Archive | Processing

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.

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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.

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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.

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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.

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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.

Posted in Innovation, ProcessingComments Off on A Robust New Standardizer From Tetra Pak Makes Life Easier For Dairy

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.

 

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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.”

Posted in Energy, Environment, Ingredients, Packaging, ProcessingComments Off on GEA Awarded Large-scale Contract For Nutritional Powders Plant in New Zealand

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.

Posted in News, ProcessingComments Off on New Bake Production Line For Northumbrian Fine Foods Increases Capacity

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.

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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.

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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.

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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.

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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.

Posted in ProcessingComments Off on GEA Sets Standards With the Most Efficient Milk Powder Plant in the World

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.

Posted in Processing, ResearchComments Off on Cooking Process Can Reduce Fat in Dairy Sauces By Up to 20%

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.

Posted in Processing, Quality AssuranceComments Off on Quality Control of Milk and Milk Products With FT-NIR Spectroscopy

CPM Wolverine Proctor – A Total Solution Supplier For Breakfast Cereal Manufacturers

By Robin Holding, Commercial Director, CPM Wolverine Proctor Ltd

The breakfast cereal industry sector has seen a fairly steady growth over the last few decades with new markets such as Asia and Eastern Europe developing a taste for UK and western style foods. However, in recent times, the major cereal manufacturers have been challenged by calls for recipe changes, on-the-go product varieties and now, drinkable versions of what hitherto were traditional market favourites.

This presents a great challenge to the cereal 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 and R & D resources to remain competitive, but also because they value the depth of experience that we have built up over the years and around the world. 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.

Project Management and Engineering Resources

In order to meet demand, we have developed our project management and engineering resources across the board, 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, from raw material intake right through to finished product packaging.

Dryer feed end.

Dryer feed end.

For all types of breakfast cereals, we are able to offer complete plants based on traditional batch steam cooking or extrusion cooking, drying and tempering, flaking and shredding, baking and toasting, coating and decorating. Our recent acquisition of TSA Griddle Systems now enables us to add to the breakfast capability with waffles and pancake systems, in addition to our tried and tested granola and cereal bar lines.

Complete Plant Design

Having embraced the latest in computer graphics and software, we use “Inventor” packages to design a complete plant in 3D and can ensure that it will fit into an existing factory without problem by digitally scanning the facility at the outset of a project. This saves huge amounts of time and money because potential interference problems are caught before any metal is cut.

At the detailed engineering level, hygiene continues to be a major driving force for our new design features, benefitting the cereal manufacturer 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 machinery manufacturers and specialists, we can offer cereal manufacturers 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 major breakfast cereal manufacturers 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.

Posted in ProcessingComments Off on CPM Wolverine Proctor – A Total Solution Supplier For Breakfast Cereal Manufacturers

European SprayDry Technologies Introduces ESDT15 Development and Small Scale Production Spray Dryer

Dehydrated food and powdered dairy products have seen their markets grow for many years, with new and improved products appearing on our shelves daily. One common factor linking all products is the extensive development and testing they undergo. European SprayDry Technologies, based in the United Kingdom, has recently introduced an additional model to their highly successful pilot scale spray dryer range. The model ESDT15 is an innovative spray dryer designed specifically for product development and small scale production.

The ESDT15 is harmonised to other models within the pilot scale range, being an all stainless steel appliance from feed tank to powder collection and only requires an electrical and compressed air supply to start production. The machines comes in food grade finish with 316 stainless steel wet contact surfaces and dry contact surfaces, support frame, access platforms, hand railing and ladders all 304 stainless steel as standard.

An upgraded version in pharmaceutical execution is also available to suit the higher standards of material, finish and documentation required by this manufacturing sector.

Standard execution includes primary air/powder separation via cyclone with optional secondary containment reverse jet bag filters available for all model types. Other options include explosion venting and CIP cleaning nozzles.

The unit includes a feed vessel, peristaltic feed pump and two-fluid atomiser plus automatic clean-out needle, exclusively designed and manufactured for European SprayDry Technologies.

Process air is drawn into the system and filtered through G4/EU4 pre filters and F8/EU8 main filters. Process air heating is provided by an electrical heater.

Product discharge is achieved using a high efficiency cyclone to separate the product from the conveying air stream, with finished product collected in receptacles.

A single fan is located on the units exhaust. Both exhaust fan and feed pump are supplied with variable speed control. The control system can be supplied as either Allen Bradley or Siemens PLC.

Industrial Monitors

European SprayDry Technologies continue to utilise Hope Industries range of Industrial monitors with a 23” touchscreen as standard. The standard model is complete with temperature transmitters positioned on the inlet duct, chamber cone and exhaust duct and pressure transmitters on the atomiser air pressure and inlet air filter health monitor.

The chamber is self-supporting with access provided to the profiled chamber door and roof mounted atomiser via access platforms, hand railing and vertical ladders. Upgrades are available for additional platform areas and stairs.

This model ESDT15, like all models in the ESDT pilot scale spray dryer range, is supplied with a 12 month spare parts kit and a 12 month warranty as standard.

First Installation

The first ESDT15 will be installed in the UK at the beginning of October 2016 with further orders secured for delivery to both UK and mainland Europe.

The pilot scale range of spray dryers are a recent addition to the established ESDT equipment portfolio which includes large scale bespoke production spray drying plants.

Evaporators, continuous vibratory fluid beds and agglomerators are available to compliment both the pilot scale and production scale spray drying range, for more information visit www.spray-dryer.com or contact Gareth Hine, Director of Sales on 07740 175272.

Posted in New Product Development, ProcessingComments Off on European SprayDry Technologies Introduces ESDT15 Development and Small Scale Production Spray Dryer

GT2e Brings Speed and Flexibility to New Lines

Heat sealing specialists Proseal has played a key supporting role in the development of the new production facilities at 2 Sisters’ Scunthorpe factory. The ambitious cutting and retail packing project is able to deliver 1.2 million birds per week, and it is therefore vital that every part of the line can deal with this high throughput.

Proseal’s involvement has seen the company supply 12 of its latest automatic, large capacity, high-speed GT2e inline tray sealers with free flow gas flushing for MAP (Modified Atmosphere Packaging) packs. Designed to accept randomly spaced trays from any conveyor and able to be fully integrated with other line equipment, the GT2e features Proseal’s pioneering and innovative E-seal® technology.

proseal1october2016High Performance

This high performance, high precision electric seal system delivers an increased seal force of 600% while reducing compressed air usage by 92%. This enables manufacturers to achieve the high quality seal reliability demanded of the retail sector while at the same time achieving valuable cost savings and sustainability benefits.

Another unique feature is the machine’s Pro-Motion high accuracy tray infeed system, which uses following motion and intelligent buffering technology to enable trays to feed continuously into the sealer without stopping. An auto-detect product flow monitoring system regulates the speed of the infeed conveyor according the amount of trays being supplied. This typically increases speeds by up to 30%.

Rugged Construction

proseal2october2016Like all Proseal equipment, the GT2e offers a rugged construction to food industry approved hygiene standards with full wash-down protection. The company’s established ‘Auto Tool’ connection system enables tool changes to be carried out in around five minutes, while downtime is further minimised by the use of quick-change conveyor belts, and an auto-lock film reel holder. A user-friendly menu-driven control panel provides step-by-step prompts for easy operation.

Equally important, the GT2e has the flexibility to perform any style of heat seal to a pre-formed tray, including atmospheric, MAP, VMAP, Skin, Skin Plus and Skin Deep. Customers can simply select the format types they require and these can be added to or taken off at any time. This allows food manufacturers to change their pack formats in line with customer demands without having to invest in new equipment.

Capable of up to 14 cycles per minute for gas flushing, the GT2e has the speed, flexibility and reliability to meet the requirements of 2 Sisters’ new world-class facility.

Posted in Automation, PackagingComments Off on GT2e Brings Speed and Flexibility to New Lines

Pacepacker Services Leads the Way With Automation Awareness Workshops

Pacepacker Services is teaming up with renowned equipment manufacturer and training provider Festo, to offer Automation Awareness Workshops for its customers, involving all those with a stake in the automation process in smoothing the journey, while maximising the benefits and, ultimately, ROI. The workshops will focus on how customers can integrate systems and extract full benefit from them quickly and efficiently. The half-day events will be free to a given number of attendees from each company.

Increasing numbers of manufacturers in sectors such as food and drink are recognising the benefits of automation, whether in terms of output, yield, reliability, product quality or traceability. However fewer are aware of the less obvious factors influencing how readily that desired result can be fully achieved.

“From upstream machines, which affect the efficiency of the rest of the line, to missed opportunities in enlisting the positive support of the workforce, it is important that we educate our customers and increase overall awareness as part of the process of integrating automation,” explains Pacepacker’s Business Development Manager, Paul Wilkinson.

Each workshop is specifically crafted to be extremely useful and relevant to the specifics of each company’s operations, with full engagement from key company stakeholders, from operators and line supervisors, to engineering team members and directors.

Other opportunities the workshops will highlight include practical preparations for installation and how to manage training or recruitment to ensure customers have the correct in-house expertise to meet the needs of automation.

“This is about smoothing the process of automation inside the factory, it’s about you and your team being ready, and it is about external factors which may affect how the overall system performs,” says Paul. “The end result may be all to do with speed, product quality, reduced wastage and rejects or a combination of all of these and more. Ultimately, this is about maximising return on investment (ROI), in the shortest possible time.”

pacepacker2october2016In practical terms, this new approach to automation awareness could well reduce the period when the line is either not running at all, or running below its optimal performance.

Paul adds: “From Pacepacker’s point of view, we want satisfied customers. This is yet another way we can demonstrate the high levels of support we consistently provide our customers with.”

Festo, though known principally as a manufacturer of automation systems and components, has a strong track record in training and consultancy rooted in its real-world experience. In fact, the company runs 2,900 courses worldwide every year, training no fewer than 42,000 individuals.

The Festo-designed workshops will bring together attendees from different companies at Pacepacker’s head office in Essex. For larger customers, there will be the opportunity for cross-site events where representatives of different operations will be able to pool their experiences and observations.

“Pacepacker is in alignment with our objective to look beyond the supply of components and solutions and to help our customers not just succeed, but to excel in their markets,” explains Neil Lewin, Senior Consultant for Festo Training & Consultancy. “The course will raise awareness of the complete approach required when engaging in automation projects, and provide customers with a strategic plan for implementation of automation in to their plant. The end result being a solution that meets its promises on ROI and sustainability.”

A white paper and ‘automation checklist’ will perform a similar function for businesses installing smaller systems. For further information contact Pacepacker Services on +44 (0)1371 811544, or visit www.pacepacker.com.

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Gemak Equips New Village Dairy Yogurt Plant

Earlier this year, Gemak was awarded a contract to manufacture and commission a state-of-the-art continuous yogurt processing plant at Llaeth y Llan, Village Dairy where Gareth Roberts and his family have been producing superb, award winning yogurts since the ‘80s. Plenty of hard work and perseverance has helped create a beautiful Welsh yogurt that people throughout Great Britain love eating!

The new plant is in operation, capable of a fully automated continuous blending and processing of 3000 l/h yogurt. The plans for the new plant come on the back of a successful growth in Village dairies fruit yogurt market.

Village Dairy General Manager, Owain Roberts says: “We are very excited about our new plant and opportunities it brings to our business. With the new plant we have been able to achieve consistent and repeatable quality, exacting recipes, better controls and advanced data accumulation, improved efficiency and better yields with a much faster output rate. Gemak has delivered on every promise. We have visited Gemak at their new production plant and were very impressed with their quality, manufacturing, level of engineering and their experience in dairy processing. They also offered the quickest lead time and most competitive prices in the market.”

General view of mixing and pasteurisation.

General view of mixing and pasteurisation.

Fully Automated

The fully automated processing plant incorporates a continuous inline yogurt mix preparation and pasteurisation system for different recipes. A number of recipes can be entered consecutively at the start of the shift into the Scada system with the desired quantity and destination vessels for a non-stop processing shift with continuous recipe change-overs. With the touch of a button the system weighs and accurately feeds the necessary ingredients into a mix vessel, blends, dehydrates, homogenises, pasteurises, holds and cools before sending the recipes with desired quantities into pre-selected vessels for fermentation.

The yogurt is than cooled to the desired temperature and fed to bespoke design ribbon blenders for fruit addition followed by very gentle, accurate and effective blending without impacting on the viscosity of yogurt. From here the yogurt is packed into tubs. Gemak also supplied 2 CIP units for raw and finished, raw milk reception unit and water chiller.

Benefits

Fermentation room.

Fermentation room.

The new application removes a timely process of pre-mixing and preparing of the blends for the base prior to pasteurisation with a new in-line automated liquid and powder recipe blend process in-line with the continuous pasteurisation. The benefits of the new system to Village Dairy are reduced labour with 60% reduction in energy use, 70% increase in processing speed, 60% improvement in process controls, monitoring and recording.

Kursat Uysal from Gemak UK says: “Village dairy is very well known and admired for their superb yogurt quality that they developed and perfected over the last 30 years with a loyal customer base. I am also one of those customers – so you can imagine the pressure.

“We were given the task not only to design and commission a fully automated turnkey yogurt processing plant with improvements in all areas which we have a lot of experience and know how in but also to match/improve on the current product quality, taste and viscosity. We are very pleased to have lived up to our customer’s expectation and delivering on our promise. Gemak specialise in process solutions for the dairy industry and has manufactured and installed over 300 turnkey dairy plants around the world since 1986.”

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Innovative Self-priming Pump Does Double Duty For Dairies

By Allan Bruun, Industry Manager, Dairy, Market Unit Food, Alfa Laval

Are you looking for a self-priming pump that improves energy efficiency and reduces noise levels, as well as meeting the latest hygienic design standards? Using airscrew technology, the Alfa Laval LKH Prime sets a new standard in self-priming pump technology.

Based on the Alfa Laval LKH premium range of centrifugal pumps the Alfa Laval LKH Prime is specifically constructed for pumping liquids containing entrained air, making it an excellent choice as a CIP return pump. The Alfa Laval LKH Prime is 40 percent more energy efficient and operates at noise levels 80 percent below conventional liquid-ring pumps. As all pumps in the LKH family, the Alfa Laval LKH Prime is EHEDG certified and authorized to carry the 3-A symbol.

Versatile and efficient, the Alfa Laval LKH Prime is therefore of interest to dairy owners and operators who are concerned with:

  • Reducing energy consumption
  • Improving the work environment
  • Reducing installation costs.

Reducing Energy Consumption

alfalaval1october2016compressedThe hydraulic efficiency of the Alfa Laval LKH Prime reaches over 50% (Image 1). This means the Alfa Laval LKH Prime offers an added advantage over liquid-ring pumps, which typically reach efficiencies of approximately 30 percent. Its high efficiency is easily attainable at a wide flow range, which translates into substantial savings no matter the duty point.

Improving the Work Environment

The Alfa Laval LKH Prime also contributes to a better work environment. It reduces the noise emission level by up to 80 percent compared to conventional liquid-ring pumps. With a noise level of a mere 74dBA, the Alfa Laval LKH Prime efficiently eliminates the need for these protective measures.

Reducing Installation Costs

While the Alfa Laval LKH Prime is primarily designed for CIP return duties, the hygienic design means it may also be used to pump dairy products. For instance, the Alfa Laval LKH Prime is a reliable pump for emptying milk tanks. Because of the pump’s ability to handle both CIP return liquid and dairy products, it is possible to eliminate the need for a separate liquid-ring pump.

The Alfa Laval LKH Prime combines the gentle product treatment and hygienic design of the LKH range with the liquid-ring principle. In many cases, this can reduce the number of pumps required for an installation from two to just a single pump.

Reducing the installation costs from two liquid-ring pumps to one Alfa Laval LKH Prime pump results in:

  • Lower capital investment, one pump instead of two
  • Lower piping, cabling and automation costs
  • Lower spare parts and service costs.

Service is a key element of any Alfa Laval offering and the commonality of spares, including the shaft seal, in the LKH range translates into reduced spare parts inventory and fast maintenance.

Working Principle

As the pump starts up, a liquid ring is formed in the pump head canister (image 2) and the recirculation pipe is filled (2), thereby achieving the initial prime. This liquid ring is formed in the space between the diameter of the inlet pipe, and the outer diameter of the offset canister housing the airscrew. The resultant liquid ring creates a water seal between the airscrew hub and the top of the canister (3).

alfalaval2october2016compressedAn air column is created between the airscrew hub and the liquid ring (1). The air column is separated into air pockets by the airscrew and then forced into the impeller’s suction stage. Some of the priming liquid re-circulates over the recirculation pipe (2). Air is removed until the content is just a few percent and no pockets are generated. The pump then acts as a traditional centrifugal pump, transferring the liquid from the suction stage (4) through the discharge (5).

When there is no air present, the canister and recirculation loop have no function and are completely filled with liquid. The liquid passes through the canister into the impeller’s suction stage. Here again, the pump acts as a traditional centrifugal pump, transferring the liquid through the discharge at a higher velocity and pressure.

Summary

alfalaval3october2016compressedThe Alfa Laval LKH Prime Pump delivers:

  • Reduced energy consumption
  • Improved working environment
  • Reduced installation cost
  • And have spare parts commonality with the Alfa Laval LKH pump range making it easy to service.

Allan Bruun is Alfa Laval’s Dairy Industry Manager, responsible for the heat transfer and fluid handling business. Allan coordinates commercial and technical market intelligence between sales channels, dairies and central Alfa Laval functions seeking to optimize the customers’ processes and increase the competence level of the organization. Allan holds university degrees in mechanical and electrical engineering as well as business administration. Contact: allan.bruun@alfalaval.com.

About Alfa Laval

Alfa Laval’s worldwide organization works closely with customers in nearly 100 countries to help them stay ahead in the global arena. Alfa Laval is listed on Nasdaq OMX, and, in 2015, posted annual sales of about SEK 39.7 billion (approx.4.25 billion Euros). The company has about 17.500 employees.

Posted in Enterprise, Environment, Hygiene, Processing, Quality AssuranceComments Off on Innovative Self-priming Pump Does Double Duty For Dairies

New Video Provides Easy Training For Homogenizer Maintenance

As part of its investment in comprehensive support services, SPX FLOW has released a new video that provides maintenance personnel with detailed instruction and training on how to inspect and maintain its leading APV Gaulin homogenizers. SPX FLOW’s APV Gaulin range of homogenizers have been proven to offer leading dispersion results across a wide range of applications into a variety of industries including dairy, food, beverage, cosmetics and pharmaceuticals. The experience and understanding SPX FLOW has of this process ensures optimal results for even the most sophisticated emulsions. To preserve optimum performance, however, the equipment needs to be properly maintained. A new step-by-step online video gives maintenance personnel clear and detailed instructions on how to remove and inspect packing gland components, plungers and check valves as well as inspection of drive belts to ensure machine reliability and performance is well maintained.

SPX FLOW’s growing library of online service videos helps to support its customers as efficiently as possible; giving them easy access to the information they need to keep their process equipment operating smoothly and economically. The videos provide clear and easy to follow visual guides that technicians can use to make sure work is being carried out correctly and safely while utilizing genuine SPX FLOW parts.

The new APV Gaulin homogenizer maintenance and inspection training video can be found on SPX FLOW’s YouTube channel.

Posted in Processing, Training & EducationComments Off on New Video Provides Easy Training For Homogenizer Maintenance

SKF Corrosion Resistant Bearings: Full Menu Option For Food Safety and Reliability

In response to the food and beverage industry’s changing needs, SKF has developed a comprehensive range of bearings meeting safety requirements, designed for reduced maintenance and long life in a wide range of production environments. Product safety is the top priority for food and drink manufacturers, consumers and regulators alike. The latest industry requirements, like the US Food Safety Modernization Act and ISO 22000, require companies to place increased emphasis on equipment and processes designed to prevent product contamination during manufacture.

Bearings used in food production machinery present multiple challenges in this context. The wide temperature variations, high humidity and chemically aggressive environments found in food production can lead to accelerated corrosion and wear. That challenge is compounded by wash-down protocols involving pressurized water jets and chemical cleaning agents. Even maintenance and bearing replacement procedures create risks of contamination from dropped parts or spilled lubricants.

The foundation of SKF’s offering is the Food Line range of deep groove ball bearings, which feature industry standard stainless steel rings, rolling elements, cages and seal backing plates. For the most demanding environments, meanwhile, the MRC Ultra corrosion resistant range uses proprietary high nitrogen corrosion resistant (HNCR) stainless steel rings and ceramic rolling elements for dramatically improved fatigue life.

As standard the bearings in both ranges are pre-lubricated with NSF in category H1 grease suitable for incidental contact in food production environments. In accordance with FDA recommendations, the synthetic rubber seals used in the bearings are coloured blue for optical detectability. In addition the SKF Food Line stainless steel deep groove ball bearing seals have EC approval.

An alternative to conventional grease lubrication is SKF’s Solid Oil technology, a polymer matrix saturated with food grade lubrication oil that keeps contaminants out and resists wash-down chemicals and water without emulsifying. Solid Oil completely fills the internal space within the bearing, encapsulating the cage and rolling elements. The resulting lack of internal voids eliminates “breathing”, where temperature changes between operation and cleaning cycles can allow conventional bearings to draw in moisture, causing corrosion. The Solid Oil matrix also contains two to four times more oil than conventional greased bearings, meaning lubricant life is extended, reducing routine maintenance requirements and a particular benefit in hard to reach areas.

SKF can use its extensive experience of the food and beverage production environment to develop custom solutions for the most demanding applications. One major ice cream producer, for example was suffering premature bearing failures in its hardening tunnels, as a result of corrosion due to moisture ingress in the bearings. The problem was exacerbated by breathing during cleaning cycles when bearing temperate rises rapidly from -45°C to +25°C.

SKF replaced the conventional bearings use in the machine’s 32 hubs with MRC HNCR units, lubricated with food grade Solid Oil and further protected by a custom machined, FDA approved optically detectable secondary seal. The new design has extended expected bearing life for the customer from one year to six[1], and eliminated the need for periodic relubrication with traditional grease, significantly reducing the risk of product contamination and also providing further productivity benefits.

Find more information on SKF’s corrosion resistant bearings for the food and beverage industry onhttp://www.skf.com/group/industry-solutions/food-and-beverage/product-news.

Posted in Food Safety, Processing, Quality AssuranceComments Off on SKF Corrosion Resistant Bearings: Full Menu Option For Food Safety and Reliability

Tunnock’s Expansion Aided By Food IT Experts at Sanderson

“The administrative burden for any food manufacturer is huge these days,” says Bruce Reidford of Tunnock’s. He was responsible for choosing the Sanderson food manufacturing IT system, today known as UnityF8, on which Tunnock’s has expanded its business. “We just could not have coped without UnityF8,” he says. “It would have been impossible to manage our expansion into global markets and to manage the regulatory demands. Sanderson has understood the way we operate, our values and our needs.”

Reidford’s role sees him in charge of administration, finance and IT, and he also has involvement in operational matters within the factory.  “Without the support of sophisticated technology like UnityF8, we’d need an army of clerks running around carrying out this work,” he says. Tunnock’s uses the software to manage every aspect of the organisation, from ordering and receiving raw ingredients, to managing production and sales ledger processing, through to final despatch and distribution.

Sanderson3August2016Meeting the Needs of Customers

Tunnock’s customers range from the major supermarkets to independent retailers – this diversity could pose challenges in terms of meeting the needs of customers large and small. However Reidford says “We’re able to balance conflicting requirements very easily with UnityF8. We schedule orders through the system and attach priority listings to them. This also helps us at the other end of the line, with transport scheduling and loading.”

At goods-in and despatch, Tunnock’s uses radio data terminals (RDTs) which are linked directly to the Sanderson system. All goods are bar-coded and the RDTs enable Tunnock’s to locate both raw materials and finished goods quickly and efficiently. In common with most manufacturers, Tunnock’s is continuously striving to ensure its processes are as effective as possible. A key part of this improvement drive is using UnityF8 ‘s integrated factory floor data capture functionality.

“With increases in costs such as energy and raw materials, we have to know exactly what is happening on the factory floor, where any waste is – both physical and process – and where the best areas are, so that we can learn from that. This is about reducing downtime, reducing costs and raising efficiency. We know we can be more effective by cutting waste, using labour more efficiently and automating certain lines.”

Sanderson2August2016New Developments

Reidford continues: “The new developments to UnityF8 enhance our capability and ensure that we can remain one step ahead. As the regulatory demands become greater and greater, we have to look at the best way of meeting those. Often the reporting requirements and structures change, but UnityF8 means we can cope with all of that very easily. Sanderson are very responsive and an excellent business partner.”

As a specialist business management system for the food industry – or what you may call a food enterprise resource planning (ERP) system – Sanderson UnityF8 provides control and visibility across the organisation. Its inherent flexibility has proved particularly crucial to Tunnock’s, as the system has been able to grow and expand to help the business drive forward into new international markets.

“I looked at several solutions and I was confident from the start that Sanderson was the best fit for our business,” he recalls. “UnityF8 is a very effective, reliable and dependable product. But it’s not just about software. We wanted true commitment from an IT supplier to work with us to solve our business problems. That was as important as the software itself. We’ve grown with Sanderson and we’ve been delighted to have them as our business partner.”

For further information contact Sanderson on Tel +44 (0)333 1231400 or visit www.sanderson.com/food.

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Arla Foods Chose to Go ALL-IN

More and more Arla plants are investing in ceramic bearings from CeramicSpeed to reduce damage on production equipment. The benefits of ceramic bearings in the production equipment are nothing short of novelty, and rumor has it that the Danish manufacturer CeramicSpeed, is leading the way. Proof of that is their long-term collaboration with Arla Foods that gets convinced by the benefits of the CeramicSpeed bearings, one dairy plant at a time.

The latest case study comes from their collaboration with Arla Foods Brabrand, a large Danish Arla plant, which was very familiar with the consequences of expensive and unplanned production breakdowns and the significant costs these damages caused. They found the answer in the replacement of all bearings with CeramicSpeed bearings, and on critical equipment combining it with monitoring.

At Arla Robust Processes are Essential

CeramicSpeed2August2016At Arla Foods Brabrand, there is a great focus on constant and robust processes, since the company production is based on orders. This is why it is extremely important to ensure that there are no weak links in the production line. Since the production must not stop until the finished product is obtained, production breakdowns have great financial consequences. Thanks to their longer lifetime, lower energy consumption and the guarantee of a better uptime in production, Arla Foods Brabrand chose bearings manufactured by CeramicSpeed to save significant costs within a few years.

Bearings and Monitoring as Part of Production Efficiency

“Trying to fix immediate problems is expensive and impossible to plan ahead,” says Michael Helm from Arla Foods Brabrand. This is why, it is essential for him, to find a model that secures better uptime in production. “In collaboration with ME Aarhus and CeramicSpeed, we have found a solution. We have started the process of replacing everything with CeramicSpeed bearings in all of our machinery, implementing monitoring on critical machines at the same time. Through this, we can take action before the damage actually occurs, that is before the following financial consequences appear. In our experience, the maintenance cycle is improved with CeramicSpeed bearings, thanks to the bearing lifetime that is much longer than standard steel bearings. To us, this has resulted into a better use of resources in our maintenance department, and fewer costs for the maintenance of production equipment. Now, the need for maintenance is considerably smaller and we can act before the damage occurs.”

CeramicsSpeedGraphAugust2016An Investment that Pays Off

At Arla Foods Brabrand, CeramicSpeed has seen the same pattern as with other industrial companies. The extra cost you pay for CeramicSpeed bearings has very little importance compared to the frequent breakdowns and related costs. For this reason, the dairy has chosen to go ALL-IN, which means making all of their equipment more efficient by replacing their bearings with CeramicSpeed bearings and combine the replacement process with monitoring in critical areas.

“Over time, we expect less breakdowns caused by the bearings. This is, without a doubt, based on the high-quality of CeramicSpeed balls and the other components in the bearings. This is not a standard bearing, but a bearing in which, the focus is on the machine in which it will operate. Even though the bearings are a bigger investment, the price is not decisive. The saved costs for other machine parts that also typically break in connection with breakdowns and the loss of production capacity, result in a smaller total expense. There is actually a great deal of money to be saved,” says Michael Helm.

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CPM Wolverine Proctor – A ‘One-stop Shop’ For Customers

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. CPM Wolverine Proctor has manufacturing facilities in Europe and the USA and customers are becoming progressively more reliant on the company as a system supplier, partly because they have had to reduce their own staff numbers to remain competitive.

As a consequence, CPM Wolverine Proctor has developed its project management and engineering resources across the board, bringing in new design initiatives and process knowledge, allowing the company to draw on experiences that may have come from unexpected applications in other industry sectors and enabling it to offer a truly turnkey supply.

CPMWolverine1August2016For breakfast cereals, CPM Wolverine Proctor is able to offer complete plants based on traditional steam cooking and extrusion cooking, drying and tempering, flaking and shredding, baking and toasting, coating and decorating. CPM Wolverine Proctor’s recent acquisition of TSA Griddle Systems now enables it to add to the breakfast capability with waffles and pancake systems, in addition to its tried and tested granola and cereal bar lines.

Using “Inventor” software, CPM Wolverine Proctor is able to design a complete plant in 3D and ensure that it will fit without problem by digitally scanning an existing facility at the outset of a project.

Teaming up with other machinery specialists, CPM Wolverine Proctor can offer customers a ‘one-stop shop’ for everything from raw material handling through to finished product palletization, all managed by a dedicated project management team.

CPM Wolverine Proctor’s continuing drive to be the preferred machinery supplier means that it talks to customers about what they like and dislike, listening to their ideas and identifying the priorities for their business. Only then can CPM Wolverine Proctor hope to meet and exceed their expectations.

CPM Wolverine Proctor is proud to be a major supplier to the global leader in breakfast cereal manufacture.

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“Let’s Create Your Success!” With GEA at Chillventa 2016

GEA1August2016From October 11 to 13, 2016, Chillventa will turn the trade show fairgrounds in Nuremberginto an international meeting point for the world of refrigeration, HVAC, and heat pumps. “Let’s create your success!” is GEA’s motto at this year’s Chillventa. Analogous to the classical Tangram puzzle with its infinite opportunities, the products and solutions from GEA offer virtually unlimited possibilities for individual customer requirements in a great diversity of applications and industries. GEA will present innovative products in its range of commercial and industrial compressors, ice generators, solutions along the entire cold chain as well as product animations in hall 7, booths 306 and 504. Furthermore the Service team is looking forward to show the comprehensive range of service for the first time and will be available during the days of the exhibition.

Efficiency enhancement with the semi-hermetic compressors in the GEA Bock HG series

The HG series of semi-hermetic compressors – the GEA Bock HG22e, HG34e, HG44e, HG56e, HG66e, HG76e and HG88e models – have now been optimized and offer top efficiency as well as optimized running quietness. These compressors profit from an efficient valve plate system, electric motors from the latest generation, and improved gas passage – which enables them to achieve optimal efficiency. The oil pump lubrication system enables a greater control range with frequency inverters.

Whereas the models already on the market have been optimized, the GEA Bock HG56e represents a completely new 6-cylinder series. The new HG56e series replaces the previous 4-cylinder HG5 series and the smallest series of the HG6 compressors. It offers greater efficiency and optimized running quietness, and its three model sizes cover the displacement range from 73.8 to 100.4 m³/h (at 50 Hz).

The semi-hermetic compressors GEA Bock HG22e, HG34e, HG44e, HG56e, HG66e, HG76e, and HG88e (left to right).

The semi-hermetic compressors GEA Bock HG22e, HG34e, HG44e, HG56e, HG66e, HG76e, and HG88e (left to right).

The compressors HG22e, HG34e, HG44e, and HG56e operate with an optimized standard valve plate design. The two series HG66e and HG76e, to be launched on the market, will feature the proven-successful mexxFlow design concept. The combination of the double lamellar ring design of the mexxFlow valve plate, featuring flow-optimized characteristics, with a cylinder head especially designed for this valve plate, has enabled an efficiency increase of the compressors by up to 20%, depending on application.

Minimum space requirement and top performance: the new GEA RedAstrum heat pump

GEA3August2016An innovation in the heat pump range will soon go into production: the GEA RedAstrum, a new series of standardized ammonia heat pumps designed for indoor installation. With this system, the refrigerant ammonia remains in the machine room. The distribution of heat to the user takes place via a water circuit, which extends the application range of the heat pump. The performance of RedAstrum and the heat it supplies, at temperature levels between 55 and 80 °C, makes it ideal for industrial applications – especially for heating water in industrial processes – or for feed of heat into nearby or remote district-heating networks. In addition to its outstanding efficiency, the RedAstrum impressively applies a further advantage: thanks to its compact design, it can be effectively installed and operated in machine rooms. Speed-controlled screw compressors contribute to low power consumption in full- and part-load conditions as well as a high COP with their optimal internal volume ratio and heat exchangers that had already been used in the GEA Blu chillers. These heat exchangers ensure very good heat transfer from the ammonia to the water circuit.

Sustainable compressor technology for natural refrigerants: the GEA Bock HG series

For subcritical and transcritical CO2 applications, GEA offers a range of compressors that now includes a displacement of 6.2 to 38.2 m³/h (at 50 Hz), with 2, 4, or 6 cylinders. These compressors are characterized by great reliability, excellent running behavior, a broad frequency band for minimal part-load requirements, slight oil carry-over, and outstanding efficiency. The semi-hermetic 6-cylinder piston compressor HG46 CO2 T, for example, is currently the largest of its kind for transcritical CO2 applications and offers long-standing field experience. In addition to its displacement up to 38.2 m³/h, it is also impressive owing to its outstanding coefficient of performance (COP). The great efficiency of transcritical GEA CO2 compressors has been confirmed by ASERCOM certification for a number of compressor models.

GEA compressors for applications with natural refrigerants: GEA Bock HG34e CO2, HG46 CO2 T, and HG56e HC (left to right).

GEA compressors for applications with natural refrigerants: GEA Bock HG34e CO2, HG46 CO2 T, and HG56e HC (left to right).

GEA also offers efficient solutions for hydrocarbons: the HC range (HC = hydrocarbons), with displacement of 5.4 to 279.8 m³/h, satisfies all stipulations of the F-Gas Regulation. This provides planning assurance to plant contracting companies, operators, and investors. In addition to the already optimized and well-establish model HG44e HC, GEA will present new 6-cylinder compressors for hydrocarbons: the GEA Bock HG56e HC series, with three models, covers the range with displacements from 73.8 to 100.4 m³/h. HC compressors for applications with hydrocarbons are available in an extensive displacement range, including ATEX applications, Zone 1 and Zone 2.

The GEA Grasso M series: extended portfolio for smaller capacities

GEA5August2016With its new, smaller screw compressors, GEA now rounds off its GEA Grasso M series downward by adding smaller output ratings. The former spectrum of offerings began at volumetric displacements of 471 m³/h (at 2,940 rpm) and extended to 870 m³/h. The expanded series now begins at 231 m³/h. The new small models benefit from the proven and energy-efficient design: they are engineered for the speed range from 1,000 to 6,000 rpm, which allows them to cover a broad load range. The internal volume ratio (Vi) can be controlled in an extended range, which allows energy-optimized operation even at reduced condensation temperatures.

In addition, the pressure-activated check valve ensures minimal pressure drop on the suction side. The GEA Grasso M series furthermore offers an integrated suction filter and an adaptive coupling casing, which simplifies integration into a package. The GEA Grasso M series represents the development of an industrial screw compressor that differs above all from conventional screw compressors in reliability and efficiency.

The GEA Splitpack – a GEA Geneglace ice generator and GEA Bock Plusbox, perfectly matched

The GEA Splitpack combines the GEA Geneglace ice generator with the GEA Bock Plusbox to provide a complete solution. The split system allows the ice generator to be installed on the shop floor, near the process. In contrast, the Plusbox, a complete outdoor condensing unit, is installed outside at a distance of up to 20 m from the ice generator.

GEA6August2016The Plusbox features proven semi-hermetic GEA piston compressors, with maximum displacements of 18.8 to 33.1 m³/h. A speed-controlled fan at the condenser ensures efficient ice production, even with high outdoor temperatures, since it assures a constant temperature of condensation. The GEA Splitpack operates with the refrigerants R404A or R134A and is available with GEA Geneglace ice generator F15, F30, F90H, or G100. Maximum production is 400 to 2,200 kg/day, depending on the ice generator used.

Posted in Conferences & Exhibitions, ProcessingComments Off on “Let’s Create Your Success!” With GEA at Chillventa 2016

Processing, blending and filling to customers’ specifications

sternmaid_pilot-plant_fluid-bed-technology_01At Health Ingredients Europe, the contract manufacturer SternMaid will present a diversity of possibilities for outsourcing production processes. The company has a wide range of plant and machinery at its disposal, consisting of mixers for powders and liquids, milling machines, various packaging lines and a multifunctional fluid bed processor. Food ingredients in powder form, such as vitamins and proteins, or dry beverage bases and dietary supplements can be processed, blended and packaged just as the customer wishes.

Processing

With the aid of fluid bed technology, SternMaid is able to modify the structure of the particles and thus their behaviour in practical use to permit specific applications – to mask an odour or taste and achieve better dispersibility, to reduce the proportion of dust or to protect the product against external influences. For example, powder mixtures can be agglomerated to form tablettable premixes or permit easy dosing in beverage dispensers or capsule coffee makers. Process air temperatures from 20 to 130 °C make it possible to adjust the drying conditions more flexibly to the products –important, for instance, in the gentle drying of enzymes.

Contract blending

For contract blending SternMaid has three blending lines for small and medium-size orders between 100 and 10,000 kg. Four other lines are designed for large quantities over ten tonnes; these are fully automated and capable of measuring and weighing in as many as 15 different raw materials. For highly sensitive applications such as allergen-free foods the company has a separate section of the plant with a counter-current container blending line designed to pharmaceutical standards. All the lines have a blending accuracy of up to 1:100,000 and flexible filling options.

Contract packaging

In the co-packing field SternMaid also has state-of-the-art packaging lines capable of filling both industrial and retail packs. Besides filling sacks, fibreboard boxes and FIBCs, the lines can handle cans and tubs, tubular bags and folding boxes in sizes from 50 to 5,000 grams.

Posted in Ingredients, Packaging, ProcessingComments Off on Processing, blending and filling to customers’ specifications

Au2mate Delivers the Fully Integrated Factory Automation System For the Arla Foods Ingredients Hydrolysates Factory

By Klaus Dam, Managing Director of Au2mate A/S

This article gives an overview of the design and implementation process for the highly advanced factory automation system at the Arla Foods Ingredients Hydrolysates factory opened in June 2016.

The project has been implemented in close cooperation with AFI as the end user and Process Engineering as the main engineering contractor and with Au2mate as the supplier of the factory control system.

The Hydrolysates plant is complex both in terms of processes and applied automation technology and at the same time the performance requirements are set very high; this includes user friendliness, process optimization, waste, energy consumption, detergents and plant uptime.

The plant automation solution is based upon the latest yet proven technologies and equipment from leading manufacturers, ensuring the investment and future development of the plant.

The engineering standards applied as the basis for the solution are leading international standards ensuring the quality today as well as flexibility with regard to future support and development. The project is fully documented accordingly.

The software solution is designed according to S88/S95 which forms a robust platform supporting superior management of the dairy inclusive of fully integrated manufacturing order execution.

Extended use of well proven software modules in accordance with Arla Foods standards, guidelines and best practices ensures straightforward future development, extensions and maintenance.

AFI Hydrolysates factory situated in Nr. Vium in the Western Part of Jutland, Denmark.

AFI Hydrolysates factory situated in Nr. Vium in the Western Part of Jutland, Denmark.

The solution designed and implemented at the AFI Hydrolysates factory is embedding the joint Au2mate expertise and good automation practice gained from conducting major automation projects over more than 3 decades.

To future proof the plant it is most important to recognise that the plant automation system is designed in a flexible manner in order to facilitate that the process can be optimised concurrently during the life time of the plant aligned with changes in production requirements, process requirements and on-going changing and upgrading of production standards.

From an automation perspective the key to achieve this is to design the hardware as well as the software in a modular, standardised and well documented way. And further that the applied technology for the plant automation system is transferred to the operational organisation of the AFI Hydrolysates factory.

Below in this article there is a more detailed description of the design and functionality of the control system as well as the implementation and project management of the project. Please refer to below photo showing a part of the process area.

Design and Functionality of the AFI Hydrolysates Factory Control System

Part of the process area.

Part of the process area.

The plant is equipped with a comprehensive automation system comprising I/O, PLC, SCADA, MES as well as communication networks.

Operation of the plant takes place from 10 pcs. Wonderware InTouch operator stations located in the central control room as well as in the field for operation and monitoring of the plant.

The control system is based upon 20 pcs Siemens S7-414 PLCs for the process. Interface to the plant items takes place via ET200 modules located in I/O boxes in the plant process area. The interface boxes are connected to the PLCs via Profinet. Interface to the MCC takes place via ET200 modules located in the MCC panel connected to the PLCs via Profibus. Interface to selected process instruments also takes place via Profibus.

The server part of the control system is based on Wonderware System Platform and includes 4 servers running a Historian server and a redundant pair of Application Servers. For more information please refer to the below figure 1 showing the Automation Architecture.

Figure 1: Arla Foods Ingredients Hydrolysates Automation Architecture.

Figure 1: Arla Foods Ingredients Hydrolysates Automation Architecture.

The software part of the system is designed according to Arla Foods standards for PLC, HMI, Data collection, Recipe management, OEE and reporting. The control system structure follows the basic principles in the ISA S88 Batch Model. The MES application is S95 structured and designed according the latest international standards.

The plant is fully automatic and requires a minimum of operator interaction and the automatic sequences will control the process under full control system monitoring and supervision.

The PLC software is developed for control and monitoring of the individual plant units forming the entire Hydrolysates process. The software comprises modules for automatic control, regulation and monitoring of the plant as well as handling of operator interaction. The software is structured according to S88 and extensively tested and simulated to obtain optimal commissioning of the plant.

The software for automatic control of the process energises actuators, valves and pumps in a predetermined sequence hereby initiating the individual processes. The key components and process parameters are carefully monitored during process operation, including e.g. monitoring of states, pressures and temperatures. Alarm handling and logging includes alarm state, date and time. For quality purposes, process events are logged in a database inclusive of e.g. date, time, material, recipe number and production order.

The application software for the HMI/SCADA system is based on Arla Foods standards. The software is developed as user friendly graphics based operator pictures ensuring an efficient operator dialogue during operation as well as monitoring of the plant. Please refer to photo below showing the central control room.

The central control room.

The central control room.

The MES solution is based upon the platforms from SAP, Microsoft, Wonderware and Arla Foods, providing a fully documented and open standard platform, safeguarding the investment and ensuring straightforward future development of the plant. The SQL database is designed according to S95 forming the backbone for the required MES applications and reports.

The plant is running recipe controlled production based upon the use of Arla Foods recipe system RMS as well as integration with SAP production orders.

The collection of production data and associated reporting is based on the Arla Foods modules for data collection and reporting via MII.

The OEE functionality is based on the Arla Foods standard. The plant status is registered continuously e.g. machine error, line error, etc. and OEE reports are implemented via MII.

Implementation and Project Management of the AFI Hydrolysates Project

Klaus Dam, Managing Director of Au2mate A/S.

Klaus Dam, Managing Director of Au2mate A/S.

The project was generally executed according to Au2mate QA manual complying with leading international standards and methodologies inclusive of development of test sheets for quality assurance.

The planning and coordination of the project was performed by an appointed project manager in close cooperation with the AFI organisation and the process contractors. The project manager also coordinated and organised the work in the dedicated Au2mate project group.

The software programming of the AFI Hydrolysates plant control and MES system was carried out on the basis of Functional Design Specifications (FDS) prepared by Au2mate and approved by the process contractors. The FDSs describe all sequences and Unit operations in detail.

The detailed software Factory Acceptance Test (FAT) was carried out on the Au2mate premises prior to on-site tests. The FAT is introduced in order to ensure that as regards control, the plant operates according to the program description (FDS). The test was conducted in corporation with AFI, their representatives and the process contractors.

Training of the AFI staff was done in parallel with the project execution, in order to develop the skills required to operate, run and execute maintenance of the plant independently of external support.

Au2mateLogoJuly2016A simulation concept of the plant was created as part of the project. The concept was applied as a helping tool for the FAT as well as a training tool for training of plant operators and maintenance staff.

Key Project Learning Points

It has been a pleasure for Au2mate to act as a proactive automation supplier in the delivery of the control system for the AFI Hydrolysates factory. The project was successfully delivered on target for time, budget as well as quality.

From our perspective the goals were achieved due to clear project targets and project management by AFI, sufficient knowledgeable resources allocated to the project and excellent teamwork during the whole duration of the project between AFI and the vendors involved in the project.

 

 

 

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The Future of UK Manufacturing Debate Heats Up at the PPMA Total Show 2016 – 27–29 September 2016, NEC, Birmingham

The UK manufacturing industry looks to the future with baited breath following the results of the EU referendum. As the wider UK economy remains unpredictable, the results of the referendum could represent a unique opportunity for the manufacturing sector should businesses consider the tactical, short-term implications and realise the importance of maintaining a focus on long-term strategic planning.

Speaking about the future of the UK manufacturing sector, the Rt. Hon Lord Francis Maude, former Minister of State for Trade and Investment will join visitors at this year’s PPMA Total Show to open the 2016 exhibition and deliver the opening address on both the challenges and opportunities that lie ahead. Appearing on the PPMA Total seminar stage on the first day of the show (Tuesday 27 September) Lord Francis Maude will discuss the outcome of the recent EU referendum and reveal the future plans for the government’s ‘Exporting is Great’ campaign.

PPMA3March2016The PPMA Total Show 2016 will not only see headline speakers like the Rt. Hon Lord Francis Maude but a range of industry experts who can offer insight and advice on the future of the UK manufacturing industry. Also confirmed to speak at this year’s PPMA Total Show, Emma De-Alwis, Hygiene Specialist at Campden BRI, Claire Shrewsbury, Packaging Programme Manager for WRAP, Elliot Woolley, Lecturer for the Centre for Sustainable Manufacturing & Recycling Technologies (SMART) at Loughborough University and Joanna Stephenson, Director for Women in Packaging will join the line up to discuss a wide range of highly topical issues including contaminated food products, food and packaging waste, self-optimising Cleaning in Place (CIP) systems as well as the gender balance in the UK packaging industry.

Demonstrating the Latest Innovations in Manufacturing

Attendees to Hall 5 at the NEC in September can also find out more about the latest trends and innovations taking the industry by storm. With returning exhibitors, Bosch Packaging Technology, Schubert, and Festo, already confirmed to join the line-up, organisers are confident that the 2016 show will be bigger and better than ever before.

In fact, since the PPMA shows returned to the full control of the association in 2013, the size of its events has increased by circa 25% year-on-year. The latest edition – PPMA Total 2016 – is already 50% larger than the first show of the new regime in 2014. With over 400 exhibitors, the event has already firmly established itself as the industry event not to be missed with 2016 set to be one of the biggest and highly anticipated events yet.

PPMA1July2015New PPMA Group CEO, Andrew Mint, who joined the association on the 1st February 2016, says: “The PPMA Total Show 2016 is set to be biggest yet and the show is a great opportunity for businesses to get their brand, products and equipment in front of a high profile audience and celebrate the innovation that the industry has to offer. The show is a fantastic platform to highlight the latest innovations whilst also bringing some of the industry’s biggest issues to the fore such as the skills gap. I’m looking forward to seeing some the most exciting recent technological developments in our industry on show, as well as hearing from some of the industry’s leading figures at the PPMA Total seminar theatre.”

To register your attendance at the show please visit: http://bit.ly/28QsHuF. For more information on the PPMA Total Show 2016, please visit http://www.ppmatotalshow.co.uk/ or join the conversation on twitter @PPMATotalShow #PPMATotalShow or the PPMA Total Show LinkedIn page.

 

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Riggs Autopack Volumetric Depositors and Filling Machines on Display at PPMA Total Show 2016 – Stand A21

RiggsAutopackAugust2016Riggs Autopack Ltd will be exhibiting a selection of their high quality volumetric depositors and filling machines, transfer pumps and conveyor filling lines at this year’s PPMA Total Show, including an example of their servo drive filling machine.

Visitors to the Lancashire company stand on A21 will view a 4 head automatic depositor with conveyor, a semi-automatic servo drive filling machine with transfer pump, a micro-fill depositor for small volume deposits, and a semi-automatic bulk depositor for filling catering bags, buckets and jerry cans.

Riggs Autopack’s depositors and filling machines are available as a semi-automatic stand-alone unit for small scale producers, or as an automatic conveyor filling system for medium to large scale manufacturers. They provide damage free depositing of hot or cold liquid, semi-liquid and suspended solid products, and accurately fill most container types or size.

If you’re investing in a high quality semi or fully automatic depositing system to accurately fill jars, bottles, pots, tubs, ready meal trays, cartons, buckets, jerry cans, pouches or bags, then Riggs Autopack could have the solution.

For further information contact Riggs Autopack Ltd on Tel +44 (0)1282 440040, Email info@riggsautopack.co.uk or vist www.riggsautopack.co.uk.

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Manufacture Software and Display Systems From London Electronics at PPMA Total Show 2016 – Stand G01

LondonElectronicsAugust2016London Electronics design and manufacture software and display systems to help you optimise the efficiency of your manufacturing and logistics processes.

Tailored real-time displays and software show production figures such as rate, total, downtime, OEE, finishing time, quality % etc. Whatever is important to you, London Electronics can measure it.

Live data allows you to respond immediately to any drop in performance, which you might not otherwise notice.

London Electronics’ secure cloud-based systems allow you to view live and historic data from anywhere you may be, over a protected link. A big advantage is that you don’t need to download and special software or apps. Everything is run in your browser and is kept up to date automatically.

London Electronics’ speciality is customising systems to suit your requirements exactly. Nothing you don’t need, everything you do need, in a format which is easy to understand. Visit Stand G01 or www.london-electronics.com.

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