17 minute read
Supplier news Updates from SIBA’s Supplier
Supplier Case Study
ICE Vulcan labeller finds its Vocation in craft beer market
Clearmark Solutions has partnered with the enterprising Vocation Brewery to install its first ICE Vulcan print and apply labelling system at the Halifax factory, guaranteeing to meet GS1 criteria, saving on cost, waste and increasing turnover through quicker print runs to label boxes of beer for shipment to the top five UK multiples..
Last year, with sales of small pack craft beers soaring due to lockdown restrictions when the nation’s drinking habits became home-based, Vocation Brewery had to look at new, faster ways of applying labels to their boxes whilst being compliant with GS1 regulations. Previously, labels were printed using a desktop printer and applied by hand, meaning the process was slow and the labels were not always clearly printed or positioned in a neat, uniform way. Now with the investment in the ICE Vulcan print and apply labeller, the cost to label each box of craft beer has dropped by an incredible 90%, costing the brewery just half a penny per label. Print speeds can reach over 120ppm with a label capacity of 17,000 labels, more than twice the capacity of other labelling systems. Since John Hickling established Vocation Brewery in a rebuilt chicken shed in 2015, it has gone from strength to strength, now employing 60 staff, and selling up to 14 million cans per year. Vocation Brewery won its first listing in Tesco stores in 2016 and now supplies standard and bespoke product lines to multiple retailers including Asda, Sainsbury’s, Waitrose, Booths and Marks & Spencer. Dan Sutcliffe-Tasker, Head of Packaging at Vocation Brewery, said: “Growth in supermarket chains and orders for seasonal and one-off product lines has seen production increase to 60,000 hectolitres this year, up from 10,000 when we first started, that’s approximately 12-14million cans this year. “Everything sent to the retailer has to be boxed and labelled. We produce about 30 pallets a day, with 100 or 200 cases on each pallet. Anything other than our core brand has to have a custom label on it. Since automating our labelling process we’ve had zero defects - the ICE Vulcan print and apply system is 100% fool-proof and in hindsight we should have automated sooner.” In the early days Vocation had 26 pallets returned as a result of incorrect barcodes and human error, causing the brewer to re-call and re-label the goods, which was both time consuming and costly. With the ICE Vulcan system, using CLARiSOFT™ label design software, labels are designed and programmed for the operator to select using the CLARiTY operator touchscreen. CLARiTY allows operators to select the job from a list or pre-programmed jobs, eliminating operator intervention and human error. Vocation compared systems but were most impressed with Clearmark’s unique direct apply application rather than a blown on label which can create creased labels . Thanks to a height adjustable stand, the system can accommodate changes to box size in just a few seconds. “The main concern for us was individual placement of the label. There is no way a human operator can stand there on an eight-hour shifts and hit the same mark every time, especially when things were operating so quickly. We needed stability and guaranteed repeatability that automation is known for,” added Dan. “Since the ICE Vulcan was installed in March, accuracy has improved dramatically with no issues. The print quality is also of a higher standard as the desktop printer ink sometimes faded due to condensation on the craft board from the temperature, turning the black print grey. But we have had no issues like that with the ICE Vulcan.”
Find out more at www.clearmark.uk
Innovus launches new canning line
Innovus Engineering prides itself on listening to its customers, even more so as Covid has brought unexpected and evolving challenges for craft brewers.
In response to customer demand, it has recently added a new 1,000 can per hour model to its CF canning line range. The CF15 is a new, compact two head canning line, based on the previous success of the five head CF25 model. The CF15 retains all the industry leading features of the CF25, including the automated lid dispenser, with undercover gassing and pre-fill purge and post-fill gas injection for consistently low levels of dissolved oxygen. There is also the option to integrate a rotary infeed table, to assist the machine operator and increase the level of automation, along with further options for adding a date coder and can labeller. The CF15 canning line is suitable for standard, slim and sleek cans, and changeovers between different can heights are quick and easy. All Innovus seamers have the major advantage of a vacuum hardened cam for mechanical seaming operation. A mechanical seamer has much more repeatable performance than a pneumatic machine and is ideal for producing commercial quality double seams. Innovus seaming technology is supported by Crown Bevcan, who have recently ordered additional can seamers to add to the multiple Innovus machines installed at their Wantage R&D site in 2020. All machines are supplied with a tool kit that includes a seam micrometer and seam tear down tool, so that customers have the capability to carry out accurate seam checks. The CF15 is available on a short lead time, with prices starting at £32,500. With a capacity of 1,000 cans per hour, this canning line represents a competitive price point for breweries that want to start canning in-house. All Innovus canning machines are built in the UK, and training, service and spare parts are also all available from the UK.
Brewing Services Ltd expands
BrewMan and Sellar integrate to make trade ordering seamless for breweries
Brewery management software BrewMan and trade ordering platform Sellar are pleased to announce their new integration.
The integration makes selling to trade seamless for BrewMan and Sellar’s mutual partners. Orders, inventory and customer data will be instantly synchronised across both platforms. This means Sellar talks to Brewman and displays real-time product availability to trade buyers. Orders through Sellar are then automatically pushed back to Brewman for processing. Sellar is a trade ordering platform focused on providing the most seamless ordering experience for breweries and their trade customers. Sellar simplifies the overly complicated and time-consuming processes allowing breweries to focus on building their customer relationships. Sellar launched in 2020 and has quickly grown to working with thousands of businesses across the UK. BrewMan V7, the new web-based version of the industry-leading, brewery and distillery management software, is used
Bringing with her a wealth of operational experience and technical knowledge, Hayley Young has joined David and Rob Smith at Brewing Services Ltd.
Hayley started her brewing career designing pump clips and washing casks at Loweswater Brewery, but quickly learnt how to brew and was promoted to Head Brewer at Cumbrian Legendary Ales in 2009, where she won Champion Golden Ale of Britain for Loweswater Gold in 2011. In 2014, Hayley was headhunted to join Sharp's as Operations Brewer. She formed part of the Production Leadership Team and was ultimately responsible for the smooth running of the 250hl plant. Since 2018, Hayley has been working as a consultant, helping smaller breweries and vineyards with technical, quality and compliance issues. Holding a Diploma in Brewing from the Institute of Brewing & Distilling, Hayley is now bringing her passion for quality to the Brewing Services team.
Find out more at www.brewingservices.co.uk
by over 300 businesses in the UK and launched in June 2021. Premier Systems has completely rebuilt BrewMan to combine the features and functions that have been developed alongside brewery customers for 20 years with new modern interfaces and intuitive controls that can be accessed through a browser on any device. This allows users to calculate duty, track production, place orders, manage stock and track casks, all from their smartphones as well as at the office. Sam Williams, Commercial Director at BrewMan, said: “Both Sellar and BrewMan are designed to save time and make life easier for breweries so collaborating to make our systems work together and more efficient for our mutual partners was an obvious choice for us.” Neil Smith, Head of Product at Sellar, added: “We’re entirely focussed on building the best possible commerce experience for the industry. Integrating with Brewman is an important step towards achieving this.”
To find out more about the integration, email support@premiersystems.com or hello@sellar.io
Close Brothers launches EkegPlus
EkegPlus is a new short-term rental solution that enables brewers to only pay for containers when they are using them. This means the shorter the hire cycle, the less they are charged.
EkegPlus customers can access a container pool of over 400,000 ekegs and ecasks and have the freedom to adjust the size of their rental fleet as often as needed. The pay-asyou-fill model gives users more control, with charges calculated per day, providing the flexibility to increase output or reduce costs. This cost-per-fill option also aims to make costs more transparent. Prices start at just 99 pence per unit for the first 30 days, with a price cap for hire periods over 80 days. In addition, you can view cost-to-serve and live daily hire charges 24/7 via the PlusPortal technology. With fixed RFID tags, brewers can track and manage hundreds of containers in seconds. Plus, they have access to data that enables better understanding of products, logistics and supply chains, as well as increased asset visibility. Driven by technology, the hire cycle works in four simple steps: 1. GET containers you need – brewers can collect them from a local depot or arrange for a stockpile to be kept on site 2. FILL AND SCAN containers to start the hire cycle 3. DELIVER the product direct to a venue or to an approved wholesaler 4. COLLECT AND RESCAN the empty containers – brewers can reduce charges by collecting themselves or wait for EkegPlus to collect, automatically ending the hire cycle. The launch follows the company’s innovative use of RFID which saw them win Best Use of RFID to Enhance a Product of Service at the RFID Journal Awards in 2019. David Beswick, Managing Director, said: “Our customers told us they want competitive pricing, transparent billing, and the flexibility to send direct to venues as well as to wholesale, so that is exactly what EkegPlus brings to the market. “The new pricing model can help brewers to drive down costs. There are no surprises or hidden costs and each container cycle could cost you as little as £1 for the first month. With daily hire from 12p and charges capped for protection, there is considerable cost saving available to brewers.”
To find out more visit www.ekegplus.com
Thielmann is here to get your kegs ready to roll again!
As the hospitality industry re-opens, Thielmann is providing a full suite of maintenance services for brewers.
As the hospitality industry re-opens, Thielmann is providing a full suite of maintenance services for brewers. After more than a year and a half since the pandemic began, we are on the path back to some sort of normality. Bars, pubs, and restaurants have opened their doors once more, and after a long time dormant, Thielman is there to help get small brewers’ kegs ready to roll again. Thielmann prides itself on the resilience of its kegs, however, kegs can present performance issues when faced with prolonged lack of use. That’s why Thielmann is advising brewers that before their beer goes out to meet the public, they need to ensure their fleet is in top condition. Thielmann offers a safe, compliant keg decanting service to ensure that any wasted beer is properly disposed of. The company also offers a complete cleaning service, with bespoke processes for each keg type. This whole solution includes collection and return, even for large fleets, all turned around in record time. For wear and tear, Thielmann also offers a comprehensive repair and maintenance service. This is especially useful for fleets that have been out of action for extended periods, as prolonged storage can place stress on keg parts, particularly the spear. The service includes internal and external inspection, neck repair, chime straightening, pressure testing, and importantly, spear maintenance. On request, Thielmann can also fit its kegs with predictive maintenance features. This includes log fault analysis sensors, which evaluate the overall condition of the fleet, ensuring servicing is timely and efficient. Advanced tracking solutions are also available on request.
Find out more by emailing sales@thielmann.com
Supplier Viewpoint
The lowdown on high-end branding
In this issue, Myles Pinfold from WPA Pinfold looks at the qualities that make craft beer a premium product…
“The craft beer movement has been a phenomenon and a game changer for the sector – long may it continue. I cannot think of any other industry that has gone through such a transformation in such a short space of time. It is an exemplar for any other sector wanting to reposition to the high-end, and it is worth understanding the key factors that have enabled this success. Especially how formats that were previously on the commodity end of the beer category (keg and canned) have become the stars. Who would have thought it 15 years ago when cask ale was king (certainly for the aficionados) and PBAs (Premium Bottled Ales) held sway over the premium end of the supermarket aisle. The term ‘craft’ was first adopted by the American micro-brewers in defiance of the big monolithic and monopolistic brewers who dominated the USA with their ‘bland’ (their words, not mine) beers. The descriptor is still indefinable although it implies artisan and small scale (even though there are some pretty big craft brewers nowadays) and has come to represent an attitude and lifestyle. The ascendency of the artisan producer is not exclusive to beer, however it has probably had the biggest and most profound impact on this sector than any other by truly capturing the imagination of the consumer. This success has been to the detriment of the big brands who are now fighting back. Having tried with varying degrees of success to emulate the craft movement there is now an ongoing wave of acquisitions, based on the business paradigm ‘if you can’t beat them, buy them’ – and who can begrudge those craft beer pioneers reaping their hard-earned rewards by selling to the big brewers? For the over 2,000 independent UK brewers emerging into a post-pandemic market, what does the future hold? Certainly, picking up and running with the momentum created before the lockdowns has to be a key strategy – the consumer still appears to have a growing desire for innovation, choice and variety, and craft is still in the ascendancy. However, the market is becoming overcrowded and for the smaller brewers who lack the economies of scale, retaining a premium pricing is essential. At the end of 2018 Asahi, in association with Mintel, published an interesting report on premium brands and how they engage consumers – it gives some very salient wisdom for brewers. The report acknowledges high-end consumers’ desire for ‘quality over quantity’ and their willingness ‘to pay more for less’ if the product is truly good. However, quality in this case goes beyond simply the product itself, it is all about the qualities and values that the brand exudes and for highend consumers this means authenticity, provenance and individuality. So, if you are planning your next move and want to continue to capitalise on craft beer’s premium positioning, it is worth bearing those three essential brand characteristics in mind - capturing the hearts of consumers is essential.”
Myles Pinfold is founder and strategic director of WPA Pinfold. Find out more at www.wpa-drinks.co.uk
PakTech awarded for Global Sustainability by Business Intelligence Group
S USTAINABILIT Y IN BREWING
The Business Intelligence Group has recognised PakTech for its Sustainability Product of the Year in the 2021 Sustainability Awards program.
The Sustainability Awards honour those people, teams and organisations who have made sustainability an integral part of their business practices or overall mission. Throughout all aspects of development, PakTech embraces a sustainable and circular approach to waste, embodying the reduce, reuse and recycle principles in product designs. In addition to being 100 per cent recycled and 100 per cent recyclable, PakTech’s handles reduce unnecessary plastic with their minimalist design. The handles are reusable and recyclable infinitely. “We are proud to reward and recognise PakTech for its sustainability efforts,” said Maria Jimenez, Chief Nominations Officer of Business Intelligence Group. “It was clear to our judges that PakTech’s vision and strategy will continue to deliver results toward a cleaner, more sustainable world. Congratulations!” In all aspects of its business operations, PakTech is committed to creating a more circular and sustainable economy and society, to reducing waste and helping brands achieve their sustainability goals. The company aims to provide circular packaging solutions manufactured from 100 per cent recycled resin and its own recycled handles because it believes this practice can help achieve a circular economy, one where no plastic becomes waste and the demand for virgin plastic is greatly reduced. When PakTech handles are recycled, they are transformed back into recycled resin and used to make new handles, composite lumber, flower pots, pipes, park benches and more, completing the circular loop. The unique handles have provided leading brands and retailers globally with fully circular and sustainable packaging solutions for 30 years.
Find out more at www.paktech-opi.com
Counter Pressure Filling
Beth Kelsey from Core Equipment explores the differences in different can filling techniques…
“The first and most important concern when packaging a beverage is preventing contamination exposure by two of the main culprits that reduce shelf-life and modify taste, UV rays, and exposure to oxygen. Cans offer versatility, sustainability, and portability and are a great option for craft beverage producers, but most importantly, eliminate the disadvantages to packaging in a bottle such as UV exposure. As the can appears to have gained a permanent spot on the supermarket shelf, the debate has now shifted to the options around canning line solutions and is now on the canning line itself. Counter pressure technology gives the operator complete control over the atmospheric conditions inside the can during the fill process. The process allows for faster filling whilst simultaneously preventing oxygen absorption and product loss as the liquid travels through a series of valve operations and pressurisation. This method was previously only used by large-scale beverage producers, but this technology has been successfully scaled down and made available for craft beverage producers at an affordable price. The alternative to counter pressure filling is gravity filling. The disadvantages with gravity fill compared to counter pressure are that gravity fillers rely on head pressure and liquid temperature to control fills supplied directly from the product holding tank. By using a gravity filler, the operator can lose control over fill levels resulting in product loss as liquid is exposed to the atmosphere during the entire fill process. As foaming becomes difficult to control, this causes unnecessary overflow and oxygen absorption as liquid is piped filled into cans. Oxidation not only causes adverse effects on the aroma and flavour, but also reduces shelf life and nutrient retention of a beverage as compared to counter pressure filling. It is crucial for maintaining quality to mitigate dissolved oxygen absorption during the packaging process. In comparison, by equalising the pressure from tank to can, cans can be filled faster whilst the Snift feature allows pressure to release slowly so foaming can be controlled at the same time as maintaining carbonation levels. By keeping liquid under pressure throughout the fill process, CO2 is kept in the beverage, ensuring it tastes the way it was intended to. Nitrogen-infused beverages are also supported by counter pressure fillers, as their design means there is no fill tube that interferes with the widget.” Supplier Viewpoint
