK & Ireland.
MAP & Tray Sealing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Active & Intelligent Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-43
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Age Korsvold, CEO, Orkla.
Quality & Safety . . . . . . . . . . . . . . . . . 43-45 Food Inspection & Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PAGE 16 Energy & Environment . . . . . . . . . . . . . . . 48
- 21 S AVOURY S NACKS
Spotlight on AD in food and drink industry
David Forde, MD, Heineken UK.
Bagging KP strengthens Intersnack Group. Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade Advertising: Susan Doyle and Sylvia McCarthy . Senior Sales Executive: Paul Lees
- 22-26 G UIDE TO IT Success Story - Symington's takes a bite out of inefficiencies with Infor.
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Dr Hans Riegel, CEO, Haribo.
Production Manager: Susan Doyle
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Domino’s Pizza Group streamlines stock selection process. BT takes Friogan into the cloud. Exact and Preactor form strategic alliance. PAGE 13
Fulfil UK becomes new Sanderson customer.
James Watt, cofounder, BrewDog.
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FOOD & DRINK BUSINESS EUROPE, MAY 2013
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M E E R R G G E E R R S S M
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A C C Q Q U U II S S II T T II O O N N S S A
Gerber Emig and Refresco to Merge
Danone Expands in US Baby Food Market
Acquisition to Further Arla’s Russian Ambitions
Gerber Emig and Refresco have agreed to merge to create a leading pan-European bottler of soft drinks and fruit juices to serve retail and branded customers. Gerber Emig is a significant European bottling company with focus on juice and juice drinks. Tracing its history back to 1919, the company’s private label production is complemented by contract manufacturing for branded players. The company has volumes of about 1.5 billion litres and revenue of Eur801 million. Gerber Emig operates production plants in the UK, France, Germany and Poland. It is headquartered in Bridgwater, UK and employs about 1,700 people. Founded in 2000, Refresco is a leading European bottler of soft drinks and fruit juices for retailers and branded players with production in the Benelux, France, Germany, Iberia, Italy, the UK, Poland, and Finland. The company has volumes of about 5 billion litres and revenue of Eur1.5 billion. Refresco offers an extensive range of product and packaging combinations from 100% fruit juices to carbonated soft drinks and mineral waters in carton, PET, Aseptic PET, cans, pouches, and glass. It is headquartered in Rotterdam, the Netherlands and employs about 3,000 peope. The transaction is subject to the approval of competition authorities and is expected to be completed before the end of summer 2013. Until completion of the transaction, both companies will continue to operate independently. Integration into one corporate structure will begin following the close of the transaction.
Danone is acquiring an equity stake of over 90% in Happy Family, the fourth largest contender in the US baby food market, for an undisclosed price. Launched in 2006, Happy Family is one of the most innovative and dynamic companies in the US baby food sector, where it holds over 4% of the market. Its gross sales total more than $60 million and strong growth is expected in 2013. The transaction is subject to the approval of the relevant authorities and is expected to be finalised in the next few months. Baby nutrition is one of Danone’s four business sectors. The others are fresh dairy products, waters, and medical nutrition.
After more than five successful years in Russia, Arla has purchased the last 25% of Arla Foods Artis, the joint venture that controls its Russian activities. The former owner, Mike Lyasko, will continue to head Arla's activities in the Russian market. The acquisition makes the Russian company a whollyowned Arla subsidiary. Russia is one of Arla's three strategic growth markets, and will be delivering a significant share of the company's growth up to 2017. The goal is a threefold increase in revenue from today's level of approximately DKr600 million (Eur80.5 million). “The acquisition of the last 25% cements our ambitions in Russia. Under the agreement from 2007, we have always had the option to acquire the remaining holding, and in view of our success in the Russian market, and our ambitions in our Strategy 2017, both parties considered this to be the right
ated revenue of Eur600.2 million and adjusted EBITDA of Eur84.4 million. R&R Ice Cream was created in 2006 following the merger of UK-based Richmond Ice Cream with German ice cream manufacturer Roncadin. R&R Ice Cream has expanded through a series of strategic acquisitions, the most recent being the purchase of Fredericks, the third largest branded ice cream manufacturer in the UK, for £49.0 million.
GlaxoSmithKline to Sell Lucozade and Ribena Brands
PAI Partners to Acquire R&R Ice Cream R&R Ice Cream, the second largest take-home ice cream manufacturer in Europe, is being acquired by private equity group PAI Partners from Oaktree Capital for Eur460 million plus the assumption of debt. R&R Ice Cream operates 11 plants located in five countries in Europe, including the four largest ice cream markets in Europe. Holding leading positions in the UK, German, French and Italian ice cream markets, R&R Ice Cream offers a broad product range of private label and branded ice cream products. It primarily produces take-home ice cream products, including ice cream tubs and multi-packs of ice cream cones, ice lollies, ice cream sticks and ice cream desserts, and impulse products. For the year ended December 31, 2012, R&R Ice Cream gener-
UK-based global pharmaceutical and healthcare group GlaxoSmithKline has decided to dispose of its Lucozade glucose energy and sports drinks, and Ribena fruit juice-based drinks brands. The two brands are part of GSK’s Nutrition business which is incorporated within the Hans Christensen, senior vice president in group’s Consumer consumer international, Arla Foods. Healthcare division. The disposal is part of GSK’s time,” says Hans Christensen, efforts to reshape its business, senior vice president in conimprove strategic focus and sumer international with enhance its growth profile. responsibility for Russia and GSK’s Nutrition sales grew North America. 6% to £280 million in the first Arla's consumer product quarter. The category perfor- strategy in Russia is to build mance was driven by strong strong market positions for growth of the Horlicks brand in high-quality products within India (up 16%) and the Boost the butter and cheese categories, energy drink (up 23%). Ribena and to investigate opportunities sales grew 2% but Lucozade was to produce locally via partnerdown 2%. ships or acquisitions. Arla supplies products directly to customers in 95 different towns.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
North American Gluten Free Business Moves into UK Boulder Brands, a leading USbased global health-and-wellness company, has acquired one of the UK’s top gluten free baking
N N E E W W S S businesses, Cheshire-based Davies Bakery, from Frank Roberts & Sons for an undisclosed sum. The deal combines a leading UK gluten free bakery operation with a proven North American brand and is a major boost for driving growth and investment into the gluten free category, which is estimated to be worth in excess of £310 million. Boulder Brands will establish a subsidiary company in the UK, Boulder Brands UK, and will look to introduce its hugely successful Udi’s Gluten Free Foods brand later on in the year. In North America, Udi’s transformed the category by making food that tastes no different than conventional glutenfilled products. Davies Bakery has built up a reputation, over five generations, for producing high quality and innovative product. The deal will see the manufacture and distribution of more than 50 Udi’s products throughout the UK.
Hain Celestial Acquires Ella’s Kitchen The Hain Celestial Group, the US-based leading natural and organic products company, has acquired Ella's Kitchen and formed the Global Infant, Toddler & Kids Division. Ella's Kitchen is a manufacturer and distributor of premium organic baby food under the Ella's Kitchen brand and the first company to offer baby food in convenient flexible pouches. Ella's Kitchen offers a range of 80 branded organic baby food products principally in the United Kingdom, the United States and Scandinavia. UK-based Ella's Kitchen generated approximately $70 million in sales in calendar year 2012 and is expected to be accretive to Hain Celestial's earnings in fiscal year 2014. Details of the transaction were not disclosed. Paul Lindley, founder of Ella's Kitchen, will become chief executive of the new Global Infant, Toddler & Kids Division at Hain Celestial US, with responsibility for Hain Celestial's
Earth's Best brand as well as the newly acquired Ella's Kitchen brand.
Cott Expands UK Presence With Calypso Acquisition Cott Corporation is extending its UK and European business with the acquisition of Calypso Soft Drinks, including Mr Freeze (Europe), for an undisclosed price. Calypso Soft Drinks is a privately owned soft drinks and freezable business based at Wrexham in the UK. Calypso Soft Drinks, with revenues of approximately US$50 million (£38 million), has a strong presence in the food service channel (which includes schools) with an extensive range of branded children’s soft drinks that use its own source of natural mineral water and contain no artificial colours or flavours. Additionally, Calypso Soft Drinks is the UK’s market leader in freezables with its Jubbly, Mr Freeze and other various licensed trademark offerings. Steve Corby, Director of Cott’s UK reporting segment, comments: “The Calypso Soft Drinks acquisition falls within the diversification strategy of the UK reporting segment as it brings new soft drink packaging formats such as single serve Combi cartons, single serve cups and cuplets and two freezable formats into the Cott portfolio. Calypso Soft Drinks has
B B R R II E E F F been highly successful in providing its customers with quality and innovation. We look forward to building on the solid foundation already established.” Completion of the transaction is subject to customary conditions, including clearance from the UK’s Age Korsvold, president and chief executive of Office of Fair Trading Orkla. and is anticipated to Chaka and Bähncke. close in June 2013. “With this acquisition we Canada-based Cott is one of the world’s largest producers of are strengthening our position beverages on behalf of retailers, as the leading Nordic branded consumer goods company for brand owners and distributors. food and beverages. Rieber & Danone Strengthens its Søn has strong brands that are Position in the Water an optimal match for Orkla’s Market in Turkey product portfolio in terms of Danone is acquiring a 50.1% categories, production techinterest in Sirma, one of the nology and geography,” says leading players in the Turkish Orkla president and chief water market. Ranked 11th executive Age Korsvold. worldwide in volume, Rieber & Son has a number Turkey's bottled water market of well-known brands and grew by 20% in value in 2012. businesses. Toro is Norway’s leading supplier of sauces, soups and ready meals, among other things. Other popular Norwegian brands are Denja, Mr Lee, Vossafar and Vestlandslefsa. Vitana is one of the Czech Republic’s largest and longest-established food manufacturers. K-Salat is well-positioned in both Sweden and Denmark in the With reported sales of near- mayonnaise, remoulade and ly Eur100 million, Sirma is salad markets. Delecta is one active in plain and flavoured of Poland’s leading dessert bottled waters, and in HOD and baking mix brands. (Home & Office Delivery). Frodinge is market leader for Sirma is one of the market's refrigerated and frozen cakes fastest-moving brands. The and desserts in Sweden. deal is subject to the approval Chaka is a well-known of the competent authorities, Russian brand of nuts. and is expected to be complet- Bähncke holds the leading ed before the end of 2013. position in the Danish mustard market. In addition, Orkla’s Acquisition of Rieber & Søn is a supplier to Rieber & Son the out-of-home sector in Approved Norway, Sweden, Denmark, The Norwegian Compet- the Czech Republic and ition Authority has app- Slovakia. roved Orkla’s NOK6.1 Rieber & Son had total sales billion (Eur800 million) of NOK 4.16 billion in 2012, purchase of Rieber & Son. of which 70% were generated The deal gives Orkla own- in the Nordic region. The ership of such well-known group has around 2,600 brands as Toro, Vitana, K- employees, of whom 1,600 Salat, Delecta, Frodinge, work outside Norway.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
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COVER STORY
Haribo and the Bear Essentials To meet increasing demand for its world famous sugar confectionery, Haribo is planning new production and distribution sites in the UK and Germany.
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riginating from a small laundry kitchen Haribo has successfully adapted its products in a suburb of Bonn in 1920, Haribo to cater for individual market preferences. For has developed into one of the world’s example, French consumers prefer marshmallargest confectionery manufacturers low products such as ‘Tagada’ or ‘Chamallows’ with annual sales in the region of €2 billion. and sugar-coated candies like ‘Dragibus’. In Specialising in fruit gum products made with England, ‘Star Mix’ is the top seller among natural colours and fruit and plant extracts, the young and old alike, while in the Scandinavian group currently operates 16 factories across countries ‘Matador Mix’, a mixture of fruit Europe, employs 6,000 people and exports to flavoured gum drops and liquorice, is the most more than 100 countries. The product range popular. encompasses many flavours including cola, berries, liquorice and tropical fruits. UK Business Haribo was founded by entrepreneurial conHaribo is the UK’s number one gums and jelfectioner Hans Riegel, who invented the ‘danclies brand and has enjoyed double-digit sales ing bear’ – a little bear made out of fruit gum, growth year-on-year for the past five years. which would later become known globally as Within the overall UK sugar confectionery catthe Haribo Gold Bears. egory Haribo is the second largest brand. The Indeed, the name Haribo is derived from the company currently employs more than 500 first two letters of the founder’s first name and people in the UK and has a turnover of over surname and his home town (Hans Riegel of Dr Hans Riegel, head of Haribo. £120 million. Bonn). Haribo is still family-owned and is now Indeed, Haribo UK is one of the most headed by the founder’s son, Dr Hans Riegel, who owns 50% of the important und successful subsidiaries of the Haribo group. Haribo business and is in charge of marketing. The remainder of the company moved into the UK in 1972 by buying a stake in Dunhills, a tradiis owned by his late brother Paul’s sons - Hans Guido Riegel is head tional English company well known for the regional specialty of production and technical, while Hans Juergen Riegel and Hans ‘Pontefract Cakes’. In 1994, Haribo acquired the remaining shares Arndt Riegel are members of the supervisory board of the company. and established the Haribo brand within the UK. Haribo has successfully introduced new recipes into the UK, as well International Development as gelatine manufacturing technology from Germany, which greatly Haribo has expanded domestically and internationally by developing improved the quality of the products available. Furthermore, the comproducts which appeal pany also pioneered the use of PVC drums in the UK. to both to children Haribo’s product and packaging innovation has reinvigorated the and adults, and which entire gums and jellies category in the UK. Haribo has focused on suit local and regional developing the appeal of gums and jellies amongst children, launching tastes. This has been novelty shapes in drums to be sold as single pieces and introducing a achieved through range of Haribo branded bag ‘mixes’ containing a selection of novelty organic growth and by shapes. acquisition of compleHaribo’s continual investment in bagged confectionery has also mentary brands and resulted in Starmix becoming a massive brand worth more than £30 businesses. million in the UK. Starmix, Tangfastics and Super Mix are now the Two major acquisi- three top selling tions involved the pur- Haribo UK products. chase of Maoam in Germany in 1986 and New Production Dunhills in the UK, a Facility deal completed in To satisfy growing 1994. The Maoam demand for its prodbrand of sweets has ucts, Haribo is planbeen the best-selling ning a second producchewy candy brand in tion site in the UK at Germany for many Normanton, near LeeHaribo was founded by Hans Riegel, who invented years, and through ds. The sugar confecthe ‘dancing bear’ – a little bear made out of fruit Dunhills Haribo has tionery manufacturer Haribo has developed into one of the world’s gum, which would later become known globally as become a market purchased the 46 acre largest confectionery manufacturers with annual the Haribo Gold Bears. leader in the UK. site in Normanton for sales in the region of €2 billion. FOOD & DRINK BUSINESS EUROPE, MAY 2013
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£6 million in 2011 for the construction of a new 46,452 sq m purpose built production and distribution centre. Haribo received a grant from the Regional Development Agency in April 2011 towards funding the new factory, which is expected to employ 300 people in addition to the 500 people already employed at Pontefract. Plans have been submitted and agreed for the development of the new site at NormanHaribo currently operates 16 factories across ton. The tender procEurope, employs 6,000 people and exports to ess for the construcmore than 100 countries. tion and build of the new facility is ongoing. Announcements will be made in due course, once suppliers have been chosen. The additional plant will allow the brand to increase capacity in order to meet with continued UK demand for Haribo sweets. The new facility will produce Haribo’s full range of products. It will also provide potential for export and further expansion. The development project is located less than five miles from Haribo’s existing manufacturing site at Pontefract, which will continue to run alongside the new factory. According to Haribo, its UK business has seen double digit growth over the last five years and this increasing demand will be met by the new production facility.
ing ranges and seasonal lines have been introduced into the market over recent years, providing the consumer with more choice and treats to suit a variety of consumption occasions and price points. This variety means that Haribo can be enjoyed as an impulse purchase, as a gift, or shared and enjoyed with friends during a big night in occasion. Haribo is also starting to see popular children’s countline or pick and mix items, Haribo’s continual investment in bagged which were usually confectionery has resulted in Starmix becoming a found in local inde- massive brand worth more than £30 million in the pendent stores, UK. migrate to their own bags to fit with the consumption habits of an older consumer profile. For example, Haribo launched its Favourites range in 2012, which saw popular countlines, such as Giant Strawbs, enter the bagged market.
Market Trends Haribo’s success in the UK is based on a strong brand which offers great tasting, affordable, quality treats. Haribo is benefiting from the current trends within the UK sugar confectionery market. The gums and jellies category has continued to grow ahead of the overall market for the past few years due to new products, packaging formats and seasonal offers all designed to offer consumers good value for money. According to the German confectionery giant, there is a definite trend towards softer eating confectionery such as gums and jellies like Haribo. This is evident through the growth of these sectors and also through the decline in certain types of other confectionery such as hard boiled sweets and toffee. Recent consumer trends also show that consumers often acquire their taste for confectionery at a young age and carry it through their life stages, which also plays to Haribo’s strength of appealing to both children and adults,
Licensing Haribo is also successfully using licensed products to grow sales. In addition to driving innovation, licences can help to keep a brand front of mind – especially within the confectionery category. Furthermore, licences can bring new consumers into the sector, especially those who would not previously have considered purchasing confectionery. They also generate excitement within the category and with consumers, especially when brands support the licence agreement with through the line activity such as competitions and giveaways. For instance, Haribo has exclusivity for Smurfs within confectionery. Haribo Smurfs will become widely available ahead of the Smurfs 2 movie, which is scheduled for release Haribo has exclusivity for Smurfs within this summer. Haribo continues to confectionery. invest in a full and integrated marketing strategy which allows the brand to hit all consumer touch points, this is managed through sampling, PR, TV and radio advertising, as well as online and digital marketing activities.
Product Innovation Innovations in product, packaging and marketing have allowed Haribo to maintain its UK market leadership. A full range of pack formats, gift-
Performing Well The Haribo success in the UK has also been replicated in many of the German confectionery group’s other markets. Despite rising raw materials costs and continued weak consumer sentiment in many countries, the Haribo group is performing well with double-digit growth rates in multiple international markets. Indeed, Haribo intends buying a new property in Germany by the end of 2013 in order to further expand production and logistics. J
Haribo launched its Favourites range in 2012, which saw popular countlines, such as Giant Strawbs, enter the bagged market.
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FOOD & DRINK BUSINESS EUROPE, MAY 2013
I BEER & CIDER
Over £220 Million Capital Investment in UK Brewing and Cider Production Capital investment projects valued at over £220 million have been either completed or sanctioned by 20 companies operating across the UK brewing and cider industry during the past 18 months. he companies range in scale from major multinational brewers such as Heineken, Carlsberg and Molson Coors to regional brewers like Marston’s and Hall & Woodhouse, to craft breweries including BrewDog, Wye Valley Brewery and Purity Brewing Company. The UK’s top three cider producers – Bulmer (Heineken UK), C&C Group and Aston Manor Cider Company – are also investing in upgrading their production facilities to meet rising consumer demand and intensifying competition, following the entry of Carlsberg UK, Anheuser-Busch InBev and Molson Coors UK & Ireland into the cider market.
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James Watt, co-founder of BrewDog.
efficiency and reduce costs. The UK’s fourth largest brewer, Carlsberg UK, has increased the capacity and flexibility of its brewery in Northampton following a £60 million development programme, which culminated in the recent opening of a new £20 million bottling plant. The Northamton brewery has been expanded to a capacity of almost 7 million hectoliters to accommodate increased production following the closure of Carlsberg’s second UK brewery site in Leeds. Regional Brewery Investment A number of regional brewers and pub operators have also been investing in mod-
ernising their production facilities. Hall & Woodhouse, the Dorset-based brewer which operates in the south west of England, recently completed the construction of a new £5 million brewery for the production of its range of beer brands including Badgers. Robinsons, the UK’s largest independent family brewer, with 340 pubs across the North West and Wales, spent £12 million on expanding its brewery in 2012/13. The Stockport-based company, which includes brands such as Old Tom and Unicorn in its portfolio, is currently celebrating its 175th anniversary. Meanwhile, Marston’s is planning to install a new £5 million bottling plant, capable of 300 bottles/minute, at its Burton on Trent brewery. Massive Growth in New Breweries Although the overall UK beer market and particularly lager sales are in decline, the craft beer sector is experiencing a renaissance. While the big four national brewers have been rationalising and consolidating their brewing operations in recent years, a host of small craft breweries have sprung up to meet the growing consumer demand for locally produced beer. According to CAMRA’s Good Beer
Martin Thatcher, managing director of Thatchers Cider Company.
Big Brewers The UK’s two largest brewers are spending a combined total of over £100 million in their operations. Molson Coors UK & Ireland is undertaking a £75 million five years investment programme at its UK breweries at Burton on Trent, Alton and Tadcaster. Heineken UK is planning to invest £30 million across a number of its sites including The Royal Brewery in Manchester as part of an ongoing programme to improve
There are currently more than 1,000 breweries operational across the UK - the highest number for over 70 years.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
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large, installing new equipment or doubling production to keep up with demand.” He adds: “Beer drinkers in the present day are faced with an enormous variety and choice like never seen before on these shores.”
Gordon Johncox, managing director of Aston Manor Cider Company.
Guide 2013, there are currently more than 1,000 breweries operational across the UK the highest number for over 70 years. Indeed, a record 158 breweries have opened up in the space of just 12 months - the highest rate of new openings ever recorded in the Guide’s 40 year history. The present number of breweries in the UK is five times more than there were in operation 30 years ago, four times more than there were 20 years ago, and more than double the amount in existence just a decade ago. Roger Protz, Good Beer Guide editor, says: “A double dip recession has done nothing to halt the incredible surge in the number of brewers coming on stream, making the small brewing sector surely one of the most remarkable UK industry success stories of the last decade. In fact, the boom in new breweries has, in many cases, made the term ‘micro’ obsolete, with some small brewers having become remarkably Investment in UK Brewing Company Capital Investment Molson Coors UK & Ireland £75m Heineken UK £30m Carlsberg UK £20m Robinsons £12m BrewDog £11m West Brewing Company £9m Marston’s £5m Hall & Woodhouse £5m Sharp's Brewery £4.5m Tennent Caledonian Breweries £4m Wye Valley Brewery £2m Purity Brewing Co £1.4m Bath Ales £1.1m Truman’s £1m TOTAL £181m
Craft Beer Revolution The upsurge in consumer interest in craft beer is perhaps best exemplified by the dramatic rise of Scottish brewer BrewDog. Founded in 2007 by Martin Dickie and James Watt, BrewDog has grown from brewing 1,050 hectolitres of beer per annum and employing two people to become Scotland’s largest independent brewer, producing 35,500 hectolitres last year with 135 employees. The company almost doubled turnover in 2012 to about £12 million and opened six new BrewDog bars to take the total to ten. Reflecting this rate of growth, BrewDog was named by the Sunday Times Fast Track 100 as the fastest growing food and drink company in the UK. “The economic crisis has been our biggest catalyst for success,” says James Watt. “When times are tough, people see through the thin veneer of corporate adspeak and seek out genuine quality and value. The media say the beer market is in decline – but sales of good beers are going up and up. It is the global monolithic mega corporations peddling lame, tasteless lagers that have their head on the block, and the craft beer revolution is wielding the axe.” Having recently opened its new £8 million brewery at Ellon in Scotland, BrewDog is planning a further £3 million capital investment in response to rising demand for its products. Another small Scottish brewer, Glasgowbased West Brewing Company, is planning to increase capacity by redeveloping part of its operating site at Port Dundas at a cost of £9 million. South of the border, Wye Valley Brewery, a family-owned brewer of bottled and cask beers based in the West Midlands, is investing £2 million at its site at Stoke Lacy, including the building of a new brewhouse. Also in the West Midland, Warwickshire-based Purity Brewing Company has recently completed a £1.4 million capital investment in a new brewhouse.
The multinational brewer intends increasing its market shares in both the UK and Irish craft beer markets and also developing export sales in international markets. Molson Coors UK & Ireland recently completed a £5 million investment programme to expand processing capacity at Sharp’s Brewery to meet increasing consumer demand. Cider Market The UK cider market is maintaining steady growth despite the tough economic environment, having increased sales by 32% over the past five years to reach £2.7 billion in 2012, with sales rising by 5% in the last year alone. This momentum is set to continue in the future as new entrants and product innovation improve the range of ciders available in both the on-trade and off-trade so maintaining consumer interest and excitement in the market. Mintel forecasts that over the next five years the UK cider market will reach sales of £3.7 billion, driven partly by duty increases but also growing user numbers. Having already invested heavily in developing its cider production operations to meet escalating demand, Heineken UK is currently planning a £10 million project to upgrade its bottling operation at its cider plant in Hereford. Heineken became leader of the UK cider market following its acquisition of the British operations of Scottish & Newcastle including the Bulmers business. Second ranked C&C Group, which produces the Magners and Gaymers cider
Simon Cox, managing director of Molson Coors UK & Ireland.
Sharp Move Molson Coors UK & Ireland has moved into the fast growing UK craft beer market through acquisition. Having bought Cornwall-based Sharp’s Brewery including the Doom Bar brand for £20 million in 2011, Molson Coors UK & Ireland has been developing its cask beer portfolio and recently entered the Irish craft beer market with the purchase of the Franciscan Well craft beer brand and microbrewery in Cork City. FOOD & DRINK BUSINESS EUROPE, MAY 2013
Investment in UK Cider Production Company Capital Investment Bulmers (Heineken UK) £10m Aston Manor Cider Company £10m Thatchers Cider Company £8m C&C Group £5m Corinthian Brands £5m The Cornish Scrumpy Co £3m TOTAL £41 million
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I BREWING
The Heart of a Modern Craft Brewery brand new brewhouse system fires the A new BrewDog brewery at Ellon in Scotland. The ROLEC system is especially designed to handle the extraordinary beer types of a modern craft brewery and combines highest efficiency with maximum production flexibility. Similar concepts of the German equipment supplier are already in operation in many of the most successful international craft breweries like in Stone, Brooklyn, Lagunitas, Victory and Meantime Brewing Company. The 4-vessel system creates 100 hl hot wort per brew and is fully automated from raw material inlet until wort cooling. It consists of a mash tun, lauter tun, wort kettle and a separate whirlpool. Depending on the wort gravity this setup produces 6-8 brews per day. A possible expansion with a prerun vessel will speed up the system to 10-12 brews per day in a later stage. To handle the wide gravity ranges of the unique BrewDog recipes a special lautertun brands and has also entered the brewing business following the purchase of Tennent’s, recently completed a £5 million capital investment at its UK cider operations. Meanwhile, Aston Manor Cider Company, the largest independently owned cider producer in the UK and the third largest overall, is planning to invest £10
The upsurge in consumer interest in craft beer is perhaps best exemplified by the dramatic rise of Scottish brewer BrewDog.
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design is applied. The arrangement of piping, raking machine and quality based control allows high extract yields and corresponding malt savings and low production costs. The wort boiling system ROLEC X-Boil allows flexible batch sizes and minimized CIP demand due to a special concept for reduced fouling. The boiling parameters can be flexibly adjusted in the control sysmillion in new plant to increase its production capacity and efficiency. The familyowned Birmingham-based business operates facilities at Tiverton, Devon and the Malvern Hills. The company has already invested £10 million at its Tiverton site to expand production capacity since acquiring it three years ago. “We are committing the necessary resources to build the capability and capacity of Aston Manor and believe we are very well placed to exploit the potential in the cider market at home and abroad,” remarks Gordon Johncox, managing director of Aston Manor Cider Company. The Cornish Scrumpy Company (trading as Healey’s Cornish Cyder Farm) is planning a new £3 million production and packaging facility at its site at Callestick in Cornwall. In addition to cider, the company also produces wine, spirits, fruit juice, jam and preserves. Traditional cider maker Thatchers Cider is expanding its plant at Sandford in Somerset by constructing a new building to house new facilities for kegging, bottling, canning and end-of-line packaging under a £8 million investment project. New Entrants The buoyancy of the UK cider market has attracted the interests of the major international brewers. Carlsberg has moved into FOOD & DRINK BUSINESS EUROPE, MAY 2013
tem and the same equipment can be used both for conventional boiling methods and for modern boiling recipes with reduced total evaporations. This optimizes the thermal energy demand and achieves excellent wort quality at the same time. Strongly hopped and high gravity brews require special treatment in the whirlpool. In addition to a specific dimensioning of the system a special wort outlet piping and a trub removal concept are realized. The raw material handling includes 2 malt silos as well as an inlet for specialty malt in bags. Malt milling is done by a four roller malt mill. The automatic CIP system, the water tank plant and the wort cooling line are all integrated into the main automation system. The applied beraBREW process control system offers state-of-the-art functionality and is especially designed for intuitive and uncomplicated operation. J
David Forde, managing director of Heineken UK.
cider with the launch of its Somersby brand, while Anheuser-Busch InBev has introduced Stella Artois Cidre. Molson Coors UK & Ireland has recently extended its Carling lager brand into the increasingly competitive cider sector. However, smaller companies such as Corinthian Brands, which has developed a facility in Hereford and produces the HCC cider brand, have also entered the fray. J
I FRUIT & VEGETABLES
Green Growth at Ardo European frozen fruit and vegetable specialist Ardo has increased the flexibility of its state-of-the-art UK food processing plant at Charing in Kent. rdo has installed a new bulk packing line that is able to handle up to 400 cases an hour, packing 10kg or 15kg boxes for industrial customers. “We have an ongoing investment programme to ensure we operate as efficiently as possible and are able to meet the needs of our customers,” says Jim Everest, operations director of Ardo UK. “This new bulk packing line complements the work we do for our retail customers and is able to handle any of our frozen fruit and vegetable ranges, whether single products such as British peas or vegetable and fruit mixes.” He continues: “It makes for a more efficient use of space in the factory Each year Ardo grows, freezes and will help us provide a broader fruit, vegetables, pasta and rice. offering to ready meal manufacturers and other industrial customers. The new facility also contributes to our environmental performance as it means product can be brought direct to us for packing rather than via a third party, thus reducing road miles.”
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£15 Million Investment Ardo UK invested £15 million to consolidate its operations onto a single site at Charing, Kent in 2010 with the opening of a new state-of-the art factory and cold store for the freezing and packing of fruit, pasta, rice and vegetables for the retail trade and
Ardo UK invested £15 million to consolidate its operations onto a single site at Charing in 2010 with the opening of a new state-of-the art factory and cold store.
the food service industry. This modern facility is helping the company to meet the increasing demand from consumers for fresh-frozen vegetables and fruit. Market growth is being driven by value for money, good availability and the growing consumer perception of the quality aspects of deep freeze products. Well known for its Ardo and Shearway brands, Ardo UK was formed in 2004 following the merger of its two British operations – Ardo Shearway and Ryan Foods.
Ardo is continuing to benefit from growing consumption of frozen fruit and vegetables across virtually all its market sectors and countries.
and sells over 600,000 tonnes of
Europe’s largest supplier of frozen fruit and vegetables with an annual turnover in excess of Eur620 million. Ardo originated in the 1950s from a small family farming business, which was growing and trading vegetables near the village of Ardooie in Belgium. Ardo’s first vegetable freezing factory was built on the family farm in 1977 and the company took its name from the nearby village. Ardo has since developed its production facilities and sales throughout Europe and now operates 14 different manufacturing and packing sites across eight countries, and has a network of over 25 local sales offices. Each year the group grows, freezes and sells over 600,000 tonnes of fruit, vegetables, pasta and rice to 58
Europe’s Largest Fruit and Vegetable Supplier Ardo UK’s parent group is
FOOD & DRINK BUSINESS EUROPE, MAY 2013
countries around the world. Business Strategy The Ardo motto is ‘preserving the precious gift of nature’ and as a focused vegetable and fruit business its strategy is to be the best in three crucial areas – supply chain, quality and innovation. The Ardo product range offers a wide variety of frozen vegetables, vegetable mixes, vegetable preparations and fruit, and the company has a strong track record of continuous innovation in developing products and production methods in association with its customers. Indeed, Ardo’s goal is to maximise customer satisfaction. Green Credentials In addition to investing heavily in R&D, Ardo is also committed to sustainability. 17
For example, last year the Belgian company introduced bio-methane installations at two of its sites - at Ardooie and Geer in Belgium - allowing it to convert waste deriving from the processing of vegetables into energy and compost. Now fully operational the biomethane plants generate around 25% (Ardooie) and 15% (Geer) of the electricity required for production of fresh-frozen vegetables from the vegetable waste. This is equivalent to the total annual electricity consumption of around 5,500 households. The two biomethane plants have a combined fermentation capacity of 100,000 tonnes, of which about 40,000 tonnes is vegetable waste (skins, cutting waste, etc) supplied by the two sites themselves. The fermentation process releases biogas which is converted using a heat-power installation into green energy. Furthermore, the heat of the flue gases is also used to generate green electricity, and is used to heat the blanching system. The residue from the fermentation process, which is rich in nutrients, is converted into compost for spreading on
the fields where the vegetables which Ardo processes are grown. Ardo is also reducing the amount of packaging it uses. The investment in new packing lines at Kent and at three other sites allows Ardo to offer large size packages of 10 kg and more in blue plastic bags. This has reduced the volume of packaging used as Ardo is steadily moving away from packing in boxes with a plastic bag inside. Sustainability Ardo is committed to constantly improving the sustainability of all its operations. For example, in the UK Ardo managed to cut its CO2 emissions to 2,024 tonnes during 2012 – a fall of 102 tonnes yearon-year – so reducing its carbon footprint by.5%. “We are proud of our achievements, which stem from our commitment to ensuring we use the most cost effective and environmentally-friendly energy and business practices available,” points out Stuart Hiscott, marketing manager at Ardo UK. “Since we consolidated the company to a single site at the beginning
of 2010, we have seen significant reductions in energy use, road mileage and fuel consumption. We have now reduced our CO2 emissions by 48 per cent since 2007.” Outlook According to Ardo, 2012 will go down in the annals of European agriculture as a changeable year in terms of climate and a moderate year for harvest results, from excessive rain in one country to severe drought in another region, and even night frost in Austria in the second half of May. Indeed, really good harvest results were not recorded anywhere. In addition to the not very good to dramatically low yields of the harvest of peas, beans and spinach, Brussels sprouts and carrots also showed a clear deficit. However, rising demand for its products allowed Ardo to increase turnover and sales during 2012. Although faced with rising raw materials prices in 2013, Ardo is continuing to benefit from growing consumption of frozen fruit and vegetables across virtually all its market sectors and countries. J
Ardagh and Bonduelle Launch Next Generation Food Can fter ten years in development A Ardagh and Bonduelle have launched a new food can which delivers enhanced consumer appeal, together with significant environmental benefits. In developing a completely new steel can for Europe’s leading vegetable canner, Bonduelle, Ardagh Group has taken DWI food can production technology to a new level. The company has been able to employ nitrogen dosing techniques, similar to those used in the beverage industry, for the first time in food canning. Best in class standards have also been set
in light-weighting to provide environmental savings and increase sustainability. The new 400g can uses 15% less material than the current best in class can thanks largely FOOD & DRINK BUSINESS EUROPE, MAY 2013
to an astounding 43% reduction in the can wall thickness New design features have also enhanced the can’s appeal to the consumer. Beading on the can has been removed to form a more premium look and feel to the packaging. The new sleek surface of the can allows for premium label application or for direct printing onto the can. A further benefit to the consumer, as identified by consumer research, is the sense of freshness that comes on opening the can, created by the ‘psshhtt’ sound effect of the vacuum release. J 19
Flavour Control Through Monitoring Salt Levels in Snack Foods CL Control Instruments are P proud of having supplied and supported many DiCromat Salt Analysers to a number of Intersnack Group companies over the past 15 years in providing monitoring of salt levels in crisps, corn chips, pretzels, Pom Bears and nuts. The DiCromat is used by many snack food manufacturers from some of the largest groups to smaller speciality snack food processors being used in quality assurance monitoring laboratories, but a larger number are installed beside production lines. It is suitable for food production Snacks production testing station. area usage being manufactured entirely from plastic and metal components with an vide security of the calibrations held in IP54 waterproof rating and eliminates the memory as set-points, which are recalled use of chemicals or glassware in a food easily with a few key-strokes. environment. Instruments used in producThe 20gram sample size is more represention by non-technical operatives are usually tative than a few milligrams (used by autofitted with the CAL Guard feature to pro- titrators) of snack product. Sample prepara-
tion takes less than two minutes with the results displayed in less than 15 seconds. A dated and timed printout is available as is PC data logging. Snacks manufacturers applications range from salt in flavourings ingredients, pellets, snacks in production and finished product quality assurance. Monitoring the level of flavour deposited on the snacks ensures a more consistent flavoured product with optimisation of relatively high cost ingredients. Dynamic higher frequency salt monitoring ensures flavour consistency of your product with its customer loyalty benefits. For evaluation of the DiCromat II Salt Analyser’s precision and practicality – please contact PCL Control Instruments, Leicester LE1 4LF, England. Tel: 44 (0)116 270 0904 or email: salesservice@pclcontrol.com. J
DiCromat Salt Analyser applications • Potato crisps & chips • Extruded corn snacks • Tortilla chips • Flavours & Spices • Dry Roasted Pea Nuts • Salted nuts • Pretzels • Crisp breads Optimum flavour control when used beside-the-line in the production area. All plastic IP-54 water-proof construction for food processing environments Finished product quality assurance in a salt monitoring laboratory % Salt result: 0.1 of Mohr titration – no chemicals, chemical solutions or glassware Sample preparation time: typically 2 minutes. Result displayed in 15 seconds
For application evaluation and on-site demonstration call:
PCL CONTROL INSTRUMENTS Tel: 44 (0)116 270 0904 Fax: 44 (0)116 270 1798 Email: sales-service@pclcontrol.com Web: pclcontrol.com
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FOOD & DRINK BUSINESS EUROPE, MAY 2013
I SAVOURY SNACKS
Bagging KP Strengthens Intersnack Group The £500 million acquisition of KP Snacks from United Biscuits will allow Intersnack Group to strengthen its standing in Europe and to close the gap on clear savoury snacks market leader PepsiCo in the UK.
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ith annual sales of Eur1.65 billion and employing 6,000 people, Germanybased Intersnack Group was already one of the largest manufacturers of savoury snacks in Europe before its move for KP Snacks. Headquartered in Dusseldorf, privately owned Intersnack Group was formed in 2008 as a result of a combination of Intersnack Knabber-Geback (founded in 1968) and The Nut Company. It produces about 400,000 tonnes of snack products a year and has businesses in 14 European countries. The product range encompasses potato crisps, extruded and pellet products, nuts as well as baked products such as crackers, pretzels and salted sticks. Intersnack sells snack foods under various brand names including Chio, Funny-Frisch, Bohemia, Felix, Monster Munch, Vico, Pom-Bear and Penn State, and is also a major private label manufacturer.
UK Number Two KP Snacks is the number two snack manufacturer in the UK and famous for its iconic brands, including McCoy's, Hula Hoops, KP Nuts, Space Raiders, Nik Naks, Wheat Crunchies, Skips, Phileas Fogg, Discos, Roysters, Choc Dips, Brannigans, Frisps, KP Crisps, KP Mini Chips and Cheese Footballs. In addition to these brands, the acquisition includes KP’s UK manufacturing facilities and a head office. United Biscuits, which is owned by private equity firms Blackstone and PAI Partners, has retained ownership of its baked bagged snack brands manufactured at its biscuit factories including Mini Cheddars and Twiglets.
Winkel strongly believes in autonomy and maintaining local management and local production across its various European operations. Intersnack’s operating model makes individual companies responsible for generating long-term value. This reflects Intersnack’s policy to work as closely as possible at local level in the markets where the group is active.
With an annual turnover of £280 million, KP Snacks has shown consistent top and bottom line growth over the last five years. The company employs approximately 1,500 people. €2 Billion Turnover Business The combination with Intersnack brings together two companies with long-standing history and creates a strong alliance with combined net sales of more than £1.7 billion (Eur2.01 billion) and 8,000 employees. According to Maarten Leerdam, executive chairman of Intersnack, KP Snacks represents a strong and highly complementary fit with the Intersnack family of leading businesses throughout Europe. He comments: “Intersnack is a strong believer in the power of iconic, local hero brands, and we aim to leverage these strengths for further expansion. As a privately owned company, we operate our business with a long-term view. As such, the joint know-how of KP Snacks and Intersnack will drive the development of these iconic brands.” Intersnack has a strong track record of successfully acquiring and integrating savoury snack companies. The Intersnack board of Maarten Leerdam, Klaus Koester, Stephan Kuehne, and Johan van FOOD & DRINK BUSINESS EUROPE, MAY 2013
UK Combination In the UK, Intersnack has developed its presence through a mix of organic growth and acquisitions. Intersnack UK achieved a turnover of about £80 million in 2012, accounting for 6% of total group revenues. The UK business, with brands such as Pom-Bear, Penn State and Percy Dalton’s, will add scale to KP Snacks. Intersnack will also benefit from the competence and knowledge KP Snacks brings to support the future growth potential of the combined group. Further expansion in the UK, which is the largest and most innovative snack market in Europe, remains a key priority for Intersnack. “We appreciate the significance of acquiring a part of British heritage,” says Maarten Leerdam. “The transaction reflects our goal to accelerate the transformation of Intersnack’s strategic position in the UK.” The UK Competition Authority recently cleared the acquisition following an intensive full investigation. J
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INFORMATION INFORMATION TECHNOLOGY TECHNOLOGY
CASE STUDY
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or food and beverage companies, business is always a race. That’s why a software solution designed specifically for the unique challenges of the Beverage, Dairy, Meats and numerous other microverticals is an absolute must. With over 1,500 Food & Beverage customers worldwide – including Dr, Pepper/Snapple, Rynkeby Foods, Ter Beke, Idahoan, Kemin, HJ Heinz, Better Baked Foods and Brewster Dairy - Infor understands the unique demands these companies face and provides a proven set of industry specific functionality within its comprehensive suite of applications. This in turn provides a process-centric solution that improves efficiency and responsiveness by addressing specific variables and industry requirements, including shelf life, aging, catch weight, tank scheduling, regulatory compliance, lot tracking, and formula optimisation. With Infor’s latest release called Infor 10x, you’re looking at the most wide-ranging, user friendly suite ever built for the process sector, able to handle just about all of today’s requirements, particularly in food and beverage manufacturing. Deep industry insight and speed coming together at just the right time. As Mike Edgett, Director of Industry Marketing, Process Manufacturing says: “Process manufacturing companies are under more intense pressure than ever to perform business operations more efficiently and accurately. The ongoing need to quickly develop new and revised products by leveraging industry specific applications is critical to their success.” Infor is fundamentally changing the way information is published and consumed in the enterprise, helping 70,000 customers in 194 countries improve operations, drive growth, and quickly adapt to changes in business demands. Infor offers deep industry-specific applications and suites, engineered for speed, and with an innovative user experience design that is simple, transparent, and elegant. Infor provides flexible deployment options that give customers a choice to run their businesses in the cloud, on-premises, or both. To learn more about Infor, please visit www.infor.com.
Success Story – Symington's Takes a Bite Out of Inefficiencies With Infor
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ymington’s, one of the leading food such as Ragu and Chicken Tonight, we manufacturers in the UK, including faced an increase in throughput of around brands such as Ainsley Harriott, Aunt 30 per cent,” explained Howard Dearling, Bessie’s, Chicken Tonight and Ragu, has head of IT, Symington’s. “These particular achieved a full ROI on its brands arrive to us as preinvestment with Infor packaged goods from third Supply Chain Execution party manufacturers so (SCE). efficiency in getting them Symington’s need to scanned in, ready for disreplace a number of distribution is vital. parate systems which man“This efficiency and aged goods inwards, raw optimisation is critical as materials and finished we continue to grow at a goods so they could gain substantial rate. Our greater stock visibility investment in Infor SCE across their operations was has been key in ensuring the primary objective. we continue to offer the With the implementa- Mike Edgett, Director of Industry best customer service, tion of the new Infor appli- Marketing, Process Manufacturing based on the best business cation, Symington’s has at Infor. processes in the industry.” seen savings through “Symington’s handles a increased warehouse efficiency, reduced variety of some of the best known food transport costs, annual stock take improve- brands in the UK,” said Pieter Leijten, vice ments, lower inventory and a smaller IT president, supply chain, EMEA, Infor. footprint, leading to full ROI ahead of “That means the organisation has to schedule. In addition, the application has ensure complete availability of names like enabled Symington’s to handle a 30 per Aunt Bessie’s or Ragu, which in turn cent increase in throughput without addi- means they need to have the best waretional headcount. house management practices possible.” The speed of the ROI was boosted by Symington’s choosing to implement the Infor Food & Beverage Industry Infor SCE application out-of the-box, with suite includes: no customisations, as it was a perfect fit for their needs. M3 (ERP), Supply Chain As a result, Infor SCE has enabled increased visibility of the goods handled by Management (SCM), Product Symington’s by linking shipping notices to Lifecycle Management (PLM), specific purchase orders. In particular, the use of advanced shipping notes (ASNs) Enterprise Asset Management and single scan pallet labels has improved (EAM) & Intelligent Open goods inwards processes and boosted service levels. Network (ION) “With the acquisition of new brands
FOOD & DRINK BUSINESS EUROPE, MAY 2013
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INFORMATION TECHNOLOGY TECHNOLOGY
CASE STUDY Burts Potato Chips Savours Greater Efficiency With Help of New ERP System
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urts Potato Chips, which serves a number of farm shops, cafes and deli’s as well as high street retailers including Sainsbury’s and Waitrose, is seeing huge efficiency savings thanks to the implementation of its new ERP solution, Access SupplyChain and Access SelectPay. With aspirations to grow the business to £20 million over the next three years, the Devon-based company needed an integrated system to provide tighter controls over its financial, production processing and stock control. “Access SupplyChain is helping us to scrutinise every area of our business. It’s already saved us thousands of pounds through greater efficiency and faster access to information,” says Mike Cosby, Finance Director for Burts Potato Chips. Burts is benefiting from significant Mike Cosby, Finance Director for time and cost savings and has considBurts Potato Chips. erably reduced manual processing.
“We no longer carry out monthly stock takes as inventory is reconciled in real-time saving us around £12,000 a year,” says Mike Cosby. Burts is now conducting a perpetual inventory with barcoding improving accuracy and speed.” He adds: “With Access SupplyChain we can view the stock position on the system in real-time and know it’s 99% correct. This has given a real boost to our customer service as we have full confidence in the accuracy of the information we’re providing.” The solution is playing an important role in managing wastage too. “Access SupplyChain gives us instant visibility of production costing, enabling us to analyse and reduce product wastage. Not only does this have a financial benefit, it also has a positive environmental impact,” Mike Cosby remarks. Burts Potato Chips is able to readily carry out variance analysis, from purchase price to production costs, as well as retrospective stock valuation and comprehensive sales and product analysis – all of which was previously very cumbersome. Reporting is faster with easy access to information too. For further information on Access’ ERP system and its full software portfolio visit www.theaccessgroup.com.
CASE STUDY Domino’s Pizza Group Streamlines Stock Selection Process
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omino’s Pizza Group plc has implemented a new ‘pick-by-store’ solution, which will integrate with the group’s warehouse management system, OpenWMS from Advanced Business Solutions (Advanced). The new solution went live in April. As the leading pizza delivery company, Domino’s has seen dynamic growth over the past couple of years and has expanded further into the European markets in Germany and Switzerland. With nearly 800 stores across the UK, warehouse operation and distribution are vital for continued efficiencies and prosperity. The ‘pick-by-store’ solution will streamline the warehouse stock selection process, before goods are loaded onto delivery trucks. The solution will automatically allocate all the tasks for a single store to a picker, who then loads the stock directly onto a pallet, which is delivered to the store. The new system will enable a quick and easy loading process without the need to re-sort the goods prior to loading the trucks. The new solution will integrate with OpenWMS, Advanced’s warehouse management system, which the group has used for the last two years. Domino’s has seen improved stock accuracy, control, rotation and opera-
tional efficiency. Other benefits include two-way traceability and enhanced management of information. Glenn Jeffery, Warehouse Manager at the Domino’s Pizza 60,000 square foot Milton Keynes commissary, says: “We are confident the new ‘pick-by-store’ solution will streamline the stock selection process helping to make us much more efficient. OpenWMS has been essential for our warehouse management process and gives us the ability to monitor the availability of space in the warehouse. “We have got full traceability of all of our food products from the in-bound to the out-bound, which is key. It’s also giving us a better understanding of our stock-holding and it has given us greater control over our stock management process, reducing the number of writeoffs.” On average 1570 deliveries are made per week during a six-day 24-hour operation at Milton Keynes. The warehouse services 530 outlets which need to restock every second day. The streamlining of Domino’s warehouse operations has secured a 12% increase in warehouse picking efficiencies over the past two years. For further information visit www.advancedcomputersoftware.com/abs.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
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INFORMATION INFORMATION TECHNOLOGY TECHNOLOGY
BT Takes Friogan into the Cloud
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riogan, a market-leading Colombian producer and distributor of meat based products and by-products, has adopted BT Cloud Compute, an enhanced service that gives organisations the ability to build powerful ‘pay as you go’ cloud solutions that they can access with consistent levels of quality and security wherever they are expanding. BT Cloud Compute will help Friogan, which has five processing plants located in pastoral areas across Colombia, minimise costs and adapt its IT infrastructure quickly and easily to rapidly changing operational needs. Developed at BT’s research centre in Adastral Park, BT Cloud Compute enables Friogan to consolidate its IT infrastructure by combining its own data centres and private clouds with BT’s global cloud capabilities, providing Friogan the flexibility to tailor its choice of solution to suit changing IT needs. Automated delivery makes it easy for Friogan to launch new services and applications quickly and efficiently,
with high levels of choice, flexibility, security and control. BT Cloud Compute’s self-service dashboard gives Friogan the power to constantly monitor and manage its usage and spending. With services hosted in more than 45 datacentres around the globe and managed by customers through a transparent self-service dashboard, BT Cloud Compute is designed to help businesses like Friogan meet their stringent compliance requirements and local law and regulatory obligations by letting them decide exactly where they want their sensitive data to be hosted. BT’s cloud infrastructure uses industry standard secure data centres located in Brazil, Colombia, US, UK, Spain, Benelux, France, Italy, Singapore and Hong Kong. This will soon be extended to Germany, China, India, Argentina and Mexico.
Exact and Preactor Form Strategic Alliance
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uropean software company Exact has formed a strategic alliance with worldwide leader in advanced planning and scheduling (APS) software Preactor. The agreement formalises a long-standing relationship between the two firms, whose products complement each other. This will ensure a smooth collaboration between the companies on a global scale, to create more customer value. The agreement will see Exact expanding its existing ERP offering to a wide range of manufacturers by adding in the option for clients to access advanced planning solutions. Exact offers a comprehensive mix of business software solutions to its clients, including Exact Globe Next. The addition of Preactor products will allow Exact’s clients to schedule production
to make optimum use of finite resources to meet manufacturing deadlines. They can be integrated with existing IT software such as ERP systems provided by Exact. This means clients can lower their production costs, improve delivery times, and ensure better customer service. Jarno van Hurne, Product Marketing Director at Exact, says: “Preactor has been our partner for many years now and we have worked together to help clients across the globe. This agreement underlines our partnership. It offers our customers a reliable basis to use Exact solutions worldwide in combination with the recognised advanced planning solutions of Preactor.”
Fulfil UK Becomes New Sanderson Customer
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anderson has signed a new contract with Fulfil UK. Based in Eastleigh, Hampshire, Fulfil is a 125 year old family firm manufacturing and distributing the Marybake bakery range (muffins, flapjacks, etc.) to the NHS, the foodservice sector (including 3663) and approximately 1,200 independent cafes including education and tourist outlets. The Sanderson solution includes factory automation
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with recipe weighing in the factory and wireless scanning in the warehouse. The increased traceability, ready availability of information on costings and variance reporting were seen as key factors in choosing Sanderson. This, along with the reduction of manual processes and associated errors across the business, is seen as critical for the future growth plans of the family concern.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
Cargill Breaks Ground on $100 Million Investment in Indonesia argill has broken ground on a $100 milC lion investment to construct a state-ofthe-art cocoa processing facility in Gresik, in the East-Java region of Indonesia. The new facility is to meet the growing demand amongst customers for cocoa products and to encourage the development of the Asian cocoa sector. The new facility will be Cargill’s first cocoa processing plant in Asia and demonstrates the company’s commitment to develop and grow the Asian cocoa industry. The investment will also strengthen the company’s Indonesian cocoa sourcing network and cocoa sustainability activities. Cargill will create approximately 200 new jobs in Indonesia, as well as additional positions in its existing R&D application centres in Kuala Lumpur and Beijing, and in the company’s commercial network, which it is strengthening to better serve the needs of customers in Asia. The new facility, which is expected to be operational by mid-2014, will process approximately 70,000 metric tonnes of cocoa beans into a broad range of tailored products for customers in the Asian market. These products will include high quality cocoa liquor and butter, as well as Cargill’s premium quality Gerkens® cocoa powders. “We are excited to be taking this step to strengthen our cocoa operations on the ground in Indonesia. We have seen a significant growth in demand for cocoa products amongst our customers across the region. This investment will enable us to support the growth of the local cocoa sector, process local Indonesian beans and provide high-quality cocoa products to serve the growing needs of
The first stones are laid at a ceremony to mark the building of Cargill’s new cocoa processing plant in Gresik, East-Java, Indonesia.
our customers in Asia,” says Jos de Loor, president, Cargill Cocoa & Chocolate. The new facility is part of Cargill’s growth strategy in Indonesia’s cocoa sector and one strand of the company’s efforts to support long-term sustainable cocoa production globally. Through the Cargill Cocoa Promise, the company is growing and sustaining cocoa farming communities while meeting the growing global demand for sustainable cocoa beans by focusing on three areas: training farmers, supporting farming communities and investing in the long-term sustainable production of cocoa. Cargill has already begun its successful farmer training programme in Indonesia which encourages the use of sustainable agricultural practices by smallholder farmers and the farming community. The company intends to train over 1,300 Indonesian smallholder cocoa farmers by 2015 through newly
created Farmer Field Schools to improve their productivity, bean quality and, as a result of the training, increase the incomes of smallholder farmers and their families. The company has also taken steps to strengthen its cocoa sourcing network in Indonesia. Cargill has been sourcing Indonesian cocoa successfully since 1995. The company now operates two cocoa buying stations across the country and, once the new cocoa facility is in operation, Cargill will double the quantity of cocoa beans it purchases from cocoa farmers to meet the demand for local processing, giving smallholder farmers a bigger market for their crops. The new facility and expanded sourcing operations in Indonesia will complement Cargill’s global network of cocoa sourcing and processing facilities located in Western Europe, Vietnam, Cameroon, Ghana, Côte d’Ivoire, Brazil and the USA. J
The Number 1 US Slimming Ingredient Comes to Europe nomenon in North America. It is the number one slimming ingredient in the US, and is now used in 100 co-branded products across the US and Canada. It has a Facebook page of its own with more than 2,700 ‘likes’ and boasts 1,400+ followers on Twitter. Antoine Dauby, Naturex Marketing Director, says: “Svetol® is a real success story for Naturex. Even though it is an ingredient, it has managed to gain a very high level of recognition among consumers across North America. We’re confident Svetol® presents a huge opportunity for companies in Europe, too.” J
vetol®, the top-selling slimming S ingredient in the US, has been launched in Europe. Developed from decaffeinated green coffee bean extract, Svetol® is clinically proven to inhibit glucose-6-phosphatase and increase the rate of fat release from the adipose tissue – a unique mechanism that results in highly effective weight management. The ingredient is produced using Naturex’s proprietary extraction process, which ensures a unique and specific profile of active molecules, in particular chlorogenic acids. Svetol® has grown to become a phe28
FOOD & DRINK BUSINESS EUROPE, MAY 2013
I SALT & SODIUM REDUCTION
A Meaty Issue – Putting Salt on Hold By Lonneke van Dijk, Category Manager Meat, Purac odium reduction is one of the food industry’s most important issues, with S studies linking excessive sodium consumption to high blood pressure and heart disease. Although consumers are not always aware of the fact processed meats like cooked ham and bacon, commonly contain high levels of sodium. Accordingly, meat might seem the ideal target for sodium reduction, but it is not simple. Salt Appeal Other than taste, salt plays two critical roles in foods. The first is preservation: by reducing water activity it slows the growth of the bacteria that are responsible for the
degradation of taste and aroma. Cutting salt levels has a dramatic effect on shelf life. In today’s convenience-driven market consumers will not accept reformulations that shorten shelf life. Texture is another key consideration in reducing sodium levels. Salt is a highly versatile with capabilities including water binding, protein gelling and emulsification. All these contribute to firmness, bite strength and juiciness. Finding Solutions Purac has a detailed understanding of the issues manufacturers face in the field of sodium reduction. Using this insight and its long-standing expertise in fermentation, Purac has created a range of labelfriendly ingredients that enable meaningful sodium reduction while retaining the taste and texture characteristics of meat products. Its market-leading natural
flavouring solution, PuraQ® Arome presents an alternative approach to sodium reduction. The award-winning PuraQ Arome NA4 is a natural flavouring designed to promote salty, meaty, and savoury notes. It mimics meat flavour, allowing processors to maintain a good flavour profile while lowering sodium content by up to 40%. Suited to all meats, PuraQ Arome NA4 is used at levels of 2 – 3.5%. As well as its flavouring capacity, it also controls water activity which aids microbiological stability, protecting shelf life. J
LomaSalt® 2.0 – The New Generation of LomaSalt® educing salt intake is not an easy matR ter, since most of the salt consumed on an everyday basis is already contained in the food itself. About 75% of sodium consumed is from ‘hidden sources’ in processed foods, 15-20% comes from unprocessed foods, and only a small proportion is added during cooking or at the table. The World Health Organisation (WHO) recommends a maximum of five grams of salt a day, but the amount consumed in Europe is much greater than this. Consumers rate taste very highly and will accept healthier products only as long as they do not have to sacrifice palatability. Furthermore, in many applications the total exclusion of salt is not possible for technical reasons. Dr Paul Lohmann, part of the Lohmann Group, has recently introduced its latest innovation called Loma-Salt® 2.0. An innovative composition of ingredients in
this LomaSalt® variety creates an entirely new taste experience. That typical bitter taste of potassium common in commercially available salt replacement products (including potassium chloride), is now FOOD & DRINK BUSINESS EUROPE, MAY 2013
avoided by this new combination of different mineral salts, says the company. According to Dr Paul Lohmann, the advantages of LomaSalt® 2.0 are: * 50 % less sodium with 100 % taste; * Extra salty; * Authentic alternative to cooking salt with a pure, typical salty taste without any offtaste; * Easy handling - simply replace cooking salt 1:1 with LomaSalt® 2.0; * Contains no glutamate, yeast extracts or other flavorings/ taste enhancers; * All ingredients are approved in the EU for use in food; * No E number * Rich in potassium - Health claim: “Potassium contributes to maintaining normal blood pressure.” According to Regulation (EU) No. 432/2012 to establish a list of permitted health claims made on foods. J 29
I SALT & SODIUM REDUCTION
Kudos Blends – The Ingredient For Success in Low Sodium Baking ith the drive to reduce salt and in parW ticular, sodium intake, high on the health agenda of many developed countries, including Europe and the USA, UK-based bakery ingredients firm, Kudos Blends, is playing a leading role in helping the global baking industry meet their sodium reduction targets and develop healthier, high quality products. Established in 1999 with a vision to drive innovation in the baking industry, Kudos Blends specialises in the production and supply of technically-driven zero sodium and low sodium bakery raising agents. It assists bakers throughout the world to meet increasingly challenging European Commission (EC) and World Health Organisation (WHO) targets being set to reduce consumers’ dietary sodium content. Blending Science and Baking Through continuous investment in research and innovation over the past 15 years and by accumulating extensive scientific and practical knowledge and expertise, Kudos
Blends has grown to become an important player in the baking sector and a worldwide, renowned expert in sodium reduction. Its groundbreaking PELL™ range of premium baking powders has been designed and developed to optimise the quality, texture, taste and shelf life of baked goods and it is second to none in the market. Today, Kudos Blends’ PELL™ baking powders are used by some 80% of the companies supplying the UK bakery market and they are sold globally through a network of international distributors. And more than half of Kudos Blends’ sales to UK bakers are driven by its low sodium product range, which are now used in the production of many of the country’s best known and well-loved bakery brands. Baking Worth its Salt The scientific evidence is compelling – a reduction in salt intake could have a very positive impact on people’s health, as salt intake plays a critical role in regulating blood pressure. In fact, according to the WHO, populations with low salt intake, all other things being equal, will have a lower average blood pressure level and decrease their risk of Cardiovascular Disease. The baking industry has risen admirably to the challenge of reducing sodium levels in its products and Kudos Blends has been at the forefront of this drive to cut down on salt. Through a thorough understanding of the chemistry of baking, Kudos Blends has worked hard to develop a range of raising agents designed specifically to help bakers meet their sodium reduction targets, while maintaining the taste and quality of their end products and the efficiency of their baking processes. Kudos Blends’ PELL K range of low sodium baking powders offers up to a 50% reduction in sodium levels for bakers who prefer to use a ‘turnkey’ solution to achieving sodium reduction rather than working with individual functional ingredients such as potassium bicarbonate or sodium bicarFOOD & DRINK BUSINESS EUROPE, MAY 2013
Dinnie Jordan, founder and director of Kudos Blends.
bonate. For those bakers looking for a direct, one-to-one replacement for sodium bicarbonate in the baking process, Kudos Blends has developed KUDOS™ Potassium Bicarbonate HP Grade which is suitable for all bakery applications, including concentrates, premixes and blends. It has been developed using innovative technology to provide maximum stability as both packaged material and when included in premixes and baking powder blends. Its fine particle size and unique hydrophobic characteristics make it the perfect ingredient to incorporate into the baking process with no adverse effects and with no compromise on taste or end product quality. A Case in Point Dinnie Jordan, founder and director of Kudos Blends, explains: “We don’t just sell products. We sell solutions to specific problems. We are solely focused on bakery raising agents and we offer unrivalled technical support services in this area. “If bakers want to reduce sodium in their recipes, we ensure they receive the best pos31
sible product formulation for their specific application and we work to ensure all their trials and production runs operate to their highest expectations. “Meeting sodium reduction targets is vital, particularly for those bakers selling to the major retailers who are all keen to ensure their products are as healthy as possible and comply with industry efforts to reduce people’s sodium consumption. “By using potassium bicarbonate we are helping to maintain the quality and functionality that bakers expect while achieving healthier, low sodium that don’t disappoint consumers’ high expectations for quality, taste, texture, appearance and shelf life.” For example, Kudos Blends recently helped a major UK crumpet manufacturer to lower sodium levels in its products. Crumpets are unusual in that they incorporate yeast and baking powders and rely on these two components for gas release during the baking process. Added salt plays an important role in controlling yeast action and the manufacturer’s attempts to remove this had resulted in issues with end product quality. Using its scientific knowhow, Kudos Blends analysed the existing crumpet recipe and replaced the sodium bicarbonate with KUDOS™ Potassium Bicarbonate. The result was a delicious tasting crumpet baked in such a way that the manufacturer was able to reduce sodium by up to 25% while still allowing the added salt to maintain the functionality of the yeast and therefore not adversely the affect the finished product’s quality.
“One of the key challenges facing the baking sector and the food industry as a whole, has been the confusion between salt reduction and sodium reduction”, continues Dinnie Jordan. “Many primarily think of salt reduction as something to do with cutting down on sodium chloride, when in reality, the big issue is sodium reduction, which encompasses every sodium-containing ingredient, including salt itself. The plethora of sodium reduction products currently available on the market has added further to this confusion. “We have tried to address this confusion by offering a solution that works in most bakery applications to achieve sodium reduction. The major benefit of using KUDOS™ Potassium Bicarbonate is that bakers can reduce the sodium content of their products with no detrimental impact on end quality.” From the outset, Kudos Blends has been committed to dispelling the myths surrounding sodium reduction and educating bakers and the food manufacturing industry, regularly participating in lectures, conferences and food trade events in the UK and internationally. Indeed, such has been Kudos Blends’ success in the knowledge sharing process, that Dinnie Jordan is a much sought after key note speaker at major international bakery events, most recently addressing delegates at the Australian Society of Baking Conference in Melbourne.
Dispelling the Myths Kudos Blends has been at the forefront of dispelling some of the myths and confusion that have sprung up within the food industry in recent years regarding the salt reduction drive. 32
FOOD & DRINK BUSINESS EUROPE, MAY 2013
Commitment to Innovation The highly experienced bakery and laboratory applications team at Kudos Blends applies chemistry to baking in order to fully understand the baking process and is committed to continuous innovation and development to satisfy the needs of the baking industry now and into the future. The company’s headquarters and production plant at Cleobury Mortimer in Worcestershire, England incorporates sophisticated laboratory facilities and a fullsize pilot bakery, where research and development and NPD work is conducted onsite. Kudos Blends’ international reputation for research and innovation is expected to be further enhanced later this year when it releases a range of products for the replacement of sodium aluminium phosphate (SALP) which is soon to be banned for use
in the UK and European food industry in February 2014. With many bakers still using SALP as a baking agent due to its effectiveness in producing good characteristics in baked goods, there is a definite market opportunity for a reliable, effective and viable alternative. Kudos Blends’ Opus range of low aluminium products will be launched later this year. It is clear the baking industry is changing, driven by sodium reduction targets and the overall drive for healthier products. The sector, to its credit, has made significant steps forward in the battle to reduce sodium levels and many lessons have been learnt. Kudos Blends will continue to be at the very forefront of research and new product innovations to ensure the baking industry has high quality functional ingredients at its fingertips to meet increasing demands. J
I SALT & SODIUM REDUCTION
Reducing Sodium in Cheese hr. Hansen has introduced a breakC through ingredient innovation which enables cheese producers to cut sodium content by up to 50% while maintaining great taste and texture. Salt is an essential ingredient in cooking, food preservation as well as the manufacture of processed food. However, due to the link between excessive sodium consumption and high blood pressure, the World Health Organization (WHO) dietary guidelines recommend consuming less than 2,000 mg sodium, or 5 grams of salt, per day. Average sodium consumption in countries around the world ranges from 2,600 to 7,200 mg per person per day, requiring a 25-75% reduction to meet WHO recommendations. Most western countries and regions including the US, Canada and the EU have voluntary initiatives to reduce dietary sodium intake, including salt reduc-
tion in cheese. “Reducing sodium in cheese is technically challenging as it has adverse impact on taste, texture and shelf life,” explains Timothy Wallace, Enzymes Marketing Manager, Chr. Hansen. “Commercial attempts to reduce salt in cheese have been largely unsuccessful due to poor product
quality. Although consumers desire healthier foods, most are unwilling to trade quality for health.” He adds: “Using SaltLite™, cheese producers are able to reduce sodium levels up to 50% while ensuring exceptional product quality. Moreover, SaltLite™ contains only natural ingredients already used in the manufacture of cheese.” SaltLite™ is the result of Kirsten Kastberg Moeller's PhD project carried out in collaboration between Chr. Hansen and the University of Copenhagen, Denmark. In her PhD work, Kastberg Moeller explored the potential of adapting the existing cheese-making technology, by modifying process parameters and extending functionalities of added lactic acid bacteria and coagulant, to improve the flavor and texture of cheddar cheese with a 50% reduced sodium level. For further information, visit www.chr-hansen.com/saltlite. J
I SUSTAINABLE COCOA
Ghanaian Cocoa Farmers Receive First Certification Premiums Through the Cargill Cocoa Promise argill’s cocoa and chocolate business has C made its first premium payments in Ghana for the production of certified sustainable cocoa beans. In total 3,900 Ghanaian farmers received the payments for the first three months production of sustainable cocoa beans following their participation in Cargill’s farmer training programme. The payments were made at a recent ceremony in Sefwi Bekwai, in the Western region of Ghana, attended by the Managing Director of Cargill Ghana and partners including the Deputy CEO of the Ghana Cocoa Board; the licensed cocoa buying company Akuafo Adamfo; and the programme manager of the nongovernmental organisation (NGO) Solidaridad. “This payment, is the direct result of a successful public private partnership working towards sustainable cocoa in Ghana,” explains Kojo Amoo-Gottfried, Managing Director of Cargill Ghana. “Working with the Ghana Cocoa Board, Akuafo Adamfo and Solidaridad has produced genuine positive results for all participants, particularly the
cocoa farmers, who will be receiving further payments as the harvest period progresses.” These premium payments are a result of Cargill’s Cocoa Promise, the company’s commitment to make a difference around sustainability in three key areas: training cocoa farmers; supporting cocoa farming communities; and investing in the long-term sustainable production of cocoa. Cargill is on track to reach its target of training 15,000 farmers in the coming three
FOOD & DRINK BUSINESS EUROPE, MAY 2013
years. 2,500 tonnes of UTZ Certified cocoa from this first harvest cycle have been processed at Cargill’s state-of-the-art plant in Tema, Ghana, ensuring a large part of the value chain remains within the country. UTZ Certified cocoa is part of Cargill’s efforts towards developing a sustainable supply chain and can be traced from the certified farmer to final product as it becomes Gerkens® Ghana cocoa powders. Launched in 2012, the first phase of Cargill’s farmer training in Ghana has provided tuition in good agricultural practices such as pruning, plantation renewal and cocoa fermentation methods, and good environmental and social practices, with the aim of increasing productivity and yields. Moving into its second phase, farms will be thoroughly mapped to determine precise yields. Soil will also be tested for acidity, alkalinity and nutrients to ensure that optimum growing conditions are achieved. In addition the training will also address broader social aspects, such as children’s education and HIV awareness. J 33
I ADHESIVES SOLUTIONS
Alphabond Adhesives is No. 1 For Food and Drink Packaging and Labelling ne of the food and drink industry’s O fastest growing suppliers, Alphabond understands the needs and challenges of large manufacturing organisations better than most, which is why so many blue chip companies fronting major brands are turning to the company for specialist adhesive solutions. Alphabond commits large resources into developing new products that enable its customers to increase operational efficiency, cut machine downtime and maximise profitability. The company supplies a comprehensive range of adhesive solutions, including Food and Drug Association (FDA)
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approved hot melts utilising Perfecta® technology for packaging applications, and Label lock® wet glues for the labelling of
FOOD & DRINK BUSINESS EUROPE, MAY 2013
glass and plastic bottles/jars. Formulated using the latest technology, these adhesives incorporate a variety of unique features designed to deliver performance enhancing benefits and cost savings. With the ability to give adhesion to virtually any substrate, customers using Alphabond products regularly report on usage savings in excess of 30%, as well as being able to run the adhesive for longer without the need to stop and clean machine parts. One of the company’s key clients says: “We would have no hesitation in recommending Alphabond and its products to other companies, just not to our com-
petitors, as we wouldn’t want them to have the edge we have by using Alphabond!” With the recent further strengthening of its technical team, Alphabond has the resource and expertise to formulate bespoke adhesive solutions that cater specifically for the individual requirements of its customers. Alphabond says: “We believe in developing high quality adhesive solutions that optimise productivity, presentation
and profitability. This approach has proved popular with our customers, who include some of the largest and most profitable beverage and food manufacturers from Europe and Australasia.” Contact Alphabond’s adhesive experts at info@alphabond.co.uk for free advice on finding the best adhesive solution for your application, or visit www.alphabond.co.uk for information. J
All Clear For Low-migration Labels t is a known fact that constituents of any Ithrough adhesive applied to labels can migrate food packaging. Self-adhesive materials specialist HERMA is demonstrating how labels can be made much less susceptible to migration without impairing their adhesive qualities – not with a special adhesive, but by using multi-layer technology. The revelation that printing ink constituents can pass through packaging materials caused shock waves throughout the food industry. The focus of the debate is now gradually widening to encompass labels as well. More and more often, packaging specialists in the food industry are
In some circumstances, even a film used to wrap salami cannot prevent constituents of the adhesive migrating into the food. Low-migration labels are important for this reason too.
asking whether individual constituents of the adhesives applied to labels are also capable of migrating into food, and they want to know about the possible consequences. As a general rule, the risks associated with labels are appreciably lower than those related to inks. Adhesives that are certified for use with food do not contain any toxic or other substances giving cause for concern. It is only natural that food producers nonetheless wish to avoid migration as far as possible, especially since many packaging films do not offer effective barrier properties. “Very low-migration labels existed in the past, but the greater the protection afforded by the label, the less effective its adhesion," explains Dr Thomas Baumgartner, managing director of HERMA, which also has a subsidiary in the UK. "But poor adhesion is a compromise that the food industry is unable to accept. It demands absolutely reliable labelling and traceability.” Decisive Second Layer “From a technical perspective, the solution lies in reducing the proportion of constituents that are capable of migrating, without changing the adhesive properties,” points out Dr Baumgartner. “This is now possible, by applying a specially formulated second coat to the label material at the same time as the adhesive.” HERMA is a global pioneer in implementing the relevant multi-layer process on an industrial scale. Drawing attention to another key aspect, Dr Baumgartner says: “The particular adhesive is already well proven on the market; the new second layer alone is responsible for modifying the migration behaviour.” This is by no means a special product, therefore, but a solution based on extensive FOOD & DRINK BUSINESS EUROPE, MAY 2013
Sealing labels in particular often come into contact with fatty foods, such as cheese. For this reason, the adhesive applied to the label should resist migration as far as possible.
experience. The application of multi-layer technology by HERMA is emerging as standard practice, but without inflating the price of the adhesives. “If the buyers of packaging materials and consumables ask the right questions, every label printer nowadays can supply very low-migration labels that are no more expensive than comparable single-layer labels," insists Colin Phillips, division director of HERMA UK in Newbury. Approved For Direct Food Contact The food-safe adhesive 62Dps has already been tested by the reputable German institute ISEGA. Alongside a whole series of other standard adhesives, it has been certified for direct contact with dry, moist and fatty foodstuffs (reduction factor 3). “This new adhesive gives users in the packaging industry the security they need at all times,” comments Dr Baumgartner. This applies not only to the direct, often unintentional contact that is made with foodstuffs, but also in situations in which the packaging material, such as foil or film, is designed to provide, but is not always capable of ensuring a fully effective protective barrier. J 35
I TRAYS, TRAY SEALING & MAP
Setting the Pace For Packaging Technology takeholders in the packaging supply S chain have a vital role to play in the reduction of food waste. Holfeld Plastics is
would loan itself to post consumer recycling where facilities exist. And as a first-to-market Holfeld Plastics has developed a one-size-fits-all auto-denestable range of punnets across its crate fit G81 range. As the soft fruit market reels
showing its commitment to reducing the impact of packaging on the environment through innovative design and products
that reduce waste and extend shelf life. Most of Holfeld’s packaging has between 80% and 85% post consumer recyclate in the blend – substantially reducing dependency on virgin materials. For some time Holfeld has had technologies such as Modified Atmosphere Packaging (MAP) across its meat range helping to ensure the product stays fresh for as long as possible. Meanwhile the company’s crate fit G81
soft fruit punnet range offers significant air flow improvements through sloping vents in the base aiding fruit conservation and helping to preserve the soft fruit in transit, at the supermarket and in the consumer’s fridge. Holfeld has introduced rPETeCO a lightweight material for meat trays with a specific gravity reduced from 1.33 to 1.05. The weight of the resulting trays are up to 20% lighter than virgin PP trays. This has led to a 74% CO2 saving on raw materials and a 47% reduction in the carbon footprint of Holfeld products over the lifecycle. Other introductions include Holsorb in the base of some meat trays eliminating the need for an absorbent pad reducing material content. The launch of ‘Holseal’ which is a high performing mono rPET film gives an extended processing window to most sealing and MAP applications. The reduced sealing temperatures and the faster sealing times have resulted in the product being accepted in a number of ‘Primary Poultry’ packaging applications in Ireland and the Benelux region. Holseal is also more readily recyclable as it is a mono PET structure, so
from poor weather conditions, low yields and profitability this new breakthrough couldn’t have arrived at a better moment for growers and packhouses offering improved space utilisation, improved product flow between packhouse and field. With auto-de-nesting giving rise to a more reliable sealing jig the integrity of the finished product is assured. J
PA’s New MAP Automatic Tray Sealer For Meat and Poultry ackaging Automation’s eclipse range of P tray sealers has been developed to set new standards for reliability, ruggedness and return on investment in almost any food manufacturing environment in the meat and poultry sector. PA has eclipse lines installed at a number of poultry packing sites where levels of below 0.5% residual of oxygen are being achieved without the added aid of a costly full vacuum system.
The automatic eclipse SL4 which seals up to 75 packs per minute incorporates technology which requires zero compressed air FOOD & DRINK BUSINESS EUROPE, MAY 2013
for full operation. For higher throughputs the twin lane eclipse TL6 offers up to 200 packs per minute. All eclipse machines incorporate the EcoCutTM option and are capable of running film as thin as 17 micron giving a film usage reduction of 20%, while the instant response and accurate synchronisation of the servo-driven film feed system leads to fewer film breakages caused by air pressure variations. J 37
I TRAYS, TRAY SEALING & MAP
New Re-lock Packaging s part of its ongoing strategy to increase A focus on the chilled food and snacks market, Faerch Plast has developed a new Re-lock packaging tray with a convenient re-closeable feature. The latest innovation developed by the dedicated in-house design team at Faerch Plast incorporates an integral peelable film rather than a separate or hinged lid, saving on the amount of material used, leading to cost-savings as well as the production of more environmentally-friendly packaging. Produced using APET (Amorphous Polyethylene Terephthalate) for its high clarity, the Re-lock products are ideally suited to cold foods and snacks, such as fruit,
salad, dips and cold meats, where consumers like to see the contents in order to assess their freshness. The new Re-lock range features three variations on the re-closeable film lid principal, each designed to make it easier for consumers to peel back the film whilst avoiding the traditional issues experienced, such as the film peeling off in its entirety. Suitable for MAP (modified atmosphere packaging) sealing, and available in a wide range of tray shapes and sizes, the new products dispense with the need for re-closing film. Depending on which of the three closures is used, consumers re-close the product
either by clicking a tab that is attached to the film into place or slipping a tab through a pre-cut opening in the packaging. J
New Fully Automatic Traysealer Launched ULTIVAC has unveiled a new fully M automatic traysealer model in the medium output range: The T 600 seals up to 40 trays per minute and is directed primarily at small and medium-sized food producers and packers requiring a solution that is compact and capable of being fully integrated in a line. "The T 600 is a competitively priced model with which we are closing the gap in our traysealer portfolio between the slightly smaller compact model T 300 and the high-performance model T 700. We expect great interest from growing companies that
want a higher level of automation and/or want to switch from manual loading of their packaging machine to a fully automated solution," says Alexander Kult, Product Manager at MULTIVAC. The main application areas of the T 600 lie in the food sector, primarily in meat, sausage and convenience products, but it is also suitable for the packing of seafood/fish and cheese, as well as fruit and vegetables or salad products. The T 600 can produce MAP packaging with and without LID film, skin Isopak packaging and Slicepac packaging. J
I BOTTLES
Bottle It Up! – New additions to the Measom Freer Family! easom Freer have announced the addition of the svelte new M Charnwood bottle range to their stock products. These bottles are a slim shape with tapered shoulders and manufactured in clear PETG offering superb product clarity. The collection is available in 100ml (Ref 6184) with 18mm R4 415 neck & 300ml (Ref 6167) with 24mm R4 415 neck size. Also added to their existing stock ranges are the new 15ml size oval PVC Griffin bottle with 15mm R4 415 neck (Ref 6500) and 25ml round PVC Europa bottle also with 15mm R4 415 neck (Ref 6370). To compliment your bottle choice add a spray pump in new 15mm R4 415 size (Ref 49315) which joins their existing range of 18, 20, 22 & 24mm sizes, made to order (so that the dip tube can be tailored to suit the chosen bottle) in polypropylene 38
with a minimum order of 1000 units. Also stocked are gel pumps in neck sizes 20-24mm, minimum order 10,000 units and lotion pumps in neck sizes 24-31mm, minimum order 1000 units. Their stock packaging has a minimum order quantity of just a single box and upwards which means minimal lead-times, optimising your cash flow and stock management. They hold the stock, you just place the order! For further information contact Measom Freer on Tel +44(0)116 2881588, Fax +44(0)116 2813000, sales@measomfreer.co.uk or buy online at www.measomfreer.co.uk via pc or tablet. J
FOOD & DRINK BUSINESS EUROPE, MAY 2013
I RETAIL READY PACKAGING
Are You Being Honest About The Final Moment of Truth? he introduction of retail ready packagT ing in the UK led to a wholesale rethink in the way brands and retailers displayed product on shelf. Coupled with the huge efficiencies and cost-saving benefits in terms of logistics and labour, it was quickly adopted by the biggest retailers in the market. But while the past ten years have seen RRP become the standard in many areas, transforming the humble brown box from transit container to on-shelf promoter, DS Smith Packaging’s Sector Director Tony Foster argues that for some brand owners, it may be time to reassess their RRP to ensure they fulfil its true potential. The value of RRP “RRP was a complete game changer which was adopted very quickly as far as some producers and customers were concerned. “It involved a lot of rethinking in a short space of time which meant the focus was on how it would work for the operations and logistics areas of the supply chain. But that meant, in many cases, there was less focus on ensuring it looked as good as possible on the shelf to attract the shopper. “Of course RRP delivers many benefits in logistics and operations in terms of space efficiencies, reducing carbon emissions due to fewer lorry movements, as well as cost savings in terms of labour as the boxed-up
Tony Foster, Sector Director, DS Smith Packaging.
products are simply put directly onto the shelf. Challenges for RRP “However, the question now is whether there should be increased focus on the very end of the process in order to maximise the full potential of RRP and shelf ready packaging. “Our entire industry is built around bringing products to the shelf and inviting the consumer to choose one over the other, and to be drawn to that brand. The hours of manufacture, distribution and transport come down to that one single moment of truth, when your product has to be the best on show in order to attract the consumer. “Can it be said that everything is being done to ensure that critical point is being supported in the best possible way, with all the packaging and promotional tools available? “In order for RRP to continue to deliver the benefits FOOD & DRINK BUSINESS EUROPE, MAY 2013
inherent within it, it is important to really assess and reframe the thinking behind it because for some in the industry, it has become simply an operational process that they should adhere to. That can lead to the kind of RRP that sends out the wrong kind of messages which does nothing to support the central principle of helping customers to sell more. “Retailers talk about a product needing to adhere to the ‘five easies’, which are: easy to identify, easy to open, easy to shelve, easy to shop and easy to dispose. “Clearly RRP plays a key role in hitting those five points, but instead of treating that as a tick box exercise, use it as a guide to excellence, ensure each of those ‘five easies’ is achieved as best as possible. This will make it be easier for the retailer to sell more, and therefore the brand owner will sell more as well. “This is one of the reasons why we have developed the Impact & Innovation Centre in Ely. There is no more clear way to demonstrate these issues than to put it in front of peoples’ eyes, where it is instantly obvious what difference RRP makes to the entire look and feel of the product. Future of RRP “But we also recognise that RRP is evolving and developing all the time. We have seen retailers taking more interest in it at the moment because the efficiencies in restocking the shelves means their staff on the shop floor can spend more time with customers. In that way they can upsell and enhance the shopping experience. “Over the next few years, it will be
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important to develop processes which allow the packaging industry to be more agile so that packs can be customised down to the level of specific stores. Further, there could be topical messages that are appropriate to the region, or for the retailer to promote activity around a particular date. “For example we could see more Wimbledon-specific packs for London SW19 in the months of June and July, or even Glastonbury Festival-inspired messages for stores in Somerset. “We may well see increasing levels of interactive information becoming integral to the packaging, such as QR codes. Augmented reality triggers could play an increasing role where consumers can move over an image with their phone to see the how the ingredient can be put into a recipe, or the component into a
machine which could apply to car parts and accessories. “The technology is really already here but over the next few years we would expect to
see much more use of digital information within packaging. This can dramatically enhance the way brands can package and present their products on the shelf and realise the true potential of RRP. “But what is really crucial for the future of RRP is understanding how important it is to focus on that final step in the pathway to purchase. That is, when the consumer’s hand is hovering over the box and they are making their choice, that everything has been done to ensure the product is being presented and promoted in the best possible way on the shelf. “Without that, none of the effort to get the product to that point will have been worth it.” For more information, visit: www.dssmithpackaging.com. J
I PREMIUM PACKAGING
Robino & Galandrino Technology Supplied by Evolution volution Bottling and Packaging E Solutions are prominent suppliers of bottling line plant to many major premium drinks brands within the UK and Ireland. Complementing their partnership with MBF and PE LABELLERS, Evolution BPS work regularly and exclusively with TMG, Robino & Galandrino and have recently formalised their relationship with internationally renowned supplier of advanced inspection systems Logics & Controls. In conjunction with these key suppliers, Evolution BPS provide quality, innovative equipment to secure the correct solution for any project, creating a proposition that can offer full line or individual machines for all bottling and packaging sectors. In a recent project involving supplier Robino & Galandrino, who have a renowned pedigree with premium brands, Evolution BPS have supplied a prestigious west of Scotland global drinks producer with two R&G Z Astra 10 Capsule Dispenser and Spinner blocs. With R&G machines already in place elsewhere in the producers fold, their known enhanced capability made R&G and Evolution the obvious choice when it came to the replacement of existing alternative plant. Bringing innovation to their solutions is an important feature of the proposition delivered by all the suppliers working with Evolution BPS, and innovation is at the heart of the Evolution product portfolio. In this project Robino & Galandrino’s 40
patented centralised pneumatic spinning roller pressure system is fitted to give consistent pressures across all heads. The pressures can be easily changed to suit different needs for different bottle formats and in fact are automatically selected when changing products. The spinning rollers only actuate when descending down and then open prior to the heads being raised. This ensures that the capsule is not damaged during this phase and that only the correct amount of spinning takes place. This technology was particularly attractive for this project as it was capable of delivering an improved finish to the final product, a feature of particular importance to their range of premium brands where visual perfection is almost as important as product integrity. With production speeds of up to 9,600bph these machines will be capsuling some of the world’s most prestigious
FOOD & DRINK BUSINESS EUROPE, MAY 2013
whisky brands. Application to such a variety of superior brands demonstrates the wide ranging capability of these machines which will accommodate a variety of bottle sizes ranging from 200ml to 1litre. Additionally the capsules involved vary in size and include both tin and polylaminate. Working together since 2005, Evolution BPS are the exclusive representatives of Robino & Galandrino in the UK and Ireland. R&G supply all types of automatic and semi-automatic capsule application machines and wirehooding machines for sparkling products. Machines of speeds ranging from 10 bottles per minute to 40,000 bottles per hour make Robino & Galandrino a provider that offers solutions to bottling plants whether small or large scale producers. The Evolution portfolio is now fully showcased by their newly launched website, www.evolutionbps.co.uk, allowing customers to find out more about Evolution Bottling and Packaging Solutions, and the extensive range of products and services offered by Evolution to meet the needs of all bottling and food packaging sectors. J
I ACTIVE & INTELLIGENT PACKAGING
The New World of Possibilities For Packaging Andrew Manly, Communications Director for AIPIA, explains the next generation of packaging developments. ost consumers consider packaging to M be functional, but rather boring, a nuisance if it is too difficult to open, or unfriendly if it is hard to dispose of, or there is deemed to be too much of it! But what if that same packaging could extend shelf life of foods dramatically; tell consumers the condition of the product inside; remind people to take their medicine; track it throughout the supply chain; and greatly reduce theft and pilferage which adds costs for everyone? What would they think of packaging then? Unrealistic? Too expensive? Too complicated? Well the truth is this packaging revolution is happening now - its already well under way and is going to be unstoppable! And it is using the very latest materials, technologies and science to bring a new generation of packs to the market which Checkpoint Syswill dramatically cut tems claims to food waste, improve have created an security and Brand innovative solution protection as well as to allow wine botmaking packs fun tles, some costing and informative. up to £100,000, to Eef de Ferrante, be securely ‘opendirector of the Active displayed‘ on retail & Intelligent Pack shelves without aging Industry Ass affecting the ociation (AIPIA) bottle's appearexplains: ”There are ance. so many possibilities
for A&IP it can seem overwhelming at times. It not only offers many practical solutions but it is perhaps the most exciting marketing tool for a generation.” Interest is enormous from every sector of the packaging world. This is clearly demonstrated by the fact AIPIA has acquired more than 300 members in less than a year of existence. These include a large number of blue chip end users, major packaging suppliers as well as specialist providers of A&IP services and technologies.
At the push of a button, consumers could heat up the food or beverage inside the HeatGenie can without having to open the container.
So What Exactly Is A&IP? In the most general terms Active packaging relates to materials and substances, including nanomaterials, which can improve the shelf life of fresh foods, condition monitors which tell consumers if the product is still fresh, or offers security against tampering or counterfeiting. Intelligent packaging broadly covers sensors and RFID tags for both retail security and logistics, track and trace capabilities, printed electronics, smart packs, mobile commerce and codes, such as QR codes, which can offer much more information than just batch codes and sell by dates. The truth is these ‘definitions’ merely scratch the surface of the potentiality for most A&IP technologies. And, of course some can be combined to offer multiple or enhanced capabilities. For example the use of nanomaterials in printed electronics will lead to a new generation of RFID sensors which can become cheap enough for item based applications. Here and Now RFID is a well-established concept and used extensively in logistics for many industries. However both the limitations of some RFID tags’performance and cost FOOD & DRINK BUSINESS EUROPE, MAY 2013
have limited its adoption for some products, particularly where cold conditions or harsh conditions can lead to damage. All This is Changing! The new generation of tags and sensors can be read over long distances, can be highly robust and rather than costing 10 cents each can be produced for as little as 1 cent per 100. With these dramatic changes in the two largest limiting factors use of RFID technology is set to explode in the future. Its time has most certainly arrived. Likewise modern materials and new technological developments are leading to better and better capabilities to fight against microbial contamination or oxygen invasion. Some of these advances are due to better understanding of the science as much as to new packaging films. For example a recent research project has shown that the introduction of ozone into sealed packs can have a definite impact on shelf life. However it is certainly the case that new and better materials are leading the way in this area of A&IP. One recent development has enabled anti-fungal and antimicrobial formulations to be incorporated into the film during its manufacture. It can 41
A new egg pack, called Gogol Mogol, designed by Russian company Kian, is more than just an egg carton - it ‘boils’ the egg in the packaging!
even be added to your credit card, which is a major source of dangerous bacteria! Stopping the Leaks For the premium drinks industry the problem of fake products or filling original bottles with cheap copies is an enormous one. At a recent conference one major Scotch whisky distiller said it spent more on anti-counterfeiting measures in some countries than it did on marketing! Riding to the rescue is A&IP which can supply a full range of measures. One example is an NFC (near Field Communication) tag being applied to fine wines which can tell the consumer, via an app on his or her smartphone, whether the original bottle has been ‘recycled’ by fraudsters. Just tap the bottle with your ‘phone and it will give you a history of the bottle and its contents. Marketing Tool Imagine a beer label which can tell you the provenance of the particular brew, a bit about the style and flavour of the content and where it is available locally. Well, in fact, this already exists and has been used by CAMRA, the UK’s Campaign for Real Ale. Last summer in Spain, on cans of Coca Cola, a QR code (that’s the little square code you see a lot on posters and packs) when read by a smartphone would take the consumer to a whole website about the Euro 2012 football finals. A&IP has the potential to be such a strong marketing tool it is the headline topic of the AIPIA’s second world congress in Frankfurt 23-25th September 2013. Coinciding with the FachPack exhibition, AIPIA’s congress has already attracted speakers from Marks & Spencer, KMPG, Mead Cambridge Consultants has Westvaco and many of the completed the development of leading suppliers of A&IP DropTag, a Bluetooth-based RFID products and services. For sensor tag that could help more information on AIPIA logistics companies and their and the congress visit thee customers identify when a Association’s website www. package has been dropped. aipia.info J 42
FOOD & DRINK BUSINESS EUROPE, MAY 2013
I ACTIVE & INTELLIGENT PACKAGING
Seibersdorf Laboratories – Smart NFC-/RFID Transponders For Intelligent Packages ased on more than 25 years of expertise B in applied electromagnetics and antenna design Seibersdorf Laboratories has extend-
the WIMA 2013 exhibition (April 10th12th, Monaco), Seibersdorf Laboratories’ patented NFC Smart Beverage Can and NFC Smart Beverage Bottle attracted high interest.
ed its portfolio to the development of customized NFC- and RFID-based smart transponder technology, which are the key elements for intelligent product packages. Customised Solutions Such smart passive (ie battery-free) transponders are low cost and allow wireless data communication and data exchange with a corresponding reader device, eg a NFC-enabled smart phone, and they can be miniaturzied and integrated into packages, thereby enabling the package to provide specific functionalities. Depending on the particular needs, these functionalities can range from simple indicators (eg
open/closed) to sophisticated measurement tasks (eg temperature, pressure, light, etc). Understanding the specific requirements of its customers Seibersdorf Laboratories is always looking for a cost efficient and reliable solution in order to satisfy customers’ needs regarding numerous aspects, eg counterfeit protection, cooling chain management, detection of unauthorized product manipulation, tracability, marketing and advertising. A New Dimension – Smart Can and Smart Bottle One of the company’s latest developments is the NFC Smart Beverage Can and NFC Smart Beverage Bottle, enabling new dimensions in beverage marketing. After opening the can or emptying the bottle, a small low cost transponder integrated in the can opening tab or the bottle label can be wirelessly accessed by the consumer with a NFC-enabled mobile phone. Most importantly, the consumer can not only retrieve data and information from the can and bottle, but can also store data and information to the can and bottle. This creates almost infinite possibilities for product related marketing and advertising activities, eg live betting, collaborative games, market surveys, loyalty programs, etc. Recently, for the fist time presented at QUALITY
Make Your Package Smart! If you are interested in Seibersdorf Laboratories’ NFC Smart Beverage Can or NFC Smart Beverage Bottle or you are looking for a NFC- or RFID-based solution for making your package smart and/or counterfeit protected, let Seibersdorf Laboratories know. For further information, please contact +43 (0) 50550-2810, email: nfc@seibersdorf-laboratories.at or visit www.seibersdorf-laboratories.at/nfc. Seibersdorf Laboratories offer high-quality laboratory and analysis services globally as well as solution-driven Research & Development on various fields, eg electromagnetic compatibility, radio frequenzy engineering, laser and optical radiation, ionizing radiation and radiation protection. J
& HYGIENE
Labcell Introduces Innovative Dip-style Digital Refractometer abcell is adding the Atago Pen Pro dipL style digital refractometer to its range of instrumentation for the food and drink industries. This high-quality, fast and accurate instrument is believed to be unique in that it can be dipped into vessels without product samples having to be removed for testing. In non-homogeneous products, the mix can be stirred with the ‘pen’ refractometer until the reading stabilises on the integral
display. Very easy to use, the Pen Pro refractometer generates readings in around 2 seconds and, because readings are continuous, any inhomogeneity can be readily identified. The FOOD & DRINK BUSINESS EUROPE, MAY 2013
measurement range is 0.0 to 85.0% Brix with an accuracy of +/-0.2%. Temperature-compensated Brix measurements can be made in any liquids, sauces or pastes with temperatures of 10-100 degrees C. A data sheet can be downloaded directly from the Labcell website at www. labcell.com or contact the company with specific enquiries by telephone on +44 (0)1420 568150 or email mail@ labcell.com. J 43
QUALITY
& HYGIENE
I FOOD INSPECTION & DIAGNOSTICS
Quality Assurance is Paramount aramount 21, a South-Devon P family owned frozen food manufacturer, has installed an end of line
However, with our quality inspection equipment we can have complete peace of mind that our food is safe.” Loma IQ3 Metal Detector to reliably At the Devon site, Paramount uses inspect a challenging new seafood a Loma 6000 Combination product. Checkweigher and Metal Detector Inspection of the new product, system, which was purchased nearly large 10kg boxes of frozen seafood, seven years ago. The reliability of the needed to meet all food safety stanequipment and Loma’s dependable dards, HACCP requirements and maintenance service meant that Paramount’s high quality expectaParamount had no concerns choostions. A renowned name in the ing another machine from Loma. “I seafood market and respected brand was impressed with Loma Systems in the foodservice and retail industhe IQ3 system was custom-built, tries, quality is closely monitored at and delivered before time and on The end of line Loma IQ3 Metal Detector checking 10kg boxes of every stage of Paramount’s producbudget,” concludes Gary Dark. seafood. tion process from raw materials With its extensive portfolio of through to dispatch. Paramount Production Engineer, Gary Dark complementary weighing and inspection technologies, and its explains: “A new Paramount customer required the highest specifi- strong focus on the needs of the Food Industry, Loma is uniquely cation from our metal detector ensuring identification of very small resourced to provide systems that not only meet the specific quality contaminants from a large box of seafood.” assurance needs of its customers today, but offer realistic potential Reliably inspecting a large box for foreign contaminants in a for expansion or enhancement to meet the changing needs of harsh environment where products are frozen to temperatures as tomorrow. For further information visit www.loma.com. J low as -20 C was challenging. Frozen products are well known to cause reading abnormalities on any metal detector and have been traditionally difficult to inspect due to high product effect. In response to the challenges, Loma Systems specified an IQ3 end of line metal detector system with a 450x450mm aperture tunnel to easily handle large boxes. Manufactured to IP69K, built in robust stainless steel the system ensures long, reliable performance and exceeds any harsh environment cleaning specification with enhanced protection for high or low temperature washdown. Most importantly, the IQ3 offers leading sensitivities so that product integrity is not compromised. Its Automatic Variable Frequency feature enables operators to identify the point at which product effect is minimal but contaminant detection is at its strongest. Gary Dark comments: “I installed the machine myself with no problems and it was quickly up and running.” The system has a frequency operation range from 40-900kHz and has the ability to select the ‘correct’ operating frequency in seconds, eliminating past restrictions caused by single frequency and ‘limited frequency’ detectors; a key benefit for manufacturers with challenging applications such as Paramount’s. Gary Dark continues: “It is important to us that we minimise the risk of any Frozen products such as seafood have possible contaminants getbeen traditionally difficult to inspect. ting into our products.
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FOOD & DRINK BUSINESS EUROPE, MAY 2013
QUALITY
& HYGIENE
I FOOD INSPECTION & DIAGNOSTICS
Randox Food Diagnostics – Providing Reliable Food Safety Screening modern food markets consumers are Iofnputting an increasing focus on the quality their food. In order to keep this quality to the highest standard it is vital that food safety testing is rigorous and provides a complete picture of the food supply chain including safety and traceability. Regular food screening for chemical residues should play a key role in protecting the consumer. This screening ensures that only the highest quality products reach the food chain, pro-
ducing a complete safety profile for all food products. Randox Food Diagnostics offer a versatile range of kits that include an extensive list of drug residue ELISA and multi-analyte biochip products providing a range of excellent screening platforms for detection of antimicrobials, growth promoting hormones, drugs of abuse, anthelmintics and beta- lactams in animals and foodstuffs. The biochip testing platform uses the world’s only multi-analyte quantitative drug residue analyser; the Evidence Investigator. This multiplex platform provides simultaneous detection of an extensive list of compounds using sample matrices including muscle, liver/kidney, seafood, milk, honey,
urine and animal feed. This multiplex testing format reduces cost, run time and labour requirements and guarantees faster turnaround time for results and a higher throughput (675 tests in under 2 hours). J
Cheshire Farm Installs N-ice Metal Detector ward-winning ice cream producer A Cheshire Farm continues to invest in its modern factory with the recent installation of a metal detector and conveyor system from Lock Inspection Systems. The familyrun business produces over 2,000 litres of ice cream per hour, in more than 30 different flavours and a range of tub sizes from 110 ml to 5 litres. The chosen end-of-line Lock system, which replaces an outdated metal detector, meets the challenges of this very specific manufacturing environment. “Accurate inspection of ice cream can be difficult because the conductive signal varies according to the temperature of the product - even slight changes during production will make a difference. With temperatures of around -6 C at inspection, any unexpected rise or fall in ambient temperature may change the temperature of the ice cream and alter the conductive signal that it generates. Our sophisticated technology can track
Lock’s INSIGHT metal detector range reduces unnecessary rejects.
these fluctuations and make the necessary fine adjustments to ensure a consistently high level of contaminant sensitivity,” explains Rob Gray, UK sales at Lock Inspection Systems. Installed to inspect the filled tubs, the Lock metal detector and conveyor system FOOD & DRINK BUSINESS EUROPE, MAY 2013
also benefits from user-friendly data software which can store and recall over 100 product settings; allowing it to efficiently adapt to the range of different sizes. “We needed to update our detection system and chose Lock’s bespoke system based on its reputation for outstanding performance, reliability and understanding of specific manufacturing issues. It’s now a key part of our factory,” comments Graeme Fell, production manager at Cheshire Farm. Cheshire Farm’s Real Dairy Ice Cream is made using fresh whole milk and cream which is produced on the farm. Established in 1986, the business was developed as a way to create added value from the milk produced in excess of the farm’s quota restriction. Its award-winning ice cream is now supplied to over 900 pubs, restaurants, hotels and retail outlets across the north-west of England. For further information visit www.lockinspection.com. J 45
I TOTAL PROCESSING & PACKAGING PREVIEWS Navrang polyfilms holds the distinction of being the most technologically advanced manufacturers of barrier films in India. It manufactures high quality plastic films with the help of its state-of-the-art facility that is fully loaded with automatic systems for extrusion, multicolor printing, slitting, pouch/ bulk bag making and more. What set Navrang polyfilms apart from the others is the unique proprietary co-extrusion processes and custom resin blends. This core competency is achieved by the polymer and food chemistry expertise that the company possesses. The exceptional manufacturing capabilities also enable the company to offer custom design materials based on customer's special needs. The company has a state-of-the-art quality control division that are well equipped with
testing equipment. Research and development is an everyday process and providing all-round services for the customers is also one of the biggest priorities. • Our raw materials are approved by FDA, EU food regulation etc • We have a strong team of technical experts • We excel in custom resin blending and raw material handling techniques Navrang polyfilms Plot no. 830 Opp Joginimata Temple Nr. Uma Marble Santej Tal Kalol,Gandhinagar Phone: 0091-9825645450 E-mail: info@navrangpolyfilms.com Website: www.navrangpolyfilms.com
Horizontal and Vertical Produce Bagging From Erapa Erapa’s Crima wrapping machine combines the characteristics of a manual/semi-automatic flow wrapper and form fill and seal machine in one unique, compact package. The ability to be adjusted through horizontal to vertical positions to suit the product or application type provides a flexible solution to a wide range of low to medium volume packaging needs. Coupled with the additional options of print registration, date coding and weigh price systems the Crima offers a versatile, cost effective method for flow packing trays, vegetables, bakery, pasta and other granular product types as well as non-food items.
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The Crima is able to run polypropylene, laminated, perforated and polythene films up to 1000mm wide and can produce bag lengths from as little as 10mm to infinity. For further information contact Erapa (UK) on Tel +44 (0)1582 722462 or Email info@erapa.co.uk. Visit Erapa (UK) at Stand A85 at Total Processing and Packaging where the company will be exhibiting its full range of packaging machinery.
FOOD & DRINK BUSINESS EUROPE, MAY 2013
I EXHIBITION
UK's Largest Processing and Packaging Exhibition Uncovers Secret to Improving Competitiveness – Consistency and Quality his year's Total Processing & Packaging exhibition - 4-6 June 2013, NEC T Birmingham - takes place against a tough backdrop for the industry. Manufacturing output fell by 3 per cent in the year to March 2013, according to the Office for National Statistics. On top of that, the manufacturing industry is suffering a degree of collateral damage from the horsemeat scandal. The industry could be forgiven for looking glum. Luckily, there are some chinks of light amongst the darkness: some firms are finding ways to turn the crises into opportunities. Speaking about the challenges facing manufacturers during this time, Michelle Newman, Marketing Manager for Kliklok International Ltd, Stand H10, comments: “In light of the recent controversy over horsemeat, an increasing number of supermarkets are pledging to source their ingredients from reputable suppliers in the UK. It already seems that the average consumer is now favouring fish and chicken over red meat consumption. For the UK food producer, this may well lead to an unexpected upturn in overall production, which means that higher speed, labour- saving automatic packaging could be the next step.”
Graham Earl, Exhibition Manager at the Total Processing & Packaging Exhibition, adds: "It sounds counter-intuitive, but tough times can be positive for manufacturers, as they act as a catalyst for innovation. We think that this is where a show like Total comes into its own - it is a place to meet peers from across the industry, share the latest ideas and thinking, and find ways to chart a course through the tough terrain."
Challenging Perceptions Over 320 exhibitors will be on hand to demonstrate just how processing and packaging professionals can improve efficiency, accuracy and consistency while focusing on innovation. Comprising three dedicated hubs including Pakex, PPMA and Interphex, attendees are invited to discover the latest innovations in packaging design at the Pakex Hub, machinery to enhance productivity at the PPMA show and new manufacturing solutions designed specifically for the pharmaceutical industry in the Interphex hub. From design, automation and control, packaging machinery to materials and containers, no matter what industry or product you're in charge of, there is no better place to discover the latest solutions and technologies available to enhance your business and transform your production line. Learn From Industry Insiders While advice on the latest pressing industry topics can be found on a number of exhibitor stands, free-to-attend seminars will be available throughout the 3-day event featuring experts Tyrrells, M&S, Dairy Crest, B&Q, Kerry Foods, GSK and Siemens who will put the industry's pressing issues under the spotlight, share the latest advice and reveal groundbreaking industry innovations. Reflecting the three show hubs, visitors can attend seminars in the Manufacturing Forum, sponsored by Linx Printing Technologies, the Interphex Theatre, sponsored by Bürkert Fluid Control Systems and Pakex Innovation Hub, sponsored by Markem Imaje. Each hub offers a unique seminar programme packed with an exciting line up of topics. Looking to the Future Recognising the best and brightest up-andcoming talent in the industry will also be a key focus, with the return of the Ones to Watch competition and the launch of the new Packaging Design Challenge. Ones to Watch is a search for the indusFOOD & DRINK BUSINESS EUROPE, MAY 2013
try's brightest young processing and packaging professional, judged on entrepreneurial spirit and a commitment to the industry. Sponsored by Festo, the successful candidate and 'one to watch' will win more than £9,500 of in-house training from Festo's Training & Consulting portfolio. If you know a colleague that fits the bill, visit www.totalexhibition.com/otw. Got a Packaging Idea? Looking For Investment? New to the Total Processing and Packaging Exhibition 2013, the Packaging Design Challenge will offer one lucky packaging professional the chance at a real investment in their packaging innovations. Candidates are invited to submit their packaging concepts for a chance to secure a real financial investment live at the show. If you have a concept or packaging idea you'd like to see on the shop shelves, visit www.totalexhibition.com/packdesignchallenge for more information. With so much variety on offer, if you want to hear about the latest news and trends in the processing, packaging and pharmaceutical industries, you’ll start with the Total Processing and Packaging Exhibition 2013. For more information and to register, visit http://www.totalexhibition.co.uk. For more information on the Total Processing and Packaging Exhibition 2013, please visit www.totalexhibition.com or join the conversation on Twitter (@TotalExhibition) or the Total Exhibition 2013 LinkedIn group. J 47
I ANAEROBIC DIGESTION
Spotlight on AD in the Food and Drink Industry ith food and drink businessW es looking at ways to treat their waste - including effluents and out of spec food and food processing waste - in an efficient and sustainable way, at the same time as tackling rising energy bills and operational costs, anaerobic digestion (AD), a process which converts organic waste into renewable energy and high quality biofertiliser, is becoming an increasingly attractive option. Many businesses are already using AD, with all the major food retailers including Waitrose, Sainsbury’s, Asda, Lidl and CoOp sending their food waste away for treatment and others like Marks & Spencer and Premier Foods have established joint ventures to work together to treat their food waste. Food processors like Staples and Branston have invested in their own on-site plants, and Bernard Matthews has recently entered into a joint venture with Glendale Power, with Xergi contracted to design and build an AD plant at their turkey processing factory in Holton. AD is not just for solid wastes either; it works for high chemical oxygen demand (COD) liquid waste, too, with BV Dairy’s AD plant reducing
effluent treatment charges and energy costs since July 2011 and Diageo looking at AD to treat their brewery wastes. UK AD & Biogas – 3-4 July, NEC Birmingham In recognition of the significant opportunity for the AD and food and drink industries to work together, this year’s UK AD & Biogas (3-4 July, NEC Birmingham), the UK’s largest anaerobic digestion and biogas trade show, is putting AD in the food and drink industry in the spotlight. Organised by the Anaerobic Digestion and Biogas Association (ADBA), this free to attend event will show food processors and manufacturers, retailers and the hospitality sector why it makes financial sense to integrate AD into your business or get your food waste collected separately and sent for treatment through AD, including how to design and implement collection systems that work for your business, valuing your food waste feedstock, managing ongoing
operations and discussing how to make best use of the outputs from an AD plant. Offering a free two day conference, 22 seminars and workshops, free one-to-one advice clinics, AD site visits, a new transport feature area and the second UK AD & Biogas Industry Awards, UK AD & Biogas 2013 will provide all the information and contacts you need to explore how AD can work for you. Food and drink focus at UK AD & Biogas 2013: • Conference focus on the business case for AD with dedicated content for food and drink businesses • Free 'sending your food waste to AD' advice clinic • Why we need to ban food waste to landfilll – Dustin Benton, Senior Policy Adviser, Green Alliance • The food and drink industry's changing approach to food waste – conference session • Food waste in the hospitality sector: the challenges – conference session • Valuing your food waste – a practical workshop • Case studies of food and drink businesses already involved in AD. Find out more and register for free at www.adbiogas.co.uk. J
ADBA member PDM’s ReFood plant at their headquarters in Doncaster
The Staples AD plant, built by ADBA member Xergi, recycles out of
diverts food waste from landfill and generates renewable energy. Picture
specification vegetables to produce renewable energy. Picture from
from PDM Group.
Xergi.
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FOOD & DRINK BUSINESS EUROPE, MAY 2013