Total Solutions Providers
I TOTAL EVAPORATION & DRYING SOLUTIONS
Anhydro Wins Major $18 Million Contract in South America nhydro, a global leader in A evaporation and drying equipment, has been awarded
plies the high quality raw materials.
an $18 million contract for a state-of-the-art 100 tonnes a day permeate powder production line for Arla Foods Ingredients SA (AFISA) in Argentina. Featuring water recycling, energy recovery, noise and emissions control, the new line is scheduled to go on stream in March, 2010, and highlights Anhydro’s expertise in the latest energy efficient and environmentallyfriendly processing technology. Indeed environmental and sustainability issues were key to the choice of Anhydro for the project.
Adding Value to a By-product
Anhydro provides a full range of evaporation and drying equipment for the global dairy, food,
AFISA decided to extend its whey processing plant with a new powder processing line for production of various whey products including whey permeate. The new production line is designed to produce added-value whey and protein mix products, including the permeate by-product that results from production of high-value whey protein concentrate. The latter is achieved by converting the liquid permeate into a powder with better transport and storage attributes. High-quality whey and permeate powders are used in a large variety of applications such as the bakery, confectionery, dairy, baby food, meat and fish processing industries, and are in high demand in South America. The contract for the new plant will increase AFISA’s processing capacity by up to 100 tonnes of powder a day. It includes evaporation, crystallization, drying, an outlet air filtration system, and a CIP system. The whey and permeate powders from the new line will be non-caking, high-quality, food grade powder products.
industrial, pharmaceutical, and starch and ethanol industries.
Based in the small town of Portena, some 600 km north of Buenos Aires, AFISA is a joint venture between Arla Foods Ingredients of Denmark, which operates production facilities in 18 countries worldwide, and SanCor Cooperativas Unidas Limitada, a leading dairy processor in Argentina. Arla Foods Ingredients provides the technology and know-how for producing specialised milk-based ingredients, while SanCor sup36
Environmetal and Sustainability Issues
New Managing Director for Anhydro A/S Thomas Holst, 44, has been appointed managing director of Anhydro A/S. In addition to his new role as managing director of Anhydro A/S, Thomas Holst is also taking over the responsibility of the Anhydro EMEA Region. This is part of Anhydro’s new organisational structure – ‘One Global Company in 4 Regions’. In this capacity, Thomas Holst also has responsibility for the Anhydro companies in Kassel/Germany, Paris/France and Tonbridge/UK. Along with the EMEA region, as well as offices in Moscow/ Thomas Holst is the new Russia and Warsaw/Poland and the agents managing director of in this region. Anhydro A/S. Thomas Holst takes over responsibility from Allan Jorgensen, who will now concentrate on his role as chief executive of the Anhydro Group. Allan Jorgensen has until now held this position as well as that of managing director of Anhydro A/S. With the new management structure, Allan Jorgensen will focus on the future development of the group and especially implementing the new global strategy. Before joining Anhydro Group in 2004 as managing director of Anhydro GmbH and later being promoted to vice president of Starch & Ethanol Europe, Thomas Holst had a long career with Alfa Laval in Germany, Sweden and UK.
“The new Anhydro energyoptimized dehumidification system also played an important role in our decision.” The new plant will be delivered, installed and commissioned in co-operation with Anhydro’s local sales agent, Maarten Dirkzwager, and Anhydro’s local technical collaboration partner. “We are looking forward to providing a technically highly advanced production platform for an important ingredient,
AFISA maintains very high environmental and sustainability standards. “One of our reasons for selecting Anhydro for this project was their innovative environmental protection and sustainability technologies including energy recovery, water recycling, waste water reduction, noise reduction, and emissions control,” ex-plains Bjarne Schack Pedersen, chief executive of AFISA. Anhydro’s test center at Soborg in Denmark. FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
which is in high demand throughout the region,” says Anhydro regional sales manager Svend Erik Bojgaard. Anhydro provides a full range of evaporation and drying equipment for the global dairy, food, industrial, pharmaceutical, and starch and ethanol industries. Focusing on flexibility and attentiveness to individual customer needs, Anhydro enables excellence at every point along the value chain as part of its commitment to customers’ success. Anhydro acts as a strategic development partner for leading manufacturers all over the world. Through close collaboration with customers, Anhydro promotes the development of innovative concepts and optimisation of existing processes, enabling customers to introduce new products into the market as quickly and as cost effectively as possible. J
Total Baking Solutions From Gouet-Baking Systems he Gouet-Baking Systems test bakery T within the Mecatherm baking centre near Strasbourg is unique within the global bakery industry. Equipped with four fully automatic production lines and bakery machines representative of each aspect of the Mecatherm product range, the 3,000 sq m modern facility provides the group’s industrial bakery customers with the perfect environment for testing the production of varied bakery products at industrial scale. The equipment is constantly being enhanced to integrate the latest innovations in terms of dough make up, proofing, baking, cooling and freezing technologies. Providing Solutions
For some clients who are not used to fully automatic lines, the facility will provide the opportunity to fully understand how they work, the function of each module, the ease with which the line can be operated, and the range of products it is capable of manufacturing. The baking centre allows the customer to examine each element of a particular production process in minute detail in a way not possible during a visit to a line in full production. “It gives our clients the opportunity to check that we can achieve at least the same standard of quality and preferably a higher one for their products,” points out Jerome Dartiguenave of Gouet-Baking Systems. “It is very common to have clients producing large volumes of high quality products with an artisan process but who have problems in meeting the growing demands of their customers. They cannot simply double the number of people in the factory and they know that in any case they could not main-
A fully automatic line.
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tain the same level of homogeneity and quality. They come to us to see if we can industrialize their process without loosing one inch of the quality which is responsible for their success.” World Leader
Mecatherm is, of course, well known for developing, producing and installing ovens, machines and automated production lines – more than 500 lines installed - for industrial bakery products worldwide, whether fresh or frozen, fully baked or par-baked. The testing facility backed by the group’s extensive R&D resources are placed at the disposal of industrial bakers as part of Mecatherm’s philosophy of developing close partnerships with its customers and providing total baking systems solutions. Each customer’s project is unique. Taking into account product and process type and production rate, Gouet-Baking Systems aims to provide the optimum solution. “Besides our state-of-the-art crusty and artisan bread lines, which can bake on trays, earth or stone to produce high quality products at high capacity, we also offer the Double Action Oven for families of product such as puff pastry, tinbread, flat bread, buns, cakes, pastry and vegetables,” says Jerome Dartiguenave. Double Action Ovens
Gouet-Baking Systems’ Double Action Ovens are highly flexible and suitable for baking which needs high temperatures up to 500°C (for products such as pizza and pita), bottom convection (homogenous transfer of heat to the tins), high convection for a higher heat transfer (vegetables where up to 60% humidity has to be removed), or top radiation (for products that need to rise in the oven, like puff pastry, buns etc). Alternatively the Double Action Ovens can offer a finely tuned combination of radiation and convection in order to achieve the optimal quality, for instance by letting the product rise and then transfer as much heat as possible to shorten baking time, reduce weight loss and keep softness. The power and versatility of the Double Action Oven is illustrated in the following examples: * A Toast Bread without lid will be baked predominantly with radiation heat to avoid the appearance of a crust during the
rising stage that would split while the product is reaching its final size. However, a Toast Bread with lid will be baked with maximum top convection because as the product is protected by the lid, it is possible to accelerate the heat transfer without taking risk to damage the product. * A Lebanese Pocket Bread that is thin and splits in the middle will be baked with high convection in order to have a very fast baking time without drying the product in heart while achieving the pocket effect. A Greek pita with a crumb will be baked with a combination of radiation and convection in order not to create a crust that would prevent heat to find its way inside the product. * A Muffin will be baked with convection but a Madeleine with dome will need strong convection bottom heat to raise the dome and soft top radiation heat to avoid the creation of a crust. “These are a few examples of what can be achieved with the use of a real size laboratory to work with the client on the very same equipment that he will have, so that he can validate and improve the quality of his products,” explains Jerome Dartiguenave. “This is why we are always very happy to have industrial customers come to us and spend a full day working together with either their own ingredients and recipes or with ours. At the end of the day, whether it is a big artisan baker wishing to industrialize or a major food manufacturer with a big R&D staff, we always have the feeling that for both parties it was worth the time spent.” J
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
Total Mixing Solutions From Silverson Machines or nearly 60 years Silverson Machines F has specialised in the design and manufacture of quality high shear mixers for processing and manufacturing industries worldwide. Supplying customers in over 150 countries, and serving industries as diverse as food, beverages, pharmaceuticals, cosmetics and petrochemicals, Silverson has become a world leader in the field of high shear mixing. Indeed, food processors of all sizes and throughout the world now specify Silverson mixers as the ‘standard’ equipment for their manufacturing processes.
Silverson’s new UHS Range ultra-hygienic InLine mixers are the only mixers in the world to gain both 3A tpv and EHEDG Certification, offering the highest possible standards of hygienic
Key to Success
The key to Silverson’s success is based on the professionalism and commitment shown to each of its customer’s needs. Whether supplying machines from its standard range of mixers or designing equipment specifically to meet an individual customer's requirements, quality is guaranteed. With a customer base that includes many of the world’s largest companies, Silverson is constantly at the forefront of new technologies. Developing and applying new high shear mixing techniques to meet these needs, Silverson has the experience, knowledge and commitment to both quality and service to solve today’s mixing needs and those of the future. A truly international company, Silverson is represented by a network of associated companies, distributors and agents in over 60 countries, serving Europe, North America, Asia, Australasia, South America and Africa.
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Silverson high shear batch mixers will process from 4 to 30,000 litres.
and
enhanced
challenges faced by the food and beverage industry, Silverson’s experts will work with customers to ensure they get the right mixer for their specific use. Whether tackling customer concerns with reducing production times, process hygiene, powder/liquid mixing, producing stable emulsions, dissolving sugar, disintegrating solids, blending liquids of different viscosities or dispersing and hydrating gums, thickeners and stabilisers, Silverson prides itself on having the optimum mixing solution.
Food and Beverage Expertise
Silverson customers get more than just a mixer they get mixing solutions. Silverson’s unmatched level of expertise is the result of nearly 60 years of experience helping thousands of companies meet their unique mixing requirements. Well versed in the constantly changing mixing
construction
performance.
ers with integral anchor stirring and Silverson mixers. “We have received excellent advice on the various attachments that can be fitted to the Silverson machines to achieve either disintegration, emulsification, homogenisation or pumping of sauce mixes. Silverson has always given us extremely good after sales service and has provided loan machines when our own machines were being refurbished.” Fred Key continues: “As a business we have grown with the help of Silverson equipment. We now employ some fifty people with a turnover approaching £6 million. The excellent communication and close working relationship we have with Silverson has contributed to our efficiency as a manufacturer.”
Case in Point
UK-based sauces manufacturer MH Foods has been a loyal customer of Silverson Machines for the last thirty years. Currently operating from a modern factory in Slade Green, Kent, MH Foods was established in 1978 and was one of the first manufacturers of soy sauce in the UK. The company now produces a wide range of sauces, marinades and condiments. “I started the business with very little money. The first investment we made was a Silverson mixer,” says Fred Key founder and managing director of MH Foods. Further Silverson machines were added as the food company grew, the most recent investment entailing steam jacket cook-
Silverson high shear in-line mixers will selfpump at throughputs from 15 to 200,000 litres/hour.
Extensive Range of Mixers
Silverson has an extensive range of high shear mixers available that are ideal for food applications. Unlike some other equipment suppliers, Silverson has the flexibility to custom design and build machines to meet exact customer specifications. So whether the application is tomato sauces, yoghurts, gravies, jams and preserves, or a host of others, Silverson can help each customer to mix it right the first time. The Silverson range of high shear mixers ideal for food applications encompass: • Batch mixers; • In-line mixers; • Flashblend powder/liquid mixers; • Laboratory mixers; • Disintegrators; • Sanitary mixers.
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
• Improved vessel hygiene; • Liquid/liquid mix. Laboratory Mixers
The multifunctional L5M features touch screen control with digital tachometer, programmable integral timer and amperage display, all accessed via the Mode button.
Batch Mixers and In-line Mixers
Silverson high shear batch mixers and high shear in-line mixers do not simply mix - they emulsify, homogenise, solubilise, suspend, disperse and disintegrate solids. Each mixer, with its precision-engineered Silverson rotor/stator workhead, far outperforms conventional mixers, cutting processing times by up to 90%, improving quality, product consistency and process efficiency. Silverson high shear batch mixers will process from 4 to 30,000 litres, while Silverson high shear in-line mixers will selfpump at throughputs from 15 to 200,000 litres/hour. Both the batch and in-line versions will: • Eliminate agglomerates and fish eyes; • Create stable emulsions and suspensions; • Reduce particle size; • Rapidly dissolve solids; • Accelerate reactions.
The latest development in high shear laboratory mixing – the new Silverson L5 Series – is ideal for all laboratory work, research and development, QA analysis and small scale production in all industries. The L5 Series of laboratory mixers are suitable for the widest range of applications – mixing, emulsifying, homogenising, disintegrating and dissolving – with unmatched efficiency and flexibility. With a capacity from 1ml up to 12 litres and the ability to mix in-line with flow rates up to 20 litres/minute, they offer excellent reproducibility when scaling up to full-scale production and provide an accurate and easy means of forecasting the performance of larger Silverson machines under full-scale working conditions. The multifunctional L5M features touch screen control with digital tachometer, programmable integral timer and amperage display, all accessed via the Mode button. This level of instrumentation is invaluable for applications where process validation and reproducibility are required. Disintegrators
Silverson offers a range of options for disintegration of larger solids and applications such as confectionery reclaim, disintegration of solid blocks of cheese, butter, compressed raisins and dried fruit, oleoresins and frozen meat.
Silverson’s mighty Disintegrator 2500 mixing system will disintegrate, solubilise or disperse the largest of solids - up to 1 metre across - in a single operation, and in unbelievably quick times. The Disintegrator 2500 incorporates a powerful and unique Silverson mixer located in the bottom of a custom-built vessel. The
For hygienic applications, Silverson offers a full range of mixing designs including Ultra-hygienic in-line mixers, Ultramix, Flashblend and Bottom Entry Mixers.
mixer exerts a massive suction downwards from the surface of the liquid, pulling down even the most buoyant of solids, no matter what the size. These solids are literally ripped apart and dispersed throughout the mix, and with the refinement of a Silverson in-line mixer included in the system, are totally solubilised or suspended. For smaller solids, Silverson offers the Duplex Disintegrator/Dissolver, which, like the D2500 was specifically developed for the disintegration and solubilisation of solid rubbers and polymers for the lube oil and adhesive industries but has since been applied in a wide range of applications and industries such as food.
Flashblend Mixers
Ultra Hygienic Mixers
Dispersing powders into liquids and achieving a consistent homogeneous product, time after time, is one of the most difficult of all mixing applications. To satisfy this need Silverson has developed the Flashblend, a high shear system for rapid incorporation of a wide range of powders, including problematic gums and thickeners. The Flashblend is designed to incorporate powders on a continuous and semi-continuous basis at rates of up to 15,000 kilograms/hour. The system can handle a wide range of viscosities, from low viscosity products through to viscous gels. Advantages include: • Suitable for large scale production; • Agglomerate-free product; • Repeatability; • Speed; • Minimum aeration;
For hygienic applications requiring cGMP, 3A, USDA or FDA compliance, Silverson offers a full range of mixing designs including Ultra-hygienic in-line mixers, Ultramix, Flashblend and Bottom Entry Mixers. Silverson’s new UHS Range ultra-hygienic In-Line mixers are the only mixers in the world to gain both 3A tpv and EHEDG Certification, offering the highest possible standards of hygienic construction and enhanced performance. A number of advanced features have been incorporated into the new design including interchangeable single or multistage rotor/stator arrangements as standard, resulting in substantially faster mixing times and finer particle size. The units also feature ultra hygienic EHEDG approved interchangeable single or double mechanical shaft seals. J
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Silverson has developed the Flashblend, a high shear system for rapid incorporation of a wide range of powders, including problematic gums and thickeners.
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
PRODUCT HANDLING
Total Product Handling Solutions From Sigpack Systems art of Bosch Packaging P Technology, Sigpack Systems is a leading global supplier of product handling and packaging systems and the latest in robotic technology to the food, beverage and pharmaceutical industries. Sigpack Systems does not merely supply units or machines, but entire product handling and packaging systems. Its integrated systems take products directly from the production process, for example from ovens, cooling belts or spiral freezers, through the various primary and secondary packag18 Delta robots XR31 in compact washdown design at US ing stages, including case packcompany Bama. ing and palletising, if required, and into the warehouse. The product handling systems offered by its associated Bosch Packaging Technology Sigpack Systems encompass: flow-wrap- companies do not design and manufacture ping, robotics, cartoning, tray loading and the equipment, the most appropriate traditional wrapping. Product handling sys- machines or modules for the particular tems can be customised to meet the precise function are sourced from other suppliers. requirements of customers. “We can easily team up with another “We assist customers in taking their prod- machinery supplier so our customers can uct all the way from the production process benefit from our ability to install entire sysand through to the warehouse,” explains tems,” he adds. Martin Tanner, director of marketing and The food and beverage industry accounts business development at Sigpack Systems. for about 75% of Sigpack Systems’ busiIn instances where Sigpack Systems and ness, with confectionery, biscuits and
snacks, coffee and instant beverages being the main areas of activity. In addition to numbering the leading global players within each sector amongst its customer base, Sigpack Systems also supplies regional and national food and beverage companies which require high volume, high speed product handling and packaging systems. One-stop-shop Approach “We offer a one-stop-shop approach. Our aim is to make our customers’ lives easier so bakery they can place one contract with us and we take care of the rest,” Martin Tanner remarks. Sigpack Systems’ one-stop-shop offering to customers covers all aspects of bringing a product handling system project from design stage to fruition, including project management, complete engineering services and overseeing all installation and commissioning. “When a customer buys a system from us, we provide a guaranteed line performance,” he explains. “We also take care of all the interfaces and make sure that our sub-suppliers perform to spec.”
I CASE STUDY Panel One: Delicate Product Handling and Packaging at Simmers of Edinburgh ensure no damage to the product. Sigpack Systems was the partner of choice for Scottish bakery company The product then enters the ZZP4 magazine feeders, which sit next to Simmers of Edinburgh when it was installing a new manufacturing line the infeed chain of the HBM pillow pack wrappers. The products have to dedicated to its traditional Nairn’s Oat Cake range. Sigpack Systems was be carefully stripped from a vertical stack by able to supply a line to delicately handle and means of a flexible programmable counting package these easily broken products. system, complete with intelligent lane balancThe fragile, delicate oatcakes make high ing. demands on a system when they need to be The column is additionally gently braked transferred from the oven exit into an airtight, and held during the stripping operation, with pillow pack wrap style. The oatcakes are packa smart ZZP base plate mechanism which aged in individual piles before being safely releases pressure on the individual biscuit durdelivered to secondary packaging. This funcing the stripping and pushing operation of tion has to be carefully controlled to eliminate stack building in the wrapper chain. The HBM any damage and breakage of the products. pillow pack wrapper groups each individual The oatcakes arrive 16 across the oven band, stack in the chain and consistently provides are gently reduced on a 2:1 reduction system airtight packaging, which is vital as these and presented to two downstream packaging products are susceptible to moisture during machinery legs, each having four lanes. The oatcakes are gently stacked into a vibratory Gavin Love, technical director of Simmers: “In transit to the consumer. The system is also very flexible and formats system, which provides a small amount of accu- Sigpack Systems we see a company who are proud mulation for downstream machine stoppages of their equipment and its performance and this is are easily changed by means of the touchand additionally provides individual pressure reflected in the build and quality of our machinery screen when changing between biscuit counts, with no change parts required. control on the stacked columns of biscuits to on site.” FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
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PRODUCT HANDLING
The scale of the product handling and packaging projects undertaken by Sigpack Systems range in value from Eur300,000 to Eur15 million. Payback time for projects is typically between two and three years. Recent Projects Recently completed projects by Sigpack Systems include an 18-robot system installed at US bakery company Bama, which specialises in hand-held pies, biscuits and pizza crusts. The line incorFast and gentle placing of the apple pies at Bama. porates a state-of-the-art vision quality control system, which ensures that only products of exact ogy. The system incorporates a HSM pilquality are accepted from the process low-pack unit, followed by a HBM multiequipment before being accurately placed pack machine. Through close collaboration into cases. Each of Bama’s shock frozen with the customer, this part of the system is fruit pies are inspected for precise colour, capable of producing 860 packages per pattern, and dimensional shape. The sys- minute (PPM), greatly exceeding the contem distinguishes very subtle parameter dif- tractual agreement of 600 PPM using heat ferences and all product information is seal technology. The line, with 95 m/min communicated to each of the 18 robot speed of foil, is probably the quickest heat cells. The sophisticated product handling seal pillow-pack application in the world. and packaging system runs at a rate of The line was created for double bars (two 1,400 pies per minute. bars in one flow wrap) and wraps up to 930 Leading Swiss biscuit and ice cream man- bars (465 flow wraps) per minute. With a ufacturer Midor also uses vison-based robot speed of 130 m/min, the conveyor is one of technology devised by Sigpack Systems for the fastest created by Sigpack Systems. gentle handling of its delicate biscuits. The system is capable of handling more than Global Presence 800 biscuits per minute and 18 different As part of the Packaging Technology busiproduct varieties. ness of the global Bosch Group, Sigpack Spanish food company Natra, which Systems can offer a comprehensive worldmanufactures cocoa and chocolate derived wide service. About 50% of its business is products, is also using specially designed currently in Western Europe, 30% in Sigpack Systems product handling technol- North America and the balance split
between Eastern Europe/ Middle East and Asia. However, this spread is changing and Sigpack Systems is well prepared to cater for customers as they shift their focus to the emerging market regions of the world. “Most of our customers are true global players in the food industry. Besides the technology we provide, another major benefit for customers is our global reach, in terms of our international and worldwide sales network but even more importantly our service presence,” he points out. Innovation Sigpack Systems has a strong track record of innovation, both in developing new product handling technology and new packaging formats. Sigpack Systems specialises in handling delicate products that may also be sticky or soft and which require special techniques (see Panel One). Indeed, Sigpack Systems has been to the fore in developing technologies for difficult to handle products and in meeting food industry demands for higher speed and higher throughput product handling and packaging systems. The latest example of Sigpack Systems’ innovation on the packaging front is the Stickpack in a Pull Pack (see Panel Two). Another recent packaging innovation is the Burgopack, which presents the product in an innovative sliding tray. While currently used primarily for the pharmaceutical industry, the Burgopak has potential applications within the food sector. J
I PACKAGING INNOVATION Panel Two: Innovative Solution Combines Stickpack and Pull Pack Packaging Sigpack Systems has developed an integrated packaging system for tea in sealed result and ensure product quality. Stickpacks in partnership with German food service company The packaging combination is designed to replace the traditional tea bag with a modern lifestyle product that offers Bistrozucker. The system produces the perforated Stickpack as well as the secondary packagenhanced convenience to the consumer. In cooperation with Alcan Packaging the two compaing, in a Pull Pack or in a conventional Flow nies developed a ‘springback’ foil which springs Wrap style. back to a cylindrical form after filling. The partnership between leading foil producThe Stickpack filled with tea, also known as er Alcan Packaging and Bistrozucker resulted in tpod (tea portion of design), replaces the tradithe combination of the perforated Stickpack tional tea bag and is also used for stirring. and the Pull Pack, developed by Sigpack Further application possibilities for this conSystems. The Pull Pack packaging concept cept include coffee and pharmaceutical prodenables particularly fast and accurate opening ucts. for clean dispensing. Sigpack Systems developed the machine for The consumer holds the longer part of the the production and filling of the perforated product with one hand and pulls the seal fin of Stickpack, as well as the machine for the prothe shorter part with the other hand in the opposite direction. Both packaging styles, Stickpack in Pull Pack – a combination of two duction of the secondary packaging of the tpod. Stickpack and Pull Pack, guarantee a flavour- innovative packaging styles.
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FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
Kosme UK Offers the Total Beverage Solution osme UK is a leading global machinery K equipment supplier to the beverage industry offering complete, flexible and cost efficient packaging solutions for all bottling lines. Kosme’s comprehensive range of turnkey filling, labelling, capping, packaging and conveying operations guarantee a total system approach which ensures a tailor made packaging solution to all customers’ requirements. Kosme UK has seen its annual turnover rise dramatically since its inception in 2002, which is due to a culmination of excellent customer service coupled with its wide range of state-of-the-art bottling equipment. Kosme has earned a name in the world of packaging. Its product range includes a vast number of systems for all requirements of technology, which range from medium-low to high capacity. Working with customers, from comprehensive design to project management is integral to Kosme’s success. The company can now fully satisfy the most demanding of bottling requirements from a diverse equipment portfolio which includes stretch blow moulders, filling equipment, labelling machines, packaging and palletising systems and conveyor systems. Bespoke Solutions Kosme has a strong, local UK presence and is able to undertake site evaluations to ensure clients’ needs are met and a bespoke solution is specified. Also this is the ideal time to optimise efficiency in the design phase of a bottling line. Using its expertise and knowledge Kosme can work with the client to clarify layout, ergonomics, traffic
An example of Kosme's modular labelling systems.
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Kosme’s ongoing high level of customer care and service gave us confidence to approach them again. The security of having an on-site engineer during the commissioning of the labeller and their ongoing UKbased servicing has given us the peace-of-mind we needed during a vital upgrade.” Collaboration With Krones Based in Roverbella, Mantova, Italy, Kosme is an indepenOne of Kosme’s UK engineers on Britvic's Drench water dently run company that works bottling line. in close collaboration with its majority shareholder Krones, bottlenecks, equipment selection, automa- the world-wide market leading packaging tion and other possible issues before com- and bottling company. Through its missioning even begins. Kosme can identify research, development, manufacturing any production bottlenecks and install key facilities and synergy with Krones, Kosme equipment to improve production efficien- has increased its product offering to every cy. aspect of the bottling line, from the start to Kosme’s understanding of the bottling the finish product. industry means it has worked with some of Kosme machines are designed to process the biggest processors in the industry, glass, plastic and PET bottles and are ideal recently the company supplied a new for alcoholic products such as wine, spirits labeller to Britvic, to help production of and beer, as well as soft drinks and water. their new Drench spring water line. Britvic At the beginning of the line, Kosme offers project manager Max Collingwood had no custom blow moulding machines designed hesitation in choosing Kosme as he to the specific requirements of each cusexplains: “Kosme have supplied us a num- tomer. Furthermore, the company’s KSB ber of machines and when the need arose to stretch blow moulding machines have upgrade our water bottling line labeller we achieved a leading market position in the felt Kosme was an obvious choice, given PET bottle producing industry. The KSB the high standard of their service and Series represents a key step forward in the machines. Due to the urgent need and high design of complex beverage bottling plants, profile of the product line we also needed a field in which Kosme has extensive expeto be sure that the new machine could be rience in. delivered on time and within budget, so Fillers and Labellers Kosme has a wide range of fillers (from single machines to monoblocs, utilising simple rinsing or combined cycle, weight/volume fill, gas injection and capping) Kosme's fillers are an efficient solution to any requirements. Kosme continues to produce cutting edge solutions for the labelling market. The company’s range of labellers are able to satisfy any application requirement by combining the most sophisticated models with high throughput (from 2,500 to 60,000 bph), top quality execution, low cost operation, minimal maintenance and complete ease of use. There are over 60 basic models covering all the main labelling technologies, including cold glue, hot melt, self-adhesive and roll-fed.
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
Kosme's new Flypack Shrinkwrapper.
Packaging Solutions Kosme maintains an understanding of the latest trends and developments that affect its customers. Kosme applies its knowledge and experience to design and develop cost effective packaging solutions that increase productivity and efficiency. One such example is Kosme’s modular labelling machines, which have the specific intention of appealing to production line managers providing them with ‘future-proof’ solutions. Planning the future of a production line in the longterm, with certainty, is a highly difficult task that can make decision makers think twice about investing in specific machinery. When bottling, a combination of multiple neck, back and body labelling positions with either wet glue or self-adhesive labelling methods can easily be achieved with more versatility than conventional machines. Individual attachments can also be adapted, for multiple functions such as different label types, sizes and positions. Kosme’s modular labelling system is particularly useful when production lines need to utilise a number of different product labels. Essentially one combination machine can perform the roles of several independent machines. Flypack Shrink Wrapper Palletisers, depalletisers, case formers, cartoning machines, case sealers, wrappers and robots are additional key products that Kosme manufactures for companies both with medium-low output and with high throughput. Furthermore, Kosme continues to develop and invest, which is evident in the launch of its new high-speed end-ofline Flypack Shrink Wrapper to meet demand in response to the emergence of secondary packing as an important aspect of packaging lines. The Kosme Flypack machine is ideal for 48
grouping together products, such as bottles, cans and glass jars in multi-packs, running at an impressive 45 packs per minute. It utilises separate product compacting, wrapper and heat-shrink units to unite already packed products together in a secondary pack. With its tray erector and layer pad inserter module, it can also handle trays. The machine can easily cope with different formats of product including cylindrical, rectangular and square containers in glass, PET or aluminium.
invaluable as many bigger processors are finding out. Toby Heasman, brewery manager of Hall & Woodhouse which makes the famous Badger Beer brand, comments: “We are pleased with the work that Kosme did throughout the installation and commissioning of our labeller. Also within the contract, we requested an after sales service. This was closely linked into training our operators and craftsmen by Kosme technicians”. Kosme continues to supply machines to a wide range of high profile production lines and producers and supplies updated machines to replace older Kosme equipment, on the strength that the originally supplied machines have proved to be reliable, efficient and cost effective. This is testament to the quality of engineering and after-sales support that the company continues to offer. Through time, Kosme has maintained the essential features that established the company’s famous reputation over the years, custom solutions, high performance, highly reliability, and simplicity of use. Richard Portman, managing director of Kosme UK has a clear vision for the future, one that continues the balance of retaining satisfied clients and promoting new products and services to a widening scope of potential customers.
Full National Service As processors are put under increasing pressure, more and more reliance is being put Complete Package onto packaging and processing machines, “Kosme UK offers the complete package, with many production houses running competitive price, durable, cutting-edge 24/7 to keep up with demand. Due to this technology, with a comprehensive back-up trend Kosme UK has also focused on offer- service to support every beverage packaging ing a full national service for maintenance, requirement,” Richard Portman comments. parts and spares for all past and present For further details on Kosme UK and its Kosme products. complete beverage solutions please phone Because Kosme UK works closely with 01283 523713 or visit the website at their engineering colleagues in Italy, Kosme www.kosme.co.uk J UK’s team all have extensive training and experience of the machines they work on and access to the very latest diagnostic and fault-finding equipment and software. Kosme offers maintenance contracts to all customers, ensuring that a qualified engineer visits the customer either monthly or bi-monthly to identify if any parts need replacing ahead of time to prevent breakdown or downtime. Many companies benefit from this service as they use this time for the engineer to teach additional operators to use the Kosme machine. PET bottles about to enter the Kosme labeller. This ongoing training is
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
MATERIALS HANDLING
‘The Buck Stops Here’ – Materials Handling, Chilling and Freezing Solutions at Odenberg Engineering are one of the premier turnkey “andWe solution providers of materials handling, conveying and chilling freezing systems in the world, and we work with our clients to find the best solutions,” says John Power, Odenberg’s manager for the customised solutions division. “We work to deliver value with efficiently designed solutions, exactly what the customer needs to meet today’s tough production targets. That is simply what we do - a successful formula for both Odenberg and our clients and continues with a number of very large projects currently being delivered.” Impressive Customer Base Having been in business for over 40 years, Odenberg has built up an impressive customer base with projects right across the globe from Australia and China to the US and Europe, with large and small companies alike. Food and drink processing and pharmaceutical companies, make up the majority of the client listing, particularly companies involved in the meat (pork and poultry) and dairy processing sectors. Examples of current and recent projects are QPI Inc in Nebraska, USA and Newmarket Co-operative in Cork, Ireland. Work at QPI QPI Inc (Quality Pork International) is unsurprisingly involved in pork production, so much so that it is one of the largest producers in North America. Looking to expand its capabilities and take advantage of productivity improvements the company engaged Odenberg in the design, implementation and turnkey delivery of a freezing facility to handle 500 tonnes per day of pork meat plus all conveying, automated palletising, wrapping and system SCADA control.
The QPI line under construction.
The new construction and equipment was to be developed alongside the existing plant with minimal disruption while day time temperatures dropped as low as -20C. So impressed was QPI with Odenberg’s performance, attention to detail and professionalism that the scope of supply was extended and effectively doubled to provide the complete turnkey package. Delivery on this multi-million project is on time and on budget for February 2009. Newmarket Co-op Another turnkey project that has just been completed is at Newmarket Co-operative’s expansion in Cork. As part of a major multimillion expansion and to gain flexibility and productivity improvements, Newmarket wanted to automate its cheese block wrapping, cooling and handling process from its existing manual system. Due to site constraints it was not possible to place the new system adjacent to the cheese production area and as such an extensive conveying system to bring the blocks to the new cooler location and robot system to palletize the blocks was required. Against a thorough, international tender process, Odenberg won the contract based on its past track record of total system integration and project responsibility. Asked as to the success of the project, Bernard O’Connor, project leader for Newmarket Co-op. responds: ‘We chose Odenberg as the system supplier as they offered an excellent turnkey solution. The system handover was very smooth with milk volumes at 80% within two days and 100% within two weeks of final commissioning. The design layout and equipment offered a very efficient solution. We would rate the project as an example of how to make the transition from a manual to automatic production system. Operators were quick to take on the operation as the Odenberg team kept them in the loop during the installation and commissioning.’
3D design and simulation of the robotic handling system.
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009
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MATERIALS HANDLING
Key Issues extremely successful in this area with many hundreds of machines The project scope had a number of key issues which needed to be operating globally particularly in the potato, carrot and tomatoes satisfied in its integration: sectors. The key is that a very significant reduction in labour input • Be operator friendly – the solution and its interfaces should be of up to 80% whilst quality and overall productivity gains can be a intuitive and easy to use, with customer and product specific simply achieved using this technology. menus and auto set-ups. • Perform a site analysis to identify areas and processes which could Steam Peeling Solutions be incorporated into the project scope at minimal cost but which The other division is Steam Peeling solutions, again for vegetable would produce clear operational and efficiency benefits for the processors. Odenberg is a market leader in this sector with the client. This includes existing site control systems may be inte- highest performance machines in their class. grated into the new equipment SCADA system. • Non disruptive implementation - production at the plant should have minimal interruption despite the scale of the modifications. This requires flexibility in hours of access and close liaising with the production department. • Low cost of ownership – the solution should use best practice design and components to provide a robust, flexible system with easy access and low maintenance requirements. • Future proof design – as much as possible to provide for future capacity. The backbone infrastructure, automatic cheese block frame, evaporator and shelving capability are sized for the future developments. • Training and support - provide full hand over to and ownership acceptance from engineering, maintenance and operators in order Odenberg Peeling Line. to extract the full benefits from the system. This is key to the usability success of the project. Odenberg has built a close relationship with the client and In both these division, Odenberg can boast some of the world’s offers full support capabilities. leading food processors and suppliers as satisfied and loyal clients Odenberg Engineering has over 150 employees and has sub- for over a quarter of a century. sidiaries and offices across the globe. In addition to the Customised Solutions Division, Odenberg has two other divisions. Challenging Environment “Yes, it is a challenging environment but we have found that when our clients look to find greater efficiencies they turn to us. We have built our reputation quietly in providing a first class service throughout the process with the focus on delivering value and usability for both current and future customer needs,” says John Power. Odenberg achieves this by focusing on the following areas: • Understanding clients’ needs. • Being experts in its field. • Deliver value to clients’ process. • Engineer robust solutions. • Use the company’s knowledge to engineer efficient/innovative solutions. • Use the latest technology to improve efficiency. It is certainly a challenging time for businesses operating in today’s unpredictable economic climate. However, working with clients to deliver cost effective solutions and keeping to the budget will grow Odenberg’s business and its clients’ businesses into the future. J Titan Optical Sorter. Optical Sorting Solutions The first, Optical Sorting designs and builds machines for the high capacity quality grading and foreign material removal in fruits and vegetables, both fresh and processed products. Odenberg has been 50
FOOD & DRINK BUSINESS EUROPE, DECEMBER/JANUARY 2009