Archive | Processing

Eilersen Electric Launches the World’s First Hygienic Beam Load Cell

Eilersen is releasing a new series of digital load cells in a hygienic (aseptic) design for dynamic weighing, process weighing, filling, packaging and general weighing applications targeted primarily at food and pharma customers. The new hygienic design is unique without any exposed bellow grooves, facilitating easy cleaning to minimize the risk of bacteria and contaminants on the load cells, and thereby ensuring an overall high level of hygiene.

All Eilersen load cells are developed and manufactured in Denmark and based on a highly accurate and very robust capacitive measuring principle. This technology allows an installation without complicated, nonhygienic stay rods and overload protection devices, which are applied in most strain gage load cell installations and result in a non-hygienic final installation.

The absence of overload protection devices in an installation with the new Eilersen hygienic load cells further improves the existing design, and thereby provides an installation which is even more simple, easy to commission and hygienic.

World’s First Hygienic Beam Load Cell

The new Eilersen beam load cell type BL is the world’s first beam load cell in a hygienic design and is characterized by the smooth bellow, which provides a clean, maintenance free installation and is unique for weighing systems using beam load cells.

Beam load cells in general are known for the difficulty when cleaning the bellows and the need for overload protection devices, both of which are not necessary when installing Eilersen beam load cells. The new hygienic design from Eilersen eliminates the difficulties in cleaning the load cell surfaces, and thereby reduces the risk of product contamination.

The new hygienic digital beam load cell type BL is produced in electropolished stainless steel, hermetically sealed (IP68) and can be supplied in capacities up to 1000kg with 0.025% accuracy. The load cell type BL is ATEX certified for installation in ATEX zone 1, 2, 21 and 22.

New Application-specific Integrated Circuit (ASIC) Provides Optimal Specifications

During development of the new range of load cells, the specifications have been optimized through a proprietary ASIC, which is manufactured for Eilersen utilizing the newest technologies.

Flexible Instrumentation

The new load cells can be supplied with the most common fieldbus interface options such as PROFINET, Profibus DP, EtherNet IP and Modbus TCP. In addition, the new hygienic load cells can be supplied with a range of digital weighing terminals that include standard firmware for most weighing applications or customized firmware.

Reliable Capacitive Technology

Eilersen has more than 40 years’ experience as experts in industrial weighing, with capacitive load cells that are known for a simple mechanical and simple electrical installation, reducing both the overall installation cost and minimizing customer’s maintenance costs. These characteristics are known and appreciated by satisfied users in more than 85 countries all over the world.

For further information contact: Eilersen Electric A/S, Kokkedal Industripark, 4 DK-2980 Kokkedal. Tel +45 49 180 100; E-mail info@eilersen.com; Web www.eilersen.com.

Posted in Hygiene, Packaging, Processing, Quality Assurance0 Comments

Hygienic Sealed Wall Kerbing Within Food and Drink Factories

In the food and drink factories it is an important factor when manufacturing, processing, packaging and distributing quality products, daily. With various processing areas in a factory it is imperative that the construction of the factory will not impede production or fail due to its impact wear.

With strict demands within the food and drink industry it is crucial to provide a highly hygienic environment to avoid all costs of contamination. The choice of material within a factory design is highly important to withstand the regular cleaning regimes as well as increasing the clean ability of the environment.

Aspen Stainless are the UK’s exclusive agent of Polysto hygienic wall kerb range. Each kerb is made from a very strong polymer with a smooth finish, the kerbing is designed to reduce the ingress of liquids and provide protection to walls, columns and the door edges from floor level.

To increase clean ability a Polysto rebated wall kerb can be installed with a resin floor to create a smooth curve. The rebated kerb eliminates the stand 90 degree angle which increases clean ability and decreases the risk of dirt traps.

When installed the wall kerb is sealed with a high quality silicone based food joint sealant, which contains a special fungicide to prevent build-up of bacteria. The high strength formula is ideal for food environments for its high humidity and temperature resistant attributes.

Accompanied with wall cladding and bump rails Aspen can provide a completely sealed hygienic surface between floors and walls. The added protection will support daily traffic and the potential loading bay collisions.

Browse the product range online, which has full technical data available to download and discuss your bespoke requirements with the Aspen Technical Team at +44 (0)115 986 6321; www.aspen.eu.com.

Posted in Hygiene, Processing, Quality Assurance0 Comments

Goliath – A ‘Spirited’ Automation Systems Provider

Goliath Packaging Systems, in business since 2007, sources, supplies, installs & after-sales services a comprehensive range of End-of-Line Automation, Materials Handling & Industrial Washing equipment to the Irish Food/Beverage sector with recent projects successfully delivered for whiskey distillers such as Cooley Distillery (Beam Suntory), Bushmill’s plus William Grant & Sons amongst others.

The Goliath product range consists of the following distinct items:

  • Liquid Filling Systems
  • Shrink Wrapping, Banding & Over Wrapping
  • Cartoning
  • Case Erecting, Case Packing & Bag-in-Box Systems
  • Manual & High Speed Labelling Systems
  • Case Sealing
  • Conveying Systems
  • Pallet Inverting & Exchange (Fixed, Mobile & Automatic In-line)
  • Pallet Stacking / Handling
  • Scissors & Vacuum Lifting Systems
  • Materials Handling Systems (Reel, Drum & Product Manipulators)
  • Pallet Elevating Systems
  • Palletising Systems (Gantry, Articulated Arm & Layer types)
  • Stretch Wrapping
  • Strapping Systems (Case & Pallet)
  • Washing Systems (Bottle, Jar, Box, Tray, Drum, Pallet, Keg & IBC etc)
  • AGV Transport
  • Weighing Systems
  • X-Ray / Metal Detection.

Centrally located in Nenagh, County Tipperary, Goliath is less than two hours from all of the major markets, while trained engineers maintain spare parts and service all installed equipment with annual service contracts (reactive / preventative) available as preferred.

To discuss your particular packaging equipment needs, please contact Goliath as follows:

Name:                    Goliath Packaging Systems Ltd

Contact:                                George O’Leary

Position:                                Director

Address:                                Well Rd., Nenagh, Co. Tipperary, Ireland

Tel / Fax:               067-37893 / 067-34794

Mobile:                  087-1222816

E-mail:                   info@goliath.ie

Web:                      www.goliath.ie.

Posted in Automation, Materials Handling, Packaging0 Comments

A Robot With ‘Matchmaking’ Knife

What chicken processor would not welcome an automatic in-line system allowing him to match hour after hour, consistently accurately and with minimum give-away customer orders for fixed weight breast fillet retail packs to fillet coming off his de-boning line.

By using Innova software to link its RoboBatcher and I-Cut technologies, Marel Poultry can offer just such a system, launched last year as ‘a Robot with a Knife’.

RoboBatcher batches breast fillet onto fixed weight retail trays or into fixed weight bulk packs.  It can handle up to three recipes or customer orders simultaneously. The Marel I-Cut 122 Portion Cutter will cut fillet to a pre-set weight, dimension or both. It can cut fillet at various angles to give a natural looking cut end product.

By linking the two technologies, I-Cut 122, the Knife, receives its instructions on what size to cut each fillet from RoboBatcher, the Robot. As each fillet enters the I-Cut 122, it is scanned and its weight assessed. This information is passed to RoboBatcher which will then decide whether the fillet can pass directly into one of its recipes or whether it needs to be trimmed to fit. This technique makes the very best use of incoming fillet, at the same time keeping give-away to an absolute minimum. Not all fillets will need to be trimmed. The technique is also particularly suited to the challenge, faced by today’s processors, of accommodating breast fillet from ever heavier birds into the lighter fixed weight retail packs demanded by the consumer.

Marel’s “Robot with a Knife” could just as easily be called ‘the Matchmaker’. The system ensures that breast fillets from the de-boning line, whose size and weight will vary, are always matched as accurately as possible to customer orders, allowing processors to fulfil these orders efficiently and with minimal give-away.

Find out more at marel.com/robotwithknife.

Posted in Control & Automation, Innovation, ProcessingComments Off on A Robot With ‘Matchmaking’ Knife

Key Technology Helps Processors Improve Product Quality, Increase Yield and Reduce Costs

Key Technology has a long history as a trusted supplier and partner to food processors worldwide. With the single most complete source of high performance digital sorting, conveying and other automation systems, Key helps processors improve product quality, increase yield and reduce costs.

Key’s high-performance laser/camera sorting systems – VERYX®, Manta®, Optyx®, Python, Spyder, Taurys™ and Tegra® – remove defects and foreign material (FM) based on colour, size, shape and structural properties. Advanced software gives digital sorters the ability to Sort-to-Grade™ (STG) and/or collect, analyze and share useful data across the enterprise via Information Analytics. Hyperspectral imaging systems, including Cayman® BioPrint® digital sorters and ADR® with CIT®, add chemometric analysis to detect invisible defects as well as a high concentration of sugars, solid content and internal diseases.

These sorters are complemented by Key’s shakers, Iso-Flo® vibratory conveyors, Horizon™ horizontal motion conveyors and Impulse® electromagnetic conveyors, which can be designed to convey, feed, align, dewater, deoil, distribute and more. Other processing equipment includes rotary size graders for sizing, grading and separating and systems for blanching, air cooling, air cleaning, washing and feeding.

In addition to world-class systems that satisfy production needs from raw receiving to the packaging line, Key’s deep industry expertise and unparalleled service contributes to its preferred supplier status.

Food processors of all sizes know they can rely on Key for single-point solutions as well as complex, multi-step processing lines. Global support includes application testing, line integration, installation and start-up, training, customizable service packages for maintenance and repairs and more.

For further information contact Key Technology at Email contact@key.net; Tel +3211249191 or visit www.key.net.

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Forsyths – An Enterprising Family Business

There has been a Coppersmiths based in Rothes, Moray, Scotland since the mid-1850s servicing the fledgling Scotch Whisky Industry in Speyside.

In the 1890s Alexander Forsyth started his apprenticeship as a coppersmith with the then owner Robert Willison who had his main operation in Alloa in the Central Belt of Scotland. When Willison came to the end of his business life in 1933 he sold each unit to the working managers, Alexander Forsyth being that in Rothes at the time.

The business prospered until the start of the 2nd World War when it was basically mothballed alongside the Scotch Whisky Industry. At the end of the war Alexander’s son Ernest (Toot) Forsyth took over the business and the company grew in conjunction with the now rapidly expanding Scotch Whisky Industry. The present chairman, Richard Forsyth, son of Ernest, started as an apprentice coppersmith in 1968 and progressed into Forsyths’ management mid 1970s.

Over this period the Morayshire Copperworks moved from its limited premises in Green Street to more spacious surroundings in the Old Station Yard.  New custom built workshops were erected and any expansion experienced was soaked up by the Scotch Whisky Industry.

Diversification

By 1979/80 over production in the industry created massive cutbacks causing 3 day weeks and mothballed distilleries. Diversification was necessary and Forsyths fabrication skills were adapted for the buoyant Papermaking Industry in the 1980s.

During this period Forsyths developed a design engineering and draughting arm which was to back up its fabrication facility. In 1981 they were offered and bought their local opposition, Grants (Dufftown) Ltd., who had a substantial electrical division, a valued add on to Forsyths services.

By the early 1990s Forsyths were in a position to compete in the lucrative Oil and Gas Industry. Premises were purchased in the North East coastal town of Buckie and developed to suit. Harbourside assembly shops were built to cater for sizeable fabrication units up to 500 tonnes which could not be transported by road.  To compliment these services Forsyths added in-house blasting and painting, scafforlding and a small civil works division to enable a complete turnkey solution.

Forsyths is a 4th-generation family-run business with bases in Rothes and Buckie. Branching out from a background in custom copper whisky stills for the Scotch Whisky industry, Forsyths now embraces high-tech fabrication in carbon and stainless steels, super duplex and titanium for amongst others the paper, pharmaceutical and oil and gas industries. The Rothes yard remains the base for the copper whisky still fabrication, and also has a “clean room” for the welding of specialist toughened steels like super duplex. Here, complex welding on another section of copper for a whisky still.
Pic: Tim Winterburn / HIE

Core Business

Whilst all of this expansion was significant to the company its core business of manufacturing and servicing equipment for the Whisky Industry was still very important and growing again for Forsyths.

In the past 20 years the Company has enlarged its portfolio to include the full design and build of turnkey distilleries for Bourbon and Rye Whiskeys, Gin, Vodka, Rum, Tequila, Malt Whiskies and in particular Irish Whiskeys to cater for the huge increases in demand.

Irish Whiskey

Forsyths have carried out maintenance and replacement for IDL Pernod Ricard’s Midleton site for the past 25 years and were delighted to be awarded the contract to build the new “Garden Stillhouse” showcasing the biggest copper pot stills in the world at 80,000 litre content, 40,000 litre charge capacity. These stills were so big they could not be transported by road and had to be shipped from the Buckie facility directly to Cork. They were designed with the latest energy efficient heating systems and have operated successfully for the last 5 years. Demand has been so great that a further three of these Pot Stills have been added to the Garden Stillhouse this year.

Besides having built five other distilleries in Ireland Forsyths have current contracts in Japan, Taiwan, China, Thailand, England and North America as well as carrying out their biggest ever contract to date – the new Macallan Distillery in Speyside, Scotland. They are increasing capacity at the famous Glenfiddich Distillery and doubling capacity at IDL’s sister company’s distillery – The Glenlivet.

Forsyths are very proud to have such a close working relationship with Irish Distillers Limited and continue to develop this relationship with further intended projects.

The company moves into its 4th generation of ownership and management with Richard E Forsyth Jnr. now well ensconced as MD ensuring continuation of this enterprising family business.

Posted in Enterprise, ProcessingComments Off on Forsyths – An Enterprising Family Business

Lighthouse Systems a Finalist at the Gatwick Diamond Business Awards

Lighthouse Systems, the UK-based Manufacturing Execution System (MES) vendor, is a Finalist at the Gatwick Diamond Business Awards, 2017, in the category ‘International Business of the Year’.

In the last 5 years, Lighthouse Systems has substantially grown through the continued collaboration with existing customers on one hand, and the on-boarding of new customers and larger MES/MOM projects on the other. This was made possible by a successful development strategy, underpinned by continued investment in people, processes, and technology.

In that period, the Lighthouse office team has grown by 20% in the USA, whilst our office space in Singapore has doubled to accommodate growth in the Asia Pacific region.Lighthouse Systems has opened an office in France and created a satellite office in the Nordic region. The year 2016 saw further investments in developing its presence in the Middle East. In regions where the company is a not directly present, Lighthouse Systems has continued to develop partnerships with local MES software integrators, such as in Israel, the Netherlands, and South-Africa.

Some of the recent implementations of Shopfloor-Online MES include projects for a French cosmetics packaging company in Mexico, a world-class food and beverage company in New-Zealand, a large privately owned German automotive firm in the USA, already using Shopfloor-Online MES at 19 of their factories worldwide.

From a product perspective, the breadth of functionalities of the manufacturing execution system Shopfloor-Online has been expanded further with the addition of plant maintenance, energy management and workflow modules.

Lighthouse Systems, which had already pioneered MES as a web-based application, is now working on a new version of Shopfloor-Online that is fully browser-independent, opening new possibilities for manufacturers to operate the MES application over the full range of devices, PC, tablet and mobiles, on any operating system.

“We are very pleased our efforts are being recognised by the region where we are head-quartered. These are exciting times for Lighthouse Systems and the MES market. We look forward to servicing manufacturers who strive for world-class operations even better in the coming year with Shopfloor-Online,” says Paul Barber, Director.

The Gatwick Diamond is home to a vast range of businesses, which span all sectors of the economy, from household names to niche companies, and from multinationals to sole traders. The Business Award Winners are those businesses or people who have shown innovation and inspiration in their work, and have demonstrated a real commitment to this world-class region.

Visit www.lighthousesystems.com for more information.

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MSL Engineering Continues to Grow into New Markets

Operating from its base in Watergrasshill, Cork, Ireland, MSL Engineering Ltd (MSL) has close to four decades of industry experience as a trusted partner engaging in specialist design, fabrication, installation, testing and commissioning of process pipework, utilities and high-purity pipework, as well as installation of process and heavy equipment. MSL also manages multi-discipline sub-contractors as part of many of it projects including heating, ventilation and air conditioning (HVAC), scaffold, cranes, insulation, painting, structural steel, sprinklers and non-destructive testing (NDT).

Having previously installed the three original Pot Stills along with the Distillation Columns and all other associated equipment and pipework during the Irish Distillers plant capacity expansion project in 2012, MSL was again awarded the contract for all mechanical works involved in the current project in Midleton.

During the intervening period MSL has continued to enjoy strong growth across its traditional markets within Ireland, while its presence in the UK, Netherlands, Belgium, Switzerland and Sweden has equally expanded.

There is a lot of development going on in Dublin at present and MSL are also being contracted for increasing amounts of work throughout Europe. This has been the biggest change for the company in recent times, but they have also increasingly focused on working with high-purity applications in mechanical engineering in line with the Biopharma industry demand.

High-purity Workshop

They built a high-purity workshop at their premises in Cork and have since won some good contracts in the fabrication and installation of high-purity pipework, which is a part of the business that continues to grow positively. The new workshop was installed in early 2016 and this allowed the company to complete the high purity elements of existing contracts. However MSL has since won a number of larger jobs for high-purity pipework for projects overseas and this enabled the h-p workshop to become fully operational during the final quarter of 2016. This high-purity facility continues to be busy and with current commitments will remain so throughout 2017.

Another aspect of the business that has helped win work in the UK and Europe is a proven track record in successfully completing modular built pre-assembled process units and pre-assembled racks in the workshop in Cork for subsequent shipping and installation. On-site installation of these modules is normally carried out by MSL as part of the overall package, however installation on site by others is also an option.

Successful Year

While 2016 proved to be a highly successful year for MSL, the company is showing no signs of slowing down. By offering a personal service and guaranteeing the highest levels of quality, MSL is set to continue to grow into new markets throughout the coming years. They have now risen to the ‘next level’ in terms of the quantity of work that they can take on and the amount of turnover that they are capable of generating. Turnover increased substantially throughout 2016 and they have expanded their presence across Ireland and overseas.

As mentioned previously, Dublin has been particularly active and MSL’s aim is to maintain their presence there over the coming months and years. They have invested in the additional resources to handle increased levels of work and their aim will be to keep those resources working and active. They really are able to offer a first-class service based on very varied projects and a lot of experience.

Although undertaking sizable jobs, the company is still managed by the owners of the business, which is something that some clients find reassuring. If issues arise requiring urgent attention it is possible to pick up the phone to speak to the owners of the business to get the matter resolved quickly. When markets are busy clients like to know when they award work that their particular contract is among the top on the contractor’s priority list, which is more likely to be the case when the business is managed by its owners with a personal commitment to successful delivery.

For further information contact MSL Engineering Ltd on Tel +353 21 4513550; E-mail info@mslengineering.ie or visit www.mslengineering.ie.

Posted in Engineering, ProcessingComments Off on MSL Engineering Continues to Grow into New Markets

IFE 2017 – A Shop Window to the Future

This March, the UK’s largest pop-up supermarket for industry buyers is coming to London’s ExCeL.  Between 19–22 March, The International Food & Drink Event (IFE) will be the global shopping hub for the industry’s most influential buyers. With 1000’s of new product launches and countless innovative offerings on display across the four-day event, trade attendees are guaranteed to leave inspired and motivated for the year ahead.

As consumer consumption habits continue to evolve at an ever increasing pace, IFE 2017 showcases the latest trends shaping the food and drink industry. As the show opening approaches, IFE shares its ultimate, not to be missed shopping list:

Adult Soft Drinks

With more and more consumers embracing a teetotal lifestyle than ever before, the demand for premium adult soft drinks is at an all time high. Buyers should expect to see more cold-pressed juices and non-alcoholic adult soft drinks at IFE 2017.

  • Fentimans – a range of botanically brewed soft drinks [Stand N2140]
  • Cawston Press Sparkling Soft Drinks – a balance of natural flavours using only pressed juice with some added sparkle [Stand N2002]
  • Sibberi Tree Water – the first and leading tree water brand available in Birch, Maple and Bamboo waters [Stand N2440]
  • Juice A Day – a range of refreshing cold press juices made from exotic fruits and garden greens [Stand N1926]

Gluten Free and Free From

Over the last five years there has been a significant rise in popularity of gluten free and free from market. No longer required for purely medical reasons, the sector is becoming increasingly popular choice with consumers looking to adopt a ‘better for you’ lifestyle. As interest in the market increases so does the demand for free from options that refuse to compromise on taste.

  • MannaVida – finely milled gluten-free flour ideal for a range of recipes [Stand N2750]
  • World Innovation Awards 2017 finalist Nutristrength – a range of protein powders produced using goat and sheep whey [Stand N2432]
  • Battle Oats – a nutritional grab ‘n’ go snack, high in protein and gluten free [Stand N1630]
  • World Innovation Awards 2017 finalist Dragsbaek – organic vegan spreadables [Stand S3410]

Alternative Proteins

Protein isn’t what it used to be. Insects, plants and algae are all new and exciting meat substitutes and IFE 2017 has a great assortment of products for those buyers interested in alternative protein options.

  • Yumpa – natural energy bars made with protein-packed cricket flour, nuts, dried fruit and seeds [Stand N2262]
  • Moellerup – a range of nutritious and delicious products from pure hemp products [Stand S2804/c]

Healthy Snacks

With consumers’ lifestyles becoming busier, many are opting to graze regularly instead of sitting down to eat a main meal and are demanding healthy snacks that provide the same blend of nutrition and convenience.

  • Deliciously Ella Energy Balls – a delicious on-the-go snack made from no more than six natural ingredients [Stand N2345]
  • Emily Crisps – healthy treats that combine real fruit and vegetables with the proper crunch of a crisp [Stand N1648]
  • World Innovation Awards 2017 finalist Mindful Bites – crunchy gluten and sugar free bites filled with a range of tasty nut butter fillings [Stand N2254]

Best of British & Irish

Consumers are continuing to choose authentic and traditional products using locally sourced produce and at IFE 2017, buyers can discover a wide range of Great British & Irish products.

  • World Innovation Awards 2017 finalist Salubrious Sauce – a range of different British inspired meal condiments [Stand N2354]
  • Biddenden Vineyards – award winning wines, pressed, fermented and bottled on a family run farm in Kent [Stand N2748]
  • Snowflake Gelato – gelato made with the best quality natural ingredients from the UK [Stand N2842]
  • De Roiste Puddings – a family owned business producing traditional black & white puddings, sausages, rashers & breakfast time terrines [Stand N2802]

Buyers attending IFE 2017 will be blown away with the ground-breaking products on offer from exhibitors and be the first to see the NPD showcased daily. The Grocery Accelerator sessions will take place every day on the Talking Trends stage and will shine a spotlight on 20 of the most promising start-up food and drink companies, giving visitors the opportunity to taste, meet and discover something amazing. Additionally, buyers looking to shop a particular trend can follow one of IFE’s “Trend Trails”. The simple to follow trail maps will highlight relevant stands to source new and on-trend produce in specific on-trend categories such as Free From, Fit for Kids, Private Label, Hot Beverages and Innovation on the go.

With so much to see and do, IFE 2017 has created a brand new Personal Itinerary planner on the website, enabling buyers to pinpoint the products, chef demos and seminars they don’t want to miss. The new tool aims to ensure that visitors leave with greater inspiration, newer ideas and wider knowledge of the industry.

Event Director, Soraya Gadelrab commented: “When we go shopping for fashion we don’t want to shop last season’s trends, and it’s no different with the food and drink industry. IFE 2017 is proud to be among the first to showcase the emerging global trends and latest NPD, we take our role as the buyers’ market incredibly seriously and are confident that some great partnerships will be formed during the four day event.”

Register now via the IFE website (www.ife.co.uk) for your free entrance badge and save paying the £25 on-the-door charge.

Posted in Conferences & Exhibitions, Ingredients, Innovation, ProcessingComments Off on IFE 2017 – A Shop Window to the Future

Flowcrete UK’s New White Paper Explores HACCP and What it Means for the Food Industry

Implementing an effective Hazard Analysis and Critical Control Point (HACCP) food safety management system is a central priority for today’s food and beverage producers, as it is critical to complying with the standards of domestic and international regulatory authorities, governments and consumers.

Flowcrete UK has produced a white paper entitled What is a HACCP Food Safety Management System and How Does it Relate to Flooring?to help food and beverage businesses learn about this preventive risk assessment tool and ensure that all facilities comply with its guidelines.

Flowcrete UK’s Managing Director, Kevin Potter, said: “We’ve worked with some of the world’s largest food producers at their most challenging plants and we’ve always ensured that the knowledge, experience and skills we’ve built up have been put to use creating floors that effectively meet the industry’s multifaceted demands.

“This white paper has been produced as part of our commitment to advise the food industry on best practice flooring, as it is essential to follow HACCP’s rules in order to ensure that the finish underfoot will provide the necessary properties for a food facility.”

As the white paper explains, being HACCP compliant is vital to fulfilling the increasingly strict requirements of industry regulators. This is exemplified by the Food Safety & Hygiene (England) Regulations 2013 which reiterates Article 5 (1) of Regulation 852/2004 of the European Parliament: “Food business operators put in place, implement and maintain a permanent procedure or procedures based on the HACCP principles.” Parallel legislation is also in force in Scotland, Wales and Northern Ireland.

When combined with the fact that many nations will require food to have been produced according to the same or similar principles, this means that failing to meet the HACCP benchmark can stop businesses from trading both domestically and internationally. 

The HACCP process involves analysing food safety hazards and putting in place appropriate controls to eliminate or reduce contamination. Getting the floor area right is central to this, as failing to do so could put the facility at risk from unwanted and difficult to eradicate bacteria build-up which could easily infiltrate and spoil produce onsite. 

In the white paper readers will be able to find out what flooring characteristics and certifications they need to look out for in order to ensure that floors within production, processing and storage areas live up to the HACCP standard.

The white paper also examines how HACCP came to be created, the role it plays in the UK’s regulations as well as the product certification scheme HACCP International, which evaluates materials, equipment and services used within the food industry.

Getting ahead with HACCP is not an option, as the future of the food industry is towards ever more regulated use of due diligence programs. For example the FSA’s Foodborne Disease Strategy, a compliance and enforcement plan, aims to secure major improvements in public protection and health through an overall better and more efficient risk-based regulatory system.

If you’d like to learn more about this increasingly important topic then click here to download and read the white paper. To discuss specifying a HACCP International certified floor for a specific food and beverage facility then get in touch with Flowcrete UK’s expert team.

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GEA Meets Craft Beer Brewers at Trade Convention in the USA

GEA will present its technology and services at the 34th Annual Craft Brewers Conference (CBC), the world’s largest trade fair for the craft brewing community. This conference, held from April 10-13, 2017, will attract craft beer brewers from all over the world to Washington, D.C. At stand 2619, GEA will welcome interested visitors to view their technological and process solutions for the craft beer industry.

The craft beer scene currently flourishes on all continents. Depending on the regions and the marketability of the products, a wide variety of technologies is required to complete the brewing process. The common denominator in the process is the fact that product quality and application flexibility must go hand-in-hand with cost-effective solutions. “It’s exactly because of these requirements that we have developed specialized brewing systems and components that offer modular expansion possibilities and flexible use – and that also can provide flexibility for experimentation by the individual brewer,” says Andreas Holleber, in charge of brewery business at GEA. “We place great emphasis on efficiency in resource input – by which we mean saving energy and water, and ensuring outstanding yield.”

In addition to components dedicated to the specific needs of craft brewers, GEA will also present its service concept at the show. This concept starts with a worldwide service network and promises an all-around, trouble-free package for craft beer brewers.

Other highlights at the GEA exhibit will include:

A brewhouse for every craft beer

The GEA CRAFT-STAR™ is designed for medium-sized specialty brewhouses, with batch sizes of 35 barrels (40 hectoliters) of hot wort. Equipped with two, three or four vessels (mash tun kettle, lauter tun, and combined whirlpool/wort kettle, depending on the configuration), it is possible to produce seven brews within 24 hours. The CRAFT-STAR™ is preassembled and tested at GEA’s Kitzingen facility in Germany as a compact “plug & play” system with process piping, instrumentation, and an automatic control system. Commissioning on site takes just a few days. With an extract yield of up to 98 percent, the brewhouse’s lauter tun offers top performance with respect to extract efficiency for special malts. At CBC, GEA visitors will have the opportunity to carefully examine a three-vessel CRAFT-STAR™ and learn more about its many special features. Beers brewed with the GEA CRAFT-STAR™ have regularly won awards, most recently, at the Great American Beer Festival 2016.

One unit – five processes with GEA centrifuge skids for craft brewers

The second highlight at the GEA stand will be a GEA centrifuge skid for craft brewers. Available in four sizes, these compact units are multifunctional and are designed for production output of 875 to 87,500 barrels (1,000 to 100,000 hectoliters) per year. A single machine allows brewers to run up to five processes – an excellent benefit in terms of efficiency. Additionally, the separator’s clarifying output can be adjusted allowing production of both cloudy wheat beer to virtually clear blond lager. With up to 30 percent reduction in production time and 10 percent increase in yield, brewers confirm they make more beer with the piped and pre-assembled skids.

You will find GEA at stand 2619.

 

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GEA Doubles Proofing Throughput For Manufacturers of Croissant and Pain Au Chocolat

GEA has recently developed a new spiral proofing and freezing system for the production of breakfast products, such as croissants and pain au chocolat, that has the ability to double output and so solve a major problem for bakeries.

Advances in up-stream production techniques – mixing, laminating, cutting and forming – have allowed bakeries to make dough for croissants and pain au chocolat at ever increasing rates with some factories able to operate at a throughput of up to six tonnes of product per hour. Until now, however, the overall production rate has been limited by the ability of proofers to operate at full capacity while maintaining product quality.

New Development

A new development from GEA, however, has solved that problem ushering in a new era of high production with the top quality bakery products customers expect. The new GEA S-Tec spiral proofer from GEA has the ability to proof bakery products with a production rate of up to six tonnes per hour, twice the capacity of most existing spiral proofing systems, thereby matching the capacity of the upstream processes.

The GEA S-Tec spiral proofer has achieved this by using a completely new air distribution system that, rather than blowing warm air with fans into the spiral, defuses it equally, at low pressure, throughout the machine thereby maintaining the perfect proofing environment throughout, eliminating hot or cold areas and achieving a uniform humidity. In this way the system is able to maintain the whole proofing area in accordance with each customer’s recipe.

Difficult to Achieve

Mathieu Nouhin from the company says that increasing the throughput to this level, while maintaining the highest possible product quality, was difficult to achieve. “To achieve the required throughput rate the S-Tec spiral proofer has a twin drum with 40 tiers on each drum representing 2,300 meters of conveyor belt,” he explains. “It’s 21 meters long, 11 meters wide and 8 meters high, so using an ordinary air flow system it would have been impossible to control the environment within such a large machine accurately. The new system, however, controls the temperature within one degree and maintains a constant humidity to allow the products to rise homogenously and achieve the texture, appearance and taste our customers expect.”

On exiting the GEA S-Tec spiral proofer the risen croissant and pain au chocolat are transferred directly to the freezer, also provided by GEA, and on for distribution to local bakeries for the real home-made taste consumers love.

For further sales information contact: David Hallifax, GEA frozen food sales support, on Tel: (Office) +44 1263 586449; (Mobile) +44 7796 148881.

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Tetra Pak Acquires Leading Manufacturer of Mozzarella Cheese Making Equipment

Tetra Pak has acquired Johnson Industries International, a company specialising in the design, development and manufacture of equipment and lines to produce mozzarella cheese. The company also manufactures a range of cheese cutting, shredding and brining equipment.

These additions broaden Tetra Pak’s wide-ranging cheese technology portfolio and strengthen its position as a leading global provider of cheese manufacturing solutions.

Based in Wisconsin, US, Johnson Industries International, is one of North America’s principal suppliers to the high-quality, high-volume segment of mozzarella cheese manufacturing.

Monica Gimre, Executive Vice President, Processing Systems at Tetra Pak, says: “The acquisition of Johnson Industries International adds essential know-how and technology in a sector of the cheese market that is growing ever-more important to our business. Many of our customers are expanding production in this category. Thanks to this acquisition, we can now ensure they have access to a complete equipment and services solution, helping minimise the complexity of plant management.”

Grant Nesheim, President of Johnson Industries International, says: “This transaction means that our innovations will be supported by the global resources and leading expertise of Tetra Pak. This will benefit our customers in the long run as they continue to receive our market-leading products and services supported by Tetra Pak’s global organisation. In recent years we have been expanding our business to other parts of the world, and we now see an exciting opportunity for further international growth through Tetra Pak channels.”

Johnson Industries International will remain in its current location and will continue to focus on its core business.

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Aseptic Food Processing Seminar – Tuesday 4 April 2017 – Campden BRI

Consumers’ awareness of and demand for high quality food products means that aseptic processing is a ‘hot topic’ again. The combination of continuous heat treatment and aseptic packaging can provide high quality food in a cost–effective way: shelf life is extended, hygiene and food safety are enhanced, and storage is convenient.

This seminar will cover:

  • Reasons for choosing aseptic processing for high–value, sensitive products
  • Target food products
  • Case studies – what can go wrong?
  • Novel approaches/technologies
  • Hygienic design
  • The importance of accurate calculations.

Key benefits of attending

  • Aseptic processing is a “Hot Topic” again. An update of current and new approaches used will help keep up with the new trends.
  • Networking with leading companies.

Who should attend?

Individuals and companies dealing with dairy products, baby food, beverages, particulated liquid foods, equipment supplying, packaging.

The speakers

Antonio Zannini – TetraPak
Dr Federico Alberini – The University of Birmingham

Event director: Flora Challou.

Members of Campden BRI: £325 + VAT
Non-members: £435 + VAT

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IFE 2017 – Bursting with Food and Drink Inspiration!

Back for 2017, IFE (The International Food & Drink Event) is getting ready to open its doors to a fantastic, vibrant four-day food and drink extravaganza, featuring more than 1,350 food and drink suppliers. Inspiring buyers and suppliers alike, IFE 2017 is expected to welcome more than 29,000 attendees from 108 countries, over 35 industry leading speakers as well as top chefs from a diverse range of culinary backgrounds and channels.

Taking place 19 to 22 March 2017 in London, the home of innovation, visit this four day extravaganza to stay up-to-date with the latest trends and network with the industry’s finest.

IFE 2017 is split into 9, easy to navigate, sections. The sections are Bakery, Cheese & Dairy, Drinks, Great British & Irish Food, Grocery, Health & Wellbeing, Ingredients, Meat & Seafood and Snacks & Confectionery. Click here to see the 2017 exhibitor list.

IFE 2017 will showcase an array of exciting and innovative food & drink products… Click to hear from some of the exhibitors.

To register for your free entrance badge and avoid paying the £25 on-the-door charge, please click here. TRADE ONLY.

Posted in Conferences & Exhibitions, Ingredients, Packaging, ProcessingComments Off on IFE 2017 – Bursting with Food and Drink Inspiration!

The Consumer Trends Presenting New Processing Challenges and the Role of Mixing and Blending

By Anders Yngwe Soderstjerna, Centre of Expertise Director, Tetra Pak

Mixing and blending ingredients into a liquid medium is a common process, however with increased pressures on manufacturers to create more diverse products – all with the same smooth and consistent homogenous natural quality – it is a process that remains as important as ever. Over the last five years there has been an increased focus on processing efficiency gains, as well as balancing the refinement of product quality and consistency. The challenge for manufacturers is to combine these improvements with a large-scale expansion of their product portfolio to meet changing consumer demands. Consumers are looking for products that cater to their nutritional needs, as well as offer an exciting experience.

There are three key trends driving consumer demand:

  1. a preference for food and beverage products that help consumers live a healthy lifestyle;
  2. a desire for products offering ‘on-the-go’ convenience,
  3. and a focus on products with a ‘natural, homemade’ quality.

Anders Yngwe Soderstjerna, Centre of Expertise Director, Tetra Pak.

The Importance of Mixing and Blending

Mixing and blending is critical because it is the processing phase in which product ‘value add’ is created. If the correct approach isn’t employed at the start of processing, the batch will either be unusable or inconsistent, therefore compromising product value significantly. By applying the right expertise from the start, manufacturers can achieve unique product characteristics that set themselves apart from the competition.

Manufacturers must have complete control over every aspect of production from beginning to end. This ranges from having the right initial mixing solution for the product, to having detailed oversight of the many different factors that affect mixing efficiency, and all important end-product quality factors such as texture and taste. Control is essential for ensuring food safety, Tetra Pak’s number one priority. The safety of a product is primarily contingent on the balance of ingredients and the level of heat applied during processing to ensure that the product is adequately sterilized. The number of ingredients variables is increasing. They are now offered in powders, pastes and multiple other forms. It is therefore important that processors can guarantee product consistency and safety, regardless of new ingredient combinations.

Powders, which have a longer shelf life, are a particular focus point for processors. They are smaller and lighter, making them more convenient to transport. However, some such as aspartame, powdered milk, and tea powders are prone to foaming and therefore require a special mixing and blending approach.

The Integral Role of Processing in Satisfying Consumer Demand

Consumer trends are driving interest in specific products. They’re looking for products that contain functional ingredients such as added vitamins and protein for general health and physical recovery from exercise. Ambient products, such as longer shelf life yoghurt and beverages are supporting on-the-go consumption, and more ‘natural’ products with fruit and nut particles are meeting the demand for a more natural, homemade quality.

These demands present new processing challenges for manufacturers. At Tetra Pak, we offer our 60-year expertise in providing automated food and beverage solutions to customers combined with a deep understanding of food technology and the challenges manufacturers are facing. To ensure we can consistently offer this service globally, we have established over ten Product Development Centres (PDCs). These centres provide customers with access to experts who can help them test recipes and machinery simultaneously, finding an optimal solution and fast tracking the process of turning ideas into new products and categories that will capture the attention of modern consumers.

In conclusion, to ensure products keep pace with the increasingly complex demands of consumers, beverage manufacturers must continue to explore and invest in their processing capabilities. Despite being an existing technology, mixing and blending remains a central processing technique for creating innovative products in the beverage space.

Posted in Ingredients, Innovation, ProcessingComments Off on The Consumer Trends Presenting New Processing Challenges and the Role of Mixing and Blending

JBT Corporation Acquires Avure, a Leading Provider of High Pressure Processing Solutions

JBT Corporation, a global technology solutions provider to high-value segments of the food and beverage industry, has purchased Avure Technologies, a leading provider of high pressure processing (HPP) systems, for $57 million. Privately held Avure is based in the US.

HPP is a cold pasteurization technology that ensures food safety without heat or preservatives, maintaining fresh food characteristics such as flavor and nutritional value, while extending shelf life.

“We are excited about the rapidly expanding market adoption of HPP across protein and liquid foods,” says Steve Smith, President of JBT FoodTech. “With the addition of Avure, JBT will be able to offer comprehensive thermal and non-thermal preservation solutions.”

“As part of JBT, Avure will benefit from our global salesforce, service support and extensive customer relationships, as well as our commitment to developing solutions that maximize customer profitability,” says Tom Giacomini, JBT’s Chairman, President and Chief Executive Officer.

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Fast, Flexible, Accurate – Ishida’s ‘Hungry Monster’

The success of the preferred supplier partnership between Ishida Europe and Tulip, one of the UK’s leading food processing companies, is ideally demonstrated by the latest installation of Ishida equipment at Tulip’s factory in Ruskington, Lincolnshire, where a bespoke line is handling 2.7 tonnes of frozen cocktail sausages every hour. With each cocktail sausage weighing approximately 10g, this equates to an impressive 270,000 sausages per hour.

The Ishida solution comprises both a 24 head and a 14 head multihead weigher from the company’s top-of-the-range RV series, the 24 head feeding a thermoformer while the 14 head is operating in conjunction with a vertical bagmaker.  Ishida also supplied the elaborate feed system, the gantry for the weighers and a bespoke tray filling system, together with a DACS-W-012 checkweigher for final weight control.

Key to the success of the new line is its ability to manage the high volume throughput with minimal product giveaway, and also its flexibility in coping with a variety of packing and production requirements.   The line has been designed to feed the sausages either to the 24 head weigher, which packs them into thermoformed trays for many of the UK’s leading retailers, or to the 14 head model which packs them into bags, mainly for the foodservice sector.

After manufacture and frying, the sausages enter a spiral freezer where they emerge at the top and are fed into the packing operation. It is particularly vital to ensure that production continues uninterrupted, and the system therefore has the ability to divert product for temporary storage – WIP (Work In Progress) as it is termed – while work is carried out on the line, for example a changeover of pack formats.

Product is then fed back to the weighing and packing system to return the packing operation to full speed.

In addition, the line is linked to another processing and packing line in the factory so that product on this line can be easily switched over to cope with high demand – for example, sales of certain products can increase by anything up to 20% when a sunny weekend has been forecast.

Centralised control of the line ensures these changes can be carried out quickly and efficiently.

The 24 head weigher is split into 4 sections with six weigh heads dedicated to each quarter of the weigher, in order to handle the sausages as efficiently as possible and maximise throughput.  The weighed cocktail sausages then pass through a 4×4 configuration filling system above the thermoformer that fills 16 trays at a time at 12 cycles per minute.

Typical speeds are 192 packs per minute for a 220g tray, 180 for a 345g tray and 150 for the 480g size.  The 14 head weigher is operating at around 50 bags per minute for 4kg packs.

With each sausage weighing approximately 10g, pinpoint accuracy is vital and this is an area where the Ishida weighers perform consistently well, according to Tulip’s Project Engineering Manager Rob Hunt, who was responsible for the entire installation.

“We needed a solution that combined accuracy and speed and the Ishida weighers are consistently delivering minimal giveaway at an impressive consistency,” he comments.  “They are also very reliable, easy to use and our operators love them. We refer to this line as the ‘hungry monster’ as it is able to handle nearly anything we throw at it in terms of production throughput.”

The factory operates two eight-hour shifts, five days a week, with a comprehensive clean of the line every night in accordance with Tulip’s stringent hygiene standards.

The hygienic waterproof design of the Ishida RV weighers is certified to IP-69K specification. Features include upgraded seals and gaskets, angled surfaces for rapid wash down and water run off (ensuring faster drying times) and reduced crevices in bushings and hoppers, which help to eliminate bacteria traps.  As a result, the RV weighers installed at Tulip offer maximum hygiene while minimising downtime for cleaning.

The new line was part of a major investment project co-ordinated by Rob Hunt. This involved an extension to the existing building, which was built, fitted out and the line installed as a self-contained unit before the internal wall (which had been the original exterior wall) was removed to join up the new area with the rest of the factory.

“Our close working relationship with Ishida and our other suppliers was crucial to the success of the project,” Rob continues.  “We were very clear about what was required and we worked as a team to ensure this could be achieved.  In this way, any potential issues or problems could be identified, dealt with and solved early in the process so that they did not slow down or affect the progress of the job.”

The result was a project that was delivered on time and on budget.

The new line at the Ruskington site joins a variety of Ishida equipment which has been installed there over the years including five multihead weighers, three QX-1100 tray sealers and nine DACS-W checkweighers.

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Graduate Trainees Taste the Future of Food Manufacturing

Rising stars of the food industry saw and tasted the future when they visited the University of Lincoln’s National Centre for Food Manufacturing (NCFM) as part of their graduate development programmes. The graduates, who are currently part of schemes at Marks & Spencer and Bakkavor, visited NCFM for dedicated training days to experience the technologies that will shape the future of food production.

As a national centre of excellence for food manufacturing, the facility in Holbeach, Lincolnshire, is home to a range of pioneering robotics and automation systems that are set to play a key role in driving productivity and innovation in the sector.

Sharon Green, Deputy Head of NCFM, said: “We are dedicated to supporting the next generation of food manufacturing talent so it is a pleasure to welcome the M&S and Bakkavor graduates to our campus. In the coming years, the projects and technologies we are developing here will transform the sector. By demonstrating the APRIL robotics system and a new steam infusion cooking method at NCFM, we are able to provide a valuable insight into how the future of the industry will look.”

With M&S serving more than 32 million customers online and in-store every year, the company runs a number of different graduate schemes to support retail management, head office, and food manufacturing careers. Colleagues on the organisation’s Graduate Food Technology Scheme visited NCFM to learn how technological advancements could enhance their industry.

Bakkavor is a leading international manufacturer of fresh prepared foods. It currently produces more than 5,000 products and supplies these to global grocery retailers such as M&S, Waitrose, Tesco, Asda, Sainsbury’s and Morrisons, as well as international organisations including McDonald’s, KFC, Starbucks and Pizza Express. NCFM welcomed graduates currently enrolled onto Bakkavor’s Graduate Scheme, which is designed to equip individuals with the skills they need for higher level management.

On their separate development days at NCFM, the graduate trainees were introduced to APRIL (Automated Processing Robotic Ingredient Loading) – a ‘robotic chef’ that combines cutting-edge food processing technologies with proven robotic systems to produce high-quality food on an industrial scale.

Developed by OAL, APRIL is a fully automated robotic system that can mix, load and cook ingredients in a manner similar to professional chefs but in high volume. By using modern cooking and material handling technologies, APRIL is designed to boost production and efficiency while also improving the quality of food produced. APRIL is the first robotic system of its kind and is tipped to transform the food manufacturing industry.

The graduates also learned about advanced steam infusion cooking techniques being developed at NCFM, comparing this to other preparation methods.

Jake Norman, Innovation & Marketing Manager at OAL, said: “These sessions represent a great opportunity for us to learn what future sector leaders expect from food manufacturing, and allow us to demonstrate how robotics and automation will play a key role. We will soon see digital natives driving the move to paperless systems across the food factory, simply because it’s what they are used to.”

Jane Phillips, Graduate Agronomist at M&S, said: “The graduate away day at the National Centre for Food Manufacturing was a fantastic opportunity to explore the future developments within our industry alongside the experts that are at the forefront of these projects.”

To know more about what OAL and the NCFM do, please visit: www.oalgroup.comwww.lincoln.ac.uk/home/holbeach.

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Dutch Agri and Food Exports Achieve Record High in 2016

The Dutch agri & food sector has further strengthened its leading position in the world market. In 2016, Agri & Food exports totalled almost €94 billion, compared to €90 billion in 2015. Agricultural products accounted for €85 billion and agricultural materials, knowledge and technology accounted for €9 billion: a new record. This means the agri & food sector now comprises 22% of total exports. This is shown by provisional figures from Statistics Netherlands (CBS) and Wageningen Economic Research.

The export of agricultural products rose by over €3.6 billion (+4.4%) to €85 billion, the largest increase since 2011. The exports were mainly foodstuffs, such as vegetables, fruit, dairy, meat and processed products, in addition to high-quality floriculture. A noticeable factor is the increasing demand for Dutch agricultural materials, innovations and high-quality technology. Exports in this area totalled nearly €9 billion. Examples of such exports include energy-efficient greenhouses, precision agriculture systems (via GPS and drones) and new discoveries that make crops more resistant to the effects of climate change and diseases. In 2016, the import of agricultural products rose by 1.6% to €57.1 billion.

Dutch Minister for Agriculture Martijn van Dam says: “We have successfully reinforced our leading position in Europe and the world. Agri & food exports have significantly grown once more. ‘Made in Holland’ is no longer a label reserved only for tulips and cheese. Our worldwide reputation in the field of agricultural knowledge and technology also continues to grow. In the future, we want to continue contributing to effective, healthy and sustainable food provision around the world. And our smart, innovative products and technology will allow us to do exactly that.”

With agricultural and horticultural exports totalling €85 billion, the Netherlands is top of the league in Europe. The global leader is the United States. The Netherlands is in second place, with Germany, Brazil and China making up the rest of the top five. Of the total export figure of €85 billion, €24 billion comprises re-exports: products that the Netherlands imports, processes and then exports again. Germany is the Netherlands’ most important trading partner. Over three-quarters (77%) of total agricultural exports go to countries in Europe. These mainly consist of tomatoes, sweet peppers, cucumbers, meat and dairy products. From outside Europe, flowers and plants are the Netherlands’ most in-demand agricultural products, followed by meat and dairy produce.

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Expanding Your Export Horizons With the Use of High Pressure Processing (HPP)

Brexit has definitely focused the minds of food processors and manufacturers on the risks that will have to be faced in the coming years. Since the United Kingdom voted on the 23rd of June 2016 to exit the European Union, food and beverage exports to the UK have been and still are extremely volatile. In addition, given that the process for the UK to leave the European Union has not even begun yet, it is safe to say that the road ahead is one of uncertainty. If everything goes extremely well from the Irish point of view and Ireland and the UK maintain all the current arrangements that we currently share after their exit from the European Union, we still have to deal with the elephant in the room which is the exchange rate.

According to Bord Bia, approximately €570m was wiped off the value of Irish food and drink exports last year due to the fall in value of Sterling following the UK’s Brexit vote.  Food and Drinks Industry Ireland point out that the UK is our largest trading partner for food and drink and that 41% of our food and drink exports go to the UK which has a value of €4.4bn. This reinforces the severity of the €570m wiped off the value of those exports which was close to 13%.

Increasing efficiency and taking smaller margins is not going to be enough to fix this very real problem. Perhaps in the longer term increasing our prices may also help and the exchange rates will change back in our favour. However, there must also be a reasonable chance that the value of Sterling will actually fall further, which will result in more Irish food and beverage producers, who export to the UK being put under increasing financial pressure and possibly forced out of business through no fault of their own! Or perhaps it will be their own fault because they did not plan ahead and reduce their exposure to the volatile UK market by expanding their horizons and exporting to mainland Europe.

The benefits for Irish producers exporting into Europe are immense and include the following:

  • Over 400 million inhabitants not including the UK.
  • Same currency.
  • Free access to the market, no tariffs or indeed the possibility of tariffs.
  • Huge demand for Irish food and beverage products.
  • Stable market place.
  • Possibility to grow a sustainable business.

Food safety and shelf-life are often the issues that producers say prevent them from entering the market on mainland Europe.  This is because fresh food in particular tends to have a short shelf-life so the UK is the preferred destination, however with the development of new technologies such as High Pressure Processing (HPP) this issue can in many cases be easily overcome. By using cold water and extreme pressure, HPP will kill all the harmful bacteria, yeasts, moulds and viruses in the foods and will also extend the shelf-life of the product. It is a clean, natural, non-additive process. Typical shelf-life extensions that one would expect to achieve are as shown on the following table.

Category Shelf Life Today Expected HPP Shelf Life
Sausage 10-15  Days 25-35     Days
Deli Meats 30-90  Days 80-120   Days
Cured Meats 30-90  Days 70-90     Days
Poultry 8-13    Days 20-30     Days
Ground beef/turkey 3-8      Days 20-30     Days
Seafood/Shellfish 3-8      Days 25-35     Days
Marinated Meats 10-15  Days 25-35     Days
Chilled Ready Meals 7-10    Days 25-35     Days
Chilled Soups 10-20  Days 70-90     Days
Hummus 10-20  Days 70-90     Days
Salsa 10-20  Days 70-90     Days
Dressings 10-20  Days 70-90     Days
Fresh Fruit and Veg Drinks 3-8      Days 28-90     Days
Fresh Cheese 7-10    Days 25-35     Days

HPP technology is available, approved and used throughout Europe, America and Asia. The cost of the technology is high and therefore not an option for the majority of producers to purchase for their own individual use; however the technology is available on a pay as you go basis in Ireland through a company called HPP Tolling Ltd. Their facility is open to all producers, so producers can avail of the technology and their expertise without having to invest any capital in the equipment. Their service allows producers to investigate the process and determine whether the process can add value or reduce the risk to their business by helping producers to open up new markets for their products and at the same time reduce their exposure to the UK market where for the next couple of years at a minimum, the only certainty that the UK market can offer is its uncertainty.

If you would like to further investigate how HPP can help expand your export markets, you can send a mail to hpptolling@gmail.com or contact Liam Murphy directly on (085) 8700228 all enquiries are treated in the strictest of confidence.

Posted in Food Safety, ProcessingComments Off on Expanding Your Export Horizons With the Use of High Pressure Processing (HPP)

Blakeman’s Upgrades Processing Line With Fourth Spiral Freezer

One of the UK’s leading manufacturers of sausage and meat products, James T Blakeman & Co is investing in a freezing equipment upgrade with its fourth Helix spiral system from IQF equipment specialist Starfrost. James T Blakeman & Co is a family run business that supplies sausage and meat products to the catering and ready meal industry; manufacturing 21000 tonnes of production per year.

The company has a continuous commitment to growth and improvement within the business and recently built a 40,000 sq ft state-of-the-art manufacturing facility at its site at Staffordshire in the UK. Blakeman’s latest development was to increase capacity and efficiency of its existing aging system. The firm also wanted to optimise hygiene procedures and increase flexibility of its processing line to provide opportunities for long-term business planning.

British manufacturer Starfrost has worked closely with James T Blakeman & Co for a number of years, successfully installing three spiral freezing systems over the last decade as the meat manufacture extended its processes. For Blakeman’s most recent project Starfrost was once again selected as preferred freezing equipment supplier.

Starfrost, together with parent company Star refrigeration, designed, manufactured and installed a Glacier Spiral system for Blakeman’s. The latest freezing system upgrade combines Helix Spiral Freezer technology and a unique low carbon ammonia refrigeration plant in one complete package.

The Glacier pack included a custom designed Helix Spiral Freezer with a processing capacity of 900 kg per hour of cooked sausages. The system features a stainless steel dual conveyor belt around a single rotating drum, with 28 tiers in total. In addition, the dual twin belt is equipped with optional side guards; this allows the customer to process various products simultaneously, giving increased flexibility to the processing line.

Blakeman’s Spiral Freezer features a ‘Clean in Place’ system, the CIP System is an automated cleaning system using rotating spray nozzles and spray bars, for targeted application of the detergent and sanitizer in major operating zones. Its unique design enables the process to be a repeatable, cost effective means of cleaning and sanitising the equipment, along with reducing operational downtime required for cleaning and maintenance.

The latest spiral system installed at Blakeman’s is designed to maximise uptime and requires minimal ongoing maintenance. Furthermore, the temperature control and a unique airflow is specially designed for delicate products such as skin on sausages, ensuring product quality is maintained for the customer.

Kevin Moller, Operational Manager at Blakeman’s, says: “We have worked alongside Starfrost on former freezing projects and have been very pleased with the results, they have proven to be reliable and have an understanding of our requirements, so when it came to looking for another spiral freezing system, it was an easy decision. The Glacier Helix has been designed to meet our precise specifications; it is operating effectively, enabling us to reduce maintenance and improve flexibility of our processing line, as well giving us capabilities to expand production in the future.”

Kevin Moller adds: “The primary, most important benefit of our latest install has been optimising hygienic performance within our facility, with rising safety demands within the food processing industry, food processors today must be extremely focused on hygiene within their production. The full ‘Clean in Place’ system combined with stainless steel enclosure and reverse cycle defrost allows for an effective hygienic process at Blakeman’s.”

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SonoSteam Technology Tackling Campylobacter in Poultry

SonoSteam is an innovative technology that is proving highly successful at tackling the pressing problem of Campylobacter in fresh poultry. Developed by Danish company Force Technology, SonoSteam uses a combination of steam and ultrasound to kill microorganisms such as Campylobacter on the skin and internal cavities of chicken. Force Technology has installed SonoSteam at Faccenda Foods and Cargill, two of the UK’s leading poultry processors.

The SonoSteam disinfection system also has wider use within the food industry including meat, fruits, vegetables and dairy products as well as non-food products such as conveyors, food boxes, crates and cutting knives.

Advantages of SonoSteam Technology

SonoSteam technology offers users a number of efficiency, food safety and environmental benefits along with other advantages. “This technology has proved itself capable of working day in and day out in a production environment and is not only cost effective but has been proven effective at reducing Campylobacter in an environmentally friendly way without chemicals, only water and a modest amount of energy,” explains Niels Krebs, Vice President of Force Technology.

He continues: “Delivering the best possible food safety to the customers is an important part of consumer relations. Customers can’t verify the microbiology of a product, so they have to trust the manufacturer. Complaints and products being recalled have severe consequences for the trust between consumer and manufacturer.”

Environmental Impact

Steam and ultrasound have minimum negative impact on the environment and consequently provide a cheaper, green alternative to chemicals. By using force instead of chemicals, SonoSteam will not cause bacteria to become resistant, leading to the formation of ‘superbugs’. Of course, an increased level of food safety improves public health and well being.

Niels Krebs points out: “The potentially increased shelf life caused by SonoSteam reduces food waste, an important problem concerning the environment, hunger, and increasing population. The use of force instead of chemicals makes post-treatment washing unnecessary, which ultimately saves water. Overall the whole process has a minimal impact on our environment.”

Showing Results

The installation of SonoSteam at poultry processing plants in the UK is already showing the effectiveness of the technology at tackling Campylobacter levels in fresh chicken, according to figures from the Food Standards Agency (FSA).

During the October-December 2015 period, which was covered by the most recently published FSA Retail Survey for fresh whole chickens, all poultry sold through Morrisons was SonoSteam processed by Cargill in Hereford. Half of all poultry in ASDA was processed by SonoSteam, as Faccenda Foods only supplies 50% of whole birds sold in the grocery group. The FDA results showed that ASDA dropped from 24% to 10% on birds having a Campylobacter level higher than 1000 cfu/g, while Morrisons decreased from 25% to 5% to achieve the best position in the whole survey.

So what scale of businesses within the poultry industry can benefit from installing SonoSteam technology? The current SonoSteam equipment has been designed for production lines higher than 8,500 birds per hour. “However, many producers with smaller and slower production capacities have been making enquiries for a system running at 6,000 birds/hour,” he says. “Our coming equipment to process cut parts will be more suitable for any scale of business.”

Other Applications

SonoSteam technology has applications beyond the poultry industry and is proving to be a valuable tool for other types of food processors. SonoSteam can be applied on non-food surfaces.

Niels Krebs comments: “We are currently conducting the final testing of food boxes and conveyor belts, and it’s showing great potential. Boxes and conveyor belts constitute a potential risk in cross contamination in clean environments. Microorganisms and their biofilm can build up very quickly on the surfaces, if routine cleaning is inadequate or neglected. Disinfection with certain chemicals can cause selection of dangerous ‘superbugs’ that are able to outlive standard cleaning procedures. At worst case, the bacteria can end up on food products, where it can cause illnesses and even deaths. Listeria is a well-known example of this.”

Non-food surfaces can endure more intense and consequently more efficient treatment, which takes only two seconds for each box to reach a 100% disinfection rate on all surfaces and at lower cost than chemicals.

SonoSteam is also being applied within the health sector. For example, Force Technology is currently working on cleaning boxes that have been used for transporting sterile surgery equipment. Furthermore, the company’s mattress disinfection system is now being used in Danish hospitals.

Fact Box

Five facts about SonoSteam:

1 SonoSteam is a minimal process that applies the combined effect of steam and ultrasound for effective and fast disinfection within seconds.

2 The technology is a cost effective and chemical free.

3 Four SonoSteam units are currently installed at two different poultry plants in the UK, processing nearly 4 million birds per week.

4 Ongoing trials have shown more than 80% Campylobacter reduction on birds tested positive for the highest infection levels of higher than 1,000CFU.

5 SonoSteam has many applications and is besides poultry used for disinfection of conveyer belts, food trays and even hospital mattresses.

Posted in Food Safety, Innovation, Processing, Quality AssuranceComments Off on SonoSteam Technology Tackling Campylobacter in Poultry

Maelor Foods Selects Marel Poultry For New Plant

Maelor Foods, a related company of Salisbury Poultry (Midlands), has selected Marel Poultry to supply its brand new 13,500 bph poultry processing plant in Wrexham. It is the first, completely new, state-of-the-art plant at this line speed in the UK.

After the purchase of the former cheese dairy from First Milk near Wrexham in North Wales, Maelor Foods decided to transform the site into a brand new poultry processing plant. It will feature a 13,500 bph broiler primary line from live bird handling on to distribution for whole birds to serve Salisbury Poultry (Bilston factory) for cut up and deboning portions. There will also be further deboning at the Wrexham plant itself, which has more space and more capacity for Maelor Foods to grow its business.

This is the first new, ultramodern plant to be built in the UK at this line speed, setting new standards for the industry. Marel Poultry will supply a complete kill and evisceration department, incorporating fully automated giblet and feet processing. Besides that, a Stork in-line air chilling tunnel and an elaborate grading line will be installed.

The 13,500 bph capacity is an initial start-up speed; the primary line will be prepared for future growth of Maelor Foods’ operations. Jeff Donald, Marel Poultry Area Sales manager, says, “For this project Maelor Foods has selected Marel Poultry as the most capable supplier who understands the company’s needs and has the ability to deliver a factory process fit for the future. We look forward tremendously to completing this project during 2017.”

Salisbury Poultry was founded in 1989 by Raj Mehta. The company began with 10 employees supplying local wholesalers and restaurants from its centrally located West Midlands base. Salisbury Poultry has shown year-on-year growth and now operates from modern purpose built production facilities and distribution centers, employing over 500 people.

As a part of Salisbury Poultry, Maelor Foods recently achieved “AA” BRC/SAI global accreditation together with full Red Tractor Approval.

CAPTION:

Arie Tulp (Marel Poultry Sales and Marketing Director), Jeff Donald (Marel Poultry Area Sales Manager UK), Raj Mehta (Owner and MD of Maelor Foods), Steve Hammond (Commercial Director), Paul Cardinaal (Marel Poultry Regional Sales Manager).

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A.M.P Rose – The Packaging and Processing Machinery Specialist

Established over 35 years ago, A.M.P Rose is one of the world’s leading machine builders, process and packaging solutions provider for the confectionery, chocolate and snack industries.

A.M.P Rose has evolved and developed immensely since its humble beginnings in 1978. It has managed to transform from a small supplier of rebuilt packaging machines for the confectionery industry, to a greatly successful machine builder with international renown and nearly 75% of its products being exported to over 80 countries world wide.

The wide range of new machines include cut and wrap machines for all styles of wrapping, chocolate moulding lines, chocolate wrapping, specific machines for production and packaging of hard candies, laboratory range for trials and small-scale production, as well as revolutionary feeding systems for multi-packing flow wrap machines.

Recent Addition

One of the more recent additions to the A.M.P Rose family is the ‘700/1000’ chocolate moulding line. It is available in multiple widths to suit specific customer applications and outputs. The depositor is capable of producing centre-filled products through the ‘one-shot’ method. Centres such as caramel, praline, fondant etc. can be used. It can also produce chocolate slabs with whole nuts and raisins, or with finely chopped inclusions.

The ‘750/755’ range is an extremely versatile yet low-cost cut and wrap machine which offers production speeds of up to 750 pieces/minute.

The moulding lines are from modular design, which gives them flexibility for any changes that a customer may want to do to the line in the future. Some of the changes that can be achieved include extending the cooling tunnel if the customer decides to change the product going through the line, or if they need to add a biscuit or wafer placing unit in their production. This flexibility gives consideration to a company’s future growth, and fast moving market changes that chocolate manufacturers need to adapt to at any time.

Of all the equipment A.M.P Rose produce, the specialist skill is in the design, manufacture and operation of cut and wrap machinery. The secret is not just in the production of the machine, but in adapting it to suit the different product and wrapping material characteristics that can be encountered.

The ‘750/755’ range is an extremely versatile yet low-cost cut and wrap machine which offers production speeds of up to 750 pieces/minute. The machine is capable of producing confectionery products such as bubble gum, hard candy, chewy sweets and toffees in various different wrapping styles. As well as the traditional double twist or folded ends, versions of the 750 can also produce lollipops, products with a visible design (‘whirl’ machine), cigarette style wraps, and also long bars up to 152mm in length.

Exciting Developments

NR10 machine.

2016 has seen some exciting developments in the company, as they have moved into a new purpose built factory in early January 2016. The new factory has over 100,000 sq/ft of floor space incorporating all departments – machine design featuring 3D CAD/CAM software, a modern machine and fabrication shop with CNC machine tools, software design department, metal finishing as well as electrical and mechanical assembly and testing areas.

This is not the only change of 2016 as the company logo has been changed. “We believe that this more modern design reflects our growth and professional approach to business,” says Adam Malpass, Marketing Manager. “In addition it signals a new beginning for the company and the next chapter of the company’s history.”

Coinciding with this, a brand new website had been launched as well, with the aim to make it easier to use and help to showcase the company’s capabilities as a premium supplier of food processing and packaging equipment.

Posted in Packaging, ProcessingComments Off on A.M.P Rose – The Packaging and Processing Machinery Specialist

Hänsel Processing – Sweet Competence

Hänsel Processing’s installations and machines have the most advanced technology available. They are successfully operated world-wide and about 90% of the company’s activities are generated by processing machinery with a focus on any kind of sugar confectionery products:

* Hard Candy (centre filled, aerated, laminated, milky, sugar free, medicated, specialities);

* Jelly & Fondant (gelatine, agar agar, pectin, gum arabic, starch, fondant crème, bakery fondant, milk fondant, fruit fondant);

* Toffee (milk caramel, éclair, fruit candies, chewy candies, caramel layers, specialities);

* Bar (foam sugar, candy bars, granola, torrone, halwa).

Nearly the whole range needed for the production of confectionery, from single machines to complete processing lines, is offered:

Product Overview Hänsel Processing:

CONTIGRAV®                                    raw material weighing system

CROSSFLOW®                      pre- and final cooking system

SUCROLINER®                      cooking, flavouring, blending and cooling system

STRADA®                               centre filling and forming system

ROTAMAT®                            thin film cooking system

CARAMASTER®                    controlled caramelising system

SIEDOMAT TURBOMIX®      vacuum cooking / batchwise aeration system

TURBOMAT®                                    continuous aeration system

HFD®                                      high performance beating system

JELLYSTAR®                         high performance jelly cooking

JELLY BLEND®                      flavouring and blending system

UNIBATCH®                          universal batch cooker

LSK-5®                                   Laboratory Batch Cooker.

Rotamat® 3609

The thin-layer cooker is perfectly suitable for cont. cooking of sensitive masses which tend to scorch or need gentle treatment. Cooking under vacuum & overpressure is possible without restrictions. With a very high heat transfer coefficient, modular design, special contact-free, static scrapers as well as with easy & simple maintenance the Rotamat® contributes to a smooth and excellent production of high quality products.

At the Interpack 2017 in Düsseldorf, new and known customers as well as interested personnel will be welcome in Hall 04 at Booth 4A35. Managing directors Frank Temme and Heiko Kühn will gladly be at your service, accompanied by their skilled native-speakers sales team as well as by French partner company Proform.

Interpack 2017 – 4 May – 10 May, 2017 – Düsseldorf, Germany.

Hall 4, Booth 4A35. For further information visit www.haensel-processing.de.

Posted in ProcessingComments Off on Hänsel Processing – Sweet Competence

Unique Lactose Processing System Increases Yield by up to 25%

Lactose is one of the most versatile by-products produced from the cheese making process. A derivative of whey, it offers producers a valuable income stream as the ingredient is used in many consumer products including infant formula, confectionary, sauces and beer. The innovative SPX FLOW lactose processing line offers many benefits including high yield with most of the lactose from the whey being retained.

The SPX FLOW high yield lactose plant has a unique two-pass design and is based on leading filtration/mechanical separation and fluid bed drying technology and expertise in crystallisation. Precisely designed and engineered to meet specific customer needs, it has been shown to increase productivity and maximize profits. The lactose powder produced is of premium quality with a fine white colour; free flowing properties, and excellent heat stability.

For more information and to download the new High Yield Lactose brochure, please visit www.spxflow.com/en/anhydro/

CAPTION:

Anhydro Innovation Centre.

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Rademaker Supplies Innovative Solutions For the Bakery Industry

Rademaker has managed to transform bakery traditions of the past into robust, state-of-the-art industrial bakery production lines that meet and exceed customer requirements all over the world.

Founded in 1977, Rademaker was one of the first companies to specialize in the development and supply of innovative solutions for the bakery industry. Today, Rademaker is one of the front runners in the bakery industry, with global presence and a service that goes well beyond the delivery and installation of bakery production lines and turn-key solutions alone.

Rademaker solutions are geared towards the customer’s specific dough process and products. The development process starts in the Rademaker Technology Centre, where production processes are tested in an optimal testing environment. Customers product demand are translated into a Rademaker production line that will yield maximal results in terms of product quality and return on investment, with a focus on ingredient and waste reduction.

Rademaker is an expert in stress-free dough sheeting and handling. The Rademaker portfolio contains a wide range of dough processing machines:

* Bread lines

* Laminators

* Croissant lines

* Flatbread lines

* Pizza lines

* Make-up lines

* Pie and Quiche lines

* Depositors

* Special production lines.

A unique combination of proven and new technology plus attention for detail, all based on customer requirements, guarantee Rademaker to be the perfect partner in the bakery industry.

Posted in Innovation, ProcessingComments Off on Rademaker Supplies Innovative Solutions For the Bakery Industry

A Robust New Standardizer From Tetra Pak Makes Life Easier For Dairy

Producing standard white milk is a low-margin business. It is vital to produce milk with optimal fat content to get the most out of every drop of milk. That is why the standardization of milk is such an indispensable process. At Arla Foods’ dairy in Palmers Green, London in the United Kingdom a new Tetra Pak® Standardization unit makes that process more reliable, stable and accurate than ever before.

Josette Bogerman, Regional Project Manager at Arla Foods, says the cooperative had to replace three obsolete standardizers. “Then we heard about the new equipment from Tetra Pak,” she says. “It was perfect for us to try a new unit at that point in time.”

Arla Foods’ requirements were to minimize the downtime to three days. “That is exceptional for us,” she says. “I love working with Tetra Pak. They gave us the right guarantees. We would never have had the commitment from anyone else to do it in three days.”

Automatic In-line Standardization

tetrapakarla2december2016By October 2015 Tetra Pak had installed the brand new version of the Tetra Pak Standardization unit at the Palmers Green site and the field test of the machine could begin. The standardization unit is designed for automatic in-line standardization of the fat content in milk and cream directly after milk separation. It is a highly reliable system based on extensively tested and refined automation software and high-performance, high-quality components such as flow transmitters and regulation valves.

“As for reliability – we haven’t seen it down – it’s always running,” Bogerman says. “We had a single issue and Tetra Pak dealt with it within the same day. We suspected we would have problems, since it was a field test, but it’s been a valuable experience for us.”

When Arla Foods runs a milk recipe with the milk fat set point of 3.0 % the standardization unit delivers a fat content of 3.0 % +/- 0.015 %. Says Bogerman: “We can see the difference in higher accuracy, a lot of cream is coming back into our tank. For every single batch we do, accuracy is improving.”

Stability

tetrapakarlacravendaledecember2016The equipment’s stability was one of Arla Foods’ main criteria when making the purchasing decision. The machine runs at least eight hours a day, seven days a week, all year round. “Our operators favour the new machine when it comes to short runs, since they are difficult to standardize,” she says. “It is so much more accurate. There was no choice. We had to have it. Life is much better for the operators.”

Before, Arla Foods had problems with in-tank standardization. Based on the experience of the operator, a sample was taken from the tank and the fat content was adjusted accordingly. “That has very much changed. Now we always know what’s in the tank. Our operators trust that what they read on the screen is going in the tank. Greater accuracy has started to save us money,” explains Bogerman.

Winning or Losing

In the highly competitive dairy market an efficient standardization of fat in the milk is a matter of winning or losing. “We have such a low margin on fresh milk,” Bogerman says. “For us, the big money is in cream. We can’t afford to produce milk with too much fat in it due to operator errors. To give cream away is an absolute no-no.”

The Palmers Green dairy processes about 1.2 million litres a day. A robust standardizer has become more and more important as the number of products has increased. “Different customers demand that their milk to be processed separately,” says Bogerman.

“We deal with enormous amounts of product changes and segregation. That gives us much less time for standardization in the tanks. We can’t wait to buy more and replace the other two standardizers,” she says.

Main Benefits With the New Solution

  • Highly reliable system – based on extensively tested and refined automation software
  • Maximum line utilization – with virtually non-stop production, thanks to fast, sophisticated algorithms
  • Automated measurement and control of process variations — keeps you on target to secure uniform product quality
  • High-performance, high-quality components make the system setup very robust
  • Performance guarantees on precision: +/-0.015% 24/7.

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Hygienic Drainage Design Within the Meat Processing Industry

In the meat processing industry it is vital to maintain high hygiene standards to ensure the fresh meat goods are safe for consumers. On a daily basis regular and thorough cleaning regimes are in place to avoid the risk of contamination.

There are a few factors to consider when designing a factory, which will help to contribute to a hygienic environment. A drainage system and the surrounding flooring needs to work together to provide an efficient rate of waste water removal. The flooring must provide appropriate falls, which are directed towards either a drain channel or a drain gully within a processing area, so the waste water does not start to pool.

During processing, the meat industry produces solid fats and skeleton waste, which are required to be removed from the area during wash down. It is important that any solid debris is filtered out of the waste water via a drain trash basket, which sits within a drain channel outlet or drain gully.

An anti-backflow valve can also be installed onto a drainage system to close off the drain outlet pipe in the event of a blockage. The valve therefore prevents any waste water re-entering the meat processing area, removing the risk of contaminating fresh goods.

To provide safety under foot for people working in the processing area amongst meats, oils and greases, an anti-slip stainless steel drain cover, in a ladder design with a scalloped edge, can work with the tread of a person’s footwear to prevent unnecessary slips and falls.

Aspen stainless steel products are designed to help achieve a hygienic environment, with removable components to enable all drainage parts to be easily cleaned. Browse the product range online, which has full technical data available to download, and discuss your bespoke requirements with the Aspen Technical Team today; +44 (0)115 986 6321, aspen@canalengineering.co.uk, www.aspen.eu.com.

 

Posted in Hygiene, Processing, Quality AssuranceComments Off on Hygienic Drainage Design Within the Meat Processing Industry

EU Trade Surplus in Agri-food at €18 Billion Over 12 Months

For the 12-months period November 2015 to October 2016, EU agri-food exports reached a value of €129.9 billion, corresponding to an increase by 1.9% in value terms compared to the same period one year ago, according to the latest monthly report of EU Agri-Food Trade. Considering that agri-food imports from third countries in the 12-months period November 2015 to October 2016 slightly decreased to reach €112 billion, the export surplus for the 12-months period thus increased to more than €18 billion.

The latest figures from October 2016 show that Japan has now overtaken Russia as the 4th most important export destination of EU agri-food products after the USA, China and Switzerland. The EU net-surplus in agri-food trade with Japan has been around €5 billion annually for the last years. EU producers mainly export to Japan pork, wine and vermouth, cheese and spirits and liqueurs.

Posted in Agriculture, News, ProcessingComments Off on EU Trade Surplus in Agri-food at €18 Billion Over 12 Months

Holden Installations Win Two Major RIAI Awards at Architecture Expo 2016

Holden Installations have been awarded for two of their new Panel Protection Systems products recently launched in the Irish market. These Architects choice Product Awards were for best Interior Building Product, for both their Bollards and Guardrails and PVC Cladding Systems.

Judging was by four RIAI Architects at the recent Holden stand at Architecture Expo, who highly commended both products. This is a major coup for Holden Installations, who specialise in Panel Protection Systems.

Earlier this year, Holden Installations introduced their new range of Bollards/Guardrails and protective PVC cladding onto the Irish market. Holden Installations are established since 1986 and work in three specialist area for the Food, Clean Rooms, Pharma and Data Centres.

These are Insulated panels, Sanitary Hygienic Claddings and Protections and Doors.

Their Bollards/Bump rails are very low maintenance, cost effective, excellent tested impact absorption (tested up to 9 tons) and easy to Install.

Clients love their high visibility and they are totally interchangeable.

The solid high density core means no painting and is totally Food safe.

The PVC Cladding is also very impact resistant, totally Hygienic and Sanitary registered.

Available up to 8mm thick, with unique tongue and groove connection and secret fix detail.

Client Installations in Ireland this year to date, include Kerry Group, Glanbia, Dawn, Loughnanes-Galway, Oak Park Foods, and Golden Vale Group. Other recent Installations in Europe include: Novartis, DHL, Glaxo, Tesco, Aldi, Evian, Euro Champ, El Pozo –Spain and Russia and a 70million Food Factory in Croatia.

Below are relevant links

http://holden.ie/hygiene-systems/

http://holden.ie/hygiene-systems/safety-barriers-and-bump-rails/

http://holden.ie/hygiene-systems/food-grade-bollards-and-posts/

http://holden.ie/hygiene-systems/high-impact-pvc-sheeting/

Posted in Innovation, ProcessingComments Off on Holden Installations Win Two Major RIAI Awards at Architecture Expo 2016

GEA Awarded Large-scale Contract For Nutritional Powders Plant in New Zealand

GEA has been awarded a contract by Mataura Valley Milk to construct a nutritional powders plant in McNab near to Gore in the south island of New Zealand. The plant will process fresh milk and ingredients into added value nutritional powders as well as standard skim milk and whole milk powders. The value of the order to GEA is a figure in the mid double-digit millions (EUR).

The new plant, expected to begin production for the 2018 season, will produce around 140 tonnes of nutritional powder per day. Included in the GEA scope is a milk reception and standardisation plant, powdered and liquid ingredients handling, batch formulation, evaporation and drying, powder handling and filling into 25kg bags. It will also feature a high degree of process automation and product traceability. Energy efficiency and environmental impact have also been a key focus in the plant design. 

Jürg Oleas.

Mataura Valley Milk is majority-owned by Chinese Animal Husbandry Group (CAHG), a Chinese company. Roughly half of the premium nutritional powder produced by the new plant will be exported to China, where Mataura Valley Milk expects steady growth in demand for this product. 

“This contract, which was long-awaited to win by GEA, serves as further proof of our technological leadership and strong market position in the field of dairy processing,” explains Jürg Oleas, CEO of GEA Group Aktiengesellschaft. “It also demonstrates the continuing investment appetite of our customers as they attempt to satisfy the growing consumer demand on the Chinese market for milk-based infant formula and other high-quality milk products – and that in an environment impacted by regulatory changes. Although the challenging economic conditions mean that GEA’s order intake in the fourth quarter of 2016 will not repeat the record level achieved in the same quarter of the previous year, we are confident that customers throughout the world will continue to invest in our process technologies and place major orders for all product areas and applications.”

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Loma Increases Focus on Convenience Food Market

Driven by busy ‘time poor’ lifestyles and an ageing population, the convenience food market continues to flourish. With growing demand for products that have longer shelf life, can be eaten on the move, are simple to use and boast more innovative packaging formats, Loma Systems is highlighting the suitability of its high performance combination X5c X-ray and Checkweighing unit for inspecting frozen and chilled ready meals and food-to-go options. The two integrated ‘detect and weigh’ technologies ensure food safety for brand protection, and consistency in weight, size and shape.

As well as ready meals, there is an increasing trend for portable meal options that are normally consumed off premises, with retailers continuously developing new food products that make eating on the move easier, but that also offer authenticity, premium quality and healthier choices.

Ready meals and food-to-go products often contain multiple elements or ingredients packaged in different compartments, include additional items like cutlery or condiments, and have high salt content. Plus many snacks such as nuts and cereals fluctuate in density which can make it difficult to find foreign bodies. All of these variants can create inspection challenges for convenience food manufacturers.

Capable of weighing products while simultaneously inspecting for foreign bodies in one compact and easy to use format, Loma’s X5c X-ray combination system (pictured) has been specially developed with ready meal and food-to-go processors and packers in mind. The technologically advanced machine detects physical contaminants whilst ensuring perfect product presentation and quality assurance with fill level and seal inspection, mass measurement and component counts. It can also identify lumps of product including seasoning or powder.

Loma’s X5c X-ray combination system can be easily integrated where production space is limited and helps manufacturers adhere to the latest British Retail Consortium (BRC) standards and meet major retailers’ codes of practice. The X5c X-ray machine can be bolted on to an existing CW3 Checkweigher as one unit for truly effective Critical Control Point (CCP) detection.

Built to Loma’s ‘Designed to Survive’ specifications, the X5c X-ray combination unit, including reject facility, measures just 2.5 metres in length. Produced from stainless steel, the complete combination unit is lead free and offers an unrivalled IP55 wash down design. Capable of running at speeds up to 150 packs per minute, it is operated using two independent control panels and has separate reject bins for out of weight and contaminated products.

Convenience foods packaged in foil and metallised film, as well as changes in product temperature and moisture content have no effect on the sensitivity of the foreign body inspection capabilities of Loma’s X5c.

The X5c reduces the cost of ownership of X-ray technology by 30% when compared to the company’s other X5 models, making it ideal for food companies keen to make the switch to X-ray for the first time or to replace lower performance ferrous-in-foil twin head metal detectors. This fully specified system offers good quality contaminant inspection using a reduced number of well-proven subcomponents and streamlined design.

The X5c is multilevel password protected for improved data management, which means the system can log events against individual operators. It is ideal for the detection of all metal types, glass, calcified bone, rubber and stone in various packaging. The machine is capable of handling products up to 100mm (height) x and 300mm (width) and weighing no more than 6kg – making it ideal for a wide range of inspection applications.

With significant energy saving benefits and providing the best balance of processing power to inspection, the X5c X-ray machine incorporates a detector array with 0.8mm diode pitch

offering a low 80 watt power consumption and self-contained high efficiency X-ray generator. A simple, effective cooling mechanism ensures long tank life and maintenance-free operation.

Loma’s range of CW3 checkweighers offer peace of mind that every packed product leaving the production line will have the correct weight and meet strict legal or retailer requirements.

Like the X5c, the CW3 checkweigher is designed for operation in the toughest of production environments. It boasts quick change conveyor parts and powerful AC motors plus the tubular framework delivers a hygienic design but is flexible if transport or reject systems need to be changed.

For further information visit www.loma.com.

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SORTEX F Optical Sorter For the Frozen Fruit and Vegetable Industry

Scrutiny of hygienic processing practices in the frozen fruit and vegetable sector hasintensified, following several high-profile food contamination outbreaks. Bühler, a global leader in optical sorting technology for the removal of foreign material (FM) contamination, has addressed this and claims to have developed the most hygienic optical sorter available today, to help reduce the risk of microbial contamination.

As part of its research to understand the root causes of contamination, Bühler experts undertook extensive analysis of food safety risks, based on recalls in Europe and the USA. In most cases, they found that the problem could be traced back to the accumulation of food in certain locations within the machinery, particularly hollows, crevices and other areas with poor accessibility for cleaning.

Bühler product manager, Stephen Jacobs, explains: “The past couple of years in particular have seen some very high profile cases of product contamination. For instance, earlier this year there was a major listeria outbreak in the United States[1] that was traced back to a frozen fruit and vegetable processing plant. A Food and Drug Administration (FDA) report said inspectors found chipped and cracked plastic on parts of the plant equipment, which also did not allow for proper cleaning and maintenance.

“Thorough and regular cleaning of food processing facilities and equipment is the cornerstone of good manufacturing practice and one of the key pre-requisites for maintaining hygiene standards. To ensure that the SORTEX F meets the highest possible hygiene specifications, Bühler’s food hygiene team has worked closely with institutions such as EHEDG and Campden BRI.  This included the testing of machine materials for long-term robustness and its design for trouble-free cleaning and maintenance.”

The SORTEX F features a pioneering retractable chute that can be repositioned to allow operators to physically step inside and access internal areas of the machine.  Sloped surfaces ensure that all product residue runs off, eliminating the risk of product build up.  The finish of all metal surfaces complies with the recommended requirement for safe food contact and all polymer materials are resistant to high pressure washer jets and compliant to FDA regulations.  Attention has been paid to the smallest details, such as the use of spacer brackets, to create access for cleaning between components, where bacteria could otherwise harbour undetected.  The resulting machine is an unrivalled convergence of innovations, to improve hygiene standards in the food industry.

For food processors, it has never been more important to have state-of-the-art hygienic equipment to help meet the most stringent food safety specifications. The SORTEX F optical sorter, with its innovative open access, for quick, easy and thorough cleaning, has been designed to prevent the build up of pathogenic bacteria that can induce food-borne diseases such as Salmonella, E. Coli, Listeria and Norovirus.

Well designed hygienic equipment such as the SORTEX F also brings tangible benefits for food manufacturers and processors. Not only does it reduce the risk of contamination – and, thereby, minimise the possibility of costly product recall – it also increases productivity, as less water, chemicals, time and people are needed for cleaning. Unquestionably, product changeover is shorter due to faster cleaning and so too is inspection and maintenance, due to good accessibility and easy dismantling.

Adds Jacobs “Overall, hygienic design contributes to more consistent product quality with less out-of-spec products, lower risk of spoilage, a better shelf life and thus less waste. By helping to reduce the risk of contamination, whether FM or bacterial, we are making food safer and, ultimately, saving food.”

[1] http://www.nytimes.com/2016/05/23/us/listeria-outbreak-frozen-fruits-and-vegetables-recall.html?_r=1

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New Bake Production Line For Northumbrian Fine Foods Increases Capacity

A new £1.2 million bake oven and production line at Northumbrian Fine Foods (NFF) is now fully operational and is already significantly adding to production capacity at the Gateshead-based, UK biscuit manufacturer. The new line will help meet the soaring demand for the company’s rapidly expanding range of biscuits, especially in the gluten-free sector. The oven and associated production line has increased baked production output by around 30% and created 40 new jobs in the process.

“The new bake line will enable us to further develop our range of ‘free-from’ biscuits and cookies to meet strong customer demand,” says Stewart McLelland, NFF managing director. “This investment will reinforce our leading position in the gluten-free sector and enable us to develop new markets, including export.”

The new line will focus on the production of a wide range of different biscuits including ‘indulgent’ cookies, rotary moulded biscuits and bake bars such as Granola.

As well as major supermarket own-label products, NFF also manufactures gluten-free biscuits under the Prewett’s brand. About 70% of the UK’s gluten free sweet biscuit production is carried out at the NFF site.

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Tetra Pak Launches Enhanced Standardization Unit With Industry Leading Precision

A new version of the Tetra Pak® Standardization unit has lifted the precision of the process to a new level, helping dairy manufacturers produce their products with optimal fat content and achieve savings. To produce milk with a specific percentage of fat content, an important step in dairy production is to separate fat from milk. Fat is then added back to the product according to the required specification through a process called standardization.

Designed for automatic in-line standardization, the new unit enables manufacturers to reduce the variation of so-called “cream giveaway” from the previous +/- 0.020% to +/- 0.015%.

The enhanced standardization unit has already achieved field success with international dairy co-operative Arla Foods at its dairy plant in Palmers Green, London.

In the highly competitive dairy market, efficient standardization of fat in the milk is crucial. Christian Odgaard, Regional Project Manager at Arla Foods, says: “For us, the big money is in cream. To give cream away is an absolute no-no. We were quickly impressed with the reliability and precision of the Tetra Pak Standardization unit since its installation last October. The difference in higher accuracy is obvious, a lot of cream is coming back into our tank.”

The new Tetra Pak Standardization unit is now available to customers worldwide. The unit is capable of handling a wide variety of dairy products such as white milk, cheese milk, milk powder, fortified milk and flavoured milk at a capacity of up to 75,000 litres per hour.

Posted in Innovation, ProcessingComments Off on Tetra Pak Launches Enhanced Standardization Unit With Industry Leading Precision

PPMA Celebrates its 500th Member

The PPMA Group of Associations is celebrating a double run of success after it announced its 500th member as well as record bookings for the PPMA Show exhibition in 2017.

Minebea Intec, formerly known as Sartorius Intec, a leading supplier of weighing, line inspection and process control equipment, is the latest company to join the association. The company has recently undergone a significant rebrand following its move to Japanese group, Minebea.

Speaking about the decision to join the PPMA, Colin Maher, Country Manager – UK & Ireland, Minebea Intec, says: “Following our recent rebranding and a significant focus on investing in new technologies, the time was right to join the PPMA to build the company’s profile and highlight the new technological innovations we’ll soon be launching for the manufacturing industry. The PPMA provides us with a significant platform to highlight our new product range as well as networking with our peers and potential customers across the processing, packaging and manufacturing industries.”

Minebea Intec’s product portfolio includes platform scales, process vessel and silo scales, checkweighers and equipment for detecting foreign objects for the food industry and other industry segments.

The company will also make its debut at the PPMA Show at the NEC, Birmingham in September 2017, which will be co-located with Interplas, the UK’s leading plastics industry event. MineBea Intec will join more than 200 exhibitors that have already booked stand space at the UK’s premier free-to-attend complete production line event for processing and packaging machinery.

Speaking about its record booking for 2017, David Harrison, PPMA Group Exhibition Manager, says: “With more than 6,000 sq. meters already booked, we’re confident that the PPMA Show 2017 will be bigger and better than the previous edition in 2015. Interest was already strong at this year’s Total Show event where many of the stands were booked, 12 months in advance. We had over 7,300 visitors coming to discover the latest technological innovations and discuss key business opportunities and look forward to welcoming returning and new visitors to the NEC next September for what’s set to be our biggest show yet.”

Leading companies such as Schubert, ULMA Packaging, ABB Robotics, Mettler Toledo and Beckhoff Automation are already confirmed to exhibit and will be joined by new exhibitors, such as PPMA’s 500th member, MineBea Intec and CPACK Packaging.

“This marks the end to a successful and memorable year and a great way to enter our 30th anniversary in 2017. We’ll soon be announcing plans to celebrate 30 years of helping the industry and look forward to continuing to create value for our members through the provision of new and improved services,” says Valerio Del Vecchio, PPMA Head of Marketing.

The PPMA Group of Associations comprises the Processing and Packaging Machinery Association (PPMA), British Automation and Robot Association (BARA) and the UK Industrial Vision Association (UKIVA). It was founded in 1987 with just eight ‘founder’ companies and has since seen a substantial increase in membership as well as an expansion in the type of services offered.

It also launched PPMA BEST (Business Education, Skills and Training) in 2014 – a charity designed to encourage young people to enter and develop a career in engineering within the processing, packaging, robotics, automation and industrial vision supply industries through education, training and support.

Speaking about the PPMA Group, Dr Andrew Mint, PPMA Chief Executive Officer, comments: “We’re delighted to welcome MineBea Intec as our 500th member. This is the biggest the PPMA has been since it launched in 1987 and we’re excited to build on this as we enter our 30th year. The industry continues to show resilience and we’re confident it will continue to build on recent momentum, with Brexit delivering a boost to exports and factory output beating economists’ forecasts. It’s a great time to be a part of an optimistic industry and we can’t wait to see how this continues to develop in the months ahead.”

For more information on the PPMA Group of Associations, please visit http://www.ppma.co.uk/ or call 0208 773 8111.

Posted in Packaging, ProcessingComments Off on PPMA Celebrates its 500th Member

GEA Presented Innovative Solutions For the Beverage Industry at BrauBeviale 2016

At BrauBeviale 2016 in Nuremberg, GEA presented not only this year’s innovations to the beverage business – but also its technologies, which set standards in its sector. In close collaboration with the beverage industry, GEA mechanical engineers and process technicians create tailored solutions. Customer requirements here are focused on superior-quality product results with absolutely reliable and secure production, flexibility with respect to demand fluctuations, improvements in their own productivity at ever lower operational costs, and a sustainable ecobalance.

BrauBeviale 2016 highlights at the GEA booth:

DI-BATCH-F™ batch mixing system with new recipe management allows for complete control during production. This new system processes dry substances and liquids to a finished syrup or finished beverage. A special feature of this system is its partial discharge from packing drums by means of a drum pump and a hopper tank on weight cells. This provides producers with additional flexibility regarding production volumes and with the opportunity to purchase the base ingredients in containers of different sizes.

The GEA “Plug & Brew” skids with centrifuge for trendy craft beer created a lot of interest among customers. These compact units are multifunctional and rated for outputs of 1,000 to 100,000 hectoliters per annum. GEA offers craft breweries customized solutions in the form of efficient Plug & Brew units, to assure success on the marketplace with premium product quality. With the centrifuge skid, the craft brewer can save 30 % production time with dry hopping, and can increase his yield by up to 10 %. The space-saving skids are piped and pre-assembled in four sizes and are ready for use immediately. 

gea2braubevialenovember2016With its market launch of the GEA rotoramic, GEA offers a new, energy-saving filter with ceramic membrane disks, which enables beer recovery from surplus yeast or retentate processing in fruit juice filtration. The ceramic cross-flow filter requires approx. 75 % less energy than conventional cross-flow procedures. Breweries and fruit juice producers can achieve maximum product yields together with gentle product treatment and with no quality losses.

For the production of high-quality non-alcoholic beer, GEA has developed a system for reverse osmosis with membrane filtration for de-alcoholization of beer with low feed rates. GEA offers compact plant configurations for capacities from 2.5 to 10 hectoliters per hour. The systems feature modular design and are optimized for batch processing. Automation assures high process reliability and low service expenditure.

For cold hopping technology, GEA has developed its HOPSTAR™ Dry. It is now available as a skid-mounted standardized plug & play unit and offers dosing rates from 200 to 600 grams per hectoliter. In an independent process with this system, hop pellets can be extracted with beer. The resulting enriched liquid can be used for topping up beer with special hop ingredients.

gea3braubevialenovember2016Since last year, GEA has reorganized its hygienic pump range, and has combined them in the SMARTPUMP line for standard configurations, as well as in the VARIPUMP line. The VARIPUMP models, optimized for demanding applications such as in biotechnology, pharmaceuticals, and the dairy business, offer maximum flexibility in use. These pumps generally stand out owing to their excellent surface finish and the complete absence of pores in the product contact area. The result of intensive collaboration is the new GEA Hilge HYGIA range.

Shortly before the fair, GEA also launched its new service concept: “GEA Service – For your continued success”.This GEA concept focuses on support for the customer throughout the entire life cycle of their installed systems and components: from project engineering, installation, and commissioning to maintaining and improving the performance of the customer’s plant and equipment.

At the world’s leading trade fair for the beverage and liquid food industry – drinktec, in Munich from 11 to 15 September 2017 – GEA will take the next opportunity to present its extensive offering of products and services for the beverage industry.

Posted in Conferences & Exhibitions, Innovation, ProcessingComments Off on GEA Presented Innovative Solutions For the Beverage Industry at BrauBeviale 2016

Hygienic Stainless Steel Environments Within Dairies

canalengineeringnovember2016In dairy industries it is vital that hygiene standards are kept to a very high standard. To do this, the choice of materials used in the construction of a dairy are required to cope with the daily processing and production demands.

Drainage and wall kerbing, which make up part of a dairy, are important products that need consideration. To reduce costs, many may opt for these to be made out of concrete, however over time concrete dries out and is prone to cracking. This can jeopardise a hygienic environment as unwanted bacteria will harbour in the cracks, no matter the size. Concrete is also a hard material to thoroughly clean as it is not impermeable and can absorb some moisture, weakening the structure. In time the concrete may therefore erode and cause construction issues within a dairy, which would disrupt the daily production of their goods.

Alternatively, drainage and wall kerbing can be manufactured from stainless steel. Stainless steel is resistant to caustic cleaning materials and lactic acid, which are common elements in a dairy. This resistance ensures that the stainless steel surface does not corrode, rust or weaken making it an excellent long term solution in construction.

As well as the material it is made from, the layout and design of a drainage system is also important. A drainage system will need the appropriate flow rates to cope with the volume of liquid waste water in the area. A drainage system also goes hand in hand with the flooring design so liquid waste water drains effectively into the channels or gullies. Doing this prevents any pooling or standing water, which is prone to bacteria build up.

A stainless steel wall kerbing system can also work with the flooring design. A seamless connection between the floor and the wall can be made by installing a resin wall cove onto the kerbing. This drastically improves the efficiency of cleaning by removing any creases or angled connections. In turn this reduces the amount of areas bacteria and small debris can harbour and grow.

With strict hygiene demands throughout the dairy industry, Aspen Stainless has the ability to provide a tailored product package to meet your specialist requirements using its range of drainage, wall kerbing and protection.

Browse the product range online, which has full technical data available to download and discuss your bespoke requirements with the Aspen Technical Team on Tel +44 (0)115 986 6321 or visit www.aspen.eu.com.

Posted in Hygiene, Processing, Quality AssuranceComments Off on Hygienic Stainless Steel Environments Within Dairies

Total Solutions From CPM Wolverine Proctor

By Robin Holding, Commercial Director, CPM Wolverine Proctor Ltd

The humble potato is one of the most versatile and flexible root crops known to man – there are hundreds of varieties, all with differing skin colour, flavour and texture, and our ingenuity in terms of what we do with them seems to know no bounds.

The potato on its own can be baked or roasted, cut, sliced/diced or cubed and then boiled, fried or mashed to make something that can be eaten as a snack or as part of virtually any meal, at any time of the day or night. Then there are the derivative products such as potato powder, flake or starches which can be used as they are and mixed into doughs for further processing, or modified to take advantage of their unique properties – indeed, whole industries have sprung up around them, including for applications such as wallpaper paste.

Challenges

This presents a great challenge to the potato R & D teams and, further upstream, to the machinery manufacturers. Clearly, we need to work together to develop new processes and products to be able to satisfy consumer demand, but there can often be a trade-off between what is desirable and what is practical or cost-effective. This is where it is particularly important to develop an effective dialogue between the marketing, R & D and supplier’s engineering personnel, so that ideas can be explored, analysed and then discounted or pursued as appropriate.

CPM Wolverine Proctor Ltd., has been supplying processing machinery to the food industry since early last century and continues to do so on a global basis. We have manufacturing facilities in Europe and the USA and our customers are becoming progressively more reliant on us as a total solution supplier, partly because they have had to reduce their own engineering resources to remain competitive, but also because they value the depth of experience that we have built up over the years. We have product development facilities available in both the UK and USA and we encourage our customers to carry out secure lab trials when developing a new product with us. This can cover everything from extruded snacks to pre-dried fries, roast patties or baked chips.

Project Management and Engineering Resources

In order to meet demand, we have developed our project management and engineering resources, bringing in new design initiatives and process knowledge, allowing us to draw on experiences that may have come from unexpected applications in other industry sectors and enabling us to offer a truly turnkey supply. For all types of foodstuffs, we are able to offer complete plants based on batch or continuous cooking, forming, drying, baking, roasting and toasting. Our recent acquisition of TSA Griddle Systems now enables us to add another dimension to our overall capability with waffles and pancake systems.

cpmwolverine2november2016At the detailed engineering level, hygiene continues to be a major driving force when developing our design features, benefitting the potato processor in areas such as washdown, cleaning and drainage, minimising downtime and avoiding cross-contamination, energy wastage, etc.

Naturally, we do not profess to manufacture every machine that we supply, but by teaming up with other specialist machinery manufacturers and technologists, we can offer potato processors a “one-stop shop” for everything from raw material handling right through to finished product palletization, all managed by a dedicated project management team.

Preferred Machinery Supplier

Our continuing drive to be the preferred machinery supplier means that we are actively encouraging our customers to talk to us about what they like and dislike, listening to their ideas and identifying the priorities for their business. Only then can we hope to meet and exceed their expectations by supplying them with the optimum solution.

We are proud to be a major supplier to many of the most iconic potato processing companies around the world and we look forward to continued success with them, as well as with new players in the future, whatever their product lines might be, potato-based or otherwise.

Posted in Processing, Project ManagementComments Off on Total Solutions From CPM Wolverine Proctor

Haith Multi-Wash System

In the ever demanding vegetable packing industry companies are always looking to increase margins by reducing the amount of waste while improving the quality of the product supplied to the end user.

Haith is constantly working on new designs which will not only improve pack out and quality, but also give reduced energy costs lower water usage and save labour. The latest concept, the Haith Multi-Wash, ticks all the boxes and with Haith’s all in one process transfer of vegetables from one section to the next is very gentle.

Haith Multi-Wash System offers De-stoning-barrel washing and brush polishing all in one unit, the latest and important upgrade is the split barrel which allows the washing section to rotate in the opposite direction to the polishing rollers there is a separate inverter speed control on each section giving more flexibility and control over the amount of washing and polishing required. Included in the system is a waste removal tank with water recycling, the compact all in one plug and play design makes installation and set up very simple, there are a number of options and configurations available to suit your specific requirements.

There is a feature on the control to allow simple and fast emptying of the system when changing verieties.

haith2november2016This new vegetable washing concept combines all the proven qualities of the popular Haith Supaflume De-stoner with the excellent wash quality of the Haith Semi-Submerged barrel washer whilst incorporating polishing with the tried and tested direct drive Haith Root-veg Polisher.

Vegetables are immediately introduced to water as they enter the integral de-stoner, stones and clods are removed before the crop is gently flume fed into the wash barrel. When heavy soil is present and a robust wash is required the water level can be raised so the pintle lined wash barrel is semi-submerged in water, the rubber scroll moves the potatoes through the barrel while the high pressure spray bar works with the rubber pintle to remove engrained dirt from the eyes.  The flexibility of the Multi-Wash enables the water level to be lowered, in this mode the potatoes can be sprayed with fresh water.

The next stage in the washing process, potatoes are gently transferred out of the barrel via an all new cone feeder which uses a soft rubber scroll to deliver the potatoes to brush polisher rollers, directly driven by high efficiency SEW motors, here minor skin defects can be removed and the general appearance of the crop is lifted.

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Indonesia Market Leader Chooses GEA Comas and GEA Imaforni For New Cookie Production Line

GEA has brought together the long-term expertise of its leading bakery technology companies – COMAS and IMAFORNI – to build a complete line for the production of wire-cut and soft centre biscuits at the Khong Guan factory in Jakarta, Indonesia. With an average production of 1.5 tons/hr premium cookies, the new line is fully automatic and provides significant benefits in terms of product quality and consistency, productivity and reliability.

Khong Guan is a top Indonesian manufacturer specialized in biscuits, wafers and wafer sticks. The company’s success has resulted from its insistence on using the finest ingredients, the latest machinery and robotized packaging systems to meet customers’ requirements, hygiene standards and food safety regulations.

Single Supplier

The company has used Imaforni equipment before and has always been impressed with its performance. However, this was the first time Khong Guan had built a complete line using just a single supplier. “The latest addition (2016) is a soft cookie line made up of GEA Comas and GEA Imaforni equip­ment,” explains Mr Chew Soo Kok, Director of Khong Guan. “It is capable of doing jam-filled cookies, wire-cut cookies, deposited biscuits, and bars. With the help of a food technologist to fine-tune the recipes, we were able to start-up the production line in a short period of time. The line now runs wonderfully.”

The GEA line includes a high capacity DFV3 extruder capable of simultaneously depositing two different types of dough, as well as a third, fluid filling; the hybrid steel band tunnel baking oven; and all the necessary mixing and conveying equipment. But according to Marco Gandini, GEA’s Head of Bakery Applications, the technology itself is only part of the story.

“What makes this line special is the way in which the experience of both the GEA brands has been able to come together to provide the highest performing solution,” he explains. “By choosing equipment that is of the highest quality and perfectly compatible, we have been able to build a line that is reliable and capable of producing large amounts of cookies at the finest quality for Khong Guan.”

Marco also points out that in the unlikely event of a problem there can be no doubt as to who is responsible for fixing it. “It’s a 100% GEA line,” he says. “We built it and we will maintain it at optimum performance for our customer throughout its working life.”

Sometimes the relationship between customer and supplier may be critical, but not in this case: Mr Soo Kok has no doubt that he has made the right choice with GEA. “The services provided have been first class; and the engineers are well-trained, knowledgeable and friendly which made the installation and commissioning process a smooth one. The after-sales service is equally as good with prompt replies and follow-up to our queries.”

Indonesian Market

With the increase in population in Indonesia and good economic growth, the market size for Khong Guan’s products has grown tremendously. The purchasing power of the Indonesian consumer has grown and the middle-income population is increasing and so Mr Soo Kok believes that the market will continue to grow. “However, we must introduce better quality products and new varieties of biscuits and cookies,” he explains. “To prepare ourselves for the future, we will need to continue to invest in good, and reliable equipment to ensure a high quality production output.”

All food manufacturers operate in an intensely competitive environment in which the highest standards of hygiene, production, and product innovation are essential to prosper. By choosing GEA to provide a complete production line, Khong Guan has ensured that its facilities are world class and has secured the combined expertise of some of the industry’s finest process engineers to make sure that its leading position is maintained well into the future.

Posted in ProcessingComments Off on Indonesia Market Leader Chooses GEA Comas and GEA Imaforni For New Cookie Production Line

Clean in Place (CIP) – Process Safety With the CombiLyz Conductivity Meter

By Stefan Blust, Business Manager Food & Beverage, Baumer

baumernovember2016The food and beverage industry is faced with continually rising quality standards, increasing cost pressure and strict hygienic regulations. As a result, requirements for processing systems and their efficient cleaning are growing. With an accuracy of 1% and a measuring range of 500 μS/cm to 1000 mS/cm, together with fast and accurate temperature compensation, the innovative CombiLyz conductivity meter has the ideal technical properties to support CIP safely and cost-effectively.

In order to guarantee food safety, production and filling facilities must be cleaned regularly. This is usually done using an automated CIP process (the cleaning of a process engineering system without dismantling it) and is part of a fully automated production process. In the food industry, the correct settings for a CIP process are very comprehensive, since the final CIP processes can often only be defined after the systems have been set up and meaningful tests have been carried out. There are as many requirements as there are cleaning programs. Some systems are cleaned with water only, while chemical cleaning agents like acidic or caustic solutions are used in others. Some systems recover the water from the last rinsing cycle and use it for the first rinsing cycle of the next CIP sequence in order to keep overall running costs low.

Optimum Interaction of Physical Parameters

For all cleaning processes, however, the optimum interaction of different physical parameters is critical. The exact concentration of cleaning agents, while taking into account flow rate, pressure, temperature and time, defines a reproducible process in which the CombiLyz clearly illustrates its superiority.

While the concentration of the acid or alkali is increasing, the conductivity meter controls the specified concentration of the relevant cleaning media. With precise measurements, it ensures no more chemicals are used than necessary. This saves resources and protects the environment. During the phase separation in the CIP return flow, the CombiLyz with its good temperature compensation quickly recognizes different media, even when temperatures fluctuate enormously. This reduces the losses of stored cleaning agents. After one cleaning cycle, the CombiLyz accurately measures the concentration of the remaining chemicals in the rinse water. With this information, the PLC can control the predefined media circuits exactly and reliably using valve nodes. This reduces the risk of food being contaminated by residual chemicals.

Robust Hygienic Design and User-friendliness

The robust sensing element of the meter is made completely of PEEK. In order to meet the requirements of different installations, it is available in lengths of 37 mm, 60 mm and 83 mm. Its compact design reduces the flow resistance in the line, since the pipe cross-section is only minimally influenced. Deposits and impurities can be more easily transported out of the system. The hygienically designed sensing element itself can also be cleaned very easily, which is confirmed by the EHEDG certification and conformity with the 3-A standards. Furthermore, its design is exceedingly durable, and is specially made for use in applications with frequent temperature shocks. This guarantees a long service life, reduces unnecessary downtime and thus increases system availability.

Thanks to its very user-friendly operation by touch screen and its modular housing, the CombiLyz is outstanding in its class.

The conductivity meter is available with or without CombiView. This large, illuminated display can be rotated 360° and can thus be read easily from all directions, even from a great distance. It allows different view options, for example the simultaneous display of conductivity and concentration values as well as fully customizable text (water, alkali or acid etc.). Alarms and configurations can be visualized on the device and can also be transmitted to the higher level controller. With its integrated relay, the conductivity meter can carry out simple control tasks, for example in microbreweries with a low degree of automation, where food safety is of great importance and where valves are to be addressed directly without a process control system. The same applies to retrofitting of systems being upgraded from manually controlled to partly automated processes.

The CombiLyz sensor is available as a compact and as a separate version. The latter is available with cable lengths of 2.5 m, 5 m and 10 m. If required in the application, the display and the sensing element can be installed separately. This offers maximum flexibility for optimum mounting positions.

A wide range of adapters allows hygienic installation in most standard process connections. This makes it the ideal solution for many CIP systems.

Further information visit www.baumer.com/CIP.

Posted in Food Safety, Hygiene, Processing, Quality AssuranceComments Off on Clean in Place (CIP) – Process Safety With the CombiLyz Conductivity Meter

500,000,000+ Beer and Soft Drinks Every Day Can’t be Wrong

This tagline is Union Engineering’s entrance to Brau Beviale in 2016. A tagline which is not just a large number but actually a conservatively estimated figure illustrating a story about a company that a substantial number of people are becoming acquainted with every day – around the globe.

It is the story about the company’s position as a forerunner when it comes to developing new and innovative CO2 technologies and being passionate about green footprint.

It is the number of beer and soft drinks daily produced including CO2 delivered from a Union Engineering plant.

A shared Passion

Lars Klitgaard Pedersen is General Sales Manager for the beverage segment at Union Engineering, and he explains; “for our customers the focus is of course on their end-product. They are looking at food-safety, on utility consumption and ROI, and it is our passion to provide them with the best solution for their specific needs. We have proven that we understand the market demand, and we keep improving and developing technologies meeting the key performance parameters of the market. Back in 2013, we introduced the ground-breaking and patented ECO2Brew®, which is not just able to purify CO2 without using water, but it is also over-performing when it comes to reduction in power consumption and increased recovery rate compared to the traditional technologies.”

The patented and successful ECO2Brew is ready in a version 2.0.

The patented and successful ECO2Brew is ready in a version 2.0.

Since the first ECO2Brew® installation, Union Engineering has further improved the technology and it is now ready for the grand presentation at the exhibition.

Size Matters

Craft Brewers and smaller conventional breweries can also benefit from visiting Union Engineering during the exhibition. Lars Klitgaard and his colleagues are ready to present a compact solution, which is designed for fast installation without compromising on quality and reliability. He elaborates; “We receive still more inquiries from small breweries, the need for being self-supplying with CO2 is rising. Therefore, we have developed CO2mpactBrew™, delivered as a containerised solution with all the equipment installed inside a container, featuring a maintenance aisle and easy connection points for utilities thus ensuring fast and easy installation.

“As an added benefit, by recovering your own CO2 you eliminate emissions (odours) from your fermentation process, which might otherwise require additional precautions.”

The New Standard For Self-generating Plants

For soft drink bottlers the NOxFlash® technology has more or less become the standard; a unique unit that eliminates use of the harmful and disposal demanding potassium permanganate (PPM). The unit is as standard delivered with all self-generating CO2 plants from Union Engineering. “We have supplied over 60 plants with this technology – and this has saved the customers a lot of trouble. PPM is not only difficult to get hold of; it is subject to strict rules when disposed of.” Lars Klitgaard continues, and reveals one of the reasons why the company is holding a strong position in the segment of self-generating and extraction based CO2 plants.

Union Engineering and Climeworks are joining forces in an exciting project.

Union Engineering and Climeworks are joining forces in an exciting project.

Joint Forces in the Name of Science

Besides supplying to the beverage segment, Union Engineering is also the main supplier to industrial gases companies, to desalination projects and within the biogas, natural gas treatment and petrochemical industries. The large pool of CO2 experts is also making the company a natural partner within science project. Most recently a joint project with Climeworks has become a reality.

The objective of the project is to develop a standardized, competitive, low cost, modular, standalone, and onsite plant for delivery of beverage grade CO2 to bottling companies. The CO2 stems majorly from atmospheric air and is in a first step concentrated to 99.9% by a Climeworks direct air capture (“DAC”) plant. In a second step, CO2 is purified and liquefied (“conditioning”) to achieve beverage grade CO2 purity by Union Engineering technology. The project is funded by Eurostar’s programme and is called CAPDrinks.

Curiosity as a Driver

Throughout decades, curiosity and the passion for innovation has driven the company to create new technologies, expressed through a wide range of patents and over 900 CO2 plants installed worldwide. This has resulted in a position as a world leader in CO2 technology. Learn more on union.dk and sign up for news and knowledge about CO2.

Union Engineering is at Brau Beviale in hall 6 stand 342.

Posted in Innovation, ProcessingComments Off on 500,000,000+ Beer and Soft Drinks Every Day Can’t be Wrong

Largest UK Sushi Manufacturer Uses Automation For Retailer Compliance

Ichiban UK has invested in automation to ensure compliance with retailers’ codes of practice. The OAL system has prevented label and packaging errors that can result in substantial fines and help identify areas for improvement during production. Ichiban UK is the leading supplier of both own label and branded authentic sushi for major retailers. Ichiban recognised that to maintain their excellent relationships with the retailers, the site needed to secure their factory by proactively investing in automation.

Working with OAL, a leading automation and food processing technology provider, Ichiban UK ensured the correct packaging and labelling are applied to their products by using a single automated system to control their packaging lines and integrate existing packaging devices. Julie Rice, Technical Manager, explains why Ichiban UK chose the OAL Autocoding system: “We chose the OAL system because it’s a tried and tested solution that provides the compliance we need. It’s easy to use and has helped us focus by accurately recording line stoppages and identifying areas for improvement.”

ichiban1november2016The system Ichiban UK had installed works by scanning a 2D barcode printed on every product to check and verify the date code, and packaging is correct. If a mismatch error occurs, the line stops, and the problem is investigated.

Payback has been shortened through the use of OAL’s Factory Performance software module that provides the team production information on improvement areas. When a line stop occurs operators must record a reason code on the touchscreen terminal. The recorded data is both highly accurate and can be used in real-time so actions can be taken if any issues occur. The automatic system replaces existing manual production logs, providing more accurate and reliable data, helping Ichiban UK identify areas for improvement.

By investing in automation, Ichiban UK has secured compliance with retailer codes of practice for label and date code verification whilst producing actionable data to improve production performance.

For more information on how automation can help with compliance, contact OAL on +44 1733 394 700 or visit www.oalgroup.com/connected/

Posted in Automation, PackagingComments Off on Largest UK Sushi Manufacturer Uses Automation For Retailer Compliance

MEPs Call For EU Limit on Industrial Trans Fats in Food

The EU should place mandatory limits on industrially-produced trans-fatty acids (TFA) which may increase the risk of cardiovascular disease, infertility, Alzheimer’s, diabetes and obesity for consumers, says a resolution by the European Parliament. TFA intake is mostly linked to consumption of industrially produced, partially hydrogenated oils.

MEPs mention the fact that, according to the European Commission, only one in three consumers in the EU knows about TFAs which shows that labelling measures are not enough. The Commission should therefore propose an EU legal limit on the industrial TFA content of all foods as soon as possible, and preferably within two years, say MEPs.

MEPs say that there is evidence that Denmark’s introduction of legal limits for industrial TFAs, which brought in a national limit of 2% on trans fats in oils and fats in 2003, was successful, significantly reducing deaths caused by cardiovascular disease.

TFAs tend to be used in cheaper foods,  which means that people on lower incomes are most exposed to foodstuffs with a higher TFA content. This in turn increases the potential for widening health inequalities, MEPs say. The resolution was passed by 586 votes to 19, with 38 abstentions.

 

Posted in Food Safety, Ingredients, Nutrition, ProcessingComments Off on MEPs Call For EU Limit on Industrial Trans Fats in Food

Ian Roberts of Bühler Awarded European Chief Technology Officer of the Year 2016

Ian Roberts (pictured), Chief Technology Officer of Bühler, has been awarded European CTO of the Year 2016 in large companies’ category. The award is honoring Bühler for its excellence in technology and innovation leadership, as well as top-management’s commitment to advance sustainable development.

The ‘CTO of the Year’ award is a platform to promote the importance of technology and innovation in Europe. It is given to the most prominent technology leaders of highly successful European companies: inspiring leaders and foresighted technology managers. Previous winners include Martin Curley from the Intel Corporation, Marcel Wubbolts from Royal DSM, Richard Parker from Rolls-Royce, and Gert-Jan Gruter from Avantium, among others.

Ian Roberts says: “This award reflects the hard work of the Bühler employees, the vision and commitment to innovation and sustainability of the leadership team and their audacity to drive change in an already successful company. With these initiatives, we are able to create a culture of innovation and entrepreneurship across the company.”

Ian Roberts is known as an ambassador for innovation and technology. Bühler’s innovation challenge, driven by Ian Roberts, has become an example for companies that aim at transforming their company culture, building organisational innovation capability, and leveraging partnerships with customers, suppliers, and universities. Likewise, Ian Roberts has been the architect for the launch of Mass Challenge Switzerland, contributing to the vibrant start-up scene in Europe.

Innovation plays a key role in Bühler’s strategy. Every year, the company invests up to 5% of its turnover in research and development. The latest innovations, unveiled at the Bühler Networking Days, include the CombiMill process with increased flexibility for millers, the new generation of high-precision scale Tubex with energy savings of over 90%, the energy-efficient pasta drying with Ecothermatic, as well as the Novablue solution for increased food safety.

Ian Roberts joined Bühler in 2010. He is a member of the Bühler Group Executive Board. He graduated in chemical engineering and obtained a Ph.D. in process engineering from the University of Wales, Great Britain. He held various management positions at Nestlé, acting as Director of innovation for Nestlé Mexico and as Director of the chocolate centre of excellence in Switzerland.

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Pukka Pies Selects IFS Applications 9

IFS, the global enterprise applications company, has announced that Pukka Pies, the independent UK pie manufacturer, will implement IFS Applications™ 9 to improve planning and support business growth. Founded in 1963, Pukka Pies is an independent family company based in Leicestershire. It makes over 69 million pies and pasties every year. Traditionally selling to outlets including chip shops, butchers, bakers and sporting venues, Pukka Pies has transitioned into retail and now sells to most major supermarkets and local convenience stores.

The move into retail has caused greater variances in production volumes however, and Pukka Pies was looking to replace its legacy business software with a system that could more closely measure its production processes and inventory management across its UK operations.

With IFS Applications 9, Pukka Pies has access to a single streamlined ERP solution that will enhance traceability of its supply chain, improving its ability to manage production. IFS Applications 9 will reduce the amount of duplicated paperwork while also enabling immediate reporting on company balances and inventory, a significant improvement for auditing processes.

Pukka Pies needed a new system that would future-proof its operations, improve planning, and cope with business growth. IFS Applications offers a full breadth of ERP capabilities meaning that instead of integrating additional third-party software, Pukka Pies can implement further IFS solutions to adapt to growth or changes to the business.

“IFS Applications is a great fit for Pukka Pies; the integrated payroll and HR systems were a useful addition for us, and something we didn’t see in other vendor offerings. Ensuring user buy-in was also important, as this is the first ERP system we have implemented. The system was received well internally thanks to its intuitive user interface that was easy to navigate,” says Andrew Wormald, Business Systems and Process Manager at Pukka Pies. “In IFS we have found an organization with a similar culture to us and, with a product like IFS Applications that is subject to continuous research and development, we’re excited about the potential it will enable for our business.”

IFS UK Managing Director Paul Massey adds: “Pukka Pies is a great example of a British family-run business that is looking to future-proof its operations. IFS Applications will improve efficiencies across the organization, helping it to meet current demands and provide a solid foundation for Pukka Pies’ business growth.”

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GEA Sets Standards With the Most Efficient Milk Powder Plant in the World

GEA, one of the largest suppliers of processing technology for the global dairy and food industry, has installed a high performance spray dryer as the centerpiece of the new milk powder plant in Lichfield, New Zealand. For its customer Fonterra, GEA developed the best performing and the most efficient spray dryer currently available on the market. With the capacity of 30 tons of milk powder per hour, it can process nearly 4.4 million liters of milk per day. This volume corresponds to 165 truckloads. On September 5, 2016, Fonterra started the production process, which is now being gradually expanded to round-the-clock operation.

GEA was responsible for the complete turnkey milk powder plant and provided all of the processing technology – from acceptance of the tanker to evaporation, drying and powder handling to packaging. When you know the sheer size of the spray dryer, you can clearly imagine the dimensions of the actual plant: its drying chamber weighs about 200 tons with the diameter of 18 meters. During assembly, it was lifted 34 meters above the roof of the building and had to be placed precisely within the building.

The spray dryer is the second of the kind, built by GEA. Its sister plant Darfield II, also operated by Fonterra in New Zealand, has been producing reliably high-quality powdered milk since December 2013. For Lichfield, the GEA experts developed several innovations, which simplify the processes on site and reduce the total cost of ownership. In particular, energy efficiency was a key focus for the project team. For instance, the plant requires very little process water as the evaporator condensate is filtered through the membrane of a high-pressure reverse osmosis system and, because of the GEA technology, this water can be re-used during processing. As a result, Fonterra is required to maintain much less wastewater treatment capacity at the site. By focusing on overall equipment efficiency, energy consumption and waste minimization, the completed milk processing plant is one of the most efficient in the industry.

GEALogoFonterra belongs to of the major milk producers in the world. Its Chief Operating Officer Robert Spurway points out the strategic importance of powder production to the co-operative’s overall asset mix: “Premium milk powder is a valuable product for us. The capacity the new Lichfield plant takes the pressure off during the peak of the season, meaning we have more freedom to prioritize milk into higher returning products.” Fonterra will export the premium milk powder from Lichfield to as many as 20 markets, including the Middle East, China and South-East Asia. The official opening of the milk processing plant in Lichfield is scheduled for December 2016.

“Highly-productive and efficient spray dryers, such as the one in Lichfield, play a decisive role in the industry“, says Clint Brown, responsible for the GEA operation in New Zealand. “The demand for milk in the expanding markets, such as China, can only be met by easily transportable and stable milk powder. This is processed regionally into various dairy products with the help of other GEA technologies”. To this purpose, the GEA experts plan, construct and deliver complete systems and components for production, process cooling, drying, filling and packaging of dairy products.

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PPMA Total Show 2016 Confirms Bright Future For British Processing and Packaging Industry

The UK’s latest innovations in processing and packaging machinery, materials, containers and packaging design solutions were on show at the PPMA Total Show 2016, which returned to the Birmingham NEC from the 27–29 September. The triannual PPMA Total Show welcomed 1200 leading packaging and processing machinery manufacturers to showcase the latest technological innovations and discuss key business opportunities with more than 7,300 visitors.

With the outcome of June’s referendum looming large, the Rt. Hon Lord Francis Maude, former Minister of State for Trade and Investment opened the 2016 exhibition and delivered the opening address on both the challenges and opportunities that lie ahead. Lord Maude, who drew a substantial crowd, addressed the future of the UK processing and packaging sector, discussed the potential aftermath of Brexit negotiations and future plans for the government’s ‘Exporting is Great’ campaign.

Presenting an optimistic outlook on the future, Lord Maude said: “Britain is bigger; its pattern of trade and investment is much more closely intermingled with the EU; and we should aim for and I hope achieve something much more bespoke than Norway, Canada, Switzerland or even Albania.

PPMA2July2015“When we leave the EU Britain will be able to negotiate its own free trade agreements with what are today  third world countries.  Yes, we have less clout on our own to negotiate with India, the US, Japan, China and so on.  But we have several advantages.  First, we unequivocally want Free Trade Agreements. Second, we can focus on what is of interest to us and us alone. And, third we don’t need to aim for perfection.

“I’m not going to pretend that the road ahead will always be smooth and straight.  It won’t be.  There will be twists and turns and bumps along the way.  But I have no doubt that there are huge opportunities as well; and that British manufacturing companies are incredibly well-placed to exploit them.”

Expertise on Display

Visitors to the PPMA Total Show 2016 were privy to not only headline speaker the Rt. Hon Lord Francis Maude, but a range of industry experts who tackled the most pressing issues such as hygiene compliance, food and packaging waste and the skills gap.

Adding to growing national debate on food and packaging waste, Claire Shrewsbury, Packaging Programme Manager for WRAP, educated visitors on the number of government programmes that promote both environmental improvements and the cost benefits to industry, including current projects with GlassRite Wine, and the benefits of developing recycled food grade PP processes.

PPMA2016LogoIn addition, Emma McLeod, Principal Engineer for Process Solutions Global Chocolate R&D Team at Mondelez International, gave aspiring engineers insight into the engineering opportunities in the largest industry in the UK on the final day of the show. Emma discussed her own career as well as how Mondelez are responding to the skills gap, mentoring young engineers from the beginning of their career to build their skills quickly to become chartered professional engineers.

Commenting on the seminar programme, PPMA Total Show visitor Tim Bednall, Business Development Manager, Lorein Engineering Solutions said: “Having attended a number of the seminar sessions, I must say they were great. It is nice to hear real industry experts addressing the problems of the industry as a whole. By coming to a show like this, I am able to listen to a range of expert opinions all under one roof.”

Latest Innovations in Manufacturing

The food and packaging waste debate was not restricted to the seminar stage with debut exhibitors such as TIPA Sustainable Packaging revealing its flexible food packaging that behaves just like an orange peel to the UK market.

TIPA, a developer and manufacturer of breakthrough bio-based, fully compostable, flexible packaging, also announced its partnership with UK social enterprise, Snact, who make snacks from surplus product.

Daphna Nissenbaum, CEO and co-founder of TIPA, says, “Our partnership with Snact marks a first step in the UK market. We’re currently trialling our products with a number of UK brands within the grocery retail sector and hope to see further partnerships announced as brands recognise the benefits of our technology.”

“Working with such an eco-conscious brand like Snact was a natural fit for us and we’re excited to see the roll out of our fully compostable, flexible packaging in support of such a worthy brand in the fight against food waste.”

PPMA3March2016Attendees to Hall 5 at the NEC also witnessed a number of new product launches. Fortress Technology unveiled the latest version of its Halo automatic test technology. Building on Emma De-Alwis’s seminar session on hygiene and contamination, the solution is designed to automatically check that a metal detector is identifying ferrous, non-ferrous and stainless steel contaminants as well as testing the reject system. For food suppliers, it offers a more robust, objective and auditable testing procedure, satisfying the most demanding retailer Codes of Practice.

Speaking about the 2016 exhibition, Phil Brown, Sales Director, Fortress Technology said: “There was a good mix of visitors to the show and we welcomed a number of customers to the stand, both well-acquainted and new. We took a number of orders on the stand and achieved a great deal of interest on our new Halo automatic testing technology that we unveiled and demonstrated at the show, particularly from the pharmaceutical industry.”

Discussing the success of the 2016 show, David Harrison, PPMA Group Exhibition Manager said: “The PPMA Total Show 2016 has been extremely successful and the expanded show format was well received by visitors and exhibitors alike. The show was busy and there was a real buzz on the show floor particularly on the second and third day.”

“Over 150 exhibitors have already booked stands at the PPMA Show 2017, which is a testament to how good the event was. We would like to thank everyone who took the time to exhibit or visit the show and made it a success.”

Celebrating Industry Excellence

Celebrating manufacturing success, over 400 industry leaders, government representatives and press came together on the first night of the PPMA Total Show to see the winners of the PPMA Group Industry Awards 2016 revealed.

PPMA2March2016Awards were presented in 14 hotly contested categories, covering every facet of the industry from processing and packaging to the environment, vision and automation. Among the winners, Festo & Siemens bagged two awards on the night including Most Innovative Automation System and Partnership of the Year while DC Norris took the Processing & Packaging Machinery Manufacturer of the Year and HepcoMotion walked away with the PPMA BEST (business, education, skills and training) accolade for their apprenticeship programme

Commenting on their success at the PPMA Awards, Peter Jones, HepcoMotion Marketing Manager said: “The PPMA Group Awards were a great event, honouring the latest innovation in the industry. The skills gap is a hot topic at the moment, and we’re very proud to be acknowledged for work we do in training young engineers.”

The PPMA Group CEO, Dr. Andrew Mint said: “The PPMA Group Industry Awards was a fantastic evening, celebrating the best that the British processing and packaging industry has to offer. The sheer volume of entries we received this year gave the judging panel an extremely tough task and we’d like to congratulate all those who were shortlisted and those who were successful on the night!”

The PPMA Show returns to the NEC, Birmingham, 26 – 28 September 2017. For information on exhibiting and sponsorship opportunities please email PPMA Exhibition Sales Manager scott.mckenna@ppma.co.uk.

Posted in Conferences & Exhibitions, Packaging, ProcessingComments Off on PPMA Total Show 2016 Confirms Bright Future For British Processing and Packaging Industry

Cooking Process Can Reduce Fat in Dairy Sauces By Up to 20%

Scientific research from the University of Lincoln has shown that food manufacturers can reduce fat in dairy based sauce products by up to 20% by processing with the disruptive Steam infusion Vaction™ technology. Under certain operating conditions, when passing dairy ingredients through the Steam Infusion Vaction™ unit, a fat mimetic is formed which mimics the fat properties in sauces. On bechamel, cheese and hollandaise sauce a creamier mouth feel is achieved while maintaining the sauces viscosity compared to cooking with a traditional steam jacket.

Traditionally to offer consumers a luxury, indulgent mouthfeel a butter or cream is addition is required giving the final product a high dairy fat content. The findings provide interesting areas for new product development that can offer “healthy indulgence”.

The Steam Infusion Vaction™ technology is a disruptive device that sits within a cooking vessel and uses steam as the motive forces to uniquely heat and mix food products. The University of Lincoln has researched the patented Vaction™ cooking technology under an Innovate UK funded project to scientifically identify the product development and operational opportunities of the device.

Many food manufacturers have already switched to cooking dairy based sauces with the technology. Bakkavor has been using the Steam Infusion technology to cook a dairy based porridge, Janet Prescott, Manufacturing Manager explains: “We are very happy with the retrofit of OAL’s Steam Infusion technology to manufacture porridge. We have been able to quickly master how to maximise the benefits of the Steam Infusion system and we’re confident that the technology offers the flexibility to cook a wide variety of products to delight our customers.”

Janet Prescott adds: “The system is very fast and has reduced our cooking energy consumption by 15%. It’s a quality piece of equipment that’s definitely “cook proof”. Since the installation, our engineering team haven’t had to touch the system.”

The recently released whitepaper highlights other areas of differentiation to traditional manufacturing including the prevention of Maillard reactions and retention of “homemade” colours and flavours. The Vaction™ unit creates a partial vacuum within the unit preventing exposure to high temperatures and browning of a product. Gas Chromatography-Gas Spectrometry (GCMS) identified a difference in flavour profile, whilst layperson taste panels recognised an improvement in flavour between a conventionally cooked and Steam Infusion sauce. Both highlighted the preservation of delicate “fresh flavours and prevention of “over processed” notes. The explanation for “homemade” flavours comes from the shortened cooking times and prevention of burn on contamination.

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GEA PerformancePlus – New Service Concept Ensures Optimum Productivity

With GEA PerformancePlus GEA is offering its customers service level options that extend way beyond routine preventive maintenance and complement customer Industry 4.0 strategic efforts. By combining modern condition monitoring technologies with its industry expertise, GEA provides its customers monitoring services, comprehensive analysis reports and reliable optimization recommendations. In turn, GEA customers receive valuable information to make business decisions easier and addressing challenges they face to achieve their specific performance-related goals. GEA PerformancePlus creates transparency about the current health status of the equipment, increases its availability, ensures optimum productivity, brings efficiency optimization potential to light and enables a sustainable equipment utilization. GEA PerformancePlus enables a speedy evaluation of the opportunities and risks of changing production requirements, orders can be assessed and economically scheduled in turn leading to higher productivity for GEA customers.

GEA PerformancePlus will initially be available for GEA separators; on the mid-term it will be extended to other GEA product groups.

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Quality Control of Milk and Milk Products With FT-NIR Spectroscopy

FT-NIR spectroscopy allows a rapid and efficient analysis of the major parameters fat, protein, dry matter, and lactose as well as more specialized special parameters such as salt and pH. It is utilized today in many companies for analysis of solid and paste-like products, such as milk powder, cheese, butter or yogurt. These products are measured without time-consuming sample preparation in diffuse reflection.

The optimal solution for analyzing raw milk and liquid milk products is a combination of the FT-NIR spectrometer MPA with the Liquid Sampling Module LSM, which allows semi-automatic sample feeding and auto-cleaning routines of the system. The LSM is a dual system, i.e. depending on the product and its viscosity the sample can either be pre-treated by the homogenizer or directly fed into the flow cell by a peristaltic pump. This will significantly extended the service life of the homogenizer without having to make hardware adjustments.

bruker2october2016In terms of accuracy and repeatability, the FT-NIR analysis is comparable to the traditional FT-IR systems, but has significantly more options. Not only milk, but also liquid derivatives of milk and milk products can be measured independently of the formulation with the same instrument. Even very viscous samples such as condensed milk and concentrates can be analyzed easily due to the large optical path length of the flow cell (1000 um). The combination of MPA and LSM can handle sugar containing products such as yogurt drinks, flavoured milk and even products with high fibre content such as cat milk.

In addition to the different types of milk, following sample types can be analyzed:

  • Whey and whey concentrates
  • Whey protein and lactose concentrates
  • Cream and whey cream
  • Permeate and Retentate
  • (Sweet) Condensed milk
  • Milk and yoghurt based drinks
  • Melted ice cream.

Bruker Optics offers a simple and reliable solution for the milk-processing industry together with ready-to-use calibrations for milk and dairy products.

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