August 2012
150th anniversary of Nestle’s UK confectionery business
Food & Drink Business Website:
www.fdbusiness.com
C o n t e n t s
- 2 M ERGERS & A CQUISITIONS
- 49 S EAFOOD
Coverage of British and international deals.
Buoyant export sales lift Errigal Seafood.
- 3 M ARKET F OCUS UK baby food market set for volume decline as home cooking increases.
PAGE 2 Age Korsvold, ceo, Orkla.
R EGULARS
P AGE 11 Fiona Kendrick, new ceo, Nestle UK & Ireland.
Processing & Manufacturing. . 12, 18, 22-27 Lean Manufacturing . . . . . . . . . . . . . . . . . . . . . . 22-25
- 5 C OVER S TORY
Bottling & Packaging. . 13, 17, 35, 45-47 Trays, Tray Sealing & MAP . . . . . . . . . . . . . . . . . 45-47
Transforming the confectionery market – Nestle’s UK heritage.
PAGE 15 Roger White, ceo, AG Barr.
Energy & Environment . . . . . . . . . . . . . . . 21
- 15 S OFT D RINKS AG Barr continues to invest in future growth.
PAGE 2 Michael Clarke, ceo, Premier Foods.
Storage & Logistics . . . . . . . . . . . . . . 29-34
Quality & Safety. . . . . . . . . . . . . . . . . . . . 42
Materials & Ingredients . . . . . . . . . . . . . . 56
PAGE 37 Dirk Van de Put, president & ceo, McCain Foods.
- 19 E NERGY F ROM W ASTE Agri Energy offers complete waste and renewable energy service.
Managing Director: Colin Murphy Editor: Mike Rohan Sales Director: Ronan McGlade Advertising: Susan Doyle, Neela Desai, Mark Davies and Sylvia McCarthy . Senior Sales Executive: Paul Lees
- 29 C OLD S TORAGE & L OGISTICS
PAGE 3 Patrick Coveney, ceo, Greencore.
Website: www.fdbusiness.com
ECSLA - The voice of the European cold storage industry.
London Office: Premier Publishing Limited, CTS, 34 Leadenhall Street, London, EC3A 1AT Tel: 0171 247 3238 Fax: 0171 247 3239 Premier Publishing Limited can accept no responsibility for the accuracy of contributors’ articles or statements appearing in this magazine. Any views or opinions expressed are not necessarily those of Premier Publishing and its Directors. No responsibility for loss or distress occasioned to any person acting or refraining from acting as a result of the material in this publication can be accepted by the authors, contributors, editor and publisher. A reader should access separate advice when acting on specific editorial in this publication!
- 31 & 37 F ROZEN F OODS Top 100 frozen foods manufacturers in Western Europe, 2012. It’s still all good at McCain Foods’ European business.
Production Manager: Susan Doyle
Food & Drink Business Europe is published by Premier Publishing Limited, 51 Parkwest Enterprise Centre, Nangor Road, Dublin 12. Tel: + 353 1 612 0880 Fax: + 353 1 612 0881 E-Mail: info@prempub.com
PAGE 5 David Rennie md, Nestle Confectionery UK & Ireland.
Design, Origination and Separations by Fullpoint Design (057) 8680873 Printed by GPS Colour Graphics Annual Subscription (UK and Ireland) £95 Overseas Subscription £115
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
1
M E E R R G G E E R R S S M
& &
A C C Q Q U U II S S II T T II O O N N S S A
Orkla to Become Leading Nordic Food Manufacturer Orkla has taken a significant step towards becoming a pure play branded consumer goods company by agreeing to acquire the family-owned Rieber & Son. The transaction values Rieber & Son (on a debt-free basis) at NOK6.1 billion (Eur831 million). Rieber & Son is an important supplier to grocery stores in the Nordic countries, parts of Central Europe and Russia. Its well-known brands include Toro, Vitana, K-Salat, Delecta, Frodinge, Chaka and Bahncke. In 2011, its total sales amounted to about NOK4.3 billion. EBITDA came to NOK642 million in 2010 and NO 464 million in 2011. The company has a total of 2,900 employees, of whom 1,700 work outside of Norway. “Together, Rieber & Son and Orkla will be the leading Nordic food manufacturer, with the expertise and resources to develop strong local products and brands in competition with international players,” comments Age Korsvold, chief executive of Orkla. “With this acquisition, Orkla expands its product portfolio and gains strong market positions in categories that are entirely new to us.”
Age Korsvold, chief executive of Orkla.
Premier Foods Disposing of Sweet Spreads and Jellies Business to Hain Celestial Premier Foods has agreed to sell its sweet spreads and jellies business, including the Hartley's, Robertson's, Frank Cooper, 2
focus on our Power Brands. Following completion of this sale, we will have raised around £275 million of the £330 million disposal proceeds that we committed to achieving by June 2014. This will represent a 22% reduction in our net debt since the half year.”
Unilever to Sell Frozen Meals Business in North America Michael Clarke, chief executive of Premier Foods.
Keiller, Gales and Sun-Pat brands, to The Hain Celestial Group for a cash and share consideration of £200 million. The consideration will be satisfied by £170 million in cash and the issue of shares in Hain Celestial with a value of at least £30 million at completion. The sale represents the third divestiture Premier Foods has announced this year and continues its strategy of prioritising investment behind its Power Brands and divesting selected, non-core businesses. The sale includes Hartley's, Britain's most popular jam and a category leader in jelly-tomake and ready-to-eat jelly, and a portfolio of marmalade brands in Robertson's, Frank Cooper, Keiller and the licence for Rose's marmalade. Also included in the sale are Sun-Pat, the leading brand of peanut butter in the UK, Gales, the UK's number two brand in honey and significant private label and business-to-business sales. The products are predominantly manufactured at Premier Foods’ Histon factory, near Cambridge, which will also be sold to Hain Celestial. For the year ended 31 December 2011, sales of the sweet spreads and jellies business were £165.0 million, of which 59% were branded sales. EBITDA for the year ended 31 December 2011 was £38.3 million and Trading profit was £36.1 million. Michael Clarke, chief executive of Premier Foods, comments: “This divestment is a major step forward in our strategy to simplify the business and
Unilever has agreed to sell its North America frozen meals business to ConAgra Foods for a total cash consideration of $265 million (Eur216 million). Unilever’s North America frozen meals business consists of a full range of premium, multiserve frozen entrees and appetizers under the well-known Bertolli and PF Chang’s brand names. The transaction, subject to regulatory review, includes a license for the use of the Bertolli brand name and the transfer of Unilever’s existing license with PF. Chang’s for use of the PF Chang’s Home Menu brand name. It does not include Unilever’s facility in Owensboro in Kentucky, at which the Bertolli and PF Chang’s frozen meals are currently produced. Unilever will retain the Bertolli trademark and continue its existing pasta sauce business, with manufacturing operations remaining at its Kentucky facility. Unilever’s decision to divest its North American frozen meals business is in line with its global strategy to exit the frozen foods business. Unilever previously divested its European frozen foods business. In 2011, the combined Bertolli and PF Chang’s brands had turnover of approximately $300 million.
Carlsberg Extends Ownership of Baltika Breweries Carlsberg Group has acquired a 12.1% stake in Baltika Breweries for an undisclosed sum to increase its ownership of the Russian brewer to 96.8%. When the necessary administrative steps have been completed Carlsberg Group intends to
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
launch a compulsory purchase of the remaining outstanding shares in Baltika Breweries. Russia is the world's fourth largest beer market and the Carlsberg Group firmly believes in the longterm market and profit pool growth opportunities. The transaction is in line with the Carlsberg Group's strategy of having 100% ownership of its most important subsidiaries to achieve greater operational flexibility. By having 100% ownership of Baltika, the company can be fully integrated into the Carlsberg Group which will speed up the implementation of decisions.
Greencore Makes Bolt-on Acquisition in UK Ready Meals Greencore Group has acquired International Cuisine, a private label chilled ready meal business, from the Hain Daniels Group in the UK. International Cuisine’s ready meal facility is based in Consett in County Durham and the majority of its revenue of approximately £45 million is derived from several existing Greencore ready meal customers.
M E E R R G G E E R R S S M
& &
A C C Q Q U U II S S II T T II O O N N S S A
extending presence outside the UK with an emerging convenience food business in the US.
Emmi Increases Stake in Venchiaredo
Patrick Coveney, chief executive of Greencore.
The acquired facility will also provide additional capacity for Greencore in the ready meals category in the UK, which continues to show strong growth. The gross assets acquired were £16.7 million. Greencore is one of the leading convenience food manufacturers in the UK with strong market positions across sandwiches, chilled prepared meals, chilled soups and sauces, ambient sauces and pickles, cakes, desserts and Yorkshire puddings. The group has also been
Swiss dairy group Emmi has increased its stake in Italian fresh cheese specialist Ven chiarado from 10% to 26%. Emmi has been working with Venchiaredo as a minority stakeholder since January 2010, a commercial venture which has seen it take over the sales and marketing operations of the Ramuscello-based, north Italian co-operative. By increasing its stake from 10% to 26%, Emmi will be able to participate even more effec-
tively in the growing fresh cheese market. The closer collaboration will also allow Emmi to benefit from added synergies along the value chain, notably in the context of the fresh products from Trentinalatte.
Cremonini Snaps Up Bagel Factory Italian food group Cremonini is acquiring Bagel Factory for an undisclosed sum. With over 50 shops and franchise units, Bagel Factory is the largest bagel operator in the UK and Ireland. Cremonini had a turnover of Eur3.2 billion in 2011 with 41% generated by the production of beef, cured meats and spices, 38% from its distribution activities and the remaining 21% from food service.
Eden Springs Acquires French Coffee Company Eden Springs, Europe’s leading workplace drinks provider, has taken another important step in the roll-out of its hot beverage portfolio by acquiring the office coffee service (OCS) business of DrinkSo. This is Eden’s fourth
European coffee company acquisition in less than twelve months. DrinkSo is based in Bordeaux and serves over 800 customers in the South West region of France. Its premium Espresso range is delivered in partnership with coffee giant, Lavazza. As part of its longer-term strategy to dominate the workplace beverage market through a total water and coffee service, Eden Springs has undertaken a series of other acquisitions in recent months. These include Spain’s water cooler provider, Todagua, Swiss water cooler company Eldevia, Dutch-based coffee company TheCafe, as well the UK’s Shakespeare Coffee Company and Garraways.
I MARKET FOCUS
UK Baby Food Market Set For Volume Decline as Home Cooking Increases hile the UK baby food and drink market W has been better insulated from the economic downturn than many others, new research from Mintel finds tighter household budgets have driven as many as four in ten (41%) parents to making more home-cooked food for their babies and toddlers. Sales of baby food, drink and milk have performed well and over the past five years the market has shot up in value by a healthy 51% to reach £611 million in 2012. But while value sales are thriving, usage is slowing as Britain’s parents swap manufactured baby food for homemade alternatives. Over the next five years, baby food and drink is forecast to increase in value by 15% to hit £703 million in 2017, fuelled by an increase in the average selling prices of these products. In terms of volume sales, however, sales will decrease by 3%, from 97 million kg in 2012 to 94 million kg in 2017, as birth rates are expected to turn to a slow decline, and scratch cooking continues to
pose intense competition to the market. Emma Clifford, senior food analyst at Mintel, comments: “Home cooking is one of the biggest challenges facing the baby food market. Perceived as a safer, cheaper and a more controllable alternative to manufactured baby food, home cooking offers health-conscious parents greater peace of mind, with much of the switching having been fuelled by cost considerations.” She continues: “Given the high churn in the market, continued investment in product promotion will remain key to attracting new users into the category. Parents are only in the market for FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
baby food for something like 6 months, or a bit longer for convenience, even the established brands have to keep rebuilding awareness, as their customer base keeps moving out of the market.” Within the market, the wet and dry baby food sector (such as meals, desserts and cereals) enjoyed impressive value growth of 35% between 2007 and 2012 to reach £192 million. Although much smaller than the wet and dry baby food sector, the value of the baby snacks market (including rusks, baby rice cakes, biscuit and fruit snacks) has soared by 65% since 2007 to reach £53 million in 2012. Meanwhile, the baby milk market continues to grow, increasing by 12% and 66% in terms of volume and value respectively between 2007 and 2012 to reach £355 million. By contrast, plagued by concerns over the healthiness and price of baby juice drinks, the baby drinks market contracted by 24% between 2007 and 2012 to £11.7 million. J 3
COVER STORY
Transforming the Confectionery Market – Nestle’s UK Heritage Nestle is celebrating the 150th anniversary of its UK-based confectionery business – Rowntree’s, which incorporates well known British and international brands such as Kit Kat, Aero, Polo and Yorkie.
R
owntree’s, which was acquired by Chocolate Crisp, which became Kit Kat, was Nestle in 1988, has helped to transdue Rowntree’s marketing director George form the confectionery market both in Harris. Appointed in 1933, George Harris Britain and internationally by making believed in giving products a strong identity chocolate a regular and affordable purchase. and personality. The business originated as a small, familyUnder his direction, Rowntree’s was one of owned drinking cocoa producer in the city of the first companies in the world to conduct York in the north of England in the 19th cenmarket research to find out what consumers tury. really wanted. On the basis of this, The Rowntrees were Quakers with strong Rowntree’s introduced its Black Magic chocoreligious beliefs. They built a confectionery late assortment, one of a number of products empire and in the process changed the way that made chocolate affordable for working Britons view, buy and eat chocolate. families. Rowntree’s developed from making the Indeed, the iconic Kit Kat brand, which ingredients for a chocolate drink to creating a was 75 years old in 2010, is now sold in more variety of different sweets including well than 70 countries across all five continents. known favourites such as Rowntree’s Fruit David Rennie, managing director of Nestle Kit Kat has consistently been a star performer Pastilles and Fruit Gums, Smarties, Black Confectionery UK & Ireland. within Nestle’s global confectionery business Magic, Aero, Dairy Box, Kit Kat, Polo, After and is also one of the Swiss group’s 28 billionEight, Jellytots, Matchmakers, Breakaway, Lion, Yorkie, and aire brands – brands with annual sales of over SFr1 billion (Eur830 Drifter. million). However, the enterprise which was founded by Henry Isaac Rowntree in 1862 was not an instant success and only started to Improving Working Conditions flourish when he was joined by his older brother Joseph, who In addition to the well known confectionery products it developed, brought his own business experience to the company, six years later. Rowntree’s also became famous for the facilities it provided for its Another key milestone in the company’s progress occurred in staff. The company promoted better working conditions by short1879 when Frenchman Claude Gaget arrived at the factory trying ening the working week. Its Haxby Road factory offered light, airy to sell a type of French sweet called ‘pastilles’. He was employed to working conditions and was situated in what was then countryside, create a new range for surrounded by greenery and sports fields. the company. First Unlike most employers of its era, Rowntree’s provided pensions, named Rowntree’s paid holiday and sick leave and healthcare, as well as education for Pastilles and Rown younger workers. Employees could use facilities including a swimtree’s Clear Gums, ming pool, library, gymnasium and a theatre. they were later called Rowntree’s even built a village, called New Earswick, on the outFruit Pastilles and skirts of York to help city dwellers and factory workers escape the Fruit Gums. Three slums. years later, Claude Since becoming Gaget started making part of Nestle, Rown ‘Chocolate Dragee’, or trees has played a cenchocolate beans. tral role in the develThese brightly colour opment of the Swiss ed, sugar-coated choc food and beverages olate drops were re group’s international named Smarties in the confectionery busi1930s. ness. With a global market share of about Modern Marketing 8%, Nestle is currentThe rebranding of ly the world’s third The iconic Kit Kat brand, which was 75 years old in Rowntree’s Clear Gums were later called Fruit products such as largest confectionery 2010, is now sold in more than 70 countries Gums. Chocolate Dragee and manufacturer, behind across all five continents. FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
5
York Heritage “York has a long and rich heritage in the world of chocolate and confectionery,” adds Competitive Edge Stefan Palzer. “The city’s early confectionery Nestle invests heavily to maintain a competicompanies pioneered the ideas and technology tive edge in manufacturing technology and to produce quality products on a mass scale, a efficiency. Over the past five years Nestle has tradition which Nestle continues today.” undertaken a multi-million pound investment York is one of the world’s largest for confecprogramme in its UK confectionery business. tionery manufacturing sites. It is the head Since 1988 Nestle has spent £200 million, Created by the Mackintosh business in Halifax, office of Nestle’s confectionery business in the including more than £50 million in the last northern England, in 1936, Quality Street changed UK and a hub for many of the company’s five years, transforming its confectionery fac- the way confectionery was manufactured and sold. corporate functions. It also incorporates a distory in York to create a best in class manufactribution centre, Nestle UK’s customer turing facility. The modernisation progremme has included the insight and learning centre, and Nespresso’s customer relationship construction of a new Aero factory and installation of new Kit Kat centre for the UK. wafer ovens. The Nestle York site makes over a billion Kit Kats and 183 million Aero’s each year, and employs 1,800 people. Quality Street Last year, Nestle celebrated 75 years of its innovative confectionery New Product Development assortment Quality Street brand in the UK. Created by the Nestle is also spending £7 million to expand the group’s global Mackintosh business in Halifax, northern England, in 1936, Research & Development centre for confectionery, also based in Quality Street changed the way confectionery was manufactured York. The Nestle Product Technology Centre at York develops new and sold. confectionery products and reformulates existing ones. The centre is The brand used ground-breaking technology such as the world’s responsible for developing breakthrough technologies that are the first twist-wrapping machine to make chocolate affordable for the basis of new product development. Ideas for new products can be general public. It is now the world’s number one selling boxed thoroughly tested from concept through to processing raw ingredi- chocolate assortment; exported to 70 countries including Canada, ents, to manufacturing and to packaging. New textures and flavours Denmark and France. are created at the centre as well as improved nutritional profiles. Nestle recently A key element of the centre is a pilot plant, which is being invested £20 million extended as part of the investment programme. Nestle confec- establishing a seasonal tionery specialists and engineers use the pilot plant to develop and confectionery manutest technologies, manufacturing processes and equipment before facturing centre in they are introduced in the company’s factories worldwide. There is Halifax. also a cutting-edge sensory testing facility for the tasting of protoOf course, the Ro types and finished products, which is also being extended. wntrees and Mackin “Confectionery is an exciting business which moves at a rapid tosh businesses mer pace,” explains Stefan Palzer, director of the global Product ged in 1969 to create Technology Centre Rowntree Mackin for confectionery. tosh, a publicly listed “This expansion will company that was allow us to accelerate purchased by Nestle and intensify confec- for £2.5 billion in tionery product devel- 1988, following a take opment, using sus- over battle with Swiss tainable and high rival Jacobs Suchard. quality raw materials, The deal marked the innovative manufac- largest takeover of a turing processes and British company by a reliable and efficient foreign one at that Rowntree’s Kit Kat production in the 1940s. Wafer production today. equipment.” time. Kraft Foods (including Cadbury) and Mars (including Wrigley).
Nestle UK Confectionery Head Moving to Europe David Rennie, currently managing director of Nestle Confectionery UK, has been appointed to the role of vice president Nestle Zone Europe Operations. He has been head of Nestle Confectionery UK since January 2009. During his time in confectionery he has been responsible for delivering exceptional business results with the business outperforming the market for four years in a row. David Rennie has also been responsible for driving major innovations including the introduction of Rowntree's Randoms, achieving no artificial colours, flavours and preservatives across the entire confectionery range, as well as the launch of the Nestle Cocoa Plan brought to life through the Fairtrade certification of Kit Kat four finger. In his new role David Rennie will oversee a number of countries and categories, building on learnings gained from the UK confectionery operation. He will be succeeded by Ciaran Sullivan, currently managing director of Lactalis Nestle Chilled Dairy UK & Ireland. Ciaran Sullivan joined Lactalis Nestle Chilled Dairy UK & Ireland as managing director in November 2009. Since then LNCD UK & Ireland has been one of the strongest performing chilled dairy businesses in the UK while introducing a significant number of new products across both the UK and Europe such as Yorkie Creme Dessert , Aero Finesse and Nestle Split Pots. Prior to this Ciaran Sullivan was country manager for Nestle Ireland for six years.
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Ciaran Sullivan.
7
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
09
Natural Approach Earlier this year, Nestle become the first major confectionery manufacturer in the UK to remove all artificial ingredients from its entire confectionery range. The Nestle Product Technology Centre at York Artificial colours, develops new confectionery products and flavours and preservareformulates existing ones. tives have been rep laced with alternatives in all 79 confectionery products sold by Nestle in the UK. Nestle is now using natural ingredients, such as carrot, hibiscus, radish, and lemon, to provide colour or flavour in popular products like Rolo and Smarties. Nestle made the changes in response to consumer demand in the UK for fewer artificial ingredients in food. According to consumer research, three quarters of British people look for products without artificial additives when buying confectionery. Nestle has already removed artificial ingredients from all its beverages in the UK, including Nesquik. ‘Chocolate Dragee’, or
with alternatives. The move is part of Nestle’s long-term commitment to finding natural substitutes for artificial colours, flavours and preservatives in confectionery. Similar initiatives are underway in Canada and a number of other Earlier this year, Nestle become the first major confectionery manufacturer in the UK to remove European markets. The removal of arti- all artificial ingredients from its entire ficial colours, flavours confectionery range. and preservatives builds on the ongoing work Nestle Confectionery UK has undertaken in recent years. In 2006, Nestle Confectionery UK was the first confectioner to place calorie information on front of pack across its portfolio. In 2009, it re-launched its chocolate biscuit bar range - Blue Riband, Breakaway. Toffee Crisp and Drifter now contain 99 calories with no impact on taste, while Kit Kat 2 Finger has 107 calories. chocolate beans were
Outperforming the Confectionery Market Despite the tough economic climate and reflecting the strength in depth of its brands portfolio, headed by Kit Kat, and a strong innovation programme, Nestle Confectionery UK has outperformed the British confectionery market for the last four years. In 2011, Nestle Confectionery UK’s continued growth was driven by its core brands with exceptional growth from Aero and Rowntrees, up 17.6% and 16.8% respectively, with Rolo up 31.5%. Continued innovations in confectionery include Kit Kat Pop Chocs, Rolo and Aero biscuits, Aero Caramel, and the expansion of the Ronwtree’s offering including Sour Pastilles, Jelly Aliens and Very Berry Jellies. Nestle Confectionery UK has continued to perform strongly in the first six months of 2012 growing in value by 0.4% YTD within a very competitive market category. Value growth was driven by Kit Kat (3.8%) and childhood favourites Rolo, Yorkie and Milky Bar. J
renamed Smarties in the 1930s.
Significant Milestone “This is a significant milestone. We are proud to be the only major confectionery company in the country to be 100% free of artificial preservatives, flavours or colours across our entire portfolio,” points out David Rennie, currently managing director of Nestle Confectionery in the UK but who has just been promoted to the post of vice president Nestle Zone Europe Operations. “We’ve worked very hard with our suppliers to ensure we have not made any compromises on the quality and taste of all our products.” The result of a seven-year research and development programme, the reformulation process has resulted in more than Nestle celebrated the 75th anniversary of its 80 artificial ingrediQuality Street brand in 2011. ents being replaced
New Head For Nestle UK and Ireland
Fiona Kendrick.
Fiona Kendrick, currently head of Nestle’s Global Coffee & Beverage Strategic Business Unit, will succeed Paul Grimwood as chief executive of Nestle UK & Ireland in October. Having been at the helm of Nestle UK & Ireland since January 2009, Paul Grimwood is moving to head up the Swiss food and beverage giant’s US business. Fiona Kendrick joined Nestle in 1980 in the UK. She started her career with Nestle working in sales & marketing for Findus in the Frozen Food Division. She became general manager of the division in 1991 before moving into the coffee business in 1993. Fiona Kendrick became managing director for the Beverage Division in Nestle UK in 2001, a position which she held for seven years. She moved to Nestle in Switzerland in 2008 when she became responsible for the global management of Nestle’s coffee and beverage brands. In this capacity, she has the responsibility for setting the strategic global direction for Nescafe as well as Milo, Nesquik and Nestea. Paul Grimwood.
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
11
I CONFECTIONERY
Hebenstreit – The Specialist in Wafer Production ebenstreit is recognised worldwide as H the manufacturer for state-of-the-art wafer production lines for flat and hollow wafers. Their wafer production lines, ranging from medium to high capacity, are all designed and manufactured in Germany. The scope of supply comprises the equipment for raw material feeding technology, batter and cream mixing systems, baking machines, sheet coolers, conditioning systems, cream spreading and layering machines, cooling units, cutting machines and the necessary downstream equipment for feeding the wafer fingers directly to the wrapping machines or any post-connected equipment such as chocolate enrobers, moulding lines etc. Product development, formulation improvements and technical support as well as training courses are
Hebenstreit baking machine.
evenness of the wafer sheets can be maintained over many years of production. This is of great importance when wafers are being processed in moulded products where the accuracy of the wafers leads to a very efficient usage of chocolate. Green Burner Technology
Hebenstreit cutting machine.
another very important Hebenstreit’s customer service.
part
of
Personal Touch
Owing to their medium company size, Hebenstreit can still support their customers with a special personal touch. Hebenstreit is constantly improving their technology, and, as a result of such, the output of their wafer machines has recently been increased significantly. All Hebenstreit wafer baking machines are supplied with the very strong and robust baking plate carrier that ensures that wafers are baked within a very precise tolerance. The proven technology of using a baking plate carrier in combination with the baking plate has been upgraded. Using newly designed adjustment features the 12
ments to the line to simply the operation, cleaning and the maintenance. For example, windows has been incorporated to areas that need to be monitored from newly introduced central monitoring stations, gauges and controls are clearly colour marked, central lubrication has been added where appropriate and great care has been taken to make all surfaces easy to clean by removing obstructions and eliminating trap points. Having all this in mind it is needless to say that many of the world’s popular wafer products are made with Hebenstreit’s technology and support. Contact Hebenstreit for further information and to experience “excellent engineering for delicious results”. J
A ‘green burner’ technology is applied to bake the wafers with a minimum of energy consumption. This enables wafer manufacturers to meet environmental legislation requirements and makes it easier for them to get the permits required to operate the lines where emissions are regulated. In cooperation with some major customers Hebenstreit has been undertaking a program of implementing the TPM philosophy to their production lines. TPM involves a complete reassessment of the operation and maintenance of a wafer production line from the view point of the operator and the maintenance engineer. This has led to a number of minor Hebenstreit wafers. but very significant improveFOOD & DRINK BUSINESS EUROPE, AUGUST 2012
I CONFECTIONERY
High-speed Packaging of Chocolate Products – System Solutions From One Source oesch Verpackungstechnik GmbH is an L international manufacturer of packaging machinery and systems located in the Upper Franconian town of Altendorf. As a subsidiary of the Piepenbrock Group, the company offers integrated solutions for customer-specific packaging systems. At the same time, LoeschPack offers the entire spectrum – from individual machines to multilevel, complex system solutions. The company’s product range includes packaging machines for the food and non-food sectors. LoeschPack is particularly specialised in the packaging of chewing gum, chocolates and dry-baked goods. LoeschPack’s cutting-edge production methods and comprehensive quality management are the foundation on which its sophisticated, high-tech, ec-onomical and high-quality machinery and equipment are built. Flexibility is the keyword in the dynamic confectionery industry, which LoeschPack serves primarily with fold wrapping and coiling machines for the chewing gum and chocolate industry. “With a manufacturing
Samples of small chocolate products.
penetration of more than 60 per cent, standard machines are only rarely manufactured; the requirements of international customers are too specialised for this,” comments LoeschPack CEO Andreas Graf. According to Graf, apart from high flexibility, strong performance, efficiency and packaging quality, the increasingly key deciding factor is the possibility to obtain system solutions from one source. Graf: “This saves significant time and results in a much better coordination of individual line components – which in turn benefits the customer.” Five Machine Types Form One Unit The recent delivery of a large-scale system to a customer in Asia underscores LoeschPack’s position as a competent supplier of complete
lope or cube folding. The machines have been designed to meet the highest standards of hygiene and ergonomics. In addition to a product-friendly, zero-pressure feeder, a servo-driven packaging material feeder and an automatic roll changer were also integrated into the system.
Packaging line for small chocolate products.
packaging lines. “The redesigned and improved system incorporates five different machines, which are used to package chocolate napolitains in this configuration,” explains Graf. The system from LoeschPack takes over the products in counter moulds from the upstream moulding line. A paternoster buffer system separates the processing from the subsequent packaging process. This ensures that the counter moulds can be temporarily stored in case part of the line has to be stopped. Two modular transfer robots remove the chocolate products from the counter moulds and feed them to the packaging machines for primary and secondary packaging. In order to meet the specific challenges of high-performance areas, the developers specially constructed two new machine platforms, thereby also expanding the current product range. In addition to the two-stage LRM-DUO fold wrapping machine, two dual-track high-performance LRM/2-G-S fold wrapping machines were also used in the supplied system. Express Fold Wrapping Each LRM/2-G-S machine can package up to 1,000 items a minute in a fold wrap. Besides enabling the use of various wrapping materials, the system can also perform either enve-
Twin-lane automatic fold wrapping machine LRM 2-G-S.
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Next Up – Multipacks and Outer Wrap After pre-packaging via the two fold wrapping machines, the products are transferred to the downstream, two-stage LRM-DUO machine for multipack production. This configuration has the potential to output up to 250 multipacks a minute with pack formations of eight napolitains per carton. The second machine station produces an airtight outer cellophane wrapping with tear threads. The convincing
High performance fold wrapping machine LRM-DUO.
design of the versatile and flexible LRMDUO packaging machine is extremely compact and meets high hygiene standards. This LoeschPack system brings together diverse elements such as performance, efficiency and sustainability into a single design, paving the way for further company developments: System solutions from one source. Carbon Neutral Packaging Sustainability also plays a key role for LoeschPack. “Through the use of energy-efficient motors and intelligent drive technology, we are to combine complex applications with energy savings,” emphasises Andreas Graf. Under the label ‘carbon neutral packaging’, LoeschPack already offers customers CO2neutral machines. Any emissions released during the value creation process are offset through climate protection projects. In addition, LoeschPack plants trees in Piepenbrock’s Rheinshagen forest, ensuring CO2-neutral operation of its machines at customer sites. J 13
I SOFT DRINKS
AG Barr Continues to Invest in Future Growth Despite the poor summer weather, which has impacted adversely on soft drinks consumption, and a profits warning, AG Barr remains committed to maintaining its strategy of investing in brands and developing the infrastructure and organisation capable of delivering future growth. G Barr is continuing to outperform the UK soft drinks market and in line with its goal to increase market penetration in the south of England, the Scottish company is planning to build a new soft drinks production and distribution facility at Milton Keynes, at a cost of £41 million. Founded by Robert Barr in Falkirk in 1875, AG Barr has developed into a national business with strong roots in Scotland and the north of England but with an expanding consumer and customer base throughout the UK and further afield. AG Barr has grown through a combination of building existing brands like Irn-Bru and the Barr flavour range, developing franchise brands such as Orangina and Rockstar, and acquiring new brands like Strathmore Spring Water and Rubicon to broaden the product portfolio. Indeed, AG Barr has more than doubled sales of Rubicon since acquiring the business for £60 million in 2008 to enter the UK fruit juice market. The AG Barr brands portfolio also includes Tizer and KA. Employing more than 900 people, AG Barr currently operates factories at Cumbernauld, Dunbar and Forfar in Scotland along with a production site at Tredegar in South Wales. The company has also developed five depots, located at Manchester, Birmingham, London, Sheffield and Newcastle in England, to deal with the sales, administration and distribution
A
The Rubicon brand has undergone its first national television advertising campaign.
Roger White, chief executive of AG Barr.
of products. AG Barr is active in both the carbonates and still drinks (including water) segments of the soft drinks market. The company has been steadily developing its stills brands in order to achieve a more balanced portfolio. Last year, revenue growth in carbonates was 5.8% and in stills was 9.4%, resulting in stills accounting for 23.0% of the total sales mix. Financial Performance Despite the challenging trading environment, AG Barr continues to increase revenue and volume ahead of the UK soft drinks market. Turnover increased by 6.6% to £237.0 million for the year ended January 28th 2012 and the company also produced a strong profit performance. Indeed, the soft drinks supplier has achieved organic sales growth of 27.6% over the last three years. Pre-tax profits, excluding exceptional items, increased by 6.2% to £33.6 million last year reflecting the benefits of sales volume and value enhancing revenue growth and strong cost containment measures. Post exceptional items, profit increased by 16.4% to £35.4 million. All of AG Barr’s core brands performed well, with particularly strong growth in the company’s exotic juice drinks brands, Rubicon and KA. AG Barr delivered growth across both the FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
carbonates and stills segments. In stills, AG Barr grew revenue by 9.4% against a market performance of 3.8%. This was primarily driven by growth and innovation in Rubicon and KA. AG Barr is continuing with its strategy of concentrating investment around its core brands of Irn-Bru, Barr, Rubicon and KA “AG Barr has demonstrated its resilience in the face of challenging market conditions, in particular coping with substantial raw material cost headwinds while achieving revenue growth based on brand development, innovation and improved focus on execution,” comments Roger White, chief executive of AG Barr. Innovation AG Barr’s strategy of building its brands for the long term is supported by an active innovation pipeline. Much of the company’s efforts throughout 2011 are only coming to market this year, including further focus on the exotic juice drinks portfolio, such as format and flavour developments, as well as an initial move to extend the Rubicon brand beyond its core soft drinks position. Rubicon was launched into the UK’s £800 million ice cream market in March with a range of Rubicon tub ice creams for the take home market and frozen ‘push–ups’ for impulse consumption. Production of the ice creams has been out-sourced but all commercial activ-
AG Barr has grown through a combination of building existing brands like Irn-Bru and the Barr flavour range, developing franchise brands and acquiring new brands to broaden the product portfolio.
15
Rubicon has been launched into the UK’s £800 million ice cream market.
ities including marketing and selling remain with AG Barr. Current Trading The poor summer weather has affected the performance of the UK soft drinks market. For the 26 weeks to 23 June 2012, Nielsen reported that total soft drinks market volumes were down 1% whilst value was 2% ahead. Within this overall performance, carbonates volume was flat with stills declining by 3%. During these challenging trading conditions in the first half of 2012, AG Barr has continued to grow strongly ahead of the soft drinks market and anticipates sales revenue of about £130 million for the period, an increase of over 4.5% on the prior year. “Despite the difficult operating conditions, we have maintained our strategy of investing in brand equity and extending distribution. Our core brands continue to respond well to this consistent long term approach,” says Roger White. For instance, Irn-Bru and Irn-Bru Sugar Free have both benefited from television and digital advertising campaigns, and the Rubicon brand has undergone its first national television advertising campaign. However, margins in the period have been impacted by increases to cost of goods, increased brand investment and adverse changes to the sales mix at brand, pack and channel level. Consequently, AG Barr has cautioned that profits in the first six months
ended 28 July 2012 will be slightly below the prior year. Although the company expects margins to improve in the second half, it is unlikely to offset the margin shortfalls of the first half. According to Roger White, AG Barr’s operational performance improved substantially in the final quarter of last year and the company is now beginning to see the benefits of its investment in production assets. “We are further reinforcing our confidence in our future growth prospects with the confirmation of our plans to invest in a new site, with substantial future capacity, in the Milton Keynes area,” he says. £41 Million Investment AG Barr is pushing ahead with its investment in Magnor Park in Milton Keynes. Having obtained detailed planning approval, the company has now committed to the full project, including a new credit facility through HSBC to support the development. The full project budget is about £41 million and a production commencement date for the site is scheduled for the third quarter of 2013. The new 265,000sq ft warehouse and production plant will initially support a canning facility and then PET capacity.
The project represents AG Barr’s largest investment in warehousing space, south of Scotland, to date. The new facility is expected to create over 100 new jobs in the local area. Outlook With AG Barr continuing to outperform the UK soft drinks market, which remains in growth despite the tough trading climate, AG Barr is well placed to maintain its forward momentum. The UK soft drinks market grew in value by 5.1 per cent in 2011 to reach more than £14.5 billion, according to the British Soft Drinks Association, and consumption rose by 0.7% to more than 14.6 billion litres, or 253.3 litres per person. Although the poor summer weather has resulted in volumes falling 1% in the first half of 2012, market value still increased by 2%. “We are operating in a challenging consumer environment where confidence remains fragile. However, the soft drinks market remains a robust and growing sector,” says Roger White. “The belief in our brands’ growth potential is supported by our continued investment in long term consumer equity building activity, innovation and our plans to invest in additional operating capacity to support this growth.” J
AG Barr Announces New Board Member John Nicolson is to become as independent non-executive director of AG Barr, the UK branded soft drinks group. He replaces Jonathan Warburton, who has stepped down from the board, to cut back on his outside responsibilities in order to focus more on his role at Warburtons, the UK’s largest independent baker. John Nicolson is currently president of Heineken Americas, based in New York with responsibility for a region including the USA, Brazil and Mexico. John Nicolson has also been deputy John Nicolson. chairman of Compania Cervecerias Unidas (Chile), since 2009. A UK citizen, John Nicolson has had a long career in consumer goods, in beverages in particular, including many years at Scottish and Newcastle Breweries where he was a PLC board director for eight years from 2000-2008. John Nicolson has also held the positions of director of Baltika Brewery (Russia) from 2005–2008 and chairman of that business from 2006-2007; director of Yarpivo Brewery (Russia) from 2005–2006; and director of United Breweries (India) from 2007–2009.
Aetna Group Shrinks Film Usage at AG Barr oft drinks producer AG Barr has seen S film usage shrink by between 10% and 70% following the delivery of two new Robopac Rotoplat 506 PFS power prestretch pallet wrappers, according to Aetna Group UK. Colin Gransbury, depot manager, AG Barr, says: “The machines replaced ageing equipment from another supplier and started work on the same day they were delivered to the Newcastle and Sheffield depots.” The machines are wrapping drinks from AG Barr’s full product range, including IrnBru, Tizer, Strathmore and Rockstar, with a
capacity of up to 20 pallets/hour. “We deliver on our own vehicles, direct to the retail trade across the north east of England and Yorkshire, so it is important that the presentation is good as well as the pallet being secure,” he adds. “The Rotoplats were purchased because of the film savings we could achieve, but an added bonus was ease of use – programs are pre-set for differFOOD & DRINK BUSINESS EUROPE, AUGUST 2012
ent sizes and configurations.” The company estimates it will make annual material savings of almost £12,000. Currently each wrapper is handling between 80-100 pallets of mixed stock or single product lines per day. AG Barr has four Rotoplat machines in operation at its depots. For further information visit www.aetnagroup.co.uk. J 17
HRS Expands Footprint in the Soft Drinks Industry Working With AG Barr RS Heat Exchangers, a leading heat H transfer specialist for the process industry, has recently sold equipment to UK’s largest independent soft drink maker AG Barr. The heat exchangers are cooling carbonated drinks prior to bottling. AG Barr has been in the business of making and selling soft drinks for over 130 years. The company now produces a large range of soft drinks including IRNBRU, Barr, Rubicon, KA and Rockstar energy drink (under a manufacturing and distribution agreement with brand owners Rockstar Inc USA). The company employs over 900 people across 11 sites in the UK. AG Barr is a national business with strong roots in Scotland and the north of England but with a growing consumer and customer base throughout the UK and further afield. HRS Heat Exchangers has sold three units of the MI55 series to AG Barr. The MI series heat exchanger is ideally suited for food applications involving fluids of low to intermediate viscosities. Corrugated tubes are used to increase heat transfer rates, which makes the MI series
much more efficient than normal smooth tube heat exchangers. The carbonated drinks flow through the interior tubes to bring the temperature down. Corrugated tubes create extra turbulence, which translates into a significant increase in heat transfer compared to smooth tube heat exchangers. The new MI55 heat exchangers have been vertically mounted to fit into a relatively small plant footprint left free by the removal of existing plate heat exchangers,
this was possible as HRS corrugated tube shell and tube heat exchangers offer a small footprint and occupy less space than conventional smooth tube heat exchangers. AG Barr wanted the pressure drop to be maintained to a very low level in order to use the existing pumps, and this was taken into consideration during the design phase. This additionally saves pumping power and cost. “The equipment from HRS Heat Exchangers has helped enhance the efficiency of our plant and we look forward to a long-term association with them,” says Paul Lambert, Process Improvement Manager, AG Barr. “We are very pleased with our partnership with AG Barr. Turbulence is the main factor in a heat exchanger for the thermal transfer to take place. The hygienic design makes the MI series especially suited for the soft drinks industry. HRS has designed different geometries to increase thermal efficiency in tubular heat exchangers using our unique corrugate tube profile,” says Priya Murray, Technical Manager, HRS Heat Exchangers. J
Star Caters For Frozen Food Firm With Plant Upgrade tar Refrigeration has completed a S refrigeration plant upgrade for frozen food and catering specialist apetito at its manufacturing facility in Trowbridge, Wiltshire. Star undertook a major overhaul of apetito’s existing refrigeration system to boost reliability and reduce equipment downtime. By updating the plant control system and replacing ageing components, Star has also improved energy efficiency and reduced running costs for apetito. For over 50 years, apetito has provided frozen food and catering solutions to care homes, local authorities and hospitals. The award-winning company also provides a frozen meal home delivery service across the UK via the Wiltshire Farm Foods franchise network. Originally installed by Star in 1995, apetito’s bespoke ammonia LPR (Low Pressure Receiver) system features four refrigeration plants providing multi-temperature cooling. The system supplies over 18
800kW of cooling for blast freezing and chilling, production areas, a cold store and series of chill stores at the Trowbridge manufacturing facility. Star was awarded the apetito contract following a competitive tender process. The Total Solution project was completed over 15 weekends, with all work taking place outside factory operation periods to prevent any disruption to production. Star acted as principle contractor throughout the project, with Star Technical Solutions (STS) acting as co-ordinator for CDM (Construction Design & Management) regulations. Operations manager Andy Bone of apetito says: “Star Refrigeration worked closely with apetito throughout the project and a carefully phased programme of work ensured there was no disruption to production. We’re confident that the plant upgrade and new energy enhancing control system will enable us to operate more effiFOOD & DRINK BUSINESS EUROPE, AUGUST 2012
ciently, with less production downtime and lower running costs.” For more information, phone Star Refrigeration on 0141 638 7916, email star@star-ref.co.uk or visit www.starref.co.uk. J
Apetito's manufacturing facility with new condensers mounted on a steel frame, as installed by Star Refrigeration as part of a major cooling plant upgrade.
I ENERGY FROM WASTE
Agri Energy Offers Complete Waste and Renewable Energy Service Having recently opened the UK’s largest dedicated used cooking oil biodiesel plant at Bootle, Liverpool, Agi Energy, the UK-based waste recycling and renewable energy business, is now rolling out its food waste collection service nationwide. art of ABP Food Group, one of Europe’s largest producers of beef products, Agri Energy specialises in offering a complete waste and renewable energy service to food manufacturers, caterers, distributors and retailers. Its core activity is the collection and processing of organic waste. The used cooking oil collected by Agri Energy is refined into a range of products such as industrial oils or renewable fuels. Indeed, many of the company’s catering customers also buy their fresh cooking oil from Agri-Energy as part of a complete cooking oil service.
P
National Business Established six years ago, Agri Energy has grown rapidly into a national business by acquiring some of the best regional players in the industry, and the company continues to look for investment opportunities in waste management and renewable energy in order to further strengthen and extend the services it offers to customers. Agri Energy currently employs over 400 people and operates from 15 regional locations across the UK, allowing it to offer both a local and a national service for its 50,000 customers. It also provides other waste recycling services such as food waste collection and helping customers manage other waste streams including glass, cardboard, hazardous waste and WEEE. New Biodiesel Plant The newly constructed advanced processing plant in Bootle is solely dedicated to producing biodiesel from used cooking oil and complement’s Agri Energy’s existing nation-
Agri Energy has designed a bespoke food waste collection vehicle.
The newly constructed advanced processing plant in Bootle is solely dedicated to producing biodiesel from used cooking oil.
al used cooking oil collection business. It is part of a multi million pound investment into biodiesel production by Agri Energy. The plant has been constructed on a brownfield site which has a history of reprocessing oils and fats going back over 150 years. To this end Agri Energy has been able to not only regenerate an area of Liverpool but also create green employment opportunities. The plant is capable of processing 16 million litres of biodiesel a year and has been especially designed to handle the most difficult types of raw materials. Used cooking oil collected by Agri Energy is taken to the company's Liverpool depot where the oil is ‘cleaned’. It is then transferred to the biodiesel plant via a pipe bridge, which completely removes the need for further moving of the product via vehicles, so reducing carbon emissions. Cutting Edge Technology The used cooking oil is then converted into biodiesel by going through various different stages. The onsite laboratory features cutting edge technology that enables Agri Energy to complete 32 individual checks during the production cycle of its biodiesel. Once the biodiesel has been produced, an additional 20 tests are then performed to ensure it meets the European Quality Fuel Standard, EN14214. “By using ISO 14064 methods we can measure the carbon footprint of our biodiesel to show at least 90% less greenhouse gas emissions when compared to regFOOD & DRINK BUSINESS EUROPE, AUGUST 2012
ular mineral diesel. This makes it the most sustainable type of biodiesel in the world,” explains Eddie O’Reilly, Agri Energy’s biodiesel plant manager. “This means customers can be confident that every load is of the highest quality and offers the most carbon savings.” He elaborates: “A lot of companies produce biodiesel operating a simple esterification process. This is fine for virgin oils such as rapeseed oil but will not handle the complex molecules found in used cooking oil. Our plant has two further steps that allow us to ensure that we can convert used cooking oil into EN14214 specification. In particular the plant has a distillation column that enables us to remove complex triglycerides that would otherwise cause problems in a vehicle’s fuel system.” The new plant complements Agri Energy’s existing waste recycling and renewable energy operations. “The new plant is the final step in a supply chain of recovering waste resources from the food industry and recycling them. It completes our Virtuous Cycle of Supply, Collection and Conversion,” says Adam Baisley, chief operating officer for Agri Energy. Food Waste Collection Service Having successfully grown the used cooking oil business in the UK, Agri Energy is now expanding into food waste collections for its customers. This carbon efficient service not only prevents vast quantities of food waste going to landfill it actually converts it into biofuels and sustainable, environmentally
The plant is capable of processing 16 million litres of biodiesel a year and has been especially designed to handle the most difficult types of raw materials.
19
I ENERGY FROM WASTE
Is Biofuel Part of Your Sustainable Food Cycle? By Ulf M. Johansson, Alfa Laval he question is definitely worth considerT ing. However, it does carry some controversy in the aftermath of the fuel vs. food debate emerging some years ago in midst of the biofuels boom. By today, with a decade of biodiesel production to look back upon, one can see the effects from times when edible oil feedstock was a very viable proposition and attracted large investments. Especially so in Europe and USA where it is a fair estimate that half of the installed biodiesel capacity sits idle owing to unprofitable feedstock situations coupled with plant technology incapable of
Alfa Laval Ageratec 16 million liter/year biodiesel plant for used cooking oil (UCO) like the one delivered to Agri Energy. The multiple line prefab design brings flexibility both in project execution and on an operational basis.
friendly compost via the anaerobic digestion (AD) process. The company has designed a bespoke food waste collection vehicle that is not only more fuel efficient compared to standard refuse collection vehicle but also allows bins to be emptied and weighed on-site. Customers include caterers, hospitals, schools, offices, pubs, retailers, hotels and food manufacturers, all of whom are provided with wheelie bins ranging in capacity from 120 litres, 240 litres and 360 litres depending on their requirements. The collection service operates out of and delivers to local AD plants. Operating in this way ensures the food waste travels minimal distances before it is taken to one of Agri Energy’s partnered AD plants for processing. Adam Baisley comments: “The system we
processing anything but refined virgin oil. Sadly, adding to the burden is the fact that since recycled oil and by-product streams do mainly exist in limited and fragmented volumes, this represents a considerable hurdle for ever putting profit back into the equation at these big centralized biodiesel plants from a shear logistical point of view. Biofuel From By-products is Sustainable, Ethical and Profitable Alfa Laval has been a household supplier to the global biodiesel industry ever since day one because of its global recognition as a leading supplier of equipment and engineered solutions for vegetable oil refining. With the 2010 acquisition of Ageratec, Swedish OEM for waste oil biodiesel plants and one of the most successful vendors on an international level with projects sold to over 20 countries, Alfa Laval is busy delivering more projects like the Ageratec plant for Agri Energy in Liverpool, featured in this magazine. Well entrenched in the food, fats and oil industry Alfa Laval reach out to the many companies that now begin to acknowledge the fact that by-products like low value fats, oil, tallow as well as used cooking oil do possess an excellent proposition as profitable and sustainable biodiesel feedstock and that it can help boost their bottom line and offset commodity market high and lows. Add to that the simple fact that the majority of our food cycle rely on a logistic have developed is now so effective at reducing the carbon emissions and waste disposals costs for our customers we are rolling it out across the country. Our bespoke service not only works for our customers but it is also
The onsite laboratory features cutting edge technology that enables Agri Energy to complete checks during the production cycle of its biodiesel to ensure it meets the European Quality Fuel Standard, EN14214.
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Alfa Laval high speed separators that Ageratec biodiesel refining patent revolves around, grant a process free from water, which is traditionally involved in conventional biodiesel making.
network that is dependent on fossil fuel, in most cases both before and after human consumption. Adding all up, we hear the answer loud and clear; biodiesel based on by-products yields a sustainable food cycle! J an effective way for AD facilities to develop feedstock for their plants. We have developed a valued link in the supply chain between customers who have food waste to collect and AD plants who need food waste to process biogas. Our vision is 100% resource recovery for food business and by collecting organic waste streams nationally and recycling them into biofuels, we are on our way to achieving this.” Award Winning Indeed, Agri Energy’s new service recently won the AD and Biogas Association’s ‘Innovation in Waste Collection’ award. The ADBA’s panel of independent judges described Agri Energy as the company that demonstrates the highest level of innovation in waste collection when diverting organic waste to anaerobic digestion. J 21
I LEAN MANUFACTURING
Operational Excellence – The Key to Sustainable Competitive Advantage and Profitability n today’s highly competitive market many Ipressure manufacturing plants are under intense to produce high quality product
operations and create visibility and transparency across the enterprise.
and deliver exceptional service, all at lower costs and without sacrificing customer value. Whether you sell to other businesses, consumers or both there is a consistent push to deliver Better, Faster, Cheaper. The key to success is to identify and focus on the ‘right things’ that provide differentiated value to your customers and ensure you have the ability to deliver continuous improvement over the long term. A tightly run and highly efficient organisation can undercut the competition and win market
The More Data We Understand – The More Answers We Find
22
share, as well as delivering a streamlined operation that delivers benefits straight to the bottom line. Achieving this requires a fact-based understanding of operational performance. And as such IT plays a vital strategic role; creating an operationally driven IT architecture based on integrated, end-to-end software solutions, can transcend silos to unify
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Data sitting in a database has no value to a business. There is a growing need for tools that enable not just management but operators alike to collect, connect, analyse and act on large amounts of real-time time operations data. Value is provided through tools that make the data visible in ways it can be readily understood then delivered to where it can aid understanding, support decision making and ultimately drive continuous
improvement. By transforming your manufacturing data into real knowledge and actionable intelligence you can gain the insight required to optimise performance across your production operations. QIS – Manufacturing Intelligence Software From QiSOFT
By pre-empting quality failures and improving process capability in real time QiSOFT’s unique software helps customers protect their profit margins by reducing waste, rework, downtime and raw material
costs. Leading food manufacturers across Europe trust in QIS to ensure and certify the quality of many key brands and help them identify opportunities to save money across their operations. QIS is delivered in an out-of-the box integrated business-wide suite allowing customers to analyse quality data, machine behaviour and raw material performance in real time and instantly translate the results into actionable quality and process improvements. For over 25 years QiSOFT has been working with customers in all types of industry to
enable and support a variety of different strategic initiatives; SPC, SQC, TQM, 6sigma, Continuous Improvement, OEE to name a few . The results have been dramatic – more consistent products, increased productivity and reduced costs - all leading to greater customer satisfaction and higher profits. For further information contact QiSOFT, Alexander House, Station Brow, Leyland, Lancashire PR25 3NZ UK. Tel +44 (0)1772 641133, Fax +44 (0)1772 641155, E-mail info@qisoft.com or visit www.qisoft.com. J
Dairy Crest Chooses Avaya airy Crest, the UK's leading dairy foods D business, has chosen Avaya Virtual Services Platform 7000 (VSP 7000) as part of a project to overhaul the company's IT environment and deliver robust disaster recovery capabilities across its multiple domestic and overseas locations. Avaya, a global provider of business collaboration and communications solutions and services, was selected over incumbent Cisco. Its VSP 7000, a future-ready Ethernet switching platform specifically designed for Top-of-Rack
(ToR) server aggregation in high-performance data centres, has helped Dairy Crest to transform its IT environment, consolidating its ageing, isolated infrastructure and reducing back-up times for business critical systems by 50 per cent. It is expected that a second data centre will be mirrored later this year, after which Dairy Crest expects to significantly reduce the risk of data loss in the event of a disaster scenario. This is thanks to the massive virtual backplane bandwidth -- up to 5.12 terabits, perfect for latency-
sensitive server-to-server traffic -- delivered by the VSP 7000. As a result, key reporting, financial, and supply chain platforms are protected and so is the overall operational efficiency of the business and its 6,500 staff. J
Does This Give You Food For Thought? • • • • • • • • •
Identifying bottlenecks Creating better flow and balance Establishing accurate manning levels Determining work content Reacting to fluctuating demand Achieving quicker changeovers Studying line stops/starts Increasing throughput Reducing manufacturing costs For over 30 years Scott-Grant has been helping businesses in the food and drink industry to achieve all this and more. We provide practical help to apply Lean principles with our industrial engineering expertise, and improve productivity, performance and processes. Manufacturers of food and drink in the UK and Europe have involved our productivity specialists to identify and remove any wasted or unnecessary effort, delays, decisions, processes, costs, paperwork. At the heart of it all is process improvement using accurate time data – that’s our forte. We can help you to better plan, monitor, compare, control and therefore influence every aspect of your business, whether labour intensive or automated. That’s how practical our help is! At Scott-Grant we are specialists in structuring and applying time standards so our very specialist expertise can make a huge improvement to how Lean and streamlined your business is. 15% more throughput; 18% reduction in labour costs. Check the Productivity Solutions on our website to get the detail of how we achieved these results for others in the food and drink industry: www.scott-grant.co.uk. Your competitors are coming to us. Why don’t you? J FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
23
24
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
I CUTTING, SLICING & DICING
Robotics Improve Food Safety meat processing, hygiene is an important and significant efforts are made from Iallnissuesides to continuously increase food safety. Adopting automation technologies which reduce the need for handling of meat and therefore the potential for contamination is a significant contributor to this. In fact, food processing machines are now equipped with technologies that, even in long processing lines, leave little opportunity for the development of pathogenic agents. The use of robotics has also considerably increased safety, including pick-and-place-robotics which open up new possibilities in terms of sorting and designing portions and feeding them into packs. With higher in-line volumes, the requirement increases for loading solutions and Weber slicers offer a number of loading options, including speed loading. This offers efficient and automatic infeeding of portions which is not only faster but also more hygienic. This option is designed to build-up die formats, buffer out slicer reload times and enable loading into thermoforming equipment. Robotics are also increasingly a feature in
high volume slicing applications. With the Weber Pick Robot (WPR) portions are visually spotted prior to loading so regardless of whether the portion has twisted slightly or moved through transport, the picker picks the portion in its actual position and then delivers and loads to the fixed position of the packaging machine, removing the need for manual repositioning. The picker can also rotate the portion through 90 degrees so that a packaging machine which has a pack orientation that differs to that of the slicer can still be loaded, a common occurrence in bacon slicing, for example. On its way from the slicer to the packaging machine, the unprocessed log or product
goes through a number of critical points where contact from the operator with the product is possible: during product loading of the slicer, during weight and position correction of the portion and during in-feeding into the packaging tray. Increasingly automation of the process is being introduced to remove the need for this contact. The WPR drastically reduces the necessity for manual intervention in the process, improving hygiene but also offering increased economic efficiencies and the capability to introduce completely new forms of portion design. The Weber Food Robot (WFR) also offers hygienic and flexible handling for all known portion shapes and die formats. Current uses include the precise placement of sliced meat portions onto sandwich breads and pizza, as well as accurate overlapping and placement of different meats into a single presentation for packaging. The robotics can be customized to satisfy a variety of complex tasks, serving both single and multiple slicing systems. The Weber range of slicers is available in the UK and Ireland from Interfood Technology. J
Denmark’s Favourite Grinder Now Available in UK new solution in meat grinding has been A introduced in the UK and Ireland by Interfood Technology, offering a number of new features based on extensive market research from the Danish manufacturer Carnitech. Carnitech is a name well known in meat grinding and mixing, with its equipment responsible for the entire retail MAP
(Modified Atmosphere Packaging) minced beef production in the company’s home country of Denmark. The new addition to the range is the Carnitech 280 mm CombiGrind. Designed for the grinding of deep frozen and fresh meat, the developments in the new grinder have focused on the areas which the meat processing market identified as most critical, namely hygiene, throughput, product quality, safety and nowadays - energy efficiency. One of the most significant advances is the introduction of a hygiene area, featuring an ‘air gap’ between the gearbox and product, eliminating any potential for cross contamination as the meat cannot come into contact with the driving mechanism of the grinder. Mirror finish options are also available for all meat contact areas to further improve hygiene. The capacity of the grinder is dependent on the type of meat being used but it features an impressive hopper volume of 450 litres, the option of a double knife set and Carnitech’s Bone Elimination System to ensure maximum throughput and product quality. The Bone Elimination System minimises hard particles in the end product, FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
providing air assisted blow out of the waste without the need for any external air pipes or cabling, again enhancing hygiene as well as improving aesthetics. The system has also been designed with controllability and flexibility in mind, with yield and supplier variables readily accommodated. The grinder can easily handle combinations of fresh (+2 C) and/or deep frozen blocks (-20 C) down to 3 mm. The machine comes with variable top and bottom worm speeds as well as soft start as standard to minimise energy consumption and the high energy bills that go with it these days Martin Wareham, Product Manager for Interfood Systems, the Division responsible for the Carnitech range, comments: “Danish manufacturers have a real flair for combining the heavy duty build quality demanded by modern food processing production with simplicity of operation. The Carnitech range certainly represents such an approach and with this now being strengthened by a renewed focus on hygiene, safety and throughput, we have a grinder which meets the requirements of the most demanding of processing applications.” J 27
Bring Frigo International Tel. +46 42-17 80 00 Web: www.bring.com
Temperature Bring Frigo is specialised in safe food logistics in the Nordic region. We are among the best in the market for precise deliveries and safe storage of fresh, chilled and frozen goods, all the way from the producer to the table.
Regulated Logistics
I COLD STORAGE & LOGISTICS
ECSLA – The Voice of the European Cold Storage Industry Representing the interests of thousands of refrigerated storage facilities throughout the EU with a total capacity of more than 40 million cubic metres, the European Cold Storage and Logistics Association (ECSLA) is the voice of the European cold storage industry. he ECSLA’s mission is to represent the interests of cold logistics companies at the level of European and international institutions, in order to contribute to the development of a legislative and economic framework addressing the competitiveness of industry, food quality and safety, consumer protection and respect for the environment. With its main office in Brussels, the ECSLA provides customised services to the different segments within the market: • National associations of cold stores and distribution companies; • Individual public refrigerated warehouse, cold store and logistics operators; • Suppliers of product/services to the industry; • Scientists, researchers, universities, institutions, etc. The ECSLA offers members genuine monitoring of and lobbying services with European and international institutions on different policy areas, from food safety and food hygiene to environmental performance and energy efficiency in cold stores.
T
discuss key industry trends and developments. Annual Conferences The ECSLA organises two conferences annually in the Spring and Autumn. “These conferences bring our members together, but also put them in contact with other key players in the industry,” he says. “The ECSLA is in contact with suppliers, academics, academic institutions, wholesalers, politicians and participants within the industry across the world; the conferences give them a chance to discuss the most imminent problems and challenges in the sector.” The next Cold Chain Logistics Conference & Trade Show is being held at the Hotel
extremely important that we help our members to become even more competitive and efficient so food manufacturers and retailers will continue to outsource their logistics services to our industry.” Frozen and chilled food manufacturers are also demanding higher environmental standards from suppliers. Consequently, the ECSLA is examining new technologies and operational management solutions that are environmentally friendly and reduce energy usage and costs.
Current Trends According to Theo van Sambeek, the market for cold stores is growing generally by approximately 2-4% in Europe although there are differences from country to country, with growth being higher in Eastern Europe for example. However, income rates have become stagnant which is fuelling pressure for greater efficiency. Frozen and chilled food manufacturers are demanding improved efficiency and sustainability targets from cold store operators, which are leading to closer collaboration in logistics. Opening Doors While there is pressure from cus“It is our job to talk to politicians and tomers to upgrade cold stores, this is difinfluence decision making – to open Frank Baumeister, Secretary Theo van Sambeek, Managing ficult to achieve without an increase in Director of the ECSLA. doors for our members and create frame- General of the ECSLA. prices to fund investment in new equipworks that are both legislatively and ecoment and facilities. “Although there is nomically viable,” explains Frank Baumeister, Emperador in Madrid between October15 concern about the environment, price squeezSecretary General of the ECSLA. and 16. ing is making sustainability targets The focus of the organisation is on assisting difficult,”.points out Theo van Sambeek, warehouse and logistics operators with Frozen and Chilled Foods adding that short term paybacks are important improving their performance and at the same The frozen and chilled foods industry is, of and so energy efficiency could be a driver if time helping members to reduce operational course, of primary concern to the ECSLA and there were rapid cost savings to be made. costs. its members. Industry and consumer trends Developments in cold storage technology The presence of ECSLA in Brussels has are closely monitored throughout Europe. are playing a role in helping operators improve helped to represent the interests of the cold “We keep a close eye on core concerns with- efficiency and sustainability. “Automation is logistics companies with European decision in the frozen foods sector and at the moment the solution for some but it is costly and even makers. there is an emphasis on performance and also with automation labour remains a high cost. Membership of the ECSLA offers many operational cost. We assist our members to However automation could also drive energy benefits to cold store and logistics operators achieve the best possible performance while efficiency savings too,” says Theo van including being kept up to date with the latest reducing labour and energy costing by holding Sambeek. In terms of changes in refrigerant legislative and technological developments. seminars, conducting research and hosting technology, he says that Freon (R22) systems Members also conduct industry surveys, set events,” comments Theo van Sambeek, are being changed to ammonia in the benchmarks and share their experiences and Managing Director of the ECSLA. “It’s Netherlands and France. J FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
29
STORAGE
LOGISTICS
B-Built – The Design & Build Expert -Built is a design and build construction B company operating from the Netherlands. Over the last years it has acquired extensive know-how and detailed expertise in designing and constructing large scale logistical facilities in Western Europe. This accumulated knowledge is today once again being applied in the company’s latest project in Rheine, Germany. B-Built has designed the building envelope around the optimised logistical
High bay platform (June 2012).
design, after which the legal permits were acquired.
Construction started earlier this year and will continue towards the beginning of 2013.
30
Largest Automated Cold Store in Germany The facility will consist of a high-bay frozen storage building of 8,500 sq m, rising to 37 meters high that will contain up to 68.000 pallets in a temperature of – 24 degrees Celsius. An adjacent low-bay area of 3,500
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
High bay platform (August 2012).
sq m, also temperature controlled, will contain dispatch area, mixing zone, technical area and offices. B-Built will continue to draw on its extensive knowledge to satisfy its present and future clients’ operations. Being no stranger to tender processes, B-Built often operates as design & build building contractor while facilitating building installations and process equipment. J
I FROZEN FOODS
Top 100 Frozen Foods Manufacturers in Western Europe, 2012 Company Ultimate Holding Company Ranking
Market Shares West Europe Cumulative
Company Ultimate Holding Company Ranking
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50.
10.53% 7.16% 5.53% 4.64% 2.74% 2.17% 1.79% 1.64% 1.56% 1.44% 1.20% 1.13% 1.11% 1.01% 0.93% 0.91% 0.81% 0.74% 0.74% 0.72% 0.71% 0.70% 0.70% 0.68% 0.67% 0.65% 0.60% 0.60% 0.57% 0.56% 0.55% 0.52% 0.51% 0.50% 0.50% 0.50% 0.45% 0.41% 0.41% 0.40% 0.40% 0.38% 0.37% 0.36% 0.35% 0.32% 0.32% 0.31% 0.31% 0.31%
51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83. 84. 85. 86. 87. 88. 89. 90. 91. 92. 93. 94. 95. 96. 97. 98. 99. 100.
Permira Nestlé Unilever Lion Capital McCain Oetker Pescanova Bonduelle Frosta General Mills Northern Foods Orkla Heinz Oaktree Capital Bofrost Coppen. & Wiese Apetito Arla Mars Südzucker Aker RGI Ardo 11er Nahrungsm. ConAgra Vion Icelandic Group Migros Royal Greenland LDC Cosun Arena Holding HKScan Lantmännen GEP Sammontana Baugur Sprehe Geflugel Heristo Bernard Matthews Pinguin Lutosa Greencore Triskalia Espersen Laihian Mallas Stoll & Stoll Anders Müntzing Fruttadoro Campbell Soup Pomona Farm Frites
10.53% 17.70% 23.23% 27.86% 30.60% 32.78% 34.57% 36.21% 37.78% 39.22% 40.42% 41.55% 42.66% 43.68% 44.61% 45.52% 46.33% 47.07% 47.81% 48.53% 49.24% 49.94% 50.64% 51.32% 51.99% 52.63% 53.24% 53.83% 54.40% 54.97% 55.52% 56.03% 56.54% 57.04% 57.54% 58.03% 58.48% 58.89% 59.29% 59.69% 60.09% 60.47% 60.84% 61.20% 61.54% 61.87% 62.18% 62.50% 62.81% 63.12%
ABN Amro CECAB CNP Perdigao Hofmann Menü KTG Agrar Segulah Bigard Vossko Erlenbacher Wessanen Freiremar Pescapuerta Halieutis Conserve Italia McKey Foods Blasko Danone G7 Grupo Amasua Rolli Eduardo Vieira IFRC Mantua Surgelati PHW Gruppe Peter zur Mühlen Saveurs de France Bain Capital Coopér. 3A Iberica de Congelados Pereira Bonne Bouche Lännen Tehtaat Bürger ITM Sara Lee Profood Stoever PNIC Aryzta TMF Gruppe Campofrío Foods Ardovries Connors Seafoods Delfin Own Brands Lur Berri Hennig Olsen Koopmans Domstein
Market Shares West Europe Cumulative
0.29% 0.29% 0.29% 0.29% 0.27% 0.27% 0.26% 0.26% 0.26% 0.26% 0.26% 0.25% 0.25% 0.24% 0.24% 0.23% 0.23% 0.23% 0.22% 0.21% 0.21% 0.21% 0.21% 0.20% 0.20% 0.20% 0.20% 0.19% 0.19% 0.19% 0.19% 0.19% 0.19% 0.18% 0.18% 0.18% 0.18% 0.18% 0.18% 0.18% 0.17% 0.17% 0.17% 0.17% 0.17% 0.17% 0.16% 0.16% 0.16% 0.16%
63.41% 63.70% 63.99% 64.27% 64.54% 64.81% 65.08% 65.34% 65.60% 65.85% 66.11% 66.36% 66.61% 66.86% 67.10% 67.33% 67.56% 67.78% 68.00% 68.21% 68.42% 68.63% 68.84% 69.05% 69.25% 69.45% 69.65% 69.84% 70.03% 70.22% 70.41% 70.60% 70.78% 70.97% 71.15% 71.33% 71.51% 71.69% 71.87% 72.05% 72.23% 72.40% 72.58% 72.75% 72.92% 73.08% 73.25% 73.41% 73.57% 73.73%
Products covered: Frozen pastry products, Frozen fruit, Frozen vegetables, Frozen potato, Ice cream, Frozen soup, Frozen convenience meat, Frozen fish, Frozen pizza, Frozen ready meals Countries covered: Austria, Belgium/Luxembourg, Denmark, Finland, France, Germany, Greece, Ireland/Eire, Italy, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland, United Kingdom Source: Food for Thought (FFT)
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
31
STORAGE
LOGISTICS
Union Industries Rapid Roll Doors Used Extensively in New Co-op Distribution Centres nion Industries, the UK market U leading manufacturer of industrial rapid roll Hi-Speed Doors, has completed a major installation at The Cooperative’s new Scottish Distribution Centre in Newhouse. The 23-door project follows the installation of a number of Union’s Eiger freezer doors at Coop’s distribution centre in Birtley, County Durham in 2009. This has also led to Union being engaged by Co-op to design, manufacture, install and maintain a further 24 doors at its new Distribution Centre in Andover, Hamp shire. At the 503,577 sq ft centre near Motherwell, Union has installed seven Eiger Doors in the freezers and 16 Bulldoors in the ambient and chilled areas. The majority of the fast-acting doors are 5.5 metres high and 3 metres wide to accommodate Co-op’s fleet of highreach trucks transporting products around the centre. Union’s rapid roll Eiger Door provides a superior alternative to the traditional sliding insulated type doors and also various other types of fast acting freezer doors that are appearing on the market to try and compete with the Eiger. After opening at approximately 1.6 metres per second, Eiger Door closes automatically after a short dwell time which
allows for continuous traffic flow without compromising the freezer temperature. Warm air ingress into the freezer is drastically reduced so the normal build up of ice and frost around the doorway is prevented, meaning the Co-op will benefit from the energy saving aspects of Eiger Door. It is the only industrial freezer door
that incorporates a proven bottom beam ‘Crash-Out’ device, which features across all of Union’s range of heavy duty doors. This system minimises the effect of impact damage usually caused by forklift trucks and is supported by an ‘Auto-Reset’ facility allowing the door to continue working following impact, which ensures the freezer’s operation remains uninterrupted. Two of the Bulldoor Hi-Speed Doors on site are free-standing and self-supported by a specially-designed steel-braced frame that has been fitted into an internal security fence in a high-value goods area. Co-op colleagues enter through the doors via a swipe-card system which gives restricted access into the secure area. Russell Young, National Building Manager from Co-op, says: “We have been impressed with the quality of manufacture and reliability of Union’s range of doors, and have specified them in another of our new-build distribution operations. It is important to avoid major down-time and productivity interruptions, which can be caused by vehicle damage to doors and can be common with lower cost doors. Union’s doors, however, require minimal maintenance and provide innovative impact solutions.” J
Glanbia Consumer Foods Chooses Cullina ajor food and dairy producer Glanbia M Consumer Foods has appointed Culina to manage the distribution of its chilled portfolio into the UK market. The first products to be introduced are a new range of WeightWatchers products for the large UK butter and spreads category. “A bigger presence in the UK is important to us and we recognised that branded products represented the right way to go,” says William Wake, UK country manager for Glanbia Consumer Foods. “To be successful we needed a supply chain partner that offered a full range of services and scalability to grow with us. Culina met all of our requirements.” Based in Ireland, where it is the largest milk supplier, Glanbia has grown in a 32
number of key markets in Europe and North America to become one of the biggest international dairy and food producers. Historically the company’s consumer goods division has had a low profile in the UK but
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
changes in market conditions led it to reassess its position and seek new opportunities. Feedback from retailers was encouraging when Glanbia Consumer Foods reached an agreement with WeightWatchers, which did not have a butter product in the UK, to supply two new low fat products into the UK’s giant butter and spreads category. The products both have the lowest fat content in their segments of the category, and the lead spread product has around 85 per cent less saturated fat than standard butter. The products were launched exclusively with Asda at the end of May. Glanbia Consumer Foods chose Culina as its supply chain partner after assessing the market. J
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
33
STORAGE
LOGISTICS
I WAREHOUSE MANAGEMENT
Norbert Dentressangle Wins Major Storage and Distribution Contracts nternational transport and logistics compaIbeen ny Norbert Dentressangle has recently awarded two major storage and distribution contracts – one in the UK and the other in France. Following a competitive tender process, the UK’s largest turkey farmer and supplier, Bernard Matthews, has appointed Norbert Dentressangle to manage its frozen and seasonal fresh national storage and distribution operation. Established in the 1950s, Norfolk-based Bernard Matthews Farms now employs more than 2,000 people, farms over seven million turkeys each year and supplies a wide range of fresh and frozen turkey products to many of the major grocery retailers and foodservice providers. The new contract recognised Norbert Dentressangle’s ability to deliver an innovative solution to meet
Bernard Matthews is the UK’s largest turkey farmer and supplier.
Bernard Matthews’ current requirements, along with further improvements through the continued development of the partnership. Operating 24/7/365, Norbert Dentress angle is providing frozen and chilled storage and consolidation services within its shared cold stores at Easton and Lowestoft and is responsible for the picking and delivery of orders to around 500 delivery points throughout the UK and Ireland, typically on a Day 1 for Day 2 basis. In support of the new operation, Norbert Dentressangle has invested £1.5 million in new facilities and is employing advanced communications and order tracking systems to provide operational transparency and control. The company’s advantageous twin-centre solution, combined with its service focus, food industry competence and commitment to continuous improvement were major factors in Bernard Matthews’ decision. Richard Hall, Bernard Matthews’ Supply Chain General Manager, saye: “Norbert Dentressangle put forward a highly compelling solution, supported by robust and detailed operational plans, a proven track record and the backing of a large and highly professional international organisation, all of which gave us absolute confidence to select them as our partner.” Norbert Dentressangle has also been chosen by the French supermarket chain Systeme U Ouest to provide logistics services for the 30,000 sq m controlled temperature
Norbert Dentressangle has also been chosen by the French supermarket chain Systeme U Ouest to provide logistics services for the 30,000 sq m controlled temperature logistics hub the retailer plans to build.
logistics hub the retailer plans to build in Fontenay-Le-Comte (Vendee department). The site will serve as the logistics hub for the distribution of fresh food products to 70 Systeme U Ouest supermarkets located in the Vendee, Deux Sevres, Charente and Charente Maritime departments. It will employ around 180 people and will be in operation from September 2013. Norbert Dentressangle will be in charge of logistics operations (goods reception, storage and order picking) as well as delivery to stores with a fleet of vehicles that will be Euro 6 compliant by the time operations start. The new deal strengthens Norbert Dentressangle’s status as a leading controlled temperature logistics provider in France and the rest of Europe. J
Arla Foods UK Nurtures its Inner Talent eveloping untapped talent on the shop D floor, Arla Foods, the UK’s leading dairy company, has launched a bespoke
through to the 18-month programme. “Like most companies, we have previous-
warehouse management development programme. Aiming to progress warehouse operatives already working on site, the programme will nurture talent already in the business, and is being trialed at Arla’s National Distribution Centre in Stourton, Leeds. Going through a rigorous selection process, candidates have to pass a fourround assessment in order to make it 34
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
ly always recruited externally when looking for warehouse managers as there is a skills gap between operatives and managers,” says Louise Robinson, Arla’s HR officer at Stourton NDC. “Arla is committed to a culture of continuous learning and development and empowering colleagues to progress their careers.” Consisting of 23 units, the programme teaches a variety of skills in areas such as performance management, operational understanding, leadership skills, finance and health and safety. J
National Flexible too Hot to Handle! he demands on packaging T performance can sometimes be high, especially in the food industry – and a new project for ovenable panninis to be served on commercial airlines was no exception. The panini needed to be re-heated inside the wrapper from a frozen state in a conventional oven, which required a high performance food-grade film able to withstand prolonged exposure to high temperatures without breaking down. In addition, the airlines wanted the film to be printed with a full colour photographic image to enhance the visual appeal of the product. The pannini manufacturer commissioned film packaging specialists National Flexible for the project who are well-known for their expertise in the field of converting ovenable films for this type of application. Working with their technical team they were quickly able to specify a suitable film and had knowledge of specialist inks that
would be ideally suited. The special food-grade inks are able to withstand extremes of temperature (both hot and cold) and are resistant to moisture. They have a consistent lay-down which allows for excellent image clarity when printing and the strength of their bond to the film ensures that there are no problems with ink-lift, cracking or flaking – even for surface printed films. “This was a challenging project on several
QUALITY
I FOOTWEAR
levels,” says National Flexible’s marketing manager Andy Smith. “Fortunately we have a strong background in this area so we were able to make recommendations to the customer, which saved them a lot of time in the development and testing process. This meant that we helped them to fast-track the whole project and they could supply their customer more quickly.” National Flexible are the UK’s largest distributor of polypropylene, laminates and special films. Their custom factory is purpose built to be compliant with the latest BRC standards for food-grade packaging, and they have become well known as the preferred supplier of packaging films for the food, bakery, snack, confectionery and contract packing industries. For further information contact National Flexible on Tel +44 (0)1274 685566, E-mail sales@nationalflexible.net or visit www.nationalflexible.co.uk. J
& HYGIENE
Goliath Launches Super Slip Resistant Safety Trainers ootwear manufacturer Goliath Footwear F has developed a new super slip resistant range of safety trainers. The ‘Supertrax’ range has been designed with a tri-density sole (Rubber, PU and TPU) and claims to offer the best ever slip resistance for those working in the food processing, janitorial and pharmaceutical industries. In recent slip resistance tests, the Supertrax sole had up to twice the slip resistance specified by the European Standard and is categorised by the Health and Safety Executive in the lowest slip risk category. The Supertrax styles offer a more contemporary ‘skater’ look to take into account the increasing trend for ‘leisure-look’ workplace footwear. Lead style ‘Franklin’ incorporates a steel toe cap plus a L-Protection® nailproof textile midsole, additional stitching design features and has water resistant black leather. The range includes safety styles
Supertrax slip resistant sole unit.
with microfibre uppers in black and white versions and a soft toe option which is suitFOOD & DRINK BUSINESS EUROPE, AUGUST 2012
able for low risk environments. Steve Hall, sales and marketing director for Goliath Footwear, says: “Slips in the workplace are one of the most common hazards, and we have developed a stylish product range to meet the demand for better protection. The tread pattern is designed for maximum traction with many leading edges, maximum ground contact and with a 1mm protruding rubber for liquid run off. The tests show this is one of the best performing sole units on the market.” This is a further advancement for the Goliath Footwear team who lead the world in the production of DDR injected sole technology which has revolutionised footwear for the heavy industrial and emergency services sector. The range is now available through Personal Protective Equipment distributors in the UK and Europe. J 35
inis Foodprocessing Equipment BV is a F family business that has been supplying solutions to the food industry for almost a century. Always striving to improve and exceed the expectations of its customers’ requirements, Finis continuously invests in product development and new innovations. Amongst these are the new way to peel root vegetables and a completely automatic onion peeling and processing line, using vision technology. The KGSCH is a world-class continuous peeling machine for potatoes and other root products. Due to the machine design, it uses less water and the product’s cell structure is kept intact, resulting in an end product with a longer shelf life and a hand
36
peeled look. It is perfect for any fresh peeling process and an extremely useful addition to any high volume steam peeling line as a reject peeler where it has been proven to give serious yield advantages in the process. To complement this, Finis also supplies extremely accurate potato quartering machines using vision technology and an audio detection unit to reject stones, lava rock, wood, glass etc. from process flows. Finis is also proud to introduce the first Automatic Orientation System for onions in the world. This new innovation can feed a peeling line without the need of manual labour. Adding this new way to top and tail an onion not only means less labour but
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
also significant yield advantages. Finis is an acclaimed worldwide leader in providing complete end to end processing projects. When working in partnership with customers, Finis is able to use Computer Aided Design (CAD) to visualise and deliver bespoke solutions. Finis has formed partnerships with other world renowned manufacturers to enable the company to offer turn-key projects. Each supplier has been carefully selected based on their knowledge, experience, quality and reputation. For further information contact Finis Foodprocessing Equipment BV.on Tel +31 (0)315 695569, E-mail sales@finis.nl or visit www.finis.nl. J
I FROZEN FOODS
It’s Still All Good at McCain Foods’ European Business Canada-based McCain Foods, the world’s largest manufacturer of frozen potato products, is continuing to consolidate its leadership position and achieve sustainable growth in Western Europe. stablished by brothers Harrison and Wallace McCain at Florenceville, New Brunswick, a small town on Canada’s east coast, in 1956, McCain Foods has developed into one of the world’s leading frozen food producers, employing 20,000 people and operating 55 production facilities on six continents. The company is the world’s largest manufacturer of frozen French fries. McCain Foods also produces a diverse range of frozen products, including pizza, appetizers, oven meals and desserts. Its products are sold to retailers and food service operators in more than 160 countries around the world. Still privately-owned, McCain Foods generates annual sales in excess of C$6 billion (Eur4.8 billion).
integrated farm to fork approach, the Canadian food group’s ethos is summed up in its strap line - McCain It’s All Good! This encompasses all aspects of the group’s business from the way it prepares food products to the way it works with farmers to its relationships with customers. According to McCain Foods, ‘nutritious ingredients, a healthy environment, sustainable agricultural practices and happy communities and people are essential to the production of good food’.
E
Dirk Van de Put, president and chief executive of McCain Foods.
Continental Europe McCain Foods is the fifth largest frozen foods manufacturer in Western Europe with a 2.74% share of the total market, according to Food For Thought (see ‘Top 100 Frozen Foods Manufacturers in Western Europe, 2012’ in this issue). Of course, within its speciality segment of potato products, its market share is far higher. McCain Foods is a major player in both the retail and food service (including fast food restaurants) channels. Headquartered at Villeneuve d'Ascq in France, McCain Continental Europe, employs 2,500 people and operates seven production sites in Belgium, France, Poland and the Netherlands, including the world’s largest
McCain Foods is the world’s largest manufacturer of frozen French fries.
French fry factory at Matougues, France. Within the Continental Europe region, McCain Foods works closely with 1700 farmer partners to ensure a secure and consistent supply of quality raw materials. With an estimated turnover in the region of Eur750 million, the McCain Continental Europe business spans 45 countries. UK Operations McCain Foods entered the UK market in 1965, initially with imports before building its first production facility at Scarborough in 1968. Indeed, Britain was its first major overseas market and the company then expanded into continental Europe throughout the 1970s and 1980s. Currently employing about 2,000 people across five factories in England and a seed potato business at Montrose in Scotland, McCain Foods GB leads the retail and food service industries in frozen potato products such as French fries, potato specialties, and appetisers. McCain Foods GB generated pretax profits of £40.45 million on turnover of £371.5 million for the year ended June 30th 2011. Sustainable Business Model McCain Foods is determined to reduce its environmental impact and develop a sustainable business model. Committed to a vertically FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Corporate Social Responsibility “We have historically always taken into consideration the impact of our activities on people, the environment and our business. They represent the basic pillars of our corporate responsibility program,” explains Jean Bernou, chief executive of McCain Continental Europe. “Because millions of people eat our products on a regular basis, we have developed a rigorous CSR policy.” McCain Foods has defined specific CSR (Corporate Social Responsibility) targets against which it can be measured. “Success is becoming more closely linked to CSR. The challenges we are facing in today’s society, both with regard to people and the environment, are enormous.” He continues: “Whether we’re (CONTINUED ON PAGE 40)
The Canadian food group’s ethos is summed up in its strap line - McCain It’s All Good! This encompasses all aspects of the group’s business.
37
SUPPLY CHAIN SOLUTIONS
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
39
new facility at Harnes is the largest refrigerated automated warehouse in France. This single high density warehouse allows McCain Foods to merge the storage and distribution of eight regional warehouses in Bethume, Harnes and throughout northern Europe. In addition to savings on operational costs, such as electricity, the automated warehouse reduces transportation costs and supports McCain Foods’ strategy for sustainability. The logistics service provider Kloosterboer runs the warehouse exclusively for McCain Foods.
In the UK, McCain Foods has cut salt in its foods, removed artificial colourings and now uses sunflower oil in its products to reduce saturated fat.
talking about global warming, water management, energy, biodiversity or nutrition, we, at McCain, want to know and manage more precisely the impact of our activities in light of these challenges.” In line with its corporate social responsibility strategy, McCain Foods invests significantly in reducing its environmental impact and carbon footprint while also boosting productivity. For instance, its manufacturing facilities create a large amount of waste heat, particularly from fryers. The frozen foods group has invested over C$50 million on implementing systems to capture the waste heat produced and recycle it back into the plants to pre-heat the water required for the boiler systems and other production operations. McCain Foods’ potato processing facilities worldwide now feature this technology which reduces fuel use by 9%. For example, McCain Foods GB has invested over £10 million in green initiatives at its Whittlesey site, the largest chip factory in the UK. In addition to the introduction of the latest technology to capture waste cooking heat and recycle it to heat water, the Whittlesey site is the first major UK food plant to be powered mainly by wind. Improvements in the Supply Chain McCain Foods has also been reducing its environmental impact and energy usage whilst also cutting costs within its supply chain. The Canadian food giant has been centralising logistics and focusing on route management throughout its global business with the objective of reducing both cost and road miles to customers. At Harnes in France, which is located at the centre point of McCain Foods’ plant network in Continental Europe, the company has established a new cold storage facility to centralise logistics in the region, so reducing annual kilometres driven by an estimated 180,000 and emissions generated from fuel use by 140 tonnes. With a capacity of over 70,000 pallets, the 40
Sustainable Sourcing As the world’s largest frozen potato product manufacturer, maintaining a secure and abundant supply of quality raw materials is crucial to McCain Foods. “Without potato there is no McCain Foods; without the growers, there is no potato; and without growers there is no McCain Foods,” points out Jean Bernou. Sustainable sourcing of its raw materials is key to McCain Foods’ ability to demonstrate where its products come from all the way through the value chain and to prove the cultivation techniques used have minimal impact on the environment. McCain Foods fosters close links with its farmer growers. In Great Britain, McCain Foods works closely with 300 farmers, some of whom it has worked in partnership with for three generations. McCain Foods GB processes about 13% of the national potato crop of 6 million tons, which is worth in the region of £3.5 billion at retail prices. McCain Foods GB forward contracts the growing of specialised varieties of potatoes with UK farmers, supplying them with seed potato. “When we entered the market in the late ‘60s we clearly understood then that we needed to pre-season contract to make sure the varieties in the quantity and quality we required were grown. That has been the fundamental basis of our sourcing policy ever since then,” explains Nick Vermont, chief executive of McCain Foods GB. “We are in the food industry at the capital intensive end – to rebuild our Scarborough factory today would cost some
£200 million and we would expect to run that for 40 or 50 years. A factory with a capital investment of that size needs to run every day without fail.” McCain Foods GB seeks to develop longterm partnerships with its potato growers and has encouraged the establishment of grower groups, which can benefit from economies of scale and co-operation, access to capital for investment, and improved co-ordination and logistics. McCain Foods GB now has nine grower groups, ranging in size from 10 to 25 members, and each producing between 20,000 and 60,000 tons of potatoes a year.
The latest innovation from McCain Foods is a preprepared microwaveable jacket potato.
“Our growers have to make money, otherwise they are not going to continue growing for us,” remarks Nick Vermont. “Equally, we have a responsibility as a major player to make sure we minimise our impact on the environment and the local communities in which we operate. That is increasingly important with water becoming so critical.” Customer-focused Another cornerstone of McCain Foods’ success has been its ability to innovate and consistently deliver products that meet changing consumer needs. “I don’t believe any brand, however big – McCain is a top 20 brand and we spend about £20 million a year on advertising – has a
New McCain Ready Baked Jackets to Revolutionise Meal Times The launch of McCain Ready Baked Jackets is the biggest in decades for McCain Foods, and is set to revolutionise the way people eat jacket potatoes, in much the same way that McCain Oven Chips transformed the eating of chips in the home when they were launched in 1979. McCain Ready Baked Jackets combine the taste and smell of slow oven-baked jacket potatoes but are ready to eat from frozen in just five minutes. McCain Ready Baked Jackets have been developed following consumer research that revealed that consumers love the taste of oven-baked jacket potatoes but are put off preparing them by long cooking times. The launch is being supported by a £6 million marketing programme including a television advertising campaign. Mark Hodge, McCain Foods head of brand, explains: “This is McCain’s most significant new product launch in years. McCain Ready Baked Jackets will revolutionise jacket potato eating in the UK and introduce a new way for consumers to purchase their favourite meal in a more convenient format.” He adds: “There is no secret formula. McCain takes real, simple ingredients and prepares them with care using no artificial colours or flavours. We just cross cut top-quality British potatoes, drizzle them with sunflower oil and slowly oven-bake them, so all the consumer has to do is pop them in the microwave for five minutes and decide on a topping.”
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
right to succeed. Unless we are striving to delight our consumers in new ways, in ways that they value, we are doomed to failure.” Nick Vermont continues: “McCain has been particularly lucky in GB in that in every decade for the last five decades we have had a major innovation, including Ovenable Chips, which completely revolutionised the way people prepared potatoes at home and saw a massive increase in the sale of frozen and prepared chips. We have followed that with other innovations.” The latest innovation from McCain Foods is a pre-prepared microwaveable jacket potato. Supported by a £6 million marketing campaign, the launch of McCain Ready Baked Jackets is the biggest in decades for McCain Foods GB. The company expects its new product will revolutionise the way people eat jacket potatoes, in much the same way that McCain Oven Chips transformed the eating of chips in the home when they were launched in 1979. “Innovation has been absolutely fundamental to our success along with the fact that being a privately owned business allows us to take a long-term view and I believe that in a cyclical, agricultural commodity market like potatoes, you certainly have to take a long-term view,” remarks Nick Vermont. Healthy Eating Scare While McCain Foods continues to consolidate
labelling on its packaging, to provide consumers with a quick and simple way to check the nutritional value of products.
its leadership position in the UK and Western Europe while developing emerging markets in Central and Eastern Europe, it has not all been plain sailing. The frozen foods group has had to overcome a major threat to its core French fries business since obesity became recognised as a major health problem in developed markets of the world such as North America and Western Europe. To counteract the problem, McCain Foods conducted extensive market research to ascertain consumer concerns and needs before launching a marketing campaign to restore consumer confidence in the McCain brand and the French fries market. In response to the growing consumer interest in ‘healthy eating’, McCain Foods has been reformulating its products. For example, in the UK it has cut salt in its foods by 22%, removed artificial colourings and now uses sunflower oil in its products to reduce saturated fat. McCain Foods was also one of the first UK manufacturers to introduce traffic light
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
Continued Expansion McCain Foods is continuing to expand its food empire in Europe, both organically and by acquisition. It is currently purchasing CelaVita, a leading European chilled potato producer and the market leader in the Benelux, to strengthen its core potato business and open opportunities to better serve customers with a more diverse range of product solutions. CelaVita employs over 300 people and is part of Bieze Food Group, owned by the German Wernsing Group. CelaVita’s product portfolio includes whole baby potatoes, cut, sliced, diced and mash potato, both natural and seasoned. CelaVita has strong and longstanding relationships with Dutch and international customers across the three main channels - retail, food service and food industry. Its activity is particularly focused in the Netherlands, Belgium, France, Germany, the UK and Italy. Upon completion of the acquisition, CelaVita will become a full subsidiary of McCain Foods Holland. “The acquisition of such a respected and leading player in the industry will allow us to expand our range of capabilities and grow our supply position on the European processed potato market,” says Jean Bernou. J
41
QUALITY
& HYGIENE
Unbeatable Alliance Providing Sensorbased Sorting and Peeling Solutions OMRA Sorting Solutions has unified T two champions to become undoubtedly the preferred supplier for the food market's sensor-based sorting and peeling needs. ODENBERG and BEST have created an invincible alliance when it comes to delivering sorting, safety and quality solutions throughout the process chain, as well as solutions for peeling, process analytics and chilling & freezing
market. Customers are reassured by the company’s even more comprehensive support and service network, close to its customers. TOMRA Sorting Solutions now also offers wider segment or application coverage and expertise, as well as boasting the leading sector experts and knowledge in research and development. This will enable the company to continue producing efficient, reliable state-of-the-art systems and customized solutions. In addition, the company has eight test and demonstration centers worldwide, so customers can trial their own products in its systems. A Multitude of High Technological Solutions Available
TOMRA Sorting Solutions, the pioneer in sensor-based sorting which acquired ODENBERG in 2011, purchased Belgian BEST Sorting in June 2012, to unify the two leading providers and enhance its position as the preferred supplier for the food market’s needs. The companies design and supply high-performance optical sorters and graders, peeling or process analytics systems, and chilling/freezing solutions. BEST is a strong strategic fit, complementing TOMRA Sorting Solutions' portfolio by adding leading sorting technologies, based on laser, camera and X-ray. BEST, in turn, now has access to all TOMRA Sorting Solutions’ sensor technologies. Joining Forces
After acquiring BEST, TOMRA Sorting Solutions now has more than 6,500 machines installed worldwide in the food
ODENBERG has been developing peeling and sorting solutions for the food industry for over 40 years. McCain Europe uses ODENBERG steam peeling technology at all its plants, with two new lines scheduled to be installed early 2013. TOMRA Sorting Solutions is today the preferred supplier for peeling solutions, with over 65% of the world’s French fries processed using ODENBERG equipment. ODENBERG and BEST can offer a complete sorting solution for different industries, one example is the potato industry, where they propose solutions in different positions in the process line. ODENBERG and BEST offer a holistic approach maximizing yield and efficiency; collecting real-time information from the farm to the end of a French fry line. ODENBERG and BEST provide high quality equipment to optimize the production flow, resulting in consistent high quality final consumer product. TOMRA Sorting solutions also designs and supplies a wide range of variable residence time chilling and freezing systems for boxed and naked food products. First Results
TOMRA Sorting Solutions has recently been awarded contracts totaling US$18.5 million. The order is for optical sorting and peeling equipment to be used at a new high capacity food processing plant in the US. “The acquisition of BEST was recently completed, and we are very pleased to see the first results of the merger between ODENBERG and BEST,” comments TOMRA President and CEO, Stefan Ranstrand. “These contracts are the first 42
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
acknowledgement of our market oriented strategy, and how the combined technologies of ODENBERG and BEST make us a preferred supplier.” “TOMRA Sorting Solutions now has an extensive product portfolio of sorting, steam peeling, and process analytics technologies, which was a crucial factor for the customer when deciding for TOMRA,” explains Rune Marthinussen, Head of TOMRA Sorting Solutions. “In addition, our global product support organization and track record played a key role in securing this deal.” TOMRA
TOMRA Systems ASA has two divisions: TOMRA Sorting Solutions - which now includes ODENBERG and BEST Sorting, next to Titech and CommodasUltrasort and focuses on sensor-based technologies for sorting and process analysis - and TOMRA Collection Solutions, which specializes in reverse vending, material handling and compaction. For more information, please see www.tomrasorting.com/food. J
QUALITY I
& SAFETY HYGIENE
INSPECTION SYSTEMS
Loma – Clearly Seeing the Future oma Systems designs and manufactures L inspection equipment to identify product defects and contaminants for the food
installation base, boasting 120,000 metal detector installations globally.
industry. Loma has a comprehensive range of Metal Detectors, Checkweighers and Xray systems and is committed to providing the most efficient and cost-effective solutions for all food product inspection requirements. The company was established in the UK in the 1960’s, however, today it is one of the leading global companies involved in food safety. Loma has 300 employees worldwide with machines installed in over 100 countries. Loma has an impressive
Safe, Reliable and Tough Machines
The company has a philosophy of making its name synonymous with safe, reliable, and tough machines, which deliver maximum uptime at a reasonable lifetime cost of ownership. The equipment is complemented by a good after sales service support team with a thorough understanding of the pressure on companies working in the food industry today. Loma prides itself on having the best Response Times and First Time Fix Rates in the industry. Loma’s key objective is to deliver maximum uptime from its equipment. The specific needs of industrial food production such as strict cleanliness and enhanced durability, have been key factors in Loma’s product development, and follow the company’s ethos of ‘Designed to Survive’. New Inspection Technologies
Loma’s flagship IQ3+ Metal Detector Conveyor.
The company has brought revolutionary new inspection technologies to market in the last couple of years - the launch of Loma’s IQ3 Metal Detector was heralded as a revolution in metal detection technology due to its advanced electronics. No longer are operators required to manually
optimise frequencies, which is both timeconsuming and risky. The IQ3+ version adds the benefits of an easy to use and intuitive colour touch screen; making it even simpler for operators to use and achieve maximum functionality from the equipment. Additionally, Loma’s X4 X-ray is another innovative inspection system, it is robust, hygienic and simple to use, offering customers a sophisticated, easy-to-operate and multi-functional inspection system. For more information about Loma Systems, its products and tailor made inspection solutions please visit: www.loma.com, Email: sales@loma.co.uk or telephone +44 (0) 1252 893300. J
Produce World Pioneers Internal Defect Detection in Onions roduce World Rustler, one of the P UK’s leading suppliers of onions and other alliums, will be the first company in the UK to install Near Infra-Red (NIR) technology for detecting internal defects in onions. Working in conjunction with MAF, the company which provided its grader, Produce World Rustler will be trialing the groundbreaking detection system as part of its ongoing continuous improvement campaign. Andrew Holding, business unit director for Produce World Rustler, says: “This is an exciting development that has the potential to further improve the quality of the onions which we supply to our retail customers. We are always looking for ways
to improve performance, and over the past few years the Produce World Group has made a number of substantial capital investments designed to increase efficiency and sustainability.” FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
The company has been monitoring the progress of this technology for some time, and it was always its intention to retrofit such a system to its MAF grader. NIR technology has been used for many years to detect internal defects in fruit, and Produce World Rustler was involved in trials on onions as long ago as 2007. Produce World Rustler is part of Produce World Group, one of the largest expert growers and suppliers of high quality fresh vegetables in Europe. In addition to Produce World Rustler, other Produce World Group companies include Produce World Solanum, Produce World IFP, Produce World RBO, Produce World Marshalls and Growing Trust with Las Lomas (joint venture). J 43
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
45
I TRAYS, TRAY SEALING & MAP
PA’s New MAP Automatic Tray Sealer For Meat and Poultry Products he eclipse range of tray sealers has been develT oped 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 PA’s E-Seal technology which requires zero compressed air
for full operation. The technology drives all machine operations through small servomechanisms, giving massive savings when compared to a pneumatic system resulting in significant annual savings and a sizeable reduction in carbon footprint. For higher throughputs the twin lane eclipse TL6 offers up to 200 packs per minute. All eclipse tooling has been designed to be cheaper, light weight and quick release with water proof heater mats to cope with the hygiene of meat and poultry factories. All eclipse machines incorporate the Eco-Cut 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. For further information contact Packaging Automation on Tel +44 (0)1565 755000 or visit www.pal.co.uk. J
Faerch Plast to Revolutionise Meat Packaging ollowing a return to its roots in 2009 F with the launch of an innovative range of high quality trays and containers for the meat and poultry market, Faerch Plast has now gone one step further with the introduction of MAPET® II mono packaging, which is set to compete against containers produced from multi-layer materials. The plastics recycling industry has for several years argued against the use of multilayer and laminated materials for food packaging owing to the difficulties of separating them for recycling. With better potential to be sorted and recycled, Faerch Plast is calling on the plastics recycling industry to back MAPET II as the new industry standard. The brand new packaging product, designed primarily for manufacturing trays for meat and poultry, has the same properties as multi-layer materials, but is produced from just one substrate, MONO amorphous polyethylene terephthalate or MAPET, which offers better sealability than
its predecessor, MAPET I . Traditionally the meat industry has used
trays produced from multi-layer or laminated materials to ensure adequate sealing with film. Faerch Plast wanted to develop a new type of tray produced from a single material that would have better clarity to meet the growing consumer trend to assess the quality and integrity of food products prior to purchase. The tray had to have the ability to be sealed that was similar to laminates. Similar speed, similar ability to handle the inevitable rim contamination and similar strength. MAPET II may be used with a wide range of sealing films, including market standard PE. The packer will not need to make any changes to either lidding films or machine adjustments. Simply put the trays on the machine and they will run. It is anticipated that MAPET II will be used initially for top sealed fresh meat products with further applications for various chilled foods and snacks products such as biscuits and cakes. For further information contact Faerch Plast on Tel +44 (0)20 8254 2300 or www.faerchplast.co.uk. J
I GLASS PACKAGING
Beatson Clark Builds New Furnace new £5.4 million white flint furnace A is in operation at UK glass manufacturer Beatson Clark. The furnace has a daily capacity of approximately 200 tonnes of glass and gives Beatson Clark in Rotherham the same size melting area of 70.6 sq m as the previous furnace. However, an improved design will mean greater efficiency and reduced C02 emissions in line with new Government targets. 46
The furnace rebuild is part of a £10 million investment which Beatson Clark has made this year. Its amber furnace was successfully repaired in December 2011 and new vision-based inspection equipment has also been installed. “Our staff have worked closely with the contractors to ensure a smooth installation,” says Beatson Clark’s furnace manager Dean Duke. “The new furnace and the major maintenance FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
work that has been undertaken will enable us to continue to produce quality glass for our customers for years to come.” For further information contact Beatson Clark on Tel +44 (0)1709 828141, E-mail sales@beatson clark. co.uk or visit www.beatsonclark. co.uk. J
I TRAYS, TRAY SEALING & MAP
A More Sustainable Solution For MAP By Steve Baker he issue of pack integrity for fresh and T chilled foods has implications for the whole economy. Figures from Defra suggest that some 18 million tonnes of food are wasted every year – a huge amount, both in terms of volume and in monetary value. Disturbingly, 30% of this occurs before the food even gets into the shopping basket! For the food processing industry, this is becoming an increasingly urgent issue as major retailers may return any prematurely spoiled packs direct to the manufacturer, in some cases imposing fines as well. But how can every item of Modified Atmosphere Packaging be non-destructively checked before despatch from the factory? It is a challenge that BOC – and its parent company The Linde Group – have been working on for some time. And we think we have found a solution. Many food packs contain MAP gas mix-
tures of nitrogen and carbon dioxide. Nitrogen is notoriously difficult to detect so over recent years much of industry’s research effort has focussed on identifying leaks of carbon dioxide. However, since this gas may account for a third of the mix, any leak from one pack may overwhelm the sensors and could affect the readings on subsequent scans. That could potentially overstate the number of faulty items, causing unn ecessary scrapping of product. BOC therefore went back to the drawing board. As experts in the use and handling of gases for more than a century, it was able to evaluate a wide range of options. The solution it came up with was to add a small quantity of hydrogen to the mixture of MAP gases and test for any leakage of this additional gas. Why hydrogen? Well, it is the smallest of all molecules, therefore any imperfection in the packaging, however small, would be susceptible to hydrogen leakage. In that sense, hydrogen leak detection would provide a ‘gold standard’ for pack integrity. It also does not react with the food, nor the other packaging materials or gases, but will disperse evenly through the modified atmosphere The new system only requires a very small addition of hydrogen – less than 3%. A special analysis unit has been constructed to allow fast, accurate checking of every pack on a continuous production process. The analysis unit is placed in-line at the end of the packaging machine and checks each pack as it travels along a conveyor belt. The gas analyser monitors the level of hydrogen as the packs of food pass through the unit. A background level of the gas is assumed but any spike in concentration triggers the alarm and will result in the faulty pack being ejected from the production line. BOC has been working with Linde FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
A prototype BOC/Linde in-line hydrogen leak detector unit.
Global Application Development to develop the system and is leading the commercialisation of the technology. The new system is currently in an advanced stage of development and the first commercial trial has now been completed successfully. At present, BOC is discussing further trials with other interested parties around the UK prior to a full launch of the technology in the near future. There are still opportunities for new partners to become involved in these trials. Food spoilage is a cost to the industry, one which eventually the consumer has to pay for – and ultimately it is a cost to the planet in terms of wasted resources. Hydrogen leak detection offers a way of cutting out waste and, consequently, reducing costs and environmental impacts. Steve Baker is BOC’s Technical Applications Specialist for the food sector. He can be contacted at: Steve.Baker@boc.com For more information about BOC’s products and services for the food industry please visit: www.BOConline.co.uk. BOC is a member of the Linde Group. J
47
College Road, Nobber, Co. Meath, Ireland Tel: (046) 9052466 * Fax: (046) 9052062 Email: cpl@collegeproteins.ie "College Proteins" is a business established at College Road, Nobber, Co. Meath in 1989. Since that date College Proteins has become one of Ireland's leading rendering companies.
Servicing the local, regional and national markets
College Proteins are committed to the protection of the environment.
The company produces two products - Tallow and Meat & Bone Meal - which are renewable indigenous carbon neutral fuels
EB Pressure Washers FROSSES, CO. DONEGAL
Granville Food Care Ltd. Granville Industrial Estate, Dungannon, BT70 1NJ t: +44 (0) 28 8772 6336 | f: +44 (0) 28 8772 7187
FULL BACK UP SERVICE & WARRANTY
Congratulations to Errigal Seafood for 50 years of business
SALES SERVICE HIRE
Phone: 0749736912
*
Mobile: 087 9975899
Suppliers of:
Hot and Cold Washers Domestic – Commercial – Industrial
Second-Hand Washers Steam Cleaners Compressors Vacuums Chemical and Accessories Spare Parts and Repair Service
I SEAFOOD
Buoyant Export Sales Lift Errigal Seafood Currently celebrating its 50th anniversary, Errigal Seafood is Ireland’s largest processor and exporter of shellfish products. perating from a 15,000 sq m stateof-the-art facility located at Carrick in the south-west of County Donegal, Errigal Seafood employs 137 people (rising to 200 during peak times) and has a turnover of Eur26 million. The privately owned company offers a diverse range of seafood including Brown Crab, Crab Claws, Velvet Crab, Whelks, King Scallops, Queen Scallops, Dublin Bay Prawns, Shrimp, Lobster, and Winkles. Customers can choose from an array of preparations, ranging from chilled, fresh, pasteurised, cooked or frozen. A pioneer in pasteurisation processes, Errigal Seafood was the first company to launch pasteurised Crab on the market, increasing the shelf life from 9 days to an impressive 35. The product range is available in variety of preparation formats and grades/sizes and packaged mostly to customer specifications. Errigal Seafood supplies across all trade channels. The company has a long track record of supplying the retail sector offering deliveries of chilled and frozen repacked shellfish. The retail trade currently accounts for more than half of Errigal Seafood’s business but the company also has customers in the wholesale and food service segments for its range of processed shellfish products.
O
Errigal Seafood offers a diverse range of seafood including Brown Crab, Crab Claws, Velvet Crab, Whelks, King Scallops, Queen Scallops, Dublin Bay Prawns, Shrimp, Lobster, and Winkles.
Portugal, Italy, the UK, Scandinavia and the Baltics. Errigal Seafood has introduced in-country sales teams and developed its general overseas sales capacity significantly over the past three years. “We now have offices and staff (and in some countries our own storage facilities) in France, Spain, Portugal, Sweden and the UK,” points out Aodh O'Donnell, managing director of Errigal Seafood. “We concentrate on optimising all aspects of the product/service offering to meet the needs of customers and consumers in each market. We engage with and work closely with customers in each country in the development of new market facing products to suit individual market sectors.”
Brand Building Errigal Seafood markets and distributes its range to over twenty overseas territories and uses the Donegal and Errigal brands for its products. The company also markets some of its products under the Tuskar Rock Brand. Aodh O'Donnell comments: “Significant investment has been undertaken recently to upgrade our Donegal Brand and also on developing more appropriate corporate branding. We changed our company name from Errigal Fish to Errigal Seafood, with a new company logo, launched a new multilingual web site, produced new marketing materials and implemented a comprehensive digital marketing programme.” He continues: “Our brands are associated with the high quality of the seafood range processed at the Donegal facility and the
King Scallops.
Export Focused Errigal Seafood is focused on exports with all its products sold in overseas markets, particularly Europe and Asia. The company has also exported to Canada and the US in the past. France is currently the company’s biggest market followed by Korea, Spain,
Donegal Crab.
Significant Growth Buoyed by growing export sales, Errigal Seafood is performing strongly. “In spite of the recession, our company has enjoyed a period of significant success and growth. Sales have grown by 55 % in last three years,” he says. The enterprising business has evolved significantly since being founded in 1962 by Father McDyer, a pioneering local priest who concerned by the endemic unemployment ravishing the area of South West Donegal in the 60's, set up a market gardening company in Carrick. Errigal Seafood’s enduring success is due to the quality of the seafood it sources from the the North Atlantic, the unique processing techniques the company has developed to significantly extend shelf life, and its local workforce. FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
company enjoys a high level of goodwill with a large number of long established customers. Many of these customers have partnered with Errigal Seafood for over thirty years so loyalty to these brands is high. This also differentiates the Errigal Seafood brands from its competitors.” Another key factor in the successful brand building process is the origin of the company’s seafood products. “Donegal and the pure clear waters of the North Atlantic where our products come from, and, where our processing facility is located, also contribute to our brand identity,” he explains. “The processing factory is located in an area of great natural beauty and the employees (some of whom are the third generation in their families to work with us) are proud of their skills and the tradi49
tion of working with fresh Irish seafood products.”
ments. The company’s in house NPD department, under the guidance of two qualified chefs, works in consultation with customers in each market. Recent marketing initiatives include the introduction of new packaging across all brands and some new customer communication projects. For example, the company launched a new customer e newsletter last year and has organised a number of events to celebrate
Close Links With Customers The company’s strategy is to develop close links with its customers and to align its business to meet the demands of modern retailing with its emphasis on category management, rationalised supply chains and the provision of a suite of complementary high quality convenient seafood products. Errigal Seafood is well placed to cater for the increasing demand in all markets for products that meet trends such as raised health consciousness, a more educated and adventurous consumer, a continuing need for products that suit a busy lifestyle and the growth among consumers of environmental awareness and support for ‘ethical’ products. “Errigal Seafood believes that seafood and in particular our shellfish products are ideal to meet these demands. For example, Donegal Crab in particular is lauded by seafood aficionados worldwide for its distinctive flavour and quality of meat content and it is one of the most abundant species on the planet! Trends come and go but we recognise the importance of keeping close to our markets and customers,” he com-
Dublin Bay Prawns.
its 50th anniversary with staff, the community, customers and suppliers. As part of the Anniversary celebrations, a beautiful book entitled ‘Donegal – The Home of Errigal Seafood’ has been published as a gift for customers. Featuring stunning photography of the area, it tells the story of the company and the people behind its success.
Growth Strategy To support its continued expansion, Errigal Seafood is planning further investment at its processing facility, which was only recently upgraded with a spend of Eur1.5 million on new technologies and capabilities. “The facility is world class and the company uses Lean Manufacturing techniques essential for international competitiveness.” Aodh O'Donnell elaborates: “There is an ambitious phased investment programme for the Donegal site in our 5-year strategic plan including a commitment to new Management Information systems and developing energy and recycling efficiencies. We also recently invested in achieving accreditation of the prestigious BRC quality standard and we plan to invest further in Quality Assurance initiatives and accreditation.” Errigal Seafod also intends to invest and commit resources to develop emerging markets. “Obviously BRIC countries are of interest to us and with that in mind we’ve been developing our sales presence particularly in China,” he remarks. “We recently appointed a Chinese representative to work with a dedicated sales manager - our most experienced, to grow our business there and we’re about to launch a Chinese web site.” J
THE BARRIER PACKAGING COMPANY
Wishing all at Errigal Seafoods the very best for the next 50! Thank you for your continued support.
Specialising in
Certified food hygiene training - all levels H.A.C.C.P. consultancy and training
Fish & Shellfish Packaging High Abuse Vacuum Pouches & Bags Cookable Barrier Pouches & Films Flexo & Gravure Printed Pouches & Bags
Internal and external audits
Anti-fog Lidding Films PE Liners & Sheets
Food sourcing
EPS Backing Boards & Trays Dolav & Octobin Liners Pallet Sheets Wrap & Hoods
Supplier audits
“Giving life to your products” Member F.S.P.A.
50
Visit our website at www.barpack.com – all enquiries welcome
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
I RISK MANAGEMENT
Willis Provides Local and Global Coverage illis Risk Services (Ireland) Ltd (t/a W Willis) is one of Ireland’s leading insurance brokers, pensions, actuarial and risk management consultancies. The firm employ over 230 people in its offices in Dublin, Limerick and Cork. Part of the Willis Group (NYSE:WSH), the third largest insurance broker in the world, Willis serves clients around the globe through over 400 offices in some 120 countries. A truly international company, Willis can partner you anywhere in the world and satisfy your insurance needs in every aspect of risk in the processing, manufacture, distribution and sale of food and drink on a local and global scale. Willis Food & Drink Practice
Willis provides solutions to many food and drink organisations in Ireland and the UK. Its extensive experience allows Willis to understand your business and your industry’s unique needs in all industry sub-sectors
an extortion demand, the policy provides cover for the costs of recalling a product, replacing a product, lost profit, public relations expenses and brand rehabilitation. Why Talk to Willis?
including seafood, agriculture, dairy and livestock, drinks, and food manufacturing and processing. Willis has highly valued relationships with the top food and drink insurance markets enabling its brokers to design, negotiate, select and implement superior insurance programmes for food and drink clients. Could Your Business Withstand a Product Recall?
Willis has developed an exclusive Product Recall & Contamination Insurance facility. Whether a recall is triggered by accidental contamination, malicious tamper or
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
* Dedicated Food & Drink Practice with deep industry knowledge * Bespoke Food and Drink insurance solutions * Competitive/sustainable premium savings * Premium financing options * Independent evaluation of insured and uninsured risks * Risk assessment and management tools * Dedicated claims and loss control experts * Recall experts to help with coverage and claims. For further professional advice please speak to one of Willis’s dedicated Food & Drink Practice team members at Tel +353 (0)1 407 4900, Email: salesireland@willis.ie. J
51
I PPMA 2012 PREVIEWS
Loma Launches New Combination Metal Detector and Checkweigher at PPMA oma Systems is launching its next generation CW3 Checkweigher and Lmachine IQ3+ Metal Detector Combination machine. This compact and versatile benefits from a slim line metal detector head which provides a much smaller footprint but offers the same detection performance as the previous larger metal detector. The fully integrated mechanical frame ensures easier transportation and the separate reject system reduces vibration on the weigh platform which improves reliability and performance. Additionally, the cabinet has an improved IP rating due to a stronger seal, which eliminates water
Packaging Line Automation Solutions From AutoCoding Systems utoCoding Systems, the specialist sysA tems integrator, will be demonstrating its proven range of packaging line automation solutions at this year’s PPMA exhibition. Visit Stand C16 to see how the AutoCoding system sets up and controls various packaging line devices, irrespective of manufacturer, including coding and labelling equipment,
ingress. Loma is also showcasing a new development to its flagship IQ3+ Metal Detector Conveyor which now benefits from a new transmitter board, allowing stronger field strength levels only previously seen on single frequency tuned systems, this improvement delivers a more robust detection performance. Visit stand D46: or www.loma.com, email: sales@loma.co.uk or telephone +44 (0) 1252 893300. J
barcode scanners, checkweighing and metal detection equipment and vision solutions. The AutoCoding system is already providing measurable benefits to numerous factories across the UK by reducing downtime across packaging lines and eliminating the risk of human error. The AutoCoding solution combines a number of proactive systems
to maximise the opportunity to get things “right first time” by managing the deployment of coding data and the checking of packaging issued to the line before its use. This significantly reduces the opportunity for error and by catching mistakes at source, re-works or significant changeover delays to re-code or correct the packaging are avoided. Data for products or orders can be contained centrally within the AutoCoding database or, alternatively, the AutoCoding software can be linked dynamically to any ERP or management system. AutoCoding Systems also offers a range of standard solutions for managing off-line coding, outer case and tray-end label production and the control of promotional labelling. For further information visit www.autocodingsystems.com. J
CPS Stands Out at PPMA – Hall 5, C74 hesapeake Packaging Systems (CPS), part of Chesapeake, also provide expertise and support for several standard machine C will be demonstrating its expertise as a carton packaging options together with turnkey supply. For further information machinery supplier and consultant specialising in carton erect- visit www.chesapeakecorp.com/packagingmachinery. J ing, loading and closing at September’s PPMA exhibition. CPS offers a unique combination of carton machinery and packaging knowledge that regularly supports pack innovation and increases packing line efficiencies. CPS will be demonstrating a lock-carton erector for lidded cartons and open trays at the show. The ETL60 is ideally suited to the food and confectionery sectors for primary and secondary packaging as well as the healthcare and cosmetics industries for potential high quality printed presentation/display packs. Nigel Redding, General Manager of CPS, says: “We’ve recently seen strong demand for our range of carton erectors which have been integrated with robotic loading cells. This, combined with our ability to supply fully overhauled refurbished machinery from stock, covers all of our customers’ requirements robustly and economically.” With over 40 years of experience, CPS can develop completely new and special pack solutions from concept to production and machine implementation. It can
Production Line Monitoring ondon Electronics L builds large digital screens which give live production data to the workforce, to help boost production line efficiency. Rate, Total, Down time and OEE figures or trend graphs, visible from across the shop floor, mean that everyone is in the know and can react fast to any drop in output. Auto mated email or SMS notifications to key staff members on and off site. Built to order, you can specify a simple single line display, or you can have a fully customised multi-line display with as many measurements as you need. Sealed IP65 all round. Call +44 (0)1767 626444 for your copy of the new catalogue. See http://tiny.cc/y3p3jw for more details. J
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
53
I SEAFOOD
Cool Solutions Now Available For Salmon Too ri-Pack Plastics, the Grimsby-based producer of the CoolSeal range of seafood T packaging, has developed Cool-Seal into a standard pack for white fish, shellfish and salt fish. Building on that knowledge and experience, Tri-Pack has now produced the ideal solution for the 25kg head-on salmon box. The driving force for this development has been environmental, based on the huge carbon footprint savings of polypropylene (PP) over polystyrene. These savings are achieved by the reduction of delivery journeys due to flat-pack delivery, and by the high value of recovered PP here in Europe, rather than sending the waste round the world to China. These factors conNew options tribute great financial savings salmon. in transport costs, by increas-
54
ing the pallet loading considerably. The challenge has been to design a box which can slot into existing automated salmon packing lines, including weighing, easy lidding, auto-strapping, icing and labelling. After extensive testing, which has been monitored and measured by The Grimsby Institute, and Sintef from Trondheim, for suitability for fresh chilled salmon, TriPack is confident that the CoolSeal 25kg box is an ideal alternative to EPS. Making use of Tri-Pack’s patented hi-speed production process, incorporating the sealed edges, the ledge-style tray is incredibly strong, yet lightweight, with built-in insulation for the modern cold chain. It is also very attractive, with excellent for head-on printing and colour options. The two recent develop-
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
ments which have made this practical and user-friendly are in recycling technology, and front-of-line tray erecting machinery. Recycling The contaminated material can be 100% recovered for re-use in thousands of applications in industry. With recycling conducted in Britain, NOT China, the end product represents a 100% recovery of high value raw material, meaning that even waste products have real value! Machinery By modifying existing machinery, Tri-Pack can assemble 600 trays per hour, offering huge space savings for EPS storage, and reducing lorry journeys into plants by 90%. The machinery is sturdy, reliable and proven. Demonstrations of this super kit are currently available at Tri-Pack’s Grimsby factory, and can also be seen on YouTube. J
I FRESH PRODUCE
Focus on Quality Reaps Benefits For Milne Foods Based at Birr in County Offaly, Milne Foods is Ireland’s largest producer and supplier of prepared vegetables, fruit and salads. he company is a specialist supplier of fresh chilled ready to use products to the manufacturing, retail and catering trade. Milne Foods was created over 20 years ago when company founder Patrick Milne began looking at ways of adding value to his existing product range, which at that time consisted only of fresh fruit and vegetables. Today, the company peels, slices and dices 300 tons of vegetables and salads each week at its purpose designed 53,000 sq ft production plant.
T
ing and refresher courses are used as an opportunity to refocus personnel on just how important their common sense and process/product knowledge are to the quality of the end product. Milne Foods operates an in-house laboratory which is used every day for basic housekeeping analysis. However, all shelf life and microbial analysis is out-sourced to an independently accredited laboratory. This means customers have access to independent, impartial certification on all Milne Foods’ products. Investment in Technology Milne Foods has invested substantially in packaging technology. The company loose packs all products in breathable film, as opposed to traditional vacuum packaging, and this investment has proven to be the way forward for the product category. The fresh produce company has also invested in technology that allows it to treat incoming water to the plant without the use of harsh chemicals. All outgoing water is also treated and all waste is disposed of in a safe and environmentally responsible way.
Taking pride in the quality of its finished products and in the service provided to customers, Milne Foods offers daily nationwide deliveries (in many cases same day) using its own fleet of temperature controlled vehicles. The business focuses on prepared vegetables, fruit and salad leaves. Milne Foods produces catering and retail packs of prepared vegetables, leafy salads, wet salads, par cooked vegetables and fully cooked mashed vegetables and gratins. The company is continuously developing new products that add diversity and value to its core business. Focus on Quality Product quality is of paramount importance at Milne Foods. All the company’s products are fully traceable back to the grower and carry trace back numbers and use by dates. Milne Foods only purchases raw materials from reputable sources and all incoming goods are subject to rigorous inspection. The company is continuously developing its quality management plans. It operates on the basis that every member of staff is employed by the quality department. Consequently, all staff train-
Awards Milne Foods holds the British Retail Consortium Standard, which it attained three years ago. It has achieved this standard in the following categories vegetables, salads, prepared/semi-processed fruit, vegetables and salads, vegetable mixes. Working closely with Bord Bia, the Irish food development board, Milne Foods has also been awarded both the Q mark and the Approved Quality System Mark. Indeed, Milne Foods also won Bord Bia’s overall Best Prepared Fruit & Vegetable Processor Award in 2007. J
FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
55
Kerry to Showcase Fermented, Smoke and Functional Solutions For Meat Applications For the Russian Market erry Ingredients & Flavours is launchK ing a range of ingredient and flavour solutions new to the Russian market at Agroprodmash, Russia’s premier exhibition for the food industry. Kerry is exhibiting in Pavilion 1.H, Stand 1E60 at the Expocentre Fairgrounds, Moscow between 8-12 October, 2012. Foremost amongst the launches is a monosodium glutamate free seasoning system for ham, cooked sausages, and semismoked sausages. Dimitrios Tzouvelekis, Country Manager, Kerry Ingredients & Flavours Russia explains: “The trend towards natural ingredients and cleaner labels has spread to Russia from Europe and is now an important concept in the Russian market. Kerry’s seasoning products are being launched in Russia to help our customers respond quickly to the growing concerns from Russian consumers around the use of artificial ingredients.” During the show, Kerry is also showcasing new solutions for Italian-style fermented sausages, semi-smoked sausages, new solutions for injected hams in the Premium segment, with reduced E-Numbers, and high level restructured hams with up to 250% ready product. There are also functional solutions for GOST and TU products, such as sausages, and new meat rubs and glazes which are being offered in the
Russian market for the first time. Italian-style fermented sausage seasonings and starting cultures being exhibited include Felino, Milano, Kremona and Kalibra. Semi-smoked sausage solutions being exhibited: • Haussalami – white pepper and caraway • Spice Servelat – pepper, ginger, nuez moscada • Finskiy Servelat – black pepper, ginger • Kochsalami – pepper, ginger, coriander. Kerry also offers functional solutions for GOST and TU products to create excellent bite and mouthfeel - Kerry Top Sardelki, Kerry Top Sardelki NPH·and Deltagel XE 2000. Kerry is Russia’s leading provider of rubs and glazes which give meat colour and aroma. Rubs on show include Smoky Rib Rub and Sea Salt & Pepper, while glazes
available include BBQ, Maple BBQ, and Honey and Ginger. Kerry has the broadest range of technologies and capabilities within the food and beverage ingredients and flavours market. Dealing with Kerry enables customers to work with a company that understands their needs, can propose value enhancing solutions, and can do it quickly. It is a potential ‘one stop shop’ that enables customers to stay ahead of the competition. This 1 Kerry approach is a great way for customers to do business – providing access to unique consumer and market insights, development expertise, application and pilot proficiency, plus sensory and analytical capabilities. Via a single integrated approach the expertise of a leading worldwide ingredients and flavours company, offering the world’s widest range of technology solutions and a truly global supply chain is now available. “With significant resources at our disposal, we are an established leader in the markets we serve and bring our expertise and global scale together to meet the growing needs in the Russian market. For our customers, Kerry is where it all comes together,” concludes Dimitrios. To find out more about what Kerry can offer visit www.kerry.com or Email russia@kerry.com. J
CSM's Dough Control Technology Delivers Cost Savings unique bread ingredient technology A developed by CSM Bakery Supplies reduces rework and waste during production to achieve cost savings of up to 10%. The result of two years’ intensive research, Dough Control Technology enables CSM to offer bakery ingredients which have been fine-tuned to deliver specific benefits at key points during the bread manufacturing process. “Our Dough Control Technology has been developed to address the fluctuations in production which are an inevitable part of bread manufacturing and so achieve greater consistency and efficiency,” explains Hans Moonen, CSM’s European Bread Product Development Centre Director. “We now offer DCT ingredients to create 56
doughs which can meet a range of very specific manufacturing requirements. We can achieve higher tolerances to mechanical stress for a more friction free process or create a more robust dough with a drier surface. This new technology allows us to provide a new generation of baking ingredients which intelligently support individual production processes and help to optimise costs.” Benefits of DCT extend to counteracting variations in the quality of raw materials FOOD & DRINK BUSINESS EUROPE, AUGUST 2012
particularly flour - which can cause problems such as sticky doughs or poor shapes and is particularly noticeable in pre-dough recipes. It can also be applied to address issues resulting to the use of certain equipment which was not originally engineered and designed to produce the range of bread products with specific characteristics demanded today. Equally important are the end product benefits of DCT solutions which include a fresher bread with softer crumb, increased shelf life, and no requirement for additional E-numbers. CSM’s new technology is aimed primarily at industrialised bread manufacturers across Europe and is already in use in white bread and sandwich toast applications. J