Food & drink business europe nov:dec 2013

November/December 2013

Britvic’s new strategy begins to bear fruit

Food & Drink Business Website:

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C o n t e n t s

- 3 C OVER S TORY

R EGULARS

Britvic’s new strategy begins to bear fruit.

Processing & Manufacturing. . 7 & 8, 24 & 42 P AGE 37 PAGE 3

C ONTRACT

- 10 B REWING & PACKAGING

Simon Litherland, CEO, Britvic.

Bottling & Packaging. . . . . . . . . . . . . . . 9-20 The OCME DryBlock® - A new way to design, build and manage end of line bottling. . . . . . . . . 13 HELIX heralds a boom in glass innovation. . . . . . . . . . 15 New range of fillers for the dairy world. . . . . . . . . . . . . 16

Ronald Kers, CEO, Muller UK & Ireland.

Novel approach by Thomas Hardy.

Materials & Ingredients . . . . . . . 19, 25 & 48 PAGE 42

- 21 S NACKING & B EVERAGES Mondelez International lowers sales growth target.

Mondelez International invests in new European biscuit factory.

Materials Handling . . . . . . . . . . . . . . . 27-30 PAGE 10

Chris Ward, director, Thomas Hardy Brewing and Packaging.

Jason Whooley, CEO, BIM.

Conveyors & Conveyor Belts.

Quality & Safety . . . . . . . . . . . . . . . . . 31-35 Camfil Air Pollution Control (APC) - Safe air for a safe work environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

PAGE 45

Storage & Logistics . . . . . . . . . . . . . . . . . 40

Michael O’Donnell, Island Seafoods.

Managing Director: Colin Murphy Editor: Mike Rohan

- 37 D AIRY

PAGE 21

Muller accelerates UK and US expansion.

Irene Rosenfeld, CEO, Mondelez International.

Group Operations Manager: Sylvia McCarthy Advertising: John Bent & Ian Stewart Production Manager: Sylvia McCarthy

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Irish seafood industry on course to reach sales of over €1 billion by 2017.

Island Seafoods brings Atlantic Treasures to market.

Keohane’s Seafoods makes fish easy.

PAGE 37

Heiner Kamps, CEO, Unternehmensgruppe Theo Müller.

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FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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COVER STORY

Britvic’s New Strategy Begins to Bear Fruit Having decided against a proposed £1.5 billion merger with rival AG Barr, UK and international soft drinks group Britvic is continuing to pursue an alternative development strategy of improving efficiency, streamlining the business and accelerating international expansion.

B

New Strategy Britvic’s new strategy, which was launched last May, is designed to drive market leading profit growth underpinned by margin enhancing revenue growth. It will deliver annual savings of £30 million by 2016 through operating fewer manufacturing sites by redistributing capacity, reducing the cost base and improving asset utilisation. These measures include the closure of two factories at Chelmsford and Huddersfield in Great Britain by March 2014, a warehouse in Belfast, which was closed in November, as well as creating a single GB and Ireland business unit.

The restructuring of Britvic’s GB and Ireland teams is due to be largely completed Simon Litherland, chief executive of Britvic. by the second quarter of 2014. Another initiative to streamline the business will see Ballygowan become the single water brand for GB and Ireland in spring 2014.

Fruit Shoot Recall and Proposed Merger The measures to increase operational efficiency and to simplify Britvic appears to have successfully bounced back from an embar- the organisational structure will lead to an overall reduction in the rassing product recall of its children’s brand Fruit Shoot in July headcount of between 10% and 15%.

2012, due to a ‘packaging safety issue’ linked to a new bottle cap.

Simon Litherland, chief executive of Britvic, explains: “The stratThe recall, which cost Britvic £25 million, following a few years of egy has two parts, firstly our full portfolio markets of GB and less than impressive financial performances left the company at a Ireland and secondly the International and France business where low ebb and prompted the board to agree to an all share merger we will leverage our category leadership of kids, family and adult with rival UK soft drinks producer AG Barr in late 2012. categories.”

However, the proposed deal to create Barr Britvic Soft Drinks, He elaborates: “Delivery of the strategy requires a new streamwith annual sales of over £1.5 billion and capable of generating lined organisation structure based on three clear principles: annual cost synergies of £35 million, was referred to the UK Simplicity to reduce complexity, enabling faster decision making Competition Commission. Under the original merger agreement, and a lower cost operating model; Focus against fewer strategic priBritvic shareholders would have owned 63% of the combined orities matching resources and capability to execute better and; business with AG Barr shareholders the remaining 37%, reflecting Accountability ensuring we have clear ownership to deliver the perthe relative market capitalisation of the two companies at the time. formance.”

The proposed deal lapsed once it was referred to the Competition Britvic is on track to deliver £30 million of cost savings per Commission. annum by 2016, £10 million of which will be invested into the During the delay, Britvic management came up with its own international growth opportunities, especially in the US where a cost savings plan and strategy to improve profitability and to grow new agreement with PepsiCo Americas Beverages (PAB) should internationally, which was well received by shareholders. When lead to significant additional expansion. the proposed merger deal was finally Financial Performance approved by the Britvic’s new strategy Competition Comm- is beginning to show ission, Britvic opted results. The soft to remain indepen- drinks group has just dent and to pursue its reported strong opernew strategy. ating profit growth of ritvic is one of Europe’s leading branded soft drinks producers, armed with a strong brands portfolio including Robinsons, Tango, J2O, Fruit Shoot, Teisseire and MiWadi along with PepsiCo brands such as Pepsi, 7UP and Mountain Dew Energy, which Britvic produces and sells in Great Britain and Ireland under exclusive licenses.

Britvic is the largest supplier of branded still soft drinks in Great Britain and the number two supplier of branded carbonated soft drinks. It is also an industry leader in Ireland with brands such as MiWadi and Ballygowan, and in France with brands such as Teisseire and Fruite. Furthermore, Britvic is growing its reach into other international markets through franchising, export and licensing.

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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18.4% to £137.9 million on revenue up 4.4% to £1.32 billion for the year ended 29 September 2013.

Simon Litherland comments: “We have delivered a strong Britvic is on track to deliver £30 million of cost financial performance savings per annum by 2016, £10 million of which in a year of significant will be invested into the international growth change for our busiopportunities. ness. We have grown revenue and price in all of our business units and gained market value share, resulting in operating profit growth in excess of 18%. We have also reduced debt by nearly 10%, on the back of improved free cash flow generation.”

In GB stills, the Fruit Shoot brand has recovered from the impact of the recall in July 2012 with its take-home market share at the end of the financial year back to prerecall levels. Brand perception measures, such as “Brand you love” and “Happy to give to your child”, have also recovered from the low point of 2012. Although GB stills volume was down 1.0%, reflecting the limited availability of Fruit Shoot earlier in the year, full year revenue rose by 5.7% to £340.1 million.

Within the highly competitive GB carbonates sector, Britvic managed to protect its volume whilst growing both price and revenue. Pepsi again gained market value share, building on its gains in 2012. GB carbonates revenue increased by 3.6% to £536.4 million during the year.

International Growth Britvic also continued to develop its international business. In the US, Fruit Shoot distribution has been expanded to 32 states and the new agreement with PAB will see the brand available in 41 states next year.

Similarly, an agreement with PepsiCo South West Europe has facilitated the roll-out of Fruit Shoot in Spain. Fruit Shoot will also be available to consumers in India by mid2014, following the signing of a distribution agreement with the Narang Group.

In France, Britvic’s syrups brands continued to perform well and gained further market share. Fruit Shoot successfully returned to the market and is performing ahead of where it was pre-recall. The French business increased overall revenue grew by 6.2% to £271.0 million, outperforming the total soft drinks market which grew value by 0.9%.

In Ireland, Britvic’s own brands increased market share, despite the difficult trading conditions. However, the decline in the

licensed wholesale business was behind a 3.5% drop in revenue to £136.9 million and more than offset the sales growth in the core branded business.

Outlook “The organisation has faced a year of uncertainty, firstly with the aborted merger and then with the focus on implementing the new strategy,” comments Simon Litherland. “In 2014 we will continue to implement our new strategy and we have comprehensive plans across the group to drive growth.”

The Britvic chief executive is confident of further profitable growth during the current financial year. “While we anticipate that the consumer environment will remain challenging in 2014, trading in the new financial year is slightly ahead of a strong first quarter performance last year and we are confident of delivering EBIT in the range of £148 million to £156 million for the full year.” J

I VALVE CONTROL

Fruit Syrup Production Process is Sweeter Thanks to Smart Valve Control From Bürkert s the leading fruit syrup manufacturer in A France, Teisseire has retained traditional core values; producing concentrated fruit syrups and drinks since the 1920’s. The main production plant in Crolles, built in 1971, has recently seen a major investment in new process equipment, thanks in part to Britvic that acquired the company in 2010.

This project required Bürkert Fluid Control Systems as one of Europe’s leading process control technology providers to deploy one of the company’s latest innovations to aid process performance as well as integration.

The Bürkert 8681 control head has been used as a key enabling technology to completely change how the process valves at the plant are controlled and actuated, doing away with direct air connections to control cabinets and creating intelligent fieldbus enabled devices that increase both the reliability and efficiency of the production line.

Project Scope

The project scope was to introduce a new fluid control system which would accommodate third party control valves but also provide fieldbus communications to improve the management of the production line. Another goal was to reduce the overall maintenance stores inventory, so using just one control head type 8681 would make a significant reduction in spares.

The production plant covers an area of 73,000 sq m and produces between 300,000 and 550,000 litres of final product

every day. The existing valve control system was approximately15 years old and consisted of an assortment of different control heads, some manual, some automated, but the wide variety of components did not interact well together and overall performance was inefficient. One of the problems stemmed from the existing air supply which included oil mist from the compressor and was not suitable for control of hygienic valves, which had prevented any upgrade to a more modern control system in the past.

The project to refurbish the entire production line contained many aspects, including a new compressed air system as well as a renewed electrical supply system to include DC circuits. This work was to be carried out by other contractors, but its completion was critical to the workflow designed by Bürkert. With these improvements scheduled, the installation of the new valve control system could be finalised.

The on-site automation and electrical maintenance manager, Stéphane Gonin, specified the Bürkert 8681 control head which is optimized for decentralized automation of hygienic process valves. With a decentralised automation concept, the control head takes over all pneumatic actuation, feedback and diagnostic functions up to and including fieldbus communication.

The housing is easy to clean and features proven electrical IP protection and chemically resistant materials for use in food processing applications.

Marc Klingler, Hygienic Segment Manager at Bürkert, explains: “In the past we had been approached by Teisseire only for replacement components to keep the production line operational. However, once this project had been proposed, Teisseire was keen for us to design the new process control system, based on the 8681 control head.”

Installation

Work began on the project during the annual shutdown, which only lasted for three weeks, after which the production line had to be operational. The remainder of the work was completed by Bürkert over the

subsequent two months, without causing any interruptions to the production line. By using the 8681 control head, with its universal adapter, it can be combined with all normal commercial butterfly valves, ball valves, single and double seated valves.

In addition to the main production controls, the plant also has a clean-in-place (CIP) system which was originally a manually controlled process. As part of the planned improvements, the CIP system was to be integrated into the fully automated control system, which would greatly reduce the overall time required by maintenance engineers to perform this operation. Classic control systems, such as the legacy equipment here, using switch cabinets with valve terminals, an I/O system and fieldbus interface involve considerable expense especially in complex facilities. With this technology, the fittings at the field level are connected to the control units in the switch cabinets through a large number of long control air lines and discrete feedback connections.

Apart from planning and installation requirements for such solutions, they are not entirely optimal as regards hygiene.

Summary

In shop floor practice, the control air lines can be quite long, which increases air consumption and has a negative effect on the switching times of the fittings. The situation is compounded by the high power requirement, such as for the evacuation of air from chambers and hoses – which is undesirable in terms of energy efficiency.

The fact that the pilot valve operating level is at a distance from the fitting, makes it even more difficult to commission, main-

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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tain and extend the plant. This also applies to the monitoring of processes.

The alternative is to use a control head, such as the 8681, which allows pneumatic control of the valve, but also provides manual activation, electrical feedback, visual status indicators, fieldbus communication as well as position sensors. This device only requires a power supply, air supply and fieldbus connection to be able to provide extremely efficient and reliable process control.

In comparison to the legacy system, the new, decentralised design of the process valves offers a number of advantages. By mounting the control heads directly onto the control valves, both the length and the total number of connections are reduced, making planning, installation and maintenance much simpler. With much shorter air lines, the switching times and overall air consumption are minimised, which enhances operational reliability. The process valve switching positions are detected by an inductive, analogue position sensor and reported to the PLC system. Up to 3 switching points can be adjusted auto-

matically by a Teach-In function.

Additionally a fourth switching position can be read in and fed back via an external inductive proximity switch.

The 8681 control head is equipped with a coloured LED status display which signals the particular process valve switching position or indicates a diagnostic function such as maintenance required status or fault conditions. This provides a simple, easily identifiable indicator for the maintenance engineer, who can now spend more time dealing with issues elsewhere in the plant.

The unit as a whole eradicates any risk of external contamination thanks to a hygienic and aesthetically pleasing design.

Maintenance is safe and facilitated by external magnetic activation, a system patented by Bürkert. The useful life of the system is increased by the inductive noncontact sensor, as well as by the IP67 protection rating, pressurisation and self-ventilation of the head.

Stéphane Gonin comments: “We selected the Bürkert product as the best solution to improve our production process and the support we received from the commercial and technical teams has made the installationand commissioning of the new system very efficient.”

Marc Klingler again: “All the benefits delivered by the Bürkert package have resulted in a far more efficient use of resources such as maintenance engineer‘s time, spares inventory and a far simpler electrical and pneumatic system. The process control system now works as a fully integrated package and provides far more control and functionality than was ever possible previously.” J

I INNOVATION

FTNON Super Centrifuge Takes Second Place in Food Valley Award ith its new super centrifuge for drying W salad, Food Technology Noord-Oost Nederland BV (FTNON) has been awarded second place for the Food Valley Award 2013. The Food Valley Award is one of the most important innovation awards in the Dutch agrifood sector.

The new FTNON super centrifuge is a continuous centrifuge, whereby no buffering before or after the centrifuge is required.

The system is provided with an optimal centrifugation process, even for fragile products. By minimal use of components, the

system is easy to maintain. The operation is simple, as there are only two variables to be set. Moreover, the centrifuge is easily accessible, so that a quick cleaning is possible.

The system is able to process all kinds of leafy vegetables very well, with a high capacity, in combination with minimal foot print.

FTNON, based in Almelo (NL) and Salinas (USA), supplies complete production lines and special machinery for the processing of a.o. salads, fruit, potatoes, vegetables, mushrooms, ready meals and pet food.

For further information www.ftnon.com. J

visit

I CONFECTIONERY

Chocotech Extends German Production Plant hocotech GmbH, the innovative chocolate and candy solutions specialist, is in the final C stages of adding a new 3.000 sq m (32,300 sq ft) kitchen assembly extension to its facility in Wernigerode, Germany. This will increase the manufacturing area to 10,000 sq m (107,600 sq ft) which will allow Chocotech to become more flexible with the ever increasing kitchen sizes and the higher demand on the market place for the company’s products.

Chocotech GmbH is a 100% subsidiary of Sollich KG, the third generation family-owned company which is market leader in chocolate tempering, enrobing and bar forming. Sollich KG has also increased its plant size due to strong continuous growth.

This is the second extension to the Chocotech GmbH facility following the move to the green field location in 1995 and the manufacturing addition in 2001. Also added at that time was a state-of-the-art candy lab of 600 sq m which offers excellent opportunities to customers for product trials or/and recipe development. For further information visit www.chocotech.de. J 8

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

Invest in the Future of Automatic Packaging

By Michelle Newman, Marketing Manager of Kliklok International odern packaging equipM ment is required to have all the reliability, consistency, and adaptability expected by demanding food manufacturers.

Combined with that, packaging designers are offering more and more complexity in the style of packs. Any automatic solution that has to handle these packages must have the flexibility to accommodate all sorts of shapes, sizes, configurations and production speeds.

Boasting a history of success spanning almost 70 years, Kliklok International addresses these challenges with their range of adaptable and versatile packaging equipment, meeting the needs of food producers to increase output and reduce labour costs.

For example, the growth in the chilled convenience food market led to the development of Kliklok’s Certiwrap® range of wraparound sleeving machines. The company recognized that more and more ready meal producers and packers are now using carton board sleeves, often incorporating a ‘watch strap’ style or clear ‘windows’. This not only enables the consumer to view the product itself, but also represents a growing commitment to reducing packaging material. Given these criteria, Certiwrap cartoners have been proven to efficiently handle a wide range of economically shaped sleeves, with the added ability to incorporate features such as product retention, tamper evidence and ‘upright’ shelfready display.

Similarly, to accommodate the requirements of producers of frozen pizzas, ready meals, burgers, quiches, pies, biscuits and bagged products like cereal and confectionery, Kliklok called up on their experience and knowledge of end load packaging to develop their award winning high performance cartoner CELOX.

Since its launch this innovative machine has attracted the attention of food producers worldwide. With the benefits of rapid carton size change ability, easy access and user-friendly touch screen technology, Celox provides them with the flexibility and reliability so essential in a demanding production environment.

The more astute food producer is seizing the opportunity to invest in this type of automation which now does far more than just put the product into a carton. In fact, Kliklok packaging machinery can also offer added benefits like preventative maintenance, performance data, efficiency reports and output analysis - all via integrated touch screens with the latest programmable software, pre-

loaded with recipes to change from one pack size and format to another with minimal loss of production.

The need to keep up with increased demands within the food industry means that Kliklok is constantly staying one step ahead, by investing in new technology and designing innovative packaging equipment for such a fast-moving market Packaging operations are one of the most important factors in effecting new product innovations and achieving productivity targets. Properly selected and deployed packaging automation and innovative machine designs enable marketing, supply chain, sustainability and lean manufacturing

practice, and ultimately ensure customer satisfaction.

As we move towards a slow and possibly painful economic recovery, the general mood of the food, beverage and food packaging industry seems to be positive.

Consumers may cut back on holidays, new cars, new houses – but food is not a luxury item.

Pro-active, experienced companies in this market with a mindset towards innovation and forward thinking will adjust to these difficult times. Those wise enough to invest in automatic production and packaging systems will place themselves in a stronger position to weather the storm and stay one step ahead in this demanding and competitive industry.

For more information call +44 (0)1275 836131 or visit www.kliklok-int.com. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I

CONTRACT BREWING & PACKAGING

Novel Approach by Thomas Hardy Operating from two modern sites in England, Thomas Hardy Brewing & Packaging specialises in brewing and packaging customers’ own premium brands under confidential contracts. ith no brands of its own, Thomas Hardy is a dedicated service company focused entirely on its customers’ requirements and looks to work more as a strategic partner with its customers rather than simply sell spare capacity. The family-owned company operates from two sites – a brewing and packaging facility at Burtonwood in Cheshire, and a packaging operation at Kendal in Cumbria – employing a total of 114 people.

The company has an annual brewing and kegging capacity of 500,000 hl. It has the capacity to bottle 650,000 hl of product (approximately 13 million cases) and to cask rack 200,000 hl. Turnover in the year ending September 2013 was £18 million (excluding duty).

The Burtonwood site houses the brewery, a kegging line, a cask racking line, a PetBoy (KHS Petainer one trip keg filler) and a high speed bottling line capable of running at around 400 bottles per minute on 275ml or 330ml bottles.

The site at Kendal also operates a high speed bottling line that runs at similar speeds to the one in Burtonwood and the two bottling sites are interchangeable for various bottle sizes and packaging formats.

Other recently completed capital investment projects include a £0.25 million investment in bringing gas to site and converting a boiler, to reduce the company’s carbon footprint and improve energy efficiencies.

Continuing upgrades to liquid processing (chilling, blending), line quality checks and warehouse capacity are planned for the first quarter of next year.

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Market Trends “The contract brewing market continues to be challenging given the continuing decline in UK beer volumes, but the surge in craft and flavoured beers has been positive,” says Chris Ward, director of Thomas Hardy Brewing and Packaging. “Contract packaging has seen an increase in NPD and pack variants for the take home market, overseas

Burtonwood Brewery.

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Thomas Hardy has an annual brewing and kegging capacity of 500,000 hl.

export and price points. We have looked to meet these challenges by investing in equipment and controlling our costs, especially fuel, water and effluent.”

Constant Investment To accommodate the changing demands of its customers, Thomas Hardy invests constantly in the latest production and packaging technology in order to keep pace with developing trends within the beverages market and to remain competitive.

“On the brewing front, the brewery at Burtonwood was built by Burtonwood Plc in 1990 and so is one of the most modern medium sized breweries in the UK with huge flexibility as to what beers, ales lagers or stouts it can produce,” points out Chris Ward. “For packaging, significant investment goes in every year to allow us to keep ahead of the ever changing market, customer requirements or packaging formats. This has allowed us to do over 60 SKUs into 16 bottles types in Burtonwood and over 165 SKUs into 32 different bottle types at Kendal.”

For example, Thomas Hardy recently invested in an end of line upgrade at Kendal, installing a new Prasmatic packer in February as the final stage of a two year investment at both sites to meet an ever increasing demand for smaller take-home packaging formats as well as improve overall line speeds on both bottling lines.

The overall investment of £1.4 million included two Acmi palletisers, a Prasmatic packer, Dimac shrink tunnel, Greenstar carton erector and extra conveyor accumulation.

New Product Development “We are constantly developing new products and packaging formats under confidential agreements,” he remarks. Recent new developments include investment in a KHS PetBoy filler to allow the company to fill 15l, 20l and 30l Petainer one-trip kegs so that customers can access new international markets, target markets with poor keg returns or permit customers without keg populations to offer products on draught.

Thomas Hardy is proactive in making the necessary investments to support its customers’ needs and has sufficient capacity to take on additional contract brewing, blending and packaging for potential customers such as the major brewers, regional brewers, brand owners and soft drinks companies.

“We have the flexibility and the capacity to extend our current shift patterns to meet short term peaks or longer term contractual demands.” Chris Ward concludes: “Our aim is to become the ‘go to’ contract brewer and packer for premium branded products in the UK by developing long term customer relationships and continuing to focus on quality and service.” J

Dimac finished pack erector.

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

A Transparent Aseptic Package From Ecolean colean will begin the year 2014 E with the launch of a brand new innovation: a transparent, aseptic package solution. The package is called Ecolean Air Aseptic Clear, and with its transparency and light weight it is designed to create a unique position on the market.

Ecolean Air Aseptic Clear makes the product visible for the consumer. Suitable contents are all non-carbonated soft drinks like lemonade and ice tea. Thanks to the combination of transparency and great printability, the producer can decide how much to show of the product.

As with all Ecolean packages, Ecolean Air Aseptic Clear is lightweight and has a low environmental impact. Once emptied it becomes flat as an envelope, which means less waste volume.

Ecolean Air Aseptic Clear is available in 200 and 250 ml. For further information visit www.ecolean.com/innovations. J I APPOINTMENT

Krones Appoints a New Sales Manager in Ireland rones UK has appointed Matt K Gardiner as its new Sales Manager for Ireland. Matt has had a long career in the beverage industry; starting as a bottling technician at William Grant, he was then recruited by Krones UK as a service technician, before moving to Ireland in 2001, and later joining the Diageo Baileys’ team in Ireland.

Matt has great experience in all areas of packaging and processing. Matt Gardiner.

Mark Heath, Sales Director of Krones UK comments: “Matt has been in Ireland for a number of years, he joins us at a very exciting time for Krones in Ireland, where we are in the middle of a number of major projects, his experience of working both on the client side and of course his previous career at Krones means he will hit the ground running.”

Matt says: “I am so pleased to be back in the Krones team, having learnt so much in my time working with Baileys and William Grant, and as the Krones’ client base in Ireland increases, there is much to be done in the coming months. With the full support of my colleagues in Bolton and Neutraubling, for both service and installation, we have an unrivalled position in the Irish market.”

For further details on Krones equipment contact mark.heath@krones.co.uk. J 12

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

I TURNKEY BOTTLING SOLUTIONS

The OCME DryBlock® – A New Way to Design, Build and Manage End of Line Bottling * External and integrated reel holder, ergonomic and easy to reach. * Integrated handle applicator, placed outside the machine. * One operator panel. * Automatic film splicer. * Maximum safety standards with CE compliance. * Reduced noise thanks to the reduction of components and accumulation.

More Care For the Products An important part of the DryBlock® logic is the rationalisation of the product flow.

This has led to the elimination of accumulation, with the benefit of reducing friction and contact between containers. This reduces the risk of damage to the product, even when running ultra-light, fragile, delicate or unstable containers. he new OCME DryBlock® was presented to visitors attending the Drinktec 2013 exhibition. The DryBlock® system is a new way to design, build and manage the whole end of a bottling line. It combines the entire dry part of the line into a single, integrated and synchronized ‘Monobloc’ – several machines working together as one.

DryBlock® is designed to meet the needs and growing demands that come from the consumer goods industries, including: * Increase in efficiency: the overall efficiency of a line with DryBlock ® system is greater than the sum of the efficiency of the individual units. * Cost reduction: a single operator can manage the entire end of the line thanks to a number of innovative features inside the single machines and the whole system. * Reduction of energy consumption by up to 36%: low energy features on machines and reduction in the number of conveyor drives. * Space reduction: in a space of only 35x14 meters, a complete end of line, from the labeller to palletiser, thanks to DryBlock technology. * Unprecedented levels of flexibility: format changes are automated and made quickly, for a wide range of bottles or containers, even hard to handle bottles with shaped forms and light materials.

T

A Modular Logic DryBlock® is designed as a modular system that can be adapted to the needs of numerous industrial sectors. The various modules can include a labeller (or a sleever), a packaging machine (shrinkwrapper, trayformer, wrap-around, pick & place, combi, etc) and a palletising module that typically consists of a layer formation unit (manipulators) and one or more robots - or alternatively, traditional palletisers.

A Single Operator The DryBlock® system is controlled by a single operator who is located in a central position with respect to the whole plant. Here the operator can monitor the status of each component and govern the operating parameters through a single interface.

Easy to Implement Solutions based on the DryBlock® system come as a "turn-key" process, in order to simplify and speed up the start-up at the customer premises, with obvious practical and economic advantages.

Scalability One great advantage of the DryBlock® logic is the option to defer the investment by purchasing different components at different times. In this case, each module is designed to integrate and "dialogue" with the DryBlock® control center. This actually makes DryBlock® "scalable"; in fact, it can grow along with the needs of the company.

For further information contact OCME UK Ltd, sales@ocme.co.uk, Tel. +44 (0)1635-298171. J

Ergonomics and Safety: Ethics is Not an Option DryBlock® expresses the attention of OCME for the quality of the work environment and respect for the highest standards of safety. Some important measures have been adopted in crucial points such as: * Shorter distances for the operator. * Simplified label change. * Automatic label splicer.

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I GLASS PACKAGING

HELIX Heralds a Boom in Glass Innovation he future of packaging depends on the T industry’s ability to deliver what consumers want, when they want it. That means products which cater for brand owners’ needs for premium, image-building products, the consumer’s desire for convenience and sustainability and everyone’s basic requirement for a quality package that performs well and is cost-effective.

HELIX, the biggest innovation in wine packaging for over 20 years, is the result of a development which addresses each of these priorities. It offers easy, multiple opening and re-sealing using the cork and glass combination preferred by consumers, but eliminating the need for a corkscrew.

This brings huge value-added potential to the “popular premium” fast turnaround £5 to £10 still wine segment.

Partnership The development is the brainchild of a four year partnership between the two global leaders in wine packaging, glassmaker O-I and cork supplier Amorim. HELIX combines an ergonomically-designed, individually-moulded cork stopper and a glass bottle with an internal thread finish inside the neck, creating a high performing and sophisticated wine package. Wineries can easily implement HELIX with only a minor adjustment to existing filling lines.

Melianthe Leeman, O-I Europe’s commercial excellence and innovation leader, says: “HELIX marries all the benefits of natural cork and glass – quality, sustainability and premium image - with user-friendly convenience. It has been enthusiastically received in consumer research in France, the UK, the USA and China, illustrating that the concept has a future across the world for both Old and New World wines.” Consumers also appreciated retaining the festive ‘pop’ associated with opening a bottle of wine.

Technical tests have also proved its value. In extensive testing over two years, wine

packaged in HELIX glass bottles with cork stoppers showed no alteration in terms of taste, aroma or colour.

Award Winner Since its launch in June, HELIX has been on test with a number of European wineries and bottles are expected on shelf in the near future. It has already been recognised as a winner by the award of an Oscar d’Emballages, the most prestigious packag-

ing award in France, and a Mastroberardino Innovation Award at SIMEI, one of the most important events in the Italian wine calendar.

“HELIX meets consumers’ growing desire for sustainability and quality, while delivering the brand building and premium image packaging wineries rely upon,” adds Antonio Amorim, chairman and CEO of Amorim. “We are delighted to offer the market not only a 100% renewable, modern product, but also a solution that enhances the wine drinking experience through opening and resealing convenience.” For more information on HELIX, visit www.helixconcept.com.

O-I and Amorim serve more than 16,000 wineries across all major markets, for whom they produce over four billion wine bottles and corks every year. “The future of innovation is through collaboration,” says O-I European president Erik Bouts. “HELIX is a proven example of what can be achieved when the world’s leading companies work together.”

O-I Innovation O-I innovation is not simply aimed at the wine sector. Over the past year, the company has also introduced a glass food container featuring a pourable spout, Versaflow, and continues to develop a wide variety of imaginative and attractive options for customers in other beverage industries.

Melianthe Leeman concludes: “Whether it is better systems to boost the recycled content of our containers, more premium decorative options to appeal to luxury and craft brands or the creation of a more efficient supply chain, all our innovation stems from the essential values of glass packaging as exemplified in our Glass is Life campaign.” For more information on glass packaging and how brands across the world are using it to improve their business success, visit www.glassislife.com. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I TURNKEY FILLING SOLUTIONS

New Range of Fillers For the Dairy World EA Procomac has developed a G range of fillers specifically designed for the dairy industry.

order to optimize the performance of filling complex products with pulps and pieces and in order to considerably reduce product wastes due to flavour changeovers.

As far as the market of foil HDPE bottles is concerned, GEA Pro-comac offers a new range of suitable fillers, the main features of which are: rotary machine concept in order to ensure maximum flexibility of products and containers, neck handling “NeckFlex” in order to reduce to minimum changeover times, foil sealing on high speed turrets.

These machines with a capacity from 6.000 bph to 48.000 bph can fill HDPE or PET bottles with UHT milk or milk based products with shelf life up to 12 months or ESL with shelf life up to 120 days, with no limits as far as shape and dimensions are concerned, thanks to an innovative handling system called “Neck Flex”.

The ideal machines for filling solutions dedicated to PET will be ABF for UHT products and ABF 4C for ESL products, where 4C means Clean, Cold Chain, Carbonated in order to summarize all possible ESL or ultraclean applications in the PET world.

The ABF concept involves a preform sterilization through hydrogen peroxide vapor (VHP) on a unique carousel positioned between the oven and the blowing carousel. The blowing carousel is positioned inside the microbiological isolator, therefore once sterilized, the preform remains during all blowing-filling phases inside a completely sterile and controlled area in order to avoid bottle contaminations. Even the caps are sterilized with the same technology through a specific unit called Sterilcap VHP. The blowing process therefore takes place in a sterile ambient, with sterilizable blowing molds and with high pressure sterile air ensuring the best blowing and light-weighting performances; in fact together with ABF, GEA Procomac also presents the weight optimization concept together, “Light & Safe”, i.e. a 0,5 lt bottle weighing only 12 grams which, however, has all dim-ensional and mechanical features which a PET aseptic container must have.

Filling takes place through an aseptic filler with “on board” product tank, positioned at the centre of the filling carousel in 16

New Promo Video A new promotional video to showcase GEA Procomac’s range of technologies was launched at drinktec 2013.

Available to view on YouTube by searching for “GEA Procomac in Dairy”, the three minute promo is a visual experience that introduces viewers to a new range of GEA Procomac products. The film is an immersive, eye-catching concept that engages the emotions whilst familiarizing viewers with the GEA Procomac range of technologies and processes.

“The new film is not your typical technological, instructional video,” says GEA Procomac’s Marketing Manager Silvia Armanetti. “It is a visually pleasing platform to give viewers a further dimension through which to experience our new range of technologies.”

The film expresses bite-size pieces of information and equipment specifications to entice viewers to learn more about the GEA Procomac range and the benefits it can bring to a milk and milk based drinks production line.

For further information contact GEA Procomac SpA, Via Fedolfi 29, 43038 Sala Baganza, Parma, Italy. Phone +39 0521 839578, Fax +39 0521 833879, Web www.procomac.it. J FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

I HOT MELT ADHESIVES

Valco Melton Offers Complete End of Line Palletizing Solution alco Melton, as a leading manufacV turer of adhesive dispensing and quality inspection systems for the packaging industry, offers a complete solution for end of line palletizing processes. Hot melt and cold glue based palletizing solutions present certain advantages over traditional stretch wrap methods in the following ways: * Savings: Switching to adhesive based palletizing processes brings immediate savings by removing the large amounts of stretch wrap used to secure pallets in a traditional method. You are then automatically reducing material investment, material storage costs and material disposal costs. * Safer work environment: Adhesive based palletizers are completely automated, so there’s no need for

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the operator to handle heavy packages or to use blades. * Minimal transportation damages: By creating a secure bond between stacks, adhesive-based palletizers prevent movement during handling and transport. * Prevented storage damages: For products that need to be kept in stock, the slightest bit of moisture can severely damage the product. If the product has been covered by stretch wrap, moisture will be trapped and the product ruined.

These are just a few of the advantages.

For a more in-depth analysis of the benefits that switching to adhesive-based palletizing equipment can bring to your production line, download Valco Melton’s efficient palletizers e-guide by visiting: http://hub.am/16Ykmy4 J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

Cargill Celebrates 5 Years in Ghana and Renews its Partnership With CARE argill has celebrated the fifth C anniversary of its cocoa processing operations in Ghana by reaffirming its

Switzerland and Germany.

Cargill has announced the renewal of its partnership with CARE for an addisupport to growing and developing the tional three-year period, with a comcountry’s cocoa sector. As part of its mitment of over US$800,000. The continued commitment to sustainable renewal is part of Cargill’s global partcocoa through the Cargill Cocoa nership with CARE, and the Rural Promise, the company has announced Education Project in Ghana is key to the renewal of its partnership with supporting the Cargill Cocoa Promise, CARE to support smallholder cocoa the company’s global commitment to farmers in Ghana. the development of a sustainable cocoa “We are delighted to mark our fifth supply chain, With over 9,500 farmers year in Ghana by renewing our partneralready trained in Ghana to date, the ship with CARE to improve farmers’ Promise aims to reach over 20,000 livelihoods and support the developfarmers through dedicated farmer field ment of sustainable cocoa in Ghana,” schools by 2016. says Jos de Loor, president of Cargill’s Over the next three years, the CARE Cocoa farmers in the audience for the five year cocoa and chocolate business. “Ghana project aims to build on achievements celebration. has built its reputation throughout the since 2006 to improve livelihoods in world for its outstanding quality cocoa.

Cargill’s US$100 million state-of-the art 110 cocoa communities in Ghana.

Over the past five years we have been able processing plant is the largest of its kind in Through a community development to produce a diverse range of locally the country and processes Ghanaian cocoa approach the project will continue to processed high quality cocoa products to beans to produce Cargill’s Gerkens® improve the livelihoods of cocoa farming meet the growing demand from our cus- Ghana cocoa powders, which are made households, increase access to education for tomers across the world and create value for available to customers in 24 countries, local children and support sustainable the Ghanaian cocoa sector.” including Japan, the United States, China, cocoa production. J

Pecan Deluxe Nuts For Snacks & Confectionery ut inclusions are a significant contribuN tor to the growth of both the global and UK snack foods market, says Graham Kingston, Commercial Director of inclusions and toppings specialist Pecan Deluxe Candy (Europe). As nuts are celebrated via a National Nut Day Graham Kingston explains their popularity.

“Nuts are fantastic sources of healthy fats, protein, fibre, vitamins, minerals and antioxidants, whilst also being associated

with reduced obesity and positive health benefits such as protection from heart disease and other conditions. There is a growing national and international focus on healthy eating and the market for nutritious snacks and confectionery is undoubtedly on the increase.”

The value of the world snack foods market is expected to reach almost $335 billion by 2015 whilst the UK market alone is growing from an impressive current base of more than £2.5 billion to an anticipated £3.8 billion by 2016. Nuts are the ideal inclusion for snacks and confectionery, bringing texture, taste and health benefits. In fact, nuts feature in almost a third of all global chocolate confectionery products, with an even greater proportion of recent new product launches containing nuts.

Hazelnuts and almonds are the most popular inclusions: the chocolate sector accounts for around 31% of all product launches featuring almonds every year. The attraction for consumers

is improved mouthfeel (crunchy texture), taste and perceived health benefits.

Graham Kingston continues: “Since the misguided and generalist fear of fat as a dietary threat has evolved into much betterinformed nutritional knowledge, nuts in all their forms are enjoying a strong renaissance. Over recent years nut inclusions have almost completely reinvented their role within the worldwide market – firstly they made their way into tub, foodservice and stick ice-cream in multiple applications; then tray bakes, bakery and patisserie.

“Finally delicious desserts, confectionery and cereal bar snacks succumbed to the lure of nut inclusions, supplied in the perfect format for their respective markets, whether it’s frozen or ambient, bagged or loose product, processed or not – and in whatever quantities are required. Now, increased consumer interest in weight loss and healthy eating, in conjunction with the inevitable evolution of eating patterns, is leading to the development of new offerings that will meet consumer demand for healthier snacks to better fit into a time-poor lifestyle.” J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I COOLING TUNNELS

Hosokawa Bepex – Cooling the World osokawa’s cooling tunnel design has evolved over the years H from a standard line to the innovative design now implemented into the new HD (Hygienic Design) Cooling tunnels.

The standard Hosokawa cooling tunnel with its stainless steel construction, easy open individual hoods and high efficiency coil provides excellent cooling for your products while being easy to clean and maintain.

Hosokawa's latest evolution of this design is a tunnel that is more efficient and even more hygienic than its standard version. This re-design meets the highest standards of the most food safety conscious customers worldwide. The HD cooling tunnel is made completely from stainless steel, all welds are continuous and the specially designed coil sections offer air speeds up to 12 m/s.

The upgrades start from the ground up; the drive stand, the belt tensioning station, the discharge and in-feed tables have all been redesigned to be easier to clean, inspect and maintain. All moveable parts and components have been moved to the outside of the product zone and are easily removed. All wash down motors and sealed control boxes are mounted on stand-offs to eliminate niches and hard to clean areas.

The coil section and hoods have been upgraded as well. Both feature continuous welds and removable silicone seals. The coil section receives the most changes as the separated plenum reduces air speed prior to the MERV 14 filtration and cooling to increase efficiency. The catch pan and condensate piping can be removed for cleaning.

The blowers and motors are constructed of stainless steel, the air handling zone is completely separated from the product zone and all unnecessary components are located outside the air stream.

The gas dampers to lift and support the hoods are located outside of the product zone and mounted on stand-offs. Within the hood sections the air dividing plates are made from stainless steel and easily removed for complete access.

This new cooling tunnel sets some very high standards with regards to components, material, and overall design that simplifies cleaning, changeovers, and easy maintenance. Hosokawa’s customers can see a complete HD enrobing line together with this new cooling tunnel at Interpack 2014 in Cologne.

For further information please contact Hosokawa Bepex on Tel +49 (0)7131 907-0, E-Mail confectionery@bepex.hosokawa.com or visit www.bepexhosokawa.com. J 20

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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SNACKING & BEVERAGES

Mondelez International Lowers Sales Growth Target Faced with difficult trading conditions across its market categories, Mondelez International, the global snacking and beverages group, has revised its annual organic net revenue growth target downwards, after performing below expectations in the first nine months of its 2013 financial year. ncorporating the former Cadbury business, acquired by Kraft Foods for $19.5 billion in 2010, Mondelez Inter-national is a world leader in chocolate, biscuits, gum, candy, coffee and powdered beverages, with nine billion-dollar brands such as Cadbury, Cadbury Dairy Milk and Milka chocolate, Jacobs coffee, LU, Nabisco and Oreo biscuits, Tang powdered beverages and Trident gum.

Mondelez International recently celebrated its first anniversary after being separated from Kraft Foods’ North American grocery business in October 2012.

Armed with a strong portfolio of ‘power brands’, Mondelez International is geographically well balanced between emerging markets and mature markets.

Indeed, 40% of its 2012 annual sales of $35 billion were generated in emerging markets and 75% was derived from fast, large, growing snack categories.

I

Growth Targets Mondelez International has set long-term targets of 5-7% organic net revenue growth, high single digit growth in operating income and double digit EPS growth. The group plans to achieve these targets by continuing to invest behind its power brands and new product innovation while maintaining a clear focus on cost management.

Mondelez Internatinal is aiming to accelerate investments in emerging markets to deliver profitable growth over the

Irene Rosenfeld, chairman and chief executive of Mondelez International.

long-term and will finance this process primarily by expanding margins in North America and Europe to levels at or above the average of peer companies, and similar to the levels it is already delivering in emerging markets.

The group’s North American adjusted operating income margin was 13.9% in 2012 compared with a peer average of 18-21%. In Europe, Mondelez International’s 13% operating margin is also behind its peer group average of 13-16%.

In North America, Mondelez International is targeting a 500-basispoint improvement in operating income margin, which it expects to reach by 2016, a year earlier than originally anticipated. Its European target of improving operating income margin by 250 basis points should also be attained by 2016.

The margin improvement will be largely achieved through cost savings and efficiency initiatives currently being implemented across the supply chain, which are designed to deliver $1 billion a year in gross productivity savings.

ume/mix gains of more than 5%, doubledigit growth in emerging markets and increased global market shares, Mondelez International reported revenue growth below expectations due to weak biscuit sales in China (where the group has sales of $1 billion), continued lower coffee prices and slower global category growth, especially in emerging markets.

“Looking forward, we expect these factors will continue to pressure our top line for the remainder of the year,” says Irene Rosenfeld, chairman and chief executive of Mondelez International. The global snacking and beverages group has consequently lowered its 2013 organic net revenue growth outlook to approximately 4% from its previous guidance of the low end of 5 to 7% She adds: “In light of this more challenging environment, we're stepping up our efforts in productivity and overheads, and continue to expect adjusted operating income margin of approximately 12 percent for the full year. Additionally, we're raising our 2013 adjusted EPS target to $1.57 to $1.62.”

In the first nine months of 2013, Mondelez International increased net revenues by 1.1% to $25.8 billion.

Organic Net Revenues increased 4.3% but was held back by lower coffee revenues.

The group’s ‘power brands’ grew 7.4% as Oreo, Chips Ahoy!, Tuc, Club Social,

Performance to Date Despite achieving both revenue and operating margin growth in the third quarter of the 2013 financial year, driven by volFOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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capabilities and routes to market so that we're well-positioned when global category growth returns to previous levels.”

Given Mondelez International’s well balanced geographic footprint with 40% of sales in emerging markets and 75% derived from fast, large, growing snack categories, Irene Rosenfeld remains confident that the long-term target of 5-7% organic net revenue growth is achievable, belVita, and Barni biscuits, Cadbury Dairy Milk, Milka and Lacta chocolate and Halls candy each posted double-digit increases.

Revenues from emerging markets were up 9.9%, led by double-digit gains in the BRIC markets. Developed markets increased 0.7% as modest gains in North America and Europe were mostly offset by a low-single digit decline in Asia Pacific. Operating income increased by 10.6% to $3.0 billion and operating income margin was 11.5%.

Outlook For 2014 The challenging trading environment, which has prompted Mondelez International to revise its performance targets, will persist into next year. “We believe that the recent industry-wide slowdown in key emerging markets, especially China, is temporary,” explains Irene Rosenfeld. “But this slowdown, along with lower coffee prices, will moderate our top-line growth in 2014 to be in the 4 to 5 percent range. We will, however, continue to invest in ‘power brands’, sales

despite the slowdown in revenue growth this year and a similar outlook for 2014 She points out that even when the emerging markets slowdown, they are still growing at three to four times the rate of the developed markets. Similarly, although Mondelez International is facing slowing category growth, snacking growth overall is still much faster than most other food sectors. J

Mondelez International Invests in New European Biscuit Factory Mondelez Intenational plans to invest over $100 million in a state-of-the-art biscuit manufacturing plant at its Opava site in the Czech Republic. The investment will create 200 new roles making Oreo cookies and belVita breakfast biscuits.

Since 2009, net revenues for Oreo and belVita have grown 25% and 18% respectively in Europe.

The new plant will create extra capacity to allow the business to keep pace with future demand.

Phil Hodges, senior vice president, integrated supply chain at Mondelez Europe, says: “This new facility will help us keep up with future demand by creating additional capacity. We've used all of our supply chain and R&D expertise to create a state-of-the-art factory with lines capable of making over a million Oreo biscuits a day. After it is completed, this plant will be a model in our global supply chain network.”

The announcement is consistent with Mondelez International's commitment to invest in advantaged assets to drive sustainable and profitable growth. It builds on $240 million investment across European biscuits network since 2010, including sites in France, the UK and Central Europe.

Kliklok Supplies Wraparound Cartoning Line to Thailand ollowing their success at Propack Asia last year, Kliklok is conF tinuing to expand their presence in this region by supplying a new Certiwrap wraparound cartoning line to F&N Dairies in Thailand.

F&N Dairies, a leading manufacturer of food and beverage products, called on Kliklok to provide a fully integrated cartoning system for multiple cans of flavoured milk.

The brief was to receive cans arriving in a single lane, so Kliklok designed a ‘petal starwheel’ device to split this into two lanes, this then guides the products into a scroll infeed system which collates the cans in the required 2 x 2 and 2 x 3 formats.

Once the groups of cans are cartoned,

using Kliklok’s best-selling Certiwrap C150 machine, the finished packs travel through a right-angle transfer and flap closing unit, which closes the minor and lower major flaps to form a ‘gusset’ enabling secure product retention.

The final stage in the Kliklok line is a selectable 1-to-4 lane diverger system to take the finished packs from a single lane, and divide into up to 4 lanes, ready for transfer to the customer’s shrink wrap machine.

The Certiwrap C150 is certainly proving to be an increasingly popular choice for food and beverage companies, with over 70 Certiwrap machines installed worldwide in a variety of food packing applications. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I CONFECTIONERY EXTRUSION

BCH – A World Leader in Liquorice and Fruit Candy Extrusion Equipment K-based BCH has been developing U innovative process solutions since it started in 1835 and they are now world leaders in the production of liquorice and fruit candy extrusion equipment.

Combined with the on-site 11,000sq.ft Innovation Centre they welcome customers from all over the world to develop new and healthier solutions for the confectionery industry.

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The 100% fruit cooking & extrusion system combines BCH’s MaxiVap evaporation technology with their liquorice extrusion technology. BCH can evaporate high puree content fruit mixes with minimal impact on the fruit flavour and colour enabling the production of a healthy snack bar or pieces using 100% organic fruit ingredients in a variety of colours, shapes and flavours.

BCH has also developed a line to manufacture jelly beans from an extruded centre.

This means that jelly beans can now be manufactured on a liquorice line without the need for a starch depositing system.

This new process involves a modified liquorice recipe and reduces the production time from 48 hours to less than 16 hours.

The BCH micro confectionery extrusion line is a cost-effective solution for new start-up companies as well as certain developing markets within the Middle East, Africa and Asia who wish to gain a foothold

in the sector, without committing huge initial outlay. The new user-friendly and easyto-install solution should be of interest to those niche companies serving smaller segments of the confectionery industry. The line presents a viable option as users invariably lack the large sales volumes to warrant investment in larger, more expensive production lines and may also offer advantages to test kitchen environments. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

Cargill Cocoa Promise Achievements Recognised by Prestigious Food Ingredients Europe Awards argill’s cocoa & chocolate business was C named as one of just three companies for Best Sustainability Initiative at the recent Food Ingredients Europe Excellence Awards 2013. The global cocoa and chocolate business was recognised for the Cargill Cocoa Promise – which commits the company to working with cocoa farmers, cocoa communities and customers to secure a supply of cocoa for generations to come.

Ultimately, the Cargill Cocoa Promise aims to improve yields, incomes and livelihoods through farmer training, community support and farm development and is delivered in partnership with local networks and

farmer organisations.

Saskia Samama, Marketing Manager Sustainable Cocoa, explains: “Because we have people gathering insights and running projects in six cocoa origin countries in South America, Asia and West Africa, the scale and depth of the Cargill Cocoa Promise is unique. As a result, we can address the complex issues in each region, and we develop locally appropriate solutions.”

The Promise is already making a measurable difference around the world across its three key areas of focus. Farmer training in good agricultural practices is playing a vital part in increasing yields and incomes. So far, Cargill’s support has resulted in: * 60,000 farmers being trained each year in Côte d’Ivoire through 1,100 Farmer Field Schools; * 7,000 farmers in Cameroon being set on a path to UTZ Certified and Rainforest Alliance certification.

Community support projects are making a difference to health and education standards in cocoa producing communities. Results of Cargill-supported projects include: * 6,000 farmers being given the most up-to-date information through their mobile phones through our co-sponsorship of the Ghana CocoaLink project; * 12,500 Ghanaian children have been helped to graduate from primary school through our rural education project, delivered in partnership with CARE. Farm development activities are promoting more sustainable practices to secure the long-term health of farms. Cargill projects have, for example, resulted in: * 5 million seedlings being distributed in Brazil to ensure the long-term health of cocoa farms; * 100 development farms being set up in Vietnam, which will promote good agricultural practices. J

Big Scoop For Pecan Deluxe as Premium Ice Cream Market Hots Up 012 was one of the wettest summers on 2 record – but, as a result, this year inclusions and toppings specialist Pecan Deluxe Candy (Europe) has seen a significant surge in demand for its all-natural ingredients from major manufacturers of take-home tub and stick ice cream.

The Western European ice cream market was worth an estimated Eur9.96 billion in 2011/12, with over half of the market share in the UK and Germany accounted for by the take-home sector, and over 70% in France. Recent poor weather has impacted on beleaguered ice cream vans, whose sales have dropped by a third in just three years, but consumers have flocked instead to the retail aisles. The UK’s luxury ice cream sector has achieved year on year growth despite the economic challenges afflicting many households.

Pecan Deluxe commercial director Graham Kingston has no doubt about the driving force behind this growth: inclusions.

He explains: “The contents of supermarket freezers have changed beyond all recognition

in the last few years. Despite, or perhaps because of, the need to tighten purse strings, consumers are upgrading to luxury ice cream brands to give themselves a treat. No longer is it a simple choice between choc ice, fruit cone or vanilla tub: there’s now a massive selection of luxurious and innovative flavours, most of which are based on at least one inclusion or topping.”

The European ice cream market is dominated by four or five global manufacturers

who invest heavily in new product development, which is evidenced by the significant number of new product launches in the last 18 months including sticks and cones featuring sauce centres and chocolate pieces, alongside other creative offerings.

Household name premium stick ice cream brands have moved into tubs and an increasing number of chocolate bars are making the crossover into ice cream territory.

This is not always as simple as it may seem, as Graham Kingston says: “Many confectionery or bakery ingredients can be relatively easily reformulated or adapted for inclusion in ice cream – our cookie dough and chocolate brownie pieces, flavoured fudges and micro mallows being perfect examples. However it’s vital to identify the level of moisture content in the ice cream and how the inclusion will react to it. The majority of inclusions will require a barrier coating that doesn’t impact on the taste or texture of the product – and that’s where specialist expertise and dedicated panning facilities like ours come in.” J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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MATERIALS HANDLING

I CONVEYORS & CONVEYOR BELTS

Span Tech – The Advanced Materials Handling Specialist pan Tech specialises in designing, manuS facturing and supplying advanced materials handling systems, providing customised conveying solutions for food and beverage processors along with a variety of other industrial sectors. Modular in design, Span Tech’s continuous curving, plastic chain conveyor systems are highly versatile, offering users horizontal and vertical bends within one chain design.

Founded in 1978, Span Tech boasts 35 years of expertise and experience in materials handling using its revolutionary Designer System. Span Tech’s conveyors and accessories are engineered to optimize each customer’s ROI. Integrated designs mean every part works together seamlessly, keeping the systems up and running more efficiently than ever.

From a single conveyor or a unique solution up to a complete turnkey solution, Span Tech’s materials handling systems are now used word-wide. Already a market leader in North America, Span Tech has expanded into Central and South America, and established a European subsidiary in 2011. Span Tech works chiefly through a global network of OEMs, integrators and distributors rather than supplying directly to end users.

Unique Approach “One of the unique qualities of Span Tech is that we manufacture everything ourselves.

Most of our competitors buy parts and then assemble them together to provide solutions,” points out Enrico Berlenghi, Director Europe at Span Tech. “The founder of our company, Mr Bud Layne, a true pioneer and inventor, wanted to challenge the status quo by engineering what everyone thought impossible. Creating what we believe to be the most efficient conveying system possible.

To do so, to continuously improve and monitor our quality and systems, he needed to control the entire process in-house.”

Span Tech prides itself on providing customers with the lowest total cost of ownership, as well as the longest service life available. Over 85% of the systems supplied by Span Tech are custom-made.

Span Tech has extensive knowledge of the food and beverage industry covering meat, dairy, fruit and vegetables, brewing, soft drinks, frozen foods, bakeries, fresh and con-

venience foods. Its loyal customers include: Nestlé, Coca-Cola, Cargill, ConAgra, FritoLay, Hershey’s, Kraft, Miller Coors, McKee Foods, Heinz, Dawn Foods to name a few.

Helical Curve A fine example of Span Tech’s innovative design capability is the Helical Curve. The Helical Curves allow product to be inclined or declined while also undergoing a direction change. Span Tech believes that its helical curves feature the most aggressive elevation change in the industry, and an ergonomic modular design that provides the industry's tightest turning radius. The chain is completely captured by an integral side channel to maximize safety, and the bi-directional drive unit adds versatility.

“This offers a huge number of advantages,” remarks Enrico Berlenghi. “The product can be maneuvered in a limited or confined space for example. With our conveyors and complete system solutions we are able to match almost any requirements. Our systems are extremely reliable, and allow for the smoothest operation. The product remains exactly in place, which is really an added value.”

The TranSorter Span Tech has established an industry first with its revolutionary TranSorter technology. The TranSorter is a unique, durable, scalable and flexible sorting system incorporating innovative technology. Utilizing Span Tech’s extendable-nose Transpositor technology, the TranSorter has been designed to offer revolutionary capabilities an alternative to bulky, limited, over-priced sorting solutions, no matter the business size.

The TranSorter extends and retracts to create an opening while the belt continues to

move forward, gently depositing items into a tote, tilting device or cross-belt conveyor.

This boundary-pushing technology seamlessly integrates with Span Tech’s other conveyor systems to adapt exactly to a customer’s specific needs. The modular design comes in both 300mm and 600mm widths.

The Topper Lift Another example of Span Tech’s ability to design solutions to meet changing customer requirements is the Topper Lift. The Topper Lift is designed to lower or elevate product, while preserving product orientation coming out of a spiral cooler or other application.

The upper chain drapes down and rides on lower transport conveyor, acting as a moving top keeper to allow a much steeper angle of transport. This design combines a very compact footprint with the ability to handle products of varying sizes - even ‘unconveyables’ - without adjustment.

Best Possible Solutions “Our proprietary software, developed over the past 30 years, allows us to generate the best possible solutions in minutes,” comments Enrico Berlenghi. “We know in advance how a custom-made solution will work. The 3D models and our software allow our engineer, even in the project phase, to know how the system will perform. We only offer what we know will exceed our customers’ expectations.”

He adds: “We do our very best to reach 100 per cent satisfaction by providing the most efficient and reliable solutions. We adapt to the product, not the other way around. Most of all we do not make promises that we cannot keep, a policy held in the whole of our company.” For further information visit www.spantech-europe.com. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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MATERIALS HANDLING

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CONVEYORS & CONVEYOR BELTS

Esfo Metalbelts – A 100% Dutch Company Offering 100% Quality and Service or 30 years, Esfo Metalbelts has been a F 100% Dutch company. All development and production takes place at Esfo itself. This is unique in the world of metal conveyor belts, a market in which outsourcing abroad has led to an enormous loss in quality. Based on decades of experience, Esfo’s skilled and qualified teams know exactly what they are doing.

All of the activities needed to produce 100%-reliable and high-quality metal conveyor belts are conducted in-house and under the supervision of Esfo. Without outsourcing any details whatsoever. This way, Esfo can guarantee the end quality of its products and Esfo is not afraid to take full responsibility for what they offer. This is the wide range of conveyor belts Esfo can produce and deliver Conveyor Belts, Wire Link Belts, Wide Spiral Belts, Radius Belts, Enrober Belts, Link Plate Belts, Plastic Modular Belts, Ladder Belts, Honey Comb Belts, Biscuit Baking Belts and

Curve Conveyors.

From Planning to Practice, From Advice to Action Esfo is keen to emphasize that actual delivery of conveyor belts from Esfo Metalbelts is always preceded by a careful advisory phase and attention to the customer’s needs. Based on your planning, budget and technical requirements, Esfo will make a detailed list of your wishes. Next, Esfo will offer you specific advice about making the right choice from its large range of metal belts. In short: when it comes to Esfo’s custom-made metal products, this entirely Dutch company will take you from plan to practice, and from advice to action.

Lasting Much Longer As a result of this personal advice in the first phase of your project, the metal conveyor belt that you choose will last much longer in the specific production situation that it is purchased for. Esfo will also competently examine your current stock of metal conveyor belts and provides an expert report on its technical condition, including detailed advice on replacement if necessary.

Superior Speed - Production in Just One Day! Besides advice, attention and high quality, Esfo Metalbelts also guarantees a superior speed of delivery. This 100% Dutch compa-

ny acts quickly, responds flexibly to all your rush orders, and can make adjustments where necessary during production. To give a concrete example: for the Netherlands, Belgium and northern Germany, Esfo often produces 10-metre long, 1-metre wide conveyor belts on the same day and dispatch them also the same day. This speedy production means that you can act instantly when you need to replace your belt, meaning that you can safeguard your production continuity at all times.

Visually Appealing to Architects Besides Esfo’s traditional clients such as fastfood businesses, bakers, breweries and other food companies, an increasing number of architects are also discovering the visual appeal of Esfo’s conveyor belts. They use them as eye-catchers in the designs of their buildings, both interior and exterior. Take train stations, for instance. You will find some appealing examples of these on the website: www.esfo.nl. J

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MATERIALS HANDLING

I

CONVEYORS & CONVEYOR BELTS

AmbaFlex – Science in Spirals ith AmbaFlex’s invention of the W SpiralVeyor® in the mid nineties a new era in conveyor systems started. Continued development and expansion of the scope made AmbaFlex a leader of spiral conveyor solutions.

With over 9000 systems installed together with a global production and service organization AmbaFlex offers a spiral conveyor solution for each application and in all kinds of environments. Solutions could be seen as elevating, accumulating, sequencing, merging, cooling any application you can think of.

SpiralVeyor® SlimLine AmbaFlex offers the widest range of Spiral Conveyors. The SV series is for secondary pack Items such as bottle packs, cases and boxes.

The SVx series has multiple parallel tracks for multi secondary packing conveying. And combined with Triple-E technology, AmbaFlex offers the tallest, fastest and highest load capacity available in the market today.

reach! The best alternative for clamped or inclined elevations.

Portal Concept The Portal Concept is available on all SpiralVeyor® series. It results in a much more effective working environment for both people and goods in filling lines. Available with ONE single belt which is guided through both spirals.

And NO product transfers high up and out of

SVm Mass Flow Lift The SpiralVeyor® SVm can elevate mass flow containers up or down, and can also accumulate them. The belt consists of parallel, virtually seamless, tracks placed side by side. Total belt width possible of up to 24ft. Throughput of 120,000 product items p/h possible. J

Spiroflow’s Top-notch Testing Steers Customers in the Right Direction ery few people would buy a new car withV out a test drive, or a house without at least one visit and evaluation. So why would a manufacturer make a significant investment in new capital machinery without having the chance to test it?

Spiroflow is one of the few suppliers of conveying and weighing equipment to offer a full state-of-the-art testing process prior to purchase.

Spiroflow believes that customers should have complete confidence in the efficiency of their new systems, regardless of the level of investment. The world-leading manufacturer of conveying and weighing systems actively encourages customers, old and new, to use the

fully equipped test centre at its Lancashire site before purchasing any of its Flexible Screw Conveyors, Aero Mechanical Conveyors, Tubular Cable and Chain Drag Conveyors, Vacuum Conveyors, Bulk Bag Dischargers, Bulk Bag Fillers or Ingredients Handling and Weighing Systems.

Whether the equipment is required for efficiently conveying food ingredients such as flour, cereals and coffee granules or accurately controlling the flow of materials for the chemical and water treatment sectors, high quality testing facilities like those at Spiroflow can reassure customers that the systems they are planning to invest in will provide optimum performance and offer value for money.

Spiroflow says that carrying out thorough throughput and degradation trials using its conveying, bulk bag filling and discharging technology - replicating the client’s working conditions including temperature and humidity - can iron out any flaws and ensure each system will meet requirements.

For more information on Spiroflow’s products and services visit www.spiroflow.com or call +44 (0)1200 422525. J

New SPEC Engineering Software For Chain and Modular Belt Conveyor Applications merson Industrial Automation's new E SPEC™ (System Plast Engineering Calculator) uses built-in intelligence to evaluate applications for steel or plastic chain and modular belt conveyor by validating detailed user specifications with a red, yellow, or green rating. Where possible, the software also presents an alternative optimum solution that may reduce energy or lubrication requirements with System Plast's unique Nolu®-S wear material. The process involves three easy steps: definition of conveying requirements, application requirements with product specifications, and system layout.

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Developed by Emerson's Power Transmission Solutions business, SPEC software reports results that include required chain pull, motor speed, torque, shaft power and maximum line back pressure. The software issues alerts for incompatible parameter inputs during the process to help the user achieve successful results.

The software covers applications with carbon steel, stainless steel, several types of LF acetal for high-speed/reduced lubrication, and New Generation™ (NG™) chain designed for high-speed dry running applications.

SPEC software is free and available in nine

languages: Chinese, English, French, German, Italian, Portuguese, Russian, Spanish and Turkish. It can be downloaded from www.PowerTransmissionSolutions.com after a simple registration. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

QUALITY

& HYGIENE

I DUST & FUME CONTROL SYSTEMS

Dust Extraction Solutions From DCS K-based DCS is highly experienced in U the design and installation of dust extraction systems for the food processing and beverage industry. Typically, these installations deal with dust that is created during the process of mixing, drying, weighing, wrapping and transportation of food ingredients, and mostly require a catch-atsource solution which moves the dust, via ductwork, to a central filter unit.

Combustible dust explosions can be a risk in areas of a food processing plant and dust extraction systems are required to fully comply with the latest EU ATEX directives in relation to explosion protection of equipment, installations – and protection of personnel.

Important food and beverage projects undertaken by DCS include the installation of a state-of-the-art dust extraction plant to deal with airborne tea dust particles generated in the main line tea packing area for Taylors of Harrogate. Taylors of Harrogate is one of the few remaining family tea and coffee merchants and has been blending

Dust Extraction plant for dealing with airborne dust particles.

quality teas since 1886. Today, the company is best known for its Yorkshire Tea blends.

The system supplied and installed by DCS draws dust directly from teabag filling stations and transports it via special ‘smooth bore’ galvanised ducting for filtration by a dust collector housed in the roof space

above the tea hall. Two ATEX approved ‘Downflo’ filter units handle air volumes of 20,400 cubic metres per hour and are capable of capturing dust of less than one micron in size.

To limit the problems of noise and vibration experienced with the previous plant, DCS installed anti-vibration mountings between the plant’s structure and the building’s steelwork. As a further soundproofing measure, the two 30kW fansets were housed inside acoustic enclosures.

To avoid any disruption to production, DCS was required to remove the old dust plant and install the new system over a weekend. Large sections of the roof were removed to enable the old equipment to be lifted out by crane and the new units to be lowered into place.

Richard Martin, Project Engineer at Taylors, says, “It was a very short time window in which to complete the installation but everything went according to plan. The net result is that we have a much quieter and more efficient system.” J

Dustcontrol Streamlines Maintenance For Absolut ustcontrol manufactures and customizes D portable dust extractors, air cleaners and industrial extraction systems with very high levels of filtration. With a Dustcontrol solution users can vacuum clean or extract dust, flour, chips, oil spills and other unhealthy substances at the source and transport them elsewhere.

Dustcontrol filters pollutants up to 99.995% producing a healthier working environment, a more efficient cleaning process and thus higher production quality with less down time.

Dustcontrol has helped Swedish vodka producer Absolut to streamline its maintenance procedures by installing a centralised vacuum system. Absolut Company wanted to increase its commitment to sanitation to prevent stops in the production line and also to facilitate trou-

bleshooting.

“You have to vacuum to avoid stopping the machine,” says Christer Lind, Project Technician at Absolut Company. “We clean for 15 minutes every night and in the daytime also, if for example, a bottle breaks.”

An important goal for Absolut Company is efficiency - the proportion of time the production can run at maximum capacity.

The more stops the worse the efficiency.

Dustcontrol has provided Absolut Company with centralised vacuum systems to help make the cleaning quick and easy.

“Compared to a mobile vacuum cleaner that must be picked up and then stowed away again it is much easier and less time consuming. Everything is in one place. The simplicity makes you clean up after oneself. If you would have to pick up the equipment every time it would not get done,” says Christer Johansson.

Absolute Company’s option of the DC Green System on one of its stationary vacuum systems contributes to energy savings by its frequency control function. ”When the operators now and then, are cleaning the machines throughout the day, you benefit from the central unit going into a saving mode between the cleaning sessions and being on demand much quicker,” says Christer Johansson. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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QUALITY

& HYGIENE

I DUST & FUME CONTROL SYSTEMS

Camfil Air Pollution Control (APC) – Safe Air For a Safe Work Environment amfil APC offers the most technologiC cally advanced dust extractors available – backed by dependable service support and decades of proven experience. Camfil APC can help you: • Prevent dust-related respiratory problems, and in some cases reduce or eliminate the need for personal respirators; • Comply with current air quality requirements; • Prevent dust extractor explosions and fires caused by combustible dusts, electrical sparks and other causes; • Minimize slips, falls and visibility problems created by “nuisance” dusts in the workplace; • Reduce worker discomfort from allergens found in process dusts; • Protect valuable equipment from dust contamination.

Camfil APC’s mission is to ship extractors fast while still giving the customer what they want; to be the most customer

Camfil APC’s flagship “Farr Gold Series®” cartridge extractor combines rugged heavygauge construction with a compact modular design that provides premium performance while taking up less floor space.

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friendly company in the dust collection business; and to make the best dust extractor in the business from an end-user and maintenance viewpoint.

Camfil APC is a subsidiary of Camfil, the largest air filter manufacturer in the world. All the company’s dust collection systems (including filter cartridges) are manufactured in ISO 9001 certified facilities. Camfil APC is the only company in the business to offer both ISO 9001 and a full service dust collection testing facility, ensuring a quality product from design to shipment.

Compliance Programs

explosibility characteristics.

Products

Camfil APC’s flagship “Farr Gold Series ® ” cartridge extractor combines rugged heavy-gauge construction with a compact modular design that provides premium performance while taking up less floor space. Service benefits include easy access and fast, trouble-free filter changeout with no special tools required.

Options include safety platforms and ladders, safety monitoring filters, and a new

In recent years, the European Union has developed stricter requirements to prevent explosions from combustible dusts (ATEX). Camfil offers an integrated product, testing and technical support program to help customers analyze and solve combustible dust problems.

Camfil APC also has a program to help companies engaged in metalworking operations to understand and comply Camfil APC’s UK plant. with the strict new EPA regulation for Metal Fabrication Hazardous Air Pollutants integrated HEPA safety monitoring filter (MFHAP). Whatever air quality require- that comes mounted on top of the extracments impact your facility, whether EPA tor so that no additional floor space is and/or OSHA, Camfil APC provides a required. written guarantee of emissions perforThe Farr Gold Series extractor is mance. equipped with the award-winning “HemiPleat®” filter, which delivers lower Test Facility pressure drop than standard cartridge filCamfil APC’s state-of-the-art test lab is ters for extended service life and energy equipped to conduct a battery of bench savings. HemiPleat replacement filters are tests on dust samples, as well as simulat- available to enhance performance in most ed full-scale testing that no other manu- competitive cartridge extractors. facturer can equal. These tests provide Camfil APC also offers mobile cartridge scientific analysis of your dust to take extractors and accessories.

For further information contact Camfil the guesswork out of equipment selection and help determine the best dust Air Pollution Control, Unit C, Birch extractor design and filter media for the Business Park, Heywood, OL10 2SX, job. Camfil APC can also commission United Kingdom. Phone: +44 1706 363 tests to determine whether your dust is 820, Fax: +44 1706 363 821, Email: combustible and, if so, measure its europe.apc@camfil.com. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

QUALITY

& HYGIENE

Foam Phenomenon – Diversey™ Enduro Power™ Enhances Operational Efficiency, Food Safety and Sustainability iverse food manufacturing sectors – enced a 50% reduction in rinse time when D from poultry and fish processing to using Enduro Power™ to clean surfaces in pizza manufacturing, and from dairy processing to potato crisp frying – have tested and proven the effectiveness of Enduro Power™. This innovative range of cleaning foams from Diversey™ demonstrates up to 50% less water usage, a reduction of up to 33% in chemical levels and a rinse time up to 50% shorter than standard foams.

Specifically developed to meet the tough hygienic, environmental and financial demands of the food, beverage and dairy industries, these innovative hygiene products visibly achieve ambitious sustainability targets and performance standards.

Diversey™ Enduro Power™ clings tenaciously to all surfaces and forms a highly active and visible film. It retains contact up to four times longer than alternative foam products, increasing penetration of stubborn soils. The fact that no reapplication is required reduces labour costs, energy and water requirements, and chemical quanti-

A comparison of Enduro versus standard foam after 7 minutes.

ties. Time and water savings continue during the rinsing process, which is extremely fast due to the foam’s collapsing ability and the lack of need for extra scrubbing. A lower chemical concentration, 50% less than in standard foams in the case of implementation by fish production customers, positively adds to the sustainability balance sheet. Poultry sector customers have experi-

their facilities. Those active in the highly competitive and cost-sensitive pizza manufacturing business recorded a 20% saving in overall cleaning expenditure, making a very significant difference to operational efficiency and the ensuing bottom-line results.

A total of ten different formulations make up the Enduro Power™ family, geared to the specific needs of the food and beverage sector’s diverse spectrum of equipment, embracing conveyors, fillers, ovens, fryers and smokehouses amongst others. Enduro Plus is proven to reliably remove biofilm.

These groups of potentially harmful microorganisms are notoriously difficult to remove. The effectiveness of Enduro Power™ foam technology and the Enduro Plus formulation is validated according to the modified ASTM-E2871-12 standard test method for evaluating disinfectant efficacy against the pseudomonas aeruginosa biofilm. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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I DAIRY

Muller Accelerates UK and US Expansion From small beginnings in Germany, Unternehmensgruppe Theo Muller has developed into one of Europe’s largest dairy processors and is currently expanding rapidly in the UK and the US. lthough founded in 1896 Since 2011, the group umbrelas a village dairy at la also covers the activities of the Aretsried in Bavaria, the HK Food Group, one of the rapid expansion and interleading convenience food comnationalisation of the business panies in Germany. The product dates from 1971, when Theo range includes leading brands in Mueller, grandson of the founder, the chilled gourmet salad segtook control of the family busiment, sauces and fish specialties, ness. Theo Muller started with such as Homann, Nadler, Livio four employees, but today the and other Homann Group international dairy group employs brands.

21,000 people and has an annual turnover of around Eur4.7 billion. Reflecting acquisitions, Muller UK & Ireland increased group turnover from £450 Competitive Edge Now Germany’s largest private- millioin in 2011-12 to £1.5 billion in 2012-13.

Muller reinvests heavily in its ly-owned dairy business with business to retain a competitive operations in many other European counFollowing its successful entry into the and technological edge. For example, the English yoghurt market in 1987, Muller main factory at Leppersdorf in Saxony is one group expanded throughout Europe, adapt- of Europe’s most modern dairies and repreing its products to suit local tastes. In 2008, sents the group’s largest ever investment the enterprising dairy group made its first project with more than Eur700 million havmove beyond Europe by launching products ing been spent since 1994. Muller also in Israel and recently entered the US market invested a further Eur22 million Euros in through a joint venture with PepsiCo. the Leppersdorf site in 2007, building the Currently under the leadership of Heiner world’s first bio-ethanol facility, which proKamps, Ste-fan Muller and Dr Henrik duces 10 million litres of environmentally Bauwens, Unternehmensgruppe Theo friendly fuel additive from the bi-product Muller is Europe’s tenth largest dairy molasses every year. In 2011, a new Eur70 processor and ranks in the top 20 globally. million whey processing facility was brought Apart from Muller, its strong brands portfo- on line at the Leppersdorf site, opening up lio encompasses Wiseman, Weihenstephan, new markets for the group.

Sachsenmilch and Käserei Loose. Retail brands and basic dairy products, such as UK Expansion butter, UHT milk, lactose powder and whey Muller first entered the British market in protein, complete the portfolio.

In addition to its Heiner Kamps, chief executive of dairy processing Unternehmensgruppe Theo Müller. operations, the Muller group also incortries, a major watershed in the development porates its own of the business was the launch in 1980 of an logistics business, innovative snack with fruit sauce and dairy Culina, and a packrice in the same container - the forerunner aging company, Opof Muller Rice. This innovative combina- tipack, as well as tion of convenience and taste proved very Muller Naturfarm, popular and during the 1980s Muller intro- one of the largest duced its now famous twin-pot with yogurt fruit processing and fruit, which was the concept behind companies in GerMuller Corner.

Ronald Kers, chief executive of Muller UK & Ireland. many.

A

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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key player through its 1987 and its desserts factory at Weihenstephan and SachsenMarket Drayton in Shropshire milch brands. was established with an initial The acquisition of Wiseman investment of £30 million in 1991. Muller has been the leader and Ministerley and the move of the UK yoghurt market since into butter production are 1995 with major brands such as allowing the UK business to Muller Corner, Mullerlight and emulate the strategy adopted by Muller Rice.

Muller in continental Europe The acquisition of Robert where it has a broad portfolio of Wiseman Dairies for £279.5 mildairy products. “This model – lion in 2012 was a transformamaximizing the value of every tional deal for Muller in the UK, drop of milk – is well estabsubstantially increasing its scale lished by Muller in Europe,” and broadening its dairy portfoexplains Ronald Kers. “In the lio.

UK we can apply the same Having invested over £500 thinking across the country.” million in developing its network The acquisition of the Nom Dairy UK facility provides a platform for Muller to of dairies and depots since 1994, develop its presence in the UK private label yogurt market.

US Joint Venture the Wiseman business processes Mulller is also expanding rapidand delivers approximately one third of the Wiseman Dairies and Muller Ministerley. ly in the US after forming a yoghurt joint fresh milk consumed in Britain. The com- Reflecting acquisitions, Muller UK & venture – Muller Quaker Dairy – with bined Muller Wiseman employs over 5,000 Ireland increased group turnover from £450 PepsiCo in 2012. Having launched the people and operates from six major process- millioin in 2011-12 to £1.5 billion in 2012- Muller Corner, Muller Greek Corner and ing dairies in Aberdeen, East Kilbride, 13.

Muller FrutUp brands, Muller Quaker Bellshill, Manchester, Droitwich Spa and Dairy is aiming to capitalise on the rising Bridgwater and from 15 distribution sites. £17 Million Butter Plant demand for value-added dairy products in Muller has since completed two other To further diversify its portfolio and to the US, where consumption of yogurt and strategic acquisitions in the UK - a chilled strengthen its position within the UK dairy other value-added dairy products is generdesserts facility at Minsterley in Shropshire, industry, Muller recently constructred the ally less than half that of Europe. and private label yoghurt producer Nom UK’s largest butter Dairy UK with its state-of-the-art manufac- plant, following turing facility at Telford, also in Shropshire. investment of £17 The purchase of the Minsterley facility million. The facility has given Muller access to the Cadbury at Market Drayton chilled desserts range, including Cadbury recently commenced Mousse, Trifle and twin-pot products, commercial producwhich are sold under an exclusive licence tion. Capable of from Cadbury. producing 45,000 The acquisition of the Nom Dairy UK tonnes of butter a facility, which has a turnover of £43 million year, it will allow per annum, provides a platform for Muller Muller Wiseman to to develop its presence in the UK private optimise returns on label yogurt market. the 90,000 tonnes a “This acquisition underlines our commit- year of surplus gen- Unternehmensgruppe Theo Muller is Europe’s tenth largest dairy processor and ment to growing our presence in the UK, erated by its fresh ranks in the top 20 globally. which along with Germany and the US, is a milk, cream, The joint venture recently opened a core market for Muller,” says Heiner yoghurt and chilled deserts operations, as Kamps, chief executive of Unterneh- well as helping to replace dairy imports into new, state-of-the-art yogurt manufacturing plant in Batavia, New York. One of mensgruppe Theo Muller. the UK with home produced alternatives.

“Butter imports into the UK were above the largest yogurt plants in the US, the Muller currently operates 21 sites in the UK, employing about 6,000 people across 10,000 tonnes last year,” points out new 350,000 square foot facility can three business units – Muller Dairy, Muller Ronald Kers, chief executive of Muller UK produces approximately 120,000 cups & Ireland. “We want to start to address per hour. this by offering butter made in Britain “Expanding our brand from Europe to with cream from milk produced by British the US has been a long-time goal,” says dairy farmers.”

Theo Muller, owner of Unterneh“We are building a dairy company in mensgruppe Theo Muller. “We are proud the UK which is diverse, operates in dif- to partner with PepsiCo on this important ferent markets and allows us to innovate business venture and we look forward to and add value to milk that we buy to the years of success in this country.” benefit of the company, its employees, In addition to its worldwide soft drinks customers and the dairy farmers who sup- and snacks businesses, PepsiCo also holds ply us,“ he adds. a strong position in the global dairy prodWhile butter production at the plant is ucts market. It acquired Wimm-Billfocused on the food manufacturing cus- Dann, Russia's largest dairy company, in Having launched the Muller Corner, Muller Greek Corner and Muller FrutUp brands, Muller Quaker tomers, Muller may eventually move into 2011 and has been part of a successful Dairy is aiming to capitalise on the rising demand the branded butter market, similar to its joint venture with Almarai, Saudi Arabia's for value-added dairy products in the US. position in Germany where the group is a largest dairy company, since 2009. J 38

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

I

PRODUCT LAUNCH

Green Giant™ Fresh, A New Small But Mighty Fresh Vegetable and Salad Range am Dennigan and Company has S announced the launch of Green Giant™ Fresh, a new pre-packed range of fresh vegetables and salads, in Ireland. The new range includes seven products, conveniently packaged in handy sized re-sealable bags, the per-

fect way for those on the go to get their recommended daily servings of fruit, vegetables and salads.

Included in the Green Giant™ Fresh range are Mighty Crisp Gem Hearts, Crunchable Bite Sized Cucumber, Juicy Sweet Pear Tomatoes, Sweet Crunch Baby Broccoli, Crunchy Quick Celery Sticks, Crisp and Light Cosmo Lettuce and Seedless Sweet Snack Peppers. The range is the perfect lunch option for school kids and busy workers and is also ideal for anyone who has limited time to prepare vegetables but still want to include them in their meals.

The handy pack sizes provide an easy and convenient healthy snacking or ingredient option and provide a solution to reducing food waste as many of us buy large amounts of fresh vegetables and salads that often end up being thrown out.

Priced from €1.50 to €2.50, the Green Giant™ Fresh range is available at Spar,

Eurospar, Mace, XL and Londis stores nationwide. Plans are already in place to extend the range to other major retailers over the coming months.

For further information on the Green Giant™ Fresh range visit www.greengiantfresh.ie. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

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STORAGE

I

LOGISTICS

RETURNABLE TRANSIT PACKAGING

Renting Transit Packaging is Returning Improved Cost Benefits ourcing additional returnable transit S packaging (RTP) to fulfill temporary demand makes economic sense and can help avoid logistical challenges, which is why many food producers and retailers are increasingly turning to renting their RTP from PHS Teacrate.

Plastic RTP offers better product protection on the move under almost any circumstances and eliminates the waste that can accumulate from single trip alternatives. Renting RTP also provides a rapid return on investment and a lower cost-per-journey than other packaging materials. This flexibility of supply and commercial advantage is particularly relevant for food distribution.

PHS Teacrate, part of the PHS Group, supplies hundreds of food and drink producers across the UK with crates for transporting food items such as fresh produce,

bakery products, dairy, meat and poultry. It is a one-stop shop for a huge variety of plastic crates and trays.

The company, which supplies millions of

crates every year to food sectors, says that flexible, reliable and quick delivery of crates provides a commercial advantage for retailers, especially during peak periods such as Christmas and Easter or for other seasonal fluctuations.

PHS Teacrate’s Sales Director, Patrick Sheehy, says: “Renting RTP spreads the costs over a period of time and makes economic sense for logistics managers who do not want to plough a lot of capital expenditure into equipment they are not fully utilising throughout the year.

“We have made significant investments to meet demands for a greater choice of transit packaging options. We offer a large range of styles, flexible rental agreements with a quick turnaround.

Services such as these are what food producers are looking for when sourcing their RTP.” J

Beverage Solutions From Schoeller Allibert n the competitive and consolidating beer, Ibuilding soft drinks and mineral water market, strong brands is the key to success.

Communicating your brand at point of sale is crucial to your efforts in marketing.

Schoeller Allibert is a market leader in beverage returnable systems. Schoeller Allibert produces crates for great brands like Heineken, Radeberger, Coca Cola, Foster’s

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and Warsteiner.

By creating visually appealing crates for point of sale identity, and by including consumer ergonomics in its designs, Schoeller Allibert gives customers an edge in positioning their brands.

Many of the major innovations in plastic packaging systems were developed by Schoeller Allibert. It invented products like foldable large containers, such as the Magnum Optimum, and bottle crates with in-mould labels. In addition, Schoeller Allibert invented and optimized production techniques like injection moulding and mirror welding, each time resulting in lighter, stronger and cleaner crates and containers.

Besides a variety of beverage crates, Schoeller Allibert offers logistic products developed for the beverage industry. It provides pallets, bottle carriers and similar products to facilitate the transportation of

beverages.

For larger volumes of liquids Schoeller Allibert offers its Combo IBC Container.

The company has a comprehensive range of storage containers for parts such as crown caps, preforms or labels. Schoeller Allibert’s beverage solutions all assist in the reduction of material, energy and distribution costs. J

FOOD & DRINK BUSINESS EUROPE, NOVEMBER/DECEMBER 2013

STORAGE

LOGISTICS

Yearsley Logistics to Establish Third Superhub earsley Logistics has now received Y detailed planning permission to build a 150,000 pallet cold store at Peterborough in England. This third Superhub is planned to be built in phases, commencing in 2014 in the Great Haddon Employment Zone.

As the UK’s largest cold storage and logistics company, Yearsley Logistics has 13 sites nationwide including its head office and key distribution facility in Heywood, Lancashire.

The successful planning permission follows on from the Yearsley Logistics’ integration of the Hams Hall development late last year and the recently opened Phase 5 extension at the Heywood head office. The three Superhubs together will service the whole of the UK with a consolidation service for manufacturers into retailers.

The £65 million total investment will provide a 385,000 sq ft. part mobile rack and

Yearsley Logistics recently took delivery of 26 new Mercedes Actros units and 50 new trailers to help support growing business operations across the group.

part automated crane cold store. Automated crane stores require significantly less energy (up to 30% less) to operate due to their

design, reduced door openings and minimal lighting requirements. The whole of the new building will also be super insulated, fitted with LED lighting and solar panels, making it probably the most energy efficient in the country and ensuring Yearsley Logistics continues to lead the industry in building cost effective, sustainable solutions.

For example, solar panel installations have now been completed, by renewable energy specialist Solar Energy, at ten of the logistics group’s sites since 2011.

Managing director Harry Yearsley comments: “Several years ago we saw that the frozen industry was moving to shorter lead times. Our strategy to embrace this by investing in Superhubs in strategic locations, as well as implementing new systems and processes should comfortably deliver this and maintain our industry leading position.” J

Another Star Performance For Yearsley Logistics earsley Logistics has invested in a Y bespoke high efficiency cooling system from Star Refrigeration as part of an expansion to cold storage facilities at its flagship distribution centre in Lancashire.

A world leader in cooling and heating system innovation, Star was chosen to supply a highly efficient refrigeration plant to deliver cooling for the new cold storage chambers.

Star has over 40 years experience in industrial cooling systems for the cold storage sector and is currently providing planned preventative maintenance at the majority of Yearsley Logistics’ UK distribution sites.

The bespoke refrigeration plant was designed to provide Yearsley Logistics with over 25 years of reliable service, with the lowest possible total lifecycle costs in terms

of energy usage and maintenance. Star engineered and installed a single stage pump circulation plant, operating on natural ammonia refrigerant.

The plant has a 1.2MW (Mega Watt) cooling capacity and features three 400kW screw compressor package units, each fitted with a high efficiency electric drive motor.

The two frozen food chambers are served by a total of eight evaporators, which maintain a constant air temperature of minus 24 degrees Celsius.

The evaporators and air-cooled condensers incorporate EC fans with integral variable speed drives. This enables efficient operation and yields significant energy savings particularly during periods of part load.

The refrigeration plant is controlled via

YEARSLEY GROUP DISTRIBUTION CENTRE, HEYWOOD

Star’s fully integrated Telstar touch screen computerised control system. For more information, phone Star Refrigeration on 0141 638 7916, email star@star-ref.co.uk or visit www.star-ref.co.uk. J

Star's bespoke refrigeration plant for Yearsley Logistics.

In 2011, Solar Choice was commissioned by The Yearsley Group to install over 3000 solar panels at two of their main sites. We have now completed eight additional solar panel installations at Yearsley Group sites across the UK. We’re delighted to be associated with such a progressive and environmentally responsible company.

Installing solar panels gives a great return on investment. The cost of the equipment has fallen significantly, making it an even more viable proposition for both domestic and commercial customers.

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KER Services – Specialists in the Design and Installation of Automated Food Processing Systems ER Services has over 30 years of experiK ence providing high quality services to the fishing sector, both at sea and ashore.

KER has one of the most impressive portfolios in the industry, offering integrated solutions to Irish companies as well as a range of international clients. KER can now offer similar types of systems and processes to other sectors within the food industry KER Services’ highly trained staff provide a complete range of services from initial design and planning, equipment specification and sourcing, project management, installation through to final testing and commissioning.

KER Services can be relied upon to come up with a solution that is tailored to the specific needs of each customer and ensure total satisfaction with each and every job.

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The company has significant focus on energy efficiency, which has led to it to complete projects within forecast running costs due to the quality of its equipment and workmanship.

KER Services’ commitment to after sales service and maintenance is truly around the clock, 24/7. If you have a problem, KER Services responds immediately.

Services offered include; design, fabrication, installation and annual maintenance associated with today’s state-of-the-art fishing fleet and the harvesting industry.

This includes the following but is not limited to:

* * * * * * * * * * *

RSW systems Ozone Systems Vacuum pump systems Food Processing equipment Chills/Blast Freezers Ice Manufacture/Transport Systems PLC Systems SCADA systems Qualified fabricators Design manufacturing Electrical installations.

KER’s actions speak louder than words.

That’s why it strives to always do the right thing, acting transparently, keeping commitments and ensuring customer satisfaction always.

For further information contact KER Services Ltd on Tel 074 97 31525, Email derek@ker.ie. J

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Irish Seafood Industry on Course to Reach Sales of Over €1 Billion by 2017 Despite the challenging global and domestic market environment of the past three years, Ireland’s seafood industry achieved 38% growth in exports and is now attracting increased investor interest as it moves towards exceeding the €1 billion sales mark. he Irish seafood industry is benefiting from growing demand both at home and abroad. With global seafood consumption forecast to expand by an additional 42 million tonnes per annum by 2030, Ireland is well placed to capitalise on this rising demand.

Irish seafood exports increased by 13% in 2010/11 and growth accelerated to 20% in 2011/12 to reach a value of Eur517 million within an industry that generated seafood sales in excess of Eur845 million last year.

Further growth in both exports and domestic sales are expected in 2013.

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“These figures show an industry well on track to hit its 2013-2017 objectives of creating 1,200 jobs and generating seafood sales of over Eur1 billion,” points out Jason Whooley, chief executive of BIM (the State agency with primary responsibility for developing the seafish and aquaculture industries in Ireland). “But the reality also highlights that these targets are now dependent on the need for BIM and the industry to accelerate increased investment in the sector.”

BIM’s new development strategy for 2013-2017 - ‘Capturing Ireland's Share of the Global Seafood Opportunity’.- is targeting the production of over 45,000 tonnes of additional raw material during the period which should result in the Irish seafood industry reaching its projected exports target of Eur650 million. In addition to expanding Ireland’s existing fish supply, the BIM strategy places a strong

focus on value added processing. €8 Million Investment Earlier this year, the Irish Government awarded of Eur2.4 million in grant aid to 25 seafood processing companies under the 2013 Seafood Processing Business Investment Scheme. The Seafood Processing Business Investment Scheme is part of the Irish Government’s Seafood Development Programme and is co-funded by the European Fisheries Fund. The Scheme aims to help seafood processing companies scale up, diversify, add value to raw material and innovate as they develop new markets, enhancing profitability and job creation prospects into the future. The Scheme provides grant aid of up to 30% for value adding projects and 20% for primary processing.

Combined with associated private sector investment, the Scheme will result in total investment of over Eur8 million by the industry in 2013. The 25 companies receiving grant aid are from seven coastal counties across the country - Kerry, Dublin, Cork, Galway, Wexford, Mayo and Donegal. Companies benefiting from the funding include Island Seafoods, William Carr & Sons and Keohane Seafoods.

The Scheme was also used to support previous industry investment of Eur10 million in 2012 and Eur7 million in 2011.

Developing Scale Under its new strategy, BIM is fully committed to continuing to work with industry to create scale. “We currently have 180 registered Irish seafood companies with processing facilities in Ireland. A large number of these companies are small-scale, often family-run firms with a turnover ranging from Eur3 million to Eur10 million,” points out Jason Whooley.

He continues: “While these family-run businesses must remain an essential component of the Irish seafood landscape, we

should also give consideration to the fact that when we contrast a traditional Irish company with one of its typical European competitors then they would have turnover in the order of Eur50 million. By 2017, if not before, BIM will have helped four Irish companies generate a turnover of over Eur50 million.”

Strategic Partnerships BIM, in partnership with industry, is also encouraging a series on international strategic partnerships to develop the Irish seafood sector. Serious investment opportunities are arising as a result of the opportunities being presented by the deep-sea organic salmon farm proposed for Galway Bay for which BIM has applied to become a licensed developer. With the potential to create upwards of 500 jobs and inject Eur14.5 million into the local economy, the proposed farm is attracting major attention from potential investors with up to 21 financiers, spanning three continents, having already confirmed their interest in the Eur60 million investment.

“The need and opportunity for investment in the Irish seafood industry is clear.

Galway is only one case in point, we are also examining a similar site off the Mayo coast. BIM and the industry are seeking investors with whom they can work to grow a thriving seafood industry. Our message to investors is clear – we are ready and open for business,” says Jason Whooley. J

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Carr & Sons – The Fine Speciality Seafood Experts Carr & Sons is an Irish family business that has won international recognition for the quality and flavour of its seafood, having garnered more than 20 Great Taste Awards. illiam Carr and with his wife Mary began the business sourcing and producing quality food from Ireland’s Atlantic West coast in 1946. William Carr travelled to London in the 1950’s where he brought his much sought after wild salmon to the world famous fish markets at Billingsgate.

By the 1970’s, he had built a business concentrating on sourcing and producing quality food from the local community to sell to national and international markets. Since then the family business has grown and evolved into a fine speciality seafood producer with its own traditional smokery located in the fishing village of Killala, County Mayo in the West of Ireland.

Still a family-run business today, Carr & Sons is committed to supporting rural communities and working responsibly with local fishermen around the Irish Coast.

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Craftsmanship and Innovation Carr & Sons prides itself on its craftsmanship and skill and uses only the finest quality ingredients to prepare its innovative range of products. Over the years the company has won more than twenty Great Taste Awards.

Great Taste, organised by the Guild of Fine Food, is the acknowledged benchmark for speciality food and drink. It has been described as the ‘Oscars’ of the food world and the ‘epicurean equivalent of the Booker prize’. Indeed, the Great Taste logo is the sign consumers can trust when buying food and drink at their local retailer.

The superior quality and flavour of Carr and Sons products has once again been recognised with the awarding of 7 Great Taste Awards in 2013 including a prestigious 3 Stars for its Smoked Mackerel.

Carr & Sons Organic Smoked Salmon was awarded two stars in 2013 for its balanced flavours, smokiness and long lingering after taste that finishes with a hint of peat. The Wild Irish and Whiskey Smoked Salmon products received a gold star each for their wonderful aroma and excellent texture and flavour.

The buttery and aromatic mussels cooked in a delicate garlic sauce were deemed deserving of a Great Taste Award while the firm, juicy and sweet langoustine cocktail also impressed.

Salmon is Carr & Sons’ signature product. Its wild Salmon is caught in season from Irish rivers including the Blackwater in Munster and the Moy in County Mayo. The company’s product portfolio also encompasses shellfish including Mussels cultivated 44

in the pure clear waters off the west coast from Donegal to Bantry Bay. A fully integrated business management system ensures that all fish, ingredients and packaging are batch coded and fully traceable back to suppliers, fishermen and fishing boats all the way through the production process until it is dispatched to customers. J

Marine Harvest Ireland has been producing world class salmon since 1979. The unique nature of our sites, teamed with the skill and expertise of our staff allows us to bring our award winning salmon to discerning customers across the globe.

At our BRC accredited facility, we have the ability to work with our customers to produce salmon in a variety of formats to best suit the needs of their business.

Our Premium Irish Salmon is presented under the Donegal Silver brand, whilst our Irish Organic Salmon is available under The Irish Organic Salmon Company brand.

The quality of our products, supported by the heritage of our brands makes Marine Harvest the perfect partner to add value to your seafood category.

Email: irishsales@marineharvest.com Website: www.marineharvestireland.com Call us at: 074 919 2820

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Island Seafoods Brings Atlantic Treasures to Market Based in the fishing port of Killybegs in County Donegal, Island Seafoods is a well known Irish seafood processor which is starting to make inroads into retail and food service export markets. stablished in 1986, Island Seafoods is an Irish family owned and run company with a truly hands-on approach to business. Its fish is fully traceable from net to fork. The catch encompasses mackerel, herring, sprat and blue whiting and the company exports a few thousand tonnes of bulk product per year.

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Current turnover is about Eur3 million and the company employs 15 full time people, along with 15 part-time workers during the fishing season, and produce 80 tonnes per day.

“For 25 years our product range was bulk pelagic for export, this changed in 2010 when we started our own brand of added value seafood for the Irish market,” explains Michael O’Donnell, business development manager at Island Seafoods. “This is now growing to include export and we already have started exporting some of our retail range to the UAE.” The added value range includes Smoked Mackerel with Honey & Mustard, Smoked Mackerel with Ginger, Chili & Lime, Hot Smoked Salmon with Sundried Tomato & Chili Butter, Hot Smoked Herring with Orange & Rosemary Butter, Smoked Salmon and Hot Smoked Salmon.

“We have spent a lot of time on developing these products as we wanted to promote the brand ‘Atlantic Treasures’ to bring seafood into the 21st century and add glazes and butters to tempt the consumer,” he says.

Atlantic Treasures Sales of Atlantic Treasures have seen over 100% growth year on year since the brand launch in 2010. Island Seafoods’ new range of Smoked Mackerel with glazes won the Blas Na hEireann ‘Seafood Innovation’ award and also in 2012 won two gold stars in the Great Taste Awards UK. Virtually all of the company’s pelagic bulk sales are generated in export markets including Russia, Japan, Europe, UAE, Gaza and Africa. The customer base for the branded range is primarily in Ireland. “Our goal in 2014 is looking into markets in Europe where we can export the brand into retail and food service channels,” he says.

Island Seafoods prides itself on developing personal relationships with its customers. In early 2012 the company was short listed for the Ulster Bank Business Achievers Award for a family run business, and went on to win this category for the Ulster region. Island Seafoods works closely with each customer to adapt and develop products to meet precise requirements.

Production Plant The company’s processing site incorporates two smokers, which were installed in 2009 and have the capacity of smoking 3,000 kgs per day. In addition to handling Island Seafoods’ own retail and food service business, the facility also undertakes contract smoking for other companies.

Island Seafoods has a wastewater treatment plant onsite where effluent water from the plant is treated along with that from surrounding factories.

In 2007, Island Seafoods commissioned a hydro-electric power plant which generates 300 kw of renewable energy to facilitate the wastewater treatment plant and for export of power to the national grid.

Seafoods has a squeaky-clean carbon footprint. The hydro-electric plant saves over 350 tonnes of greenhouse gases a year, ensuring the sustainability of its operations.

The company has been MSC certified, recognizing its endeavours in sustainable fishing and promoting the best environmental choice in seafood.

Island Seafoods currently supplies canners and processors in Europe, Japan and Africa and the Baltic States with bulk pelagic products. However, with its compass firmly set on new horizons, the company has big aspirations to introduce its smoked products to a wider market, selling domestically to stores across Ireland and also exporting to the mainland European markets with its ‘Atlantic Treasures’ brand.

Island Seafoods recently received funding from the 2013 Seafood Processing Business Investment Scheme which was used to update the process in the smoking area, resulting in faster and more efficient production.

“Our future development is based prominently on export of branded products for retail and food service while also diversify the bulk pelagic products to incorporate more added value lines on these, for example salted herring, frozen mackerel fillets IQF., bulk smoking for customers,” comments Michael O’Donnell. “We base our business plan on working closely with the customer to develop products that give them a point of difference from other companies and give them a niche in the marketplace.” J

Green Credentials Inspired by green ethics, Island

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ated m o t u a t s e g r Ireland’s la acturer f u n a m t e l l pa Mid Cork Pallets & Packaging also supply all types of corrugated boxes including: Regular slotted containers (0201) and die cut styles Litho Laminated boxes Extensive range of Shelf Ready Packaging solutions MCP offer a full pallet & packaging design and Sampling Service Clondrohid, Macroom Co. Cork Telephone: 026-41311 Oranstown, Dunboyne Co. Meath Telephone: 01-8252059

Email: info@midcorkpallets.com Web Site: www.midcorkpallets.com

Mid Cork Pallets & Packaging – Your Complete Packaging Provider id Cork Pallets & Packaging Limited M has over 35 years of experience in providing Pallet & Packaging Solutions to its customers. Operating from a 25,000 square meter purpose built facility near Macroom in Cork and a 7,000 square meter storage and distribution centre in Dunboyne, Co Meath, MCP is strategically located to service the Irish market, close to all major road networks.

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with customers to find the best fit for their pallet and packaging requirements.

MCP is Ireland’s largest manufacturer of all types of timber pallets including Epal, 1200 x 1000 and specialist pallets to suit our customers’ requirements.

MCP also offers a full range of corrugated and specialist packaging products. It offers customers a stock holding and nationwide distribution service.

For solutions to your pallet & packaging

requirements call Mid Cork Pallets & Packaging on (026) 41311 or drop a line to info@midcorkpallets.com.

For more information visit www.midcorkpallets.com. J

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Keohane’s Seafoods Makes Fish Easy Keohane’s Seafoods has developed a gourmet range of premium Irish fish and shellfish dishes, prepared using locally-caught, fully-traceable and sustainable Irish seafood and other natural ingredients. eohane Seafoods is a family run business based in Cork City but, with the family’s connection laying in Bantry in West Cork. The company’s growing success can be attributed to the combined extensive experience and knowledge that comes from Michael Keohane, who has been working in the seafood business for three decades, and his son Colman Keohane. Colman Keohane also runs a successful seafood restaurant and two fish mongers.

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Business Opportunity Although Ireland is an island nation, it has one of lowest seafood consumption rates in Europe. “It’s not that Irish people don’t enjoy fish when it’s presented to them on a plate, it’s basically a fear of how to cook it,” explains Coleman Keohane. Indeed, it is this factor that the Keohanes recognised as providing an exciting new product development opportunity. Having spotted a gap in the market, Keohane’s was the first seafood company to launch microwaveable skin packs in Europe.

The Keohanes worked initially with BIM on developing their business idea and have also benefited from participation in SuperValu’s Supplier Development Programme to bring concept to reality.

seafood is landed locally in Union Hall and Castletownbere harbour in West Cork.

In line with its slogan: ‘Fish - made easy’, Keohane’s Seafoods has developed a unique range of microwaveable products for its customers. The innovative packaging allows for a quick and easy, healthy meal ready in minutes. Just pop the pack in the microwave and the top film forms a dome, allowing the product to steam cook in its own natural juices.

Indeed, a hallmark of the company is its constant innovation. Keohane’s Seafoods has created an extensive range of products. Its fresh fillet range includes Fresh Salmon, Fresh Haddock and Smoked Coley, and its fresh fillet with butter range includes Salmon Darnes with Roast Garlic and Herb Butter, and Hake Fillets with Fennel & Dill Butter.

The company also offers: Plaice, Lemon Sole, Whiting, Trout, Seafood Skewers, Smoked Haddock and Seafood Mix. Its seasonal options encompass Tuna, Sea Bass, Swordfish, Tiger Prawns and Shrimp.

Additional flavoured butter options include: Lemon & Thyme Butter, Red Chilli & Coriander Butter, Parsley & Watercress Butter, Chive Parsley & Rosemary Butter, and Lemon & Dill sauce. Keohane’s Seafoods also offers a number of additional sauces such as Mornay Sauce, Watercress Sauce, Mediterranean Tomato Sauce, and White Wine Sauce.

Modern Production Facility As demand for the Keohane’s Seafoods brand has increased, the company has

placed a huge emphasis on using the very latest production technology to ensure customers and consumers receive a consistent supply of premium quality seafood.

Keohane’s Seafoods now operates from a 20,000 sq ft state-of-the art processing facility, which has been entirely purposebuilt to meet the company’s unique requirements. The plant has the capacity to produce 30,000 skin packs per day.

Using advanced production systems and integrated quality and hygiene controls, the company exceeds all seafood industry standards. HACCP-approved and boasting the latest temperature-controlled chilled and frozen storage facilities, Keohane’s has become a trusted seafood label because of its dedication to quality, food safety and reliability.

The company has exhibited rapid growth, expanding turnover from Eur2-5 million in 2011 to an estimated Eur11 million in 2013. The workforce has increased from 11 people to 40 people during the same period. J

Pelagic Fish and Smoked Products From Norfish

Convenience and Quality Convenience and quality are central to the seafood company’s offering. All dishes in the Keohane’s Seafoods range are sealed for freshness and only require a few minutes home-preparation. The range also caters for the current demand for natural and healthy food as no preservatives, additives, chemicals, flavourings, stabilizers or GMO ingredients are used. All the company’s fresh Irish

Norfish is a family-run business founded in 1975 and is situated in the fishing port of Killybegs Ireland.

The company specialises in the processing of pelagic fish, including Whole Round Mackerel, Mackerel Fillets, Mackerel Flaps, Headed and Gutted Mackerel, Gutted Mackerel, Whole Round Horse Mackerel, Whole Round Herring, Herring Flaps, Deli Herring, Sprat and Blue Whiting.

It also processes a full range of smoked products including, Natural and Yellow Smoked Haddock Fillets, Dyed Smoked Coley Fillets, Smoked Kipper Fillets, Smoked Mackerel Fillets, Smoked Cod Fillets and Smoked Hake Fillets.

Products are processed daily in Norfish’s production facility and smoked in its state-of-the-art smokehouse. The company’s marketing strategy is focused on achieving customer satisfaction. Norfish has continually upgraded its machinery in order to compete with the quality requirements of customers from all over the world.

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Fat Replacement NPD Key to Future Success lrick & Short, the British U owned clean label starch specialist, claims that renewed focus on developing new and delicious reduced-fat food products is crucial to the success of food manufacturing in the UK and Europe.

Ulrick & Short supplies household name food manufacturers across the world with clean label non-GM ingredients, innovating across a diverse range of food industry sectors including bakery, meat, dairy, soups and sauces. The company has refined its range of Delyte™ functional fat replacers into what it claims is the best on the market for processed foods, extremely versatile across multiple applications and reducing fat and calorie content with the simplest reformulation.

Ulrick & Short director Adrian Short explains: “There’s no question that reducing fat – butters and milk solids - and salt con-

tent in food is now acknowledged as one of the food industry’s primary challenges.

Almost half of the UK’s food manufacturing and retail industry has just signed up to a government-backed pledge to reduce saturated fat in their products.* Even the confectionery and biscuit sector has announced its aim to introduce reduced-fat versions of

old favourites in an effort to improve the healthiness of our nation’s snacks.

“Functional fat replacers will be absolutely crucial to achieving this. Delyte™ is a unique product, a clean label fat replacer which is by far the best product on the market in terms of label declaration. In taste tests Delyte™ has performed better than full-fat equivalents, providing indulgence in both texture and mouthfeel. It’s very wellestablished as a fat replacer in baked goods, and sauce and dessert formulations are also perceptively creamier but healthier – the ideal solution.”

As well as offering increased process tolerance, Delyte™ is allergen-free and can be used in multiple hot and cold applications.

The range is also proving its worth in sports and vending drinks – a perfect example of NPD in action. J

Cargill Launches Co-op Academy argill has established the first business C skills program for cocoa farmer cooperative executives in Côte d'Ivoire with the launch of the Cargill Co-op Academy.

The program, which is new and unprecedented in the cocoa sector, is the latest initiative under the Cargill Cocoa Promise and provides co-operative leaders with the management skills to make their organisations more professional, efficient and successful.

The Cargill Co-op Academy provides co-operative managers with 28 days of intensive training, followed by a year of personalized and on-the-ground coaching.

The program includes training and support around good governance, the structure and principles of a co-operative, people management skills, improving operational management, enhancing financial and auditing techniques, and developing business and marketing plans.

“Supporting and strengthening farmer organisations is central to Cargill’s commitment to securing a long-term supply of high quality cocoa and to improving cocoa farmers’ livelihoods,” says Lionel Soulard, Managing Director Côte d'Ivoire, Cargill Cocoa & Chocolate. “With our Co-op 48

Academy program, it is the first time this level and scale of training is offered to the cocoa sector. It provides cooperative leaders with the knowledge to improve the day-to-day running of their co-op’s, and crucially enables them to develop the skills to grow their business successfully.

Ultimately our customers will significantly benefit from this ground-breaking enterprise to sustain a high-quality supply of cocoa.”

The Academy aims to reach over 400 cooperative leaders across 110 of Cargill’s partner co-operatives. The first 40 executives from 10 cocoa co-operatives recently graduated upon completion of the Cargill Co-op Academy and were recognised dur-

ing a ceremony in Abidjan.

The Cargill Co-op Academy has been developed in partnership with TechnoServe, a non-profit organization that develops business solutions to poverty, and INPHB (Côte d'Ivoire’s leading university), and is supported by the International Finance Corporation (IFC), The Sustainable Trade Initiative (IDH) and Emerging Leaders, an NGO focused on bringing leadership training to farmer communities.

The Cargill Cocoa Promise is the company’s global commitment to the development of a sustainable cocoa supply chain and to making a difference in three key areas – improving the lives of cocoa farmers, supporting cocoa farming communities, and investing in the future of cocoa farming. Co-operatives are a key partner in the cocoa value chain and Cargill aims to improve co-operative farming around the world.

Under the Cargill Cocoa Promise, Cargill invests and provides financing, training and support to secure a sustainable cocoa supply chain in cocoa producing countries including in Côte d'Ivoire, Ghana, Cameroon, Vietnam, Indonesia and Brazil. J

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