BETTER PLANT, BETTER PRODUCTIVITY, BETTER PROFIT

FEBRUARY 2015

FOOD PROCESSING

New packaging lines for United Biscuits

How to save on energy costs

The changing face of retail

w w w . f p o n t h e n e t . n e t

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2 229/01/20159/01/2015 12:5512:55 FOOD PROCESSING Contents

February 2015 Vol 84 No 02

All change for retail? CASE STUDY VISION SYSTEMS 4 Dalco Food installs vegetarian 18 Inspection cure for drink processors dough mixture solution The problems at Tesco seemed insurmountable last year: an accounting ACRYLAMIDE scandal, falling prices and consumers QUESTIONS AND ANSWERS 20 The big debate turning away in their droves towards 6 New EHEDG section for UK and discount retailers. But January has seen Ireland HEATING + VENTILATION something of a turning point with new 22 Substantial payback for RHI CEO Dave Lewis implementing a series NEWS of strategic changes that have been 8 Fit to trade? warmly received by both the market and REGULATORY ISSUES industry. Lewis has hired a new PR team, 24 Are you prepared for workplace SECTOR FOCUS: UNITED incidents? announced closures of under-performing BISCUITS stores and launching an online network 10 New fl ow-wrap technology for for suppliers that will enable businesses Harlesden ENERGY MANAGEMENT to interact with the retailer. Shares in the 26 Producing more for less retail giant have already risen, although they are nowhere near the CHOCOLATE ROASTING 13 What’s involved? SKILLS numbers that Tesco used 29 A one stop solution? to enjoy. If you’d like to comment on the retailer/ DRIVES MOTORS AND supplier relationship for an 14 CONTROLS Follow FP on upcoming feature, please What’s new in the market? @FPEditor get in touch at Find us on [email protected] Helen Bahia search for Food Processing

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Editor Helen Bahia Circulation ‘Copyright in the contents of this magazine ISSN 0264-9462 [email protected] Telephone +44(0)1732 359990 is the property of the publishers or relevant Food Processing is published Sales Manager Daniel Birchmore Email [email protected] contents providers. The publishers monthly on a controlled circulation [email protected] Typeset by Origination-Studio.co.uk and sponsors of this magazine are not basis in the UK and Eire. Available Classifi ed Manager Pennie Wood Design Steve Gibbs responsible for the results of any actions or on subscription to others in the [email protected] IML Group plc omissions taken on the basis of information UK at £127.00 a year. Single Production Manager David May Blair House, 184–186 High Street, in this publication. In particular no liability copy price is £12.00. European Business Development Manager Tonbridge, Kent, TN9 1BQ Iain McLean Telephone 01732 359990 can be accepted in respect of any claim rate is £154.00 a year. Overseas [email protected] Fax 01732 770049 based on or in relation to material provided rate (outside Europe) is £225.00 Director Dan Jago E-mail [email protected] for inclusion.’ a year.

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 3 229/01/20159/01/2015 12:5512:55 FEATURE CASE STUDY Dutch processor improves forming process Dalco Food, a Dutch protein specialist, has increased throughput and improved its product forming process.

DALCO FOOD SPECIALISES in developing “Mixing“Mixing in nitrogennitrogen is a ggoodood way of and producing meat and vegetarian meal quickly chillinchillingg mixtures to the ideal components. A family run business, the processingprocessing temperature of approximately company has been operating for over 35 -2°C,”-2°C,” says van den Hanenberg.Hanenberg. years. “Since“Since installinginstalling the technolotechnology,gy, The company faced a problem with its productsproducts holdhold ttheirheir sshapehape bbetter,etter, vegetarian dough mixture, prior to being soso we waste lessless food.food. If tthehe formed. A dough that is too hot is sloppy, mixturemixture isis sloppy,sloppy, more can’t hold its shape and in the case of Dalco Food, can stick to the forming plate, resulting in unnecessary waste. Without the time to spare to store the dough in a cold chamber prior to forming, and the addition of ice water proving insufficient, the company sought a new solution.

Dalco Food are now able to quickly of it remains stuck to the forming plate, but to any new mixer as well as retrofitted to an and easily set their mixture to the that is a thing of the past now and this existing one. ideal temperature and texture means a saving of two per cent for us.” By fitting the liquid nitrogen injection Freshline® LIN-IS is a cooling method that solution to the mixers, Dalco Food are now injects liquid nitrogen continuously or at able to quickly and easily set their mixture “We are processing more and more intervals through nozzles that are fitted in to the ideal temperature and texture. The vegetarian products and to form them the bottom of any type of mixer, helping to accurate and replicable temperature properly, we had to find another way of chilling control product temperature, prevent control of the dough ensures that the them,” explains Stefan van den Hanenberg, microbial growth and increase throughput. It forming step is successful, increasing the Director of Operations at Dalco Food. “You is widely used by meat, fish, fruit rate at which products can be can chill meat by mixing it with a frozen and vegetables, dairy, ready made and reducing waste product, but you can’t do that with vegetarian meals and prepared food by two per cent. goods. They consist largely of dry ingredients processors globally as “We’ve been such as soya, wheat and herbs, to which we the temperature working with Dalco add ice water, which gives a mixture with a control solution is Food for over 20 temperature of approximately 7°C.” adaptable and years, so the The company selected Air Products’ programmable to team know that Freshline® Liquid Nitrogen Injection Solution numerous food they can trust (LIN-IS) to optimise its product forming types, the advice that process. The process rapidly cools the depending on our specialists vegetarian dough mixture prior to formation, their offer, as well as which optimises its forming process and composition, rely on our increases throughput. Dalco Food has a starting products and long-standing relationship with Air Products, temperature and distribution utilising their freezing and modified desired end network,” says Ann atmosphere packaging technology and gases temperature. The Callens, Food Manager at since 1996. equipment can also be fitted Air Products.

Feb 15 | Food Processing 4 www.fponthenet.net

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 5 229/01/20159/01/2015 12:5512:55 OPINION QUESTIONS AND ANSWERS The who, what, where and why of EHEDG UK & Ireland

After 26 years, the European Hygienic Engineering and Design Group has a dedicated regional section that covers the UK and Ireland. Andy Buchan, EHEDG UK and Ireland representative and MD of ACO Building Drainage, considers the role of the new regional section and the benefits it will bring to the UK and Irish food sector. THE EUROPEAN HYGIENIC ENGINEERING advantage or profit. Its reach spans across 55 have the resources or expertise to run their own AND DESIGN GROUP (EHEDG) is a not-for- countries and in a global industry which is in-house technical departments, but they still profit organisation set up to improve hygienic dealing with increasing demand for pre- need access to globally recognised, market- engineering and design across the food and prepared foods and a reduction in the use of leading knowledge and research in order to drinks industry for all aspects of manufacturing preservatives, its work in hygienic design has improve their own standards and to compete. and engineering. And the latest development is never been more important. All of this can be provided by EHEDG and it is great news for the industry. EHEDG has more than 350 experts our hope that SMEs engage with the group and worldwide developing new technical guidelines take advantage of the services EHEDG has to When was the EHEDG UK and Ireland or updating existing ones. To date, it has offer in order to further improve standards in formed and who was behind its creation? published more than 40 guidelines on topics their own operations. The creation of EHEDG UK and Ireland was from air handling to food grade lubricants and driven primarily by a group of individuals that factory design. This guidance is shared with What are your goals and what support will include Eric Partington of the Nickel Institute, the industry via EHEDG’s comprehensive you give industry over the next 12 months? Debra Smith of Vikam, John Holah of annual yearbook as well as via EHEDG- One of our core goals is to encourage Holchem, Craig Ledley of Campden BRI, approved training programmes. companies to join and become involved with hygienic engineering consultant Andy By collaborating with equipment EHEDG UK and Ireland. Our aims are also to Timperley and myself. manufacturers, food manufacturers, leading share expert knowledge and best practice But there are many organisations from research institutes and public health authorities, guidance by setting up a series of training across the food and drink industry that are globally EHEDG is able to promote and improve sessions and seminars, and to help facilitate the already actively involved. Our first meeting in food hygiene during every stage of food inclusion of hygienic engineering and design as November was attended by more than 20 manufacturing and processing. It is genuinely a study subject on further and higher education representatives from major food manufacturers, committed to working with academia and all courses. leading academic bodies, research companies parts of the industry. Ultimately, our activities will complement the and industry equipment suppliers who operate This collaborative approach is a key strength work of EHEDG globally, which also includes through the UK and Ireland. in an industry which has been traditionally slow contributing to European legislation and to talk about issues and share knowledge. The influencing regulatory bodies by demonstrating Many food companies in the UK and creation of a regional section covering the UK practically how existing regulations and industry Ireland are still relatively unaware of EHEDG and Ireland gives organisations working within standards can be met. and the benefits it can bring to their our food industry the opportunity to become businesses, so how can having a regional actively involved with the EHEDG and to get And finally, how can our readers learn more section help? their support at a local level. about EHEDG and membership in the UK EHEDG and its regional sections are not-for- The formation of EHEDG’s regional section in and Ireland? profit organisations that work for the benefit of the UK and Ireland will be particularly beneficial For more information, please visit the food industry rather than for commercial for smaller organisations. SMEs simply don’t www.ehedg.org.

Feb 15 | Food Processing 6 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 6 229/01/20159/01/2015 12:5512:55 Things are heating up in June 2015...

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 7 229/01/20159/01/2015 12:5512:55 NEWS INSIGHT Getting fi t to trade

The fundamentals of the retail landscape look encouraging; the recession is behind us and many of the factors required for long-term growth are in place. Yet the environment continues to become more challenging, as John Nevens, Co-Founder at Bridgethorne explains.

FIGURES FROM THE OFFICE OF Category strategy Thorntons NATIONAL STATISTICS show that inflation Whether a market leader or a company Last year, Thorntons claimed a 12.8% drop and retail sales are down, as is total health aspiring to be a market leader or a in sales in the quarter to the beginning of productivity. On the other hand, with business looking to influence the category October was due to a change in the way competition increasing the market is more in which it trades, having a category retail multiples placed their orders. The fragmented, as shown by the recent strategy in place is essential. A category company blamed the drop in its sales on relative performance of the different retail strategy should ideally provide an the timing of commercial orders, although multiples, and the landscape is changing. aspirational future view of the category in Thorntons’ sales to supermarkets have Consumers are becoming increasingly which it operates with the aim to deliver overtaken its high street sales for the first aware and are looking for greater levels of long-term incremental value. It should be time. This demonstrates the importance for convenience, fundamentally changing the an overarching approach that positively suppliers to really get to grips with the way way they shop as a result. impacts and informs all commercial the multiples work and to ensure that they But the need for food isn’t changing. decision making. This will help companies have the information, the strategies and Consumers still need to consume, and become more targeted and more relevant the practical plans in place to ensure their shoppers need to shop. Retailers need a to their customers. Collaboration is key, as business meets the needs of the retailer margin and every business across the a category strategy is not about growing a rather than expecting it to work the other board wants to grow and become more business at the expense of others, it is way round. profitable. The challenge, therefore, is the about helping the entire category to grow, extent to which suppliers need to change so that everyone can benefit. elevating the shopper into a central to adjust to these societal changes. Using the central premise that shoppers’ position in planning can make a In the drive to do everything, there is a needs are met at the point of purchase, the supplier’s commercial activities far real risk of succeeding in doing nothing category strategy should address more informed and genuinely though. The secret to success lies in implementation of the right range, space, optimise commercial spend sticking to the basics and doing the simple promotions, layout, merchandising and things better. This doesn’t necessarily marketing, based on identified needs and mean a wholesale change, but an the way that shoppers shop. It should also Tea adjustment to the way they already work. In identify quantified strategic opportunities A contrasting situation is forming with UK practice, this means addressing three core for both the category and the retailer that consumers embracing herbal teas and fruit areas: focuses on the major drivers and tactics infusions at the expense of traditional English Category strategy that will increase value; all underpinned by breakfast tea, a long-held staple for the Shopper management consumer and shopper research and data consumer. Year on year growth in speciality Online driven results to give it credibility. tea and fruit and herbal infusions has been

Feb 15 | Food Processing 8 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 8 229/01/20159/01/2015 12:5512:55 INSIGHT NEWS

6% and 5% respectively, compared to a made by shoppers who may or may not be seen. The overall decline of -4% over the decline of 5% value for the mainstream tea consumers as well. Failure to acknowledge period is modest and the rate of decline will industry. It’s a simple reflection of what we this is a risky strategy that can lead to slow as retailers invest in reinventing large see on high streets across the UK, with cafes commercial spend being misaligned. format stores to make them easier to shop and coffee shops responding to a need to It’s important to recognise that commercial and more inspirational. offer more than just standard black tea, and function doesn’t operate in isolation and that To complicate matters, the purchase brands like Twinings, Teapigs and Clipper in order for each function to work optimally, journey isn’t linear. On the whole, there is no have grown in popularity. And it’s not just the they have to work together. The shopper such thing as an internet shopper. Most smaller brands, as PG Tips and Tetley have can’t and shouldn’t be treated as merely an shoppers will shop across all channels and introduced fruit, green, herbal and activation tool, but as a strategic equal to the through all media and in an increasingly decaffeinated tea into their ranges. The consumer and the customer with clear digitised retail world, the shopper dictates perceived health and wellbeing benefits are points of connectivity between the three the purchase journey, not the retailer. drawing in younger drinkers, which has elements, and can be referred to as Ensuring that this journey is seamless and underpinned the 5% growth in sales of Integrated Shopper Management or consistent is priority and retailers expect decaffeinated tea in the past year. Shopper-ism. suppliers to organise themselves with this aim in mind. Although activities across all An effective strategy these channels should be consistent in look most shoppers will shop across all It’s clear that suppliers need to have an and feel, shopper missions and behaviour channels and through all media and effective category strategy in place with will be different by channel. Suppliers must in an increasingly digitised retail retailers that can reflect the expectations and adjust to this new reality, and retailers want world, the shopper dictates goals of both parties. But while retailers are to see suppliers having a clear online the purchase journey, not the retailer crying out for the data, analyses and reports strategy, being able to deliver the basics, that help them build a picture of the category ensuring that their plans are integrated and as a whole, many suppliers fail to carry out Online that their channel plans act as one. even these routine category management Online will be the fastest growing channel This is the challenge facing suppliers now tasks; crunching the numbers, completing over the next five years as shoppers seek and in the future. It’s not only being able to the analyses, building the reports, more convenience. It’s already here, talk the talk of shoppers and category, it’s to undertaking the range reviews and using the continually evolving, and understanding walk that walk too. insights from the data to show how to grow category management online is going to be the category for the benefit of both core to any business strategy. Although this themselves and the retailer and how best to space currently represents a channel investment. relatively low percentage of The onus is on the supplier to gather and turnover, the potential is share detailed insights with the retailer that immense, fuelled by new can make a contribution to category market entrants, the rollout planning, range reviews, shopper marketing of click & collect, lower and account management through analytics delivery charges and greater and shopper insights. This way, the supplier’s shopper engagement with expertise and level of influence with the mobile technology. retailer will increase and they can make a Over the next five years, major difference in an increasingly the three fastest growth competitive environment. channels of convenience, discount and online will Shopper management increase their sales by £31.3 Elevating the shopper into a central position billion, which is equivalent to in planning can make a supplier’s 110% of market growth and will commercial activities far more informed and be driven by shoppers’ increasing genuinely optimise commercial spend. Since preference to shop little and often, better understanding of shopper motivation substantial retailer investment in and behaviour leads to a better return on new stores and improved formats investment and more effective operation, the and the popularity of online. And challenge is to demonstrate a knowledge although superstores and and understanding of their needs. For many hypermarkets will remain the businesses, the shopper, as opposed to largest channel in the market consumer, remains an afterthought. There is by some distance, shifting an important distinction between shoppers shopper behaviour will result and consumers; purchasing decisions are in lower sales than previously

www.fponthenet.net 9 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 9 229/01/20159/01/2015 12:5512:55 SECTOR FOCUS UNITED BISCUITS New fl ow wrap technology for United Biscuits’ Harlesden factory

In 2011, United Biscuits undertook the first installation of a new flow wrap technology processing line that would lead to improved efficiency, less waste and more flexibility. Phase III was completed in late 2014 and the company now have six flow wrap lines in place at Harlesden. Food Processing visited the factory to take a closer look.

THE HARLESDEN FACTORY was built in and 44 tonnes of sugar each day and 35 full the line was excessive with up to four hours of 1902 by Alexander Grant, thanks to its trailer loads of finished product leave the site downtime. When you’re producing 2-2.5 excellent transportation links via the canal and daily. The factory runs two rich tea lines, three tonnes an hour, that’s a significant loss of railway. The factory grew from manufacturing savoury snack lines, three digestive lines and output. We had a lot of discussions about two types of biscuit to 387 product lines in the three chocolate digestive / HobNob lines, what technology to use and how to invest 1930s. By the 1950s, that number was producing 50 million snacks biscuits every money to get the most from new technology.” reduced to just four as the start of mass day and 24 million sweet biscuits every day. The company were looking to develop automation arrived at Harlesden. In 2004, the Harlesden is responsible for 40% of United something in collaboration with Bosch and first savoury snack line was installed and then Biscuit’s UK volume input and is the largest installed a pilot facility in their Manchester site in 2011, the Thames I flow wrap technology biscuit factory in Europe. As such, the that used flow wrap technology. “Throughput line was introduced, followed by Thames II in decision to move to flow wrap technology for was better, manning was less, efficiencies 2012/2013. specific product lines started back in 2008 were higher and it was a successful trial,” Now, the Harlesden site is 50,000 square and couldn’t be rushed. “What we were says McGurk. “We put together a programme metres and operates 24 hours a day. The finding was that old equipment was becoming of investment with Bosch to initially focus on factory houses 11 lines making over 115,000 more difficult to maintain and repair,” explains investing in flow wrap for the chocolate tonnes per year, 11 mixers with a throughput Kevin McGurk, Group Supply Chain Director digestive lines in Harlesden. The commercial of three tonnes per hour and 11 ovens that at United Biscuits. “From a commercial point team now have much more flexibility to run to between 70 metres and 90 metres of view, the old technology limited the number service consumers. Our team have become long. On average, the site uses 275 tonnes of of pack sizes we could achieve. The experts, alongside Bosch, in putting in these flour, 70 tonnes of oil, 55 tonnes of chocolate changeover time from changing pack sizes on new lines and working with them. The latest

Feb 15 | Food Processing 10 www.fponthenet.net

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line was up to full speed within two days of installation. It’s become a standardised technology for our biscuits in that we can use the same technology for each product, increasing our efficiencies and commercial options for the future, so it’s been a successful project all round.”

The benefits of flow wrap technology for United Biscuits One of the biggest benefits to the new technology is the easing of the bottleneck in the wrapping area. “This technology runs continuously without stopping,” explains Arthur Lawrence, Manufacturing Manager at United Biscuits. “On one line alone, we’ve increased output from 55 tonnes a day to 70 tonnes a day. The lines work on three legs each, and the advantage is that two legs can take the full output of the line, so all changeovers are done on the run, without stopping the process, saving us four hours each time. We’ve also made considerable burners about five years ago, making the gas raising agents, sodium bicarbonate and other savings in terms of waste. The same line that ovens more efficient in terms of gas usage small ingredients are fed in small batches ran at 4.5% waste is now well under 2.5% and give the same energy and heat,” says while the bulk ingredients are transferred over waste since the upgrade as we’ve saved Lawrence. from silos. “We have 11 mixers, all millimetres on each pack with the new The ovens run three digestive lines, three automated,” says Lawrence. “Typical batches wrapping. Monetarily speaking, it’s worth chocolate digestive lines, two rich tea lines vary between 600 – 750 kilograms with a over a million pounds a year.” In addition, the and three savoury lines. “Digestives are made throughput of around three tonnes per hour. new technology uses airbeds for the biscuits from a very short dough, almost like Three of our mixers sit on their own load cells to slide down before they drop onto the belt. shortbread dough,” explains Lawrence. “We so the ingredients are weighed as they’re The feed systems are much gentler than use a medium level of heat over 200°C with a dropped into the drum, all others pass the old line. “We’ve made more savings on relatively long bake time of six to six and a through a centralised weighing system for the waste reduction on the digestive rather half minutes. The oven is set up to give a lot other ingredients. Next year, we’ll be looking than the chocolate digestive, probably of heat within the initial zones to produce lift, into replacing all our silos with purpose built because the half-coated biscuit is more to bake the product and extract moisture in vessels with a view to the future. We want robust where it’s held together by the the middle zones and give it colouration in this factory to be a 160 – 170,000 tonne site chocolate,” says Lawrence. “We were the end zones. and we have to invest to do that. Because running at around six per cent waste and “The mini cheddar line bakes for a much our lines are becoming more efficient, with now it’s around two per cent.” shorter time, at a higher temperature of less waste, we need bigger silos to meet this For some of the line installations, the around 300°C and above. We then apply increased efficiency.” company had to stock build and take 14% oil including flavouring as a mist which is Product is then dropped down from the production offline for a month, while on sprayed onto the product before the mixing room through a hopper. On the others, as there was more space available, cheddars cross over the factory to be digestive line, the product is cut into small the lines could be added without any loss packed. Rich tea on the other hand is a pieces before going through a forcing roller of production. It’s also startlingly peaceful, shorter bake, at just over five minutes at a which compresses the dough into the with only a handful of people needed to run temperature between mini cheddars and moulding roller, which passes over an the lines and hardly any noise produced by digestives. The rich tea dough has a lower fat extraction web. The product size and shape the lines. more gluten formation with very elastic can be altered depending on the pressure dough.” between the two. The product then goes Ovens The Harlesden site is also responsible for through the ovens. Any excess dough is fed In the oven room, there are 10 direct gas fired chocolate HobNobs. “Made with oats and back into the system to minimise waste. radiant ovens and one forced air convection wholemeal flour, it’s quite a difficult biscuit to The rich tea dough is initially fed through a oven. The shells have been in place since the control in terms of consistency,” explains three roll sheeter. The dough is then fed 1950s and 1960s, with the equipment itself Lawrence. And above the ovens is the mixing through a series of two to one reductions. upgraded as needed. “As a business, we put area, split between bulk and small The product goes through a laminations a lot of investment into designing new ingredients. Whey powder, cheese powder, process, and the resulting layers can be seen

www.fponthenet.net 11 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1111 229/01/20159/01/2015 12:5512:55 SECTOR FOCUS UNITED BISCUITS

operators from the line to train them via workshops on how get back to basics in assessing and analysing how manufacturing lines operate, where the bottlenecks form, where waste is higher and so forth. Once they understand their production line, then they know how to fix the problem and work with management and consultants on improving waste and lowering bottlenecks and increasing throughput on their lines. It’s been a really successful trial and has upskilled our workforce at the same time.”

Engineering in the food industry McGurk believes that food engineers face a combination of issues from skills to efficiencies to developing technology. “For us, if we look at Harlesden specifically, the engineering tasks are changing,” McGurk explains. “We’ve got an ongoing, significant investment in automation. We’ve moved to changeovers on the run, which means that when breaking open a rich tea biscuit. Air countries, with their biggest growth markets technicians can manage those tasks rather pockets between the laminations are also identified as Africa, the Middle East and than engineers. Our engineers have had a developed so that moisture extraction is China. “We’ve successfully grown in India refocus on preventative maintenance, and much easier within the oven. The product already,” explains McGurk. “We invested bringing their job remit very much back to then goes through a four to one, then three to about five years ago and it’s been incredibly traditional engineering tasks. Our team is one and finally two to one reduction. The successful, particularly given the heritage of looking at the future to ensure they’re product goes through an emboss roller and UK products in India. We have supporting a modernised environment with cutter before it goes through the ovens. manufacturing facilities in India, Saudi Arabia preventative maintenance. Ultimately, we’re Again, any excess dough is fed back through and Nigeria now.” looking to lowering our overheads to make us the system. And there’s that small matter of Yildiz as competitive as possible, and a big part of The chocolate digestives are sent from the Holding acquiring United Biscuits, after that is looking at modernised ways of working ovens through a series of shell coolers to months of speculation that had several across operators, advanced team members, bring the temperature down to around 27°C. leading biscuit companies vying for their engineers and technicians in order to help Chocolate is stored at around 44°C and business. “There’s a lot of synergy with Yildiz drive the company forward.” pumped into a tempering unit. The chocolate that we’re excited about,” says McGurk. That drive also helps the company when it is applied at between 30-32°C depending on “They’re big biscuit producers, but in different comes to the skills shortage that the food and the enbrober. A bed of chocolate covers the markets to those that United Biscuits are drink industry is facing. “Enhanced automation bottom half of the biscuit before it’s cooled. strong in. They don’t have huge numbers in can be managed better through smaller While the biscuits go through to flow wrap the UK, for example, while we’re the leading engineering tasks,” says McGurk. “But there’s and roll wrap lines, the savoury products manufacturer in the UK. On the other hand, still a skills shortage in terms of pure cross over the factory to the packing area. they have a good market share in Middle engineering. We have a graduate programme The company is proposing to invest in central Eastern countries. So we’re excited and within United Biscuits that goes across the auto palletisation. The old lines were lifted looking forward to what we can achieve supply chain, and that includes engineering. from Ashby around 10 years ago and allow together.” The programme cycles graduates through the savoury products to be hand packed or The company is also focused on Lean, different functions of the business depending multipacked. “We rely on agency staff for which was implemented about seven years on their specific requirements and where hand packing,” says Lawrence. “We only ago as a company toolkit for management to they’d like to see their careers progressing, need three to four packers for an output of utilise as they strove for more efficiency on the and engineering is a large part of that. We’re 1.6 tonnes an hour in the larger multipacks. line. “We’ve refocused our Lean programme looking develop both our engineering On the automated line, we only need six staff in the past 12 months,” says McGurk. “It was management capability but also our to run the entire primary and secondary successful as a management tool but now engineering apprenticeships as well. We work packing area for savoury products.” we’re bringing it to the operators who use the with the College of North West London and equipment so that they know how to use we have engineering workshops where Future growth Lean tools and techniques so they can use students from the college come in and have United Biscuits currently exports to 130 them to drive efficiency. We’ve recently taken lectures and practical training onsite.”

Feb 15 | Food Processing 12 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1212 229/01/20159/01/2015 12:5512:55 COCOA ROASTING PROCESS INSIGHT Making chocolate from beans: what’s involved? The craft of making chocolate stems from the humble cocoa bean. Ramana Sundara, Angel Manez and Fabien Coutel from the Nestlé Product Technology Centre in York describe the process in more detail.

are generally broken in a swing-hammer debacterisation is essential in order to ensure breaker in which centrifugal force is used to that it kills any pathogens such as Salmonella break the beans against an impact plate. After and reduces the total bacterial content. To breaking, the shell and nibs, which are the avoid cross contamination, it is extremely broken pieces of the kernel, are separated by important to maintain a strict separation winnowing during which the nibs are divided between raw and roasted material. As an into a number of fractions by means of sieves alternative to batch drum type roasters, and an air classifier (or sifter) separates the continuous vertical roasters can be used for shell from the nibs. cocoa beans or nibs. This type of shaft The nibs are then sterilised by injecting roaster is divided into a number of sections; INDUSTRY DIFFERENTIATES between cocoa steam into the beans to remove any the top sections are used. Earlier researchers processing and chocolate manufacturing. microbial contamination. After sterilisation, also reported liquor roasting, which is Cocoa processing covers the activity of the nibs can be roasted directly or can be produced by a fine grinding of cocoa and converting the beans into nib, liquor, butter, alkalised first, known as the Dutch process. liquefying within its own molten fat. Special cake and powder. Chocolate manufacturing During alkalising, the cocoa nibs are treated thin-film techniques were developed for the covers the blending and refining of cocoa with an alkali solution such as potassium or roasting of the cocoa liquor. liquor, cocoa butter and various optional sodium carbonate. The Dutch process ingredients, such as milk and sugar. primarily modifies the flavour and colour of Grinding cocoa liquor and is mainly used for the The roasted nibs are coarsely ground in a Cocoa processing production of cocoa powder. hammer/ball/stone mill until the friction and Ripe cocoa pods are gathered every few days heat of the milling reduces them to a thick during the peak season. The pods are split Roasting chocolate-coloured liquid, known as ‘cocoa open by hand, and the seeds or beans, which The next step is roasting. During this process, mass’. During subsequent fine grinding, the are covered with sweet white mucilage, are the cocoa darkens to a rich brown colour and cocoa mass is refined down in ball mills to the removed ready to undergo a two-par curing acquires its characteristic chocolate flavour required particle size. It contains 53 - 56% process of curing and drying. The fresh beans and aroma. Maillard reactions play a major role cocoa butter and solidifies on cooling. This is are heaped and covered by banana leaves or in developing the flavour in the beans from the the key ingredient of all chocolate and cocoa placed in a wooden box, typically for five precursors formed during fermentation and products. Both non-alkalised and alkalised days. Pulp is an excellent medium for the drying. Moisture and acidity are also reduced cocoa masses can be pressed on hydraulic growth of microorganisms since it contains 10 during roasting. presses to produce cocoa butter and cocoa – 15% sugars. Their activities result in Whole bean roasting is the original method powder. changes is the beans due to the production of and often used to produce cocoa masses with acetic acid and alcohol, leading to the fine flavours as it helps to retain the volatile Pressing formation of cocoa flavour precursors via a cocoa flavours within the bean during roasting. The pre-heated cocoa mass is transferred into series of chemical reactions. Cocoa beans are Cocoa beans are exposed to temperatures of the so-called pots and when the pressure is dried after fermentation in order to reduce around 120 - 140°C for 15 to 45 minutes. This increased, the butter flows out of the cocoa their moisture from approximately 60% to type of roasting allows for the relatively easy mass. The cocoa solids that remain in the pots 7.5%. At this point, the dried beans consist of removal of the shell as it becomes loose form the cocoa press cake in which the fat a thin shell enclosing the kernel of the bean. during the roasting process. Currently, nib content is normally 10 – 12%. When the After harvesting, fermentation and drying, roasting is also widely used in part due to the pressing is done, the press opens and the commercial cocoa beans are bagged and distinct improvements in the cocoa powder cakes fall out. Hydraulic pressure of up to 540 then processed locally or shipped overseas in when alkalising the nib before roasting. The bar may be used. After pressing, the cakes are containers. Industrial cocoa processing nibs are roasted at temperatures between 105 broken into kibbled cake that is typically stored begins with cleaning, during which air - 120°C depending on the desired by fat content and degree of alkalisation and streams, sieves and metal detectors are all characteristics. may be blended before pulverisation to obtain utilised to remove any stones or metal Existing roasting systems often use the desired type of cocoa powder. The cocoa particles. Beans are heat treated to pop the conduction and/or convection as the heat butter is filtered and can be deodorised and shell and aid in the winnowing step. Beans transfer mechanism and an effective stored in heated tanks.

www.fponthenet.net 13 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1313 229/01/20159/01/2015 12:5512:55 TECHNOLOGY INSIGHT DRIVES MOTORS AND CONTROLS Effi ciency and connectivity: what’s new in the market? Plenty of new technology and innovations have hit the drives, motors and controls market as companies showcase their latest developments. Here, Food Processing rounds up some of the latest solutions on offer for those working in the food and drinks industry.

© Phoenix Contact

ONE OF THE BIG DRIVERS for growth in Herweck, CEO of the Process Industries COPA-DATA industry as a whole is digitalisation and and Drives Division of Siemens. “We have The continued progression towards Industry integration. Siemens have long championed aligned our portfolio including services 4.0 continues, with themes woven through digitalisation of industrial automation and along the entire lifecycle of our customers. many new products as companies look they’ve recently pinpointed the merger of Our offering unites high-grade, proven and towards integration, flexibility and industry software and digital technologies standardised products with industry-specific expandability. COPA-DATA are the company as pivotal factors behind the company’s solutions, covering all the decisive core behind the zenon product family for HMI/ continued growth. In the food and drink elements – from integrated engineering SCADA, Dynamic Production Reporting and industry, as well as other process industries, systems and process control systems integrated PLC systems, which allows stable processes and resource-saving through integral communication down to companies to establish solutions for control, technologies have been given prior the field level, for instance with process visualisation and data analysis. In particular, significance. “The value chains and work instrumentation and analytics, as well as COPA-DATA focus on security, as there is a flows taking place in the process industries Integrated Drive Systems (IDS) with growing concern that production processes call for a close-knit technological outstandingly efficient and reliable drive are open to attack, whether on site or in the partnership based on trust,” says Peter technology.” Cloud. The 128-bit encryption of the

Feb 15 | Food Processing 14 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1414 229/01/20159/01/2015 12:5512:55 DRIVES MOTORS AND CONTROLS TECHNOLOGY INSIGHT

communication between server, standby Contact includes role class libraries on the Invertek server and client, comprehensive access basis of the eCl@ss classification standard Invertek have recently launched the third control with the integrated user administration and this precision article description scheme generation range of their Optidrive general and active directory support protect the user enables developing technical systems in the purpose drives. Available in four frame sizes, from unwanted data loss. Zenon allows spirit of Industry 4.0 by allowing them to Optidrive E3 offers energy saving performance networked, secure communication. independently identify the manufacturing and is compatible with global supply voltages Often, the goal for manufacturing stations required to produce a system. for motor control up to 22kW. Optidrive E3 companies is to increase overall equipment also has extended motor control to cover IE2, effectiveness and reduce consumption in the IE3 and IE4 permanent magnet and factory, while at the same time large the goal for manufacturing synchronous reluctance motors and has been companies divide their production and companies is to increase overall developed to ensure it is easy to use globally. production and consumption data across equipment effectiveness and A robust design allows Din-rail mounting or plants at various different sites globally. This reduce consumption in the factory simple keyhole mounting as required, and the can result in optimisation potential being lost. power supply is connected at the top with the If businesses moved their data into the Cloud, motor supply connected at the base. The they could profit from tools or cross- Crouzet Automation design makes installation easy and with 14 equipment and company-wide benchmarking, Crouzet Automation has released em4, a high basic parameters, setting up the drive for a and comprehensive analyses for total performance nano-PLC with the ability to huge range of applications is simple and with consumption or for quality figures from the communicate as part of the Internet of Things. less than 60 parameters in total, Optidrive E3 entire operation. Recognising the challenges of machine-to- offers a high degree of flexibility. “Volatile and rapidly changing markets, as machine technology, Crouzet sought a The new range is available in IP20 and IP66 well as complex manufacturing processes solution to the need for connectivity of their versions and can be directly mounted to present major challenges for production installations. The new nano-PLC can be fully machines and specified with an isolator / companies,” says Jürgen Schrödel, Managing remotely controlled and has been designed to disconnect switch. Optidrive E3 is equally Director of COPA-DATA in Germany. “Flexible make a totally integrated solution available to suited to fan and pump applications, and quick-reacting production systems integrators and OEMs, allowing them to switching from industrial mode to fan or pump support companies with overcoming this reinvent their applications and generate new mode at the touch of a button. challenge and allow them to be able to business opportunities. The em4 range continually react economically.” comprises of em4 remote, fully connected to Lenze the secure infrastructure, em4 alert, capable Lenze have proved that being more efficient Phoenix Contact of sending SMS or email alerts and em4 local, does not automatically mean being bigger. Meanwhile, Phoenix Contact are also pushing designed for applications that do not require The company has launched new m200-P and towards Industry 4.0 with their demonstrator, remote communication or only a local area m500-P three-phase AC motors which a machine that illustrates how some aspects network. achieve the premium IE3 efficiency class in of the Industry 4.0 future project can be One of the main strengths of em4 remote, accordance with IEC 60034-30 without any implemented based on the example of the flagship product, is its connection to the jumps in size compared to IE2 motors. The automated control cabinet construction. internet. That means it can offer m200-P motor offers a power range between During the first step, the user creates a wiring programming, monitoring and control and 5.5 and 45kW with a variety of voltages for diagram with an ECAD system and then uses datalogging functions that allow remote direct on-line mains operation with fixed the diagram to design customised terminal management of an application, a single speeds and 400V supply, while the m500-P blocks. The wiring diagram is used as input machine or a fleet of machines, making em4 motors cover the same power rang and are for the design of further assembly stages and part of the Internet of Things. In terms of data optimised for use with frequency inverters, but serves as the basis of the wiring concept. The exchange, em4 has no embedded web can also be operated straight from the mains. idea behind this is to encourage compatibility, server, but operates on a machine to machine The m200-P motors are designed for as most companies use different engineering connection. This is essentially an exchange of simple fixed speed applications and costs are tools for separate planning steps and these raw data between the controller and the minimised by limiting the range of options, tools are generally incompatible with one dedicated server. Communication is therefore although spring-applied brakes are available another. optimised and the server’s memory space is and not grading the insulation for inverter Phoenix Contact combines standards prioritised over the em4’s embedded memory. operation. The m500-P motors suit more AutomationML and eCl@ss to create a In the under 50 I/O category, em4 is the challenging applications, while use with continuous engineering process. first automation component that can interact inverters is unrestricted and the full range of AutomationML defines systems as well as with high precision industrial sensors options includes brakes, encoders, blowers articles to be produced in the plant, which operating at 0-20 or 4-20 mA. These robust and plug connectors. allows all engineering tools to work with the inputs embedded directly in the product avoid The two new ranges reduce the amount of same files. In order to have a consistent measurement errors linked to the distance energy lost and therefore reduce energy costs interpretation of the file data, the between sensor and controller, while ensuring by up to 20%, meaning that investment in the AutomationML version used at Phoenix one per cent measurement accuracy. technology usually pays for itself within the

www.fponthenet.net 15 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1515 229/01/20159/01/2015 12:5512:55 TECHNOLOGY INSIGHT DRIVES MOTORS AND CONTROLS

first two years. Other advantages include contacts with numerous different contact ABB increasing the inertias, the starting torques and arrangements accommodated according to There are a host of new products being starting currents, which may require a design requirements.” released by ABB that are targeted re-evaluation of the drive train, as for example Solder, straight PCB or crimp terminations specifically at the food and drink sector. the gearbox may not suit the increased starting are available, depending on the end ABB’s industrial drive AVCS880 includes torque. application. And depending on customer fourth generation DTC with enhanced requirements, various plating options are performance in open and closed loop and available, as well as a comprehensive range of a higher switching frequency. And in accessories including sealing plugs, guide pins, March 2015, the ACS580 replaces ABB’s being more efficient does not guide plates, hoods, spring locks and slide most successful drive to date. The automatically mean being bigger locks. ACS355 is, according to ABB, is the ultimate drive for high pressure cleaning in Delta Electronics food and drink environments. Highly Delta Electronics have expanded their Delta resistant waterproof casing and rounded TE Connectivity Industrial Ethernet Total Solution range with edges prevent ingress of water and build With several new products in the market, TE two new industrial Ethernet switches. The DVS up of bacteria. There is no external fan, Connectivity has solutions for both factory Series features numerous management making the drive more hygienic and an automation and machine building applications. functions in order to ease configuration and to enclosed control panel behind a protective Their new range of ruggedised industrial RJ45 ensure a safe operation. IPv6 address is membrane. connectors for industrial use is equipped with suitable for larger network and neighbour ABB are also providing a new service, robust termination technology for time saving discovery. They support EtherNet/IP and their Energy and Productivity Improvement and flexible field installation. The range includes MODBUS TCP protocols that facilitate the Plan. With 10 stages, it is designed to help an Industrial RJ45 Push Pull Variant 14 remote management by SCADA and other food and drink manufacturers assess the connector with a plastic shell and an Industrial industrial devices. The rugged switches are benefits of installing motor and variable- RJ45/Fibre Optic Push Pull Variant 14 with a designed to operate in harsh industrial speed drive (VSD) technology. It features a metal shell. Both types have durability to environment and feature a wide operating six stage energy and productivity appraisal provide reliability for increased lifetime, which temperature from -40°C to 75°C. They comply that can be carried out in half a day. Data will result in cost-savings. Both also offer with international safety standards (UL 508, EN analysis, calculations, measurement, high-grade IP shielding and temperature 6090-1 and IEC 61131-2) and are fully proofed recommendations and follow-up complete resistance, which makes them suitable for against mechanical damages. the appraisal steps to deliver energy and harsh and outdoor environments. TE has also productivity improvements. launched a new range of high-speed industrial maxon motor RJ45 Cat6a field-installable connectors, which Adding to the ESCON servo controller family, enables excellent signal performance for field maxon motor has developed a miniaturised termination without tools. The connectors postage stamp-sized OEM plug-in module. the continued progression towards support 10G/s Gigabit Ethernet and their Designed to command permanent-magnet- Industry 4.0 continues, with themes connector structure and IDC contacts allow activated brushed DC motors and BLDC woven through many new products reliable installation. motors (brushless DC motors, so-called EC motors) with Hall sensors up to 48W Molex continuous output and 144W peak output, the Molex Incorporated have introduced modular high performance 4 quadrant PWM servo B&R D-Sub mixed layout connectors and cable motor controller has high usability and power The new ACOPOS P3 is a 3-axis servo assemblies through FCT electronic GmbH, a density. The servo controller has new drive that offers a power density of 4A per Molex company. The UL-approved D-Sub functionality, including RC servo signal litre, which makes it one of the most mixed layout connectors can combine power, evaluation for speed or current set values, efficient servo drives with integrated safety signal, RF and pneumatics to accommodate a current limiter and offset and the option to functions on the market. The housing is as range of industrial automation applications and predefine analogue speed ramps. With speeds small as a conventional one-axis drive, are tailored to meet specific customer up to 150,000 rpm, the OEM plug-in module which makes it possible to reduce the requirements. For harsh environments where provides extensive functionality with free amount of space required in the control regular wash-downs are required such as the configurable digital and analogue inputs/ cabinet by 69%. The short cycle time food and drink industry, up to IP69 sealing is outputs which can be operated in various opens up new opportunities for drive available. modes. control and the drive features many safety “The mixed layout series is designed As maxon motor believes that top functions that satisfy SIL 3 / PL e / Cat 4 modularly,” says Thomas Winderl, Marketing performance should not be a matter of trial and requirements, and the Safely Limited FCT, Molex. “We offer 75 and 50 Ohm coaxial error, the servo controller has been designed Torque (SLT), a new function, checks contacts, high power contacts up to 40 A, high specifically with easy start-up and user- whether the maximum permitted torque voltage contacts up to 3kV and pneumatic friendliness in mind. has been exceeded.

Feb 15 | Food Processing 16 www.fponthenet.net

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1717 330/01/20150/01/2015 10:3010:30 TECHNOLOGY INSIGHT VISION SYSTEMS Inspection cure for drink processing headaches

With difficult operating conditions, drink processors well aware of the importance of reliability and short machine cycle times. Dan Rossek, Product Marketing Manager at Omron, examines the benefits of using vision systems for inline detection.

VISION SYSTEMS FULFIL a wide range of there is also the need to evaluate the overall Communication speeds to databases, PLCs uses throughout the production process, task and measure the cost improvements, or other devices have also been improved by making them a cost-efficient, dependable taking the Total Cost of Ownership (TCO) into utilising the EtherCAT machine control solution when inspecting the exterior quality of consideration. network. This enables the implementation of products and packaging. As a quality control By adopting the latest technological motion control to be synchronised with the measure, vision systems can be used to developments, drink manufacturers can communication cycle. inspect empty containers before the actual overcome the hurdles of current inspection filling process, or for final exterior quality challenges. Using parallel hardware Best solution? inspections such as labels and booklets, or to architecture, image acquisition and pre- With so many vision systems available, it’s detect the presence of straws, for example. processing speeds have been improved. In important to identify the best solution for a For a complete quality control solution, the final addition, software image processing speeds specific application and the right tool with the exterior inspection is therefore often integrated have increased by using new algorithms. appropriate performance. If processing speed into a final inspection station, incorporating Technology features such as the ‘sparse edge’ is vital, then processors should be looking at other technologies. detection feature and variation prediction the latest vison technology which boasts to Thanks to this flexibility, vision systems tend allows fast, precise measurements to be made, be 10 times faster than their predecessors. to be utilised for higher value products, such as even if images are out of focus. The drinks processor should also be verifying serialised 2D codes on labels to fight looking for inspection performance ideally counterfeiting. In a recent project, this feature with quad core processing and a fast image successfully detected counterfeit bottles of capture rate. By choosing a system that cheap wine labelled as expensive Italian wine. offers speed, performance and versatility, operators can achieve shorter machine cycle Addressing inline detection headaches times and improved production line efficiency. However, there are still hurdles to cross in terms of technology and cost, depending on What’s next? the process and application. As an example in So, if the quality and efficiency of beverage technology, in high speed processes where the plants is to continually improve, how should detection and image speed is critical, or in inline inspection vision systems evolve? The other applications, having several inspection current ‘smart phone’ generation is used to points on a bottle demands the use of multiple having data available at their fingertips cameras. Pre-processing these different wherever they are, so users expect more camera images into a single image for intuitive interaction between devices. evaluation can be crucial for manufacturers. An Therefore, drinks manufacturers will go aspect often raised is the required flexibility to beyond the mere inspection of products and adapt inspection to different sizes, containers look at tasks that incorporate smart user and marketing programmes. interaction, interfacing between devices and In terms of cost, price pressure is a machines, data storage and evaluation. I significant hurdle too. Two very different trends believe this is certainly something that the have been generated from this, and while future holds for the drinks processing part-cost reduction is a common approach, industry.

Feb 15 | Food Processing 18 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1818 229/01/20159/01/2015 12:5512:55 Bad Spare Day!

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FP Fillers MasterMaster.indd indd 5 12/12/2014 10:310:34 33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 1919 330/01/20150/01/2015 10:3510:35 INDUSTRY INSIGHT ACRYLAMIDE The acrylamide debate

What exactly is acrylamide and how can manufacturers reduce acrylamide in their foods? Beate Kettlitz, Director, Food Policy, Science and R&D at FoodDrinkEurope investigates.

IN APRIL 2002, acrylamide was accidentally health associated with acrylamide exposure alongside the colour and flavour developed, discovered by the Swedish National Food from food sources can be fully understood. for example baking, roasting, grilling or frying. Administration along with a group of The EFSA risk assessment and scientific This of course means that food prepared at researchers at the University of Stockholm. A opinion of acrylamide is expected by home and for catering purposes can be substance that naturally forms in certain mid-2015. The food industry has collected sources of acrylamide in diets too. foods, particularly plant-based foods rich in around 36,000 acrylamide data points to For cereals, the amount of acrylamide carbohydrates and low in protein, during show the effects of mitigation strategies and formed in a given cooking process is mainly cooking at high temperatures, acrylamide is shared these with risk assessors. determined by the amount of asparagine not a new substance and has likely been part The explicit guidance from international and present in the crop. Asparagine cannot be of the human diet for thousands of years. It national regulatory authorities, including the eliminated entirely as plants use it in their isn’t added to foods by manufacturers and is WHO/FAO, European Commission DG process to store nitrogen from the soil, but in simply a by-product of processing. SANCO and several European food the future it may be possible to grow grains authorities is that the general advice on with relatively lower asparagine levels. How does acrylamide form in foods? healthy eating remains unchanged and As the food industry has worked to reduce Acrylamide is mostly formed when the natural consumers should continue to eat a balanced the level of acrylamide in foods, the dietary amino acid asparagine reacts with naturally and varied diet. intake of acrylamide from industrially occurring sugars such as glucose. It is part of processed foods has decreased. the Maillard reaction, which is the chemical Where can acrylamide be found? reaction that forms the brown colour and Acrylamide has been found in a wide range of Collaboration flavour for foods that are cooked, baked, carbohydrate rich foods which naturally In 2003, FoodDrinkEurope formed a technical toasted or roasted. contain the amino acid asparagine and expert group to openly share research and The health risk to humans remains unclear. reducing sugars (glucose and fructose). This disseminate information on how best to adapt Dietary exposure to acrylamide has been can include toast, fried potatoes, biscuits, production processes and implement identified as a potential concern by the Joint crisps and breakfast cerealscereals.. mitigation measuresmeasures.. The orgorganisation’sa FAFAO/WHOO/WHO Expert CCommitteeommittee on Food CCookingooking at temperatures sisignificantlygnificantly aboveabove ongoingongoing ggoalsoals are to evaluatevaluatee new ways to AAdditivesdditives ((JECFA),JECFA), but the committee has 120°C120°C can cause the formation of acrylamide reduce acrylamide formation identified in alalsoso statestatedd tthathat iitt iiss currentcurrentlyly not posspossibleible to researchresearch proprogrammesgrammes arouaroundnd the world; and ddetermineetermine tthehe precpreciseise llevelevel ooff rriskisk to hhumanuman toto rereduceduce acryacrylamidelamide llevelsevels in line with the health. Acrylamide in high concentrations has ALARAALARA ((asas low as reasonablreasonablyy achievable) bebeenen ffoundound ttoo cacauseuse cacancerncer iinn ananimalimal principle.principle. eexperiments,xperiments, bbutut ffurtherurther researcresearchh on FFoodDrinkEuropeoodDrinkEurope hhaveave ddevelopedev an tthehe e effectsffects o off exposure AAcrylamidecrylamide TToolbox,oolbox, avaavailableilable on the website to acrylamide is of the European CCommission,ommissi which needed before the providesprovides information on ththe methods of rrisksisks to hhumanuman acrylamideacrylamide mmitigationitigatio that are known to worworkk iinn ffoodood mamanufacturing processes and coconsidersn the ppotentialotential memethodsth of rereductionduction hahat are at pilot anandd llaboratoryaborat scale trials. It proviprovidesde a summary of the inindustry’sdu knowledge concerconcerningn the possible means tto minimise acrylamiacrylamide formation in foods.

Feb 15 | Food Processing 20 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2020 229/01/20159/01/2015 12:5512:55 ACRYLAMIDE INDUSTRY INSIGHT

The food industry sectors have can generate a large and almost industrial scale. The next revision is planned collaborated with the European Commission unpredictable variation, even for the same for mid-2015. The organisation will also and Member States to produce sector product and for the same cook, which continue its activities in research to further specific pamphlets on ways to reduce makes it difficult to predict the real intake improve mitigation strategies, both at a acrylamide in food production. First from home-cooked foods. processing and agricultural level. Although published in 2007, the pamphlets cover six FoodDrinkEurope cannot reach all individual food sectors, including biscuits, crackers and Conclusion companies, members of the organisation crisp bread, bread products, breakfast FoodDrinkEurope continues to regularly offer to be a partner in education / training for cereals, fried potato products including update the toolbox with the newest scientific both small and medium sized enterprises; potato crisps and French fries, and infant and technological developments, and they also help national authorities understand food – publication pending. The pamphlets subsequently update the related pamphlets if how and when to use the appropriate are available in all 23 official languages of the new tools are proven to be useful to try at an mitigation strategies. European Union and are aimed at SMEs. European SMEs often don’t have the resources to access the latest research EFSA scientists meet over acrylamide findings and the pamphlets meet the needs of SMEs by allowing smaller companies to consultation keep up-to-date and use the latest tools to reduce acrylamide formation in their On 11 December 2014, around 50 participants assessment and provide clear, scientifi c products. met to discuss comments to a recent advice for risk managers to use in developing While the food industry continues its efforts public consultation on acrylamide in food. regulatory or other measures.” to further mitigate acrylamide, it’s important Representatives from national food safety Nine invited guest speakers gave that the various sources of acrylamide, such agencies and scientifi c advisory bodies, presentations on issues they raised during the as home cooking and catering, are looked at the food industry and academia and EFSA online consultation. These formed the basis scientifi c experts congregated to focus for further discussions among participants. A too. There have been extensive studies into on EFSA’s recent draft description of the representative of the European Commission acrylamide formation and minimisation potential health risks of acrylamide in food and also gave a presentation on the background strategies in the laboratory and in industrial estimation of human exposure to acrylamide to the request sent to the EFSA and the next environments where the processing and in the diet. EFSA provisionally concluded that steps for EU risk managers once EFSA’s heating conditions are better controlled than acrylamide in food potentially increases the risk opinion is fi nalised. The Commission considers in home cooking. HEATOX researchers of developing cancer for consumers in all age the implementation of voluntary mitigation conducted a number of experiments related groups. measures to reduce acrylamide levels in to deep-friend French fries, crisps, oven “The meeting has been useful for us to food unsatisfactory and variable among food roasted potato wedges and toasted bread. listen, discuss, explain and better understand business operators. The Commission, together Exposure from home cooking comes the public consultation results,” said Dr with risk managers in Member States, will primarily from potato products with some Diane Benford, Chair of EFSA’s Panel on discuss further measures at EU level to reduce Contaminants in the Food Chain (CONTAM). acrylamide levels in food as low as reasonably addition of toasted and homemade bread. “This will certainly help us to refi ne our risk achievable. Home cooking, especially potato products,

www.fponthenet.net 21 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2121 229/01/20159/01/2015 12:5512:55 PROCESS INSIGHT HEATING + VENTILATION The renewable heat incentive: substantial payback?

With the Renewable Heat Incentive, could installing a heat pump offer improved energy efficiency and the possibility of significant payback? Tom Marshall, Sales Engineer at GEA Refrigeration UK explains.

THE RENEWABLE HEAT INCENTIVE (RHI) new, non-domestic installations and an in the form of heat, ground-source heat comes in two parts: the domestic and the additional 6.4TWh of renewable heat by the pumps will be able to use heat gathered and non-domestic scheme. The non-domestic end of 2015/16. stored in the ground using solar collectors scheme has been open to commercial, With the new regulations, applications providing no other subsidy, from space industrial, public sector, not for profit and submitted for ground-source and air-source cooling or process cooling or waste from heat networks since November 2011. The heat pumps are required to include: a design industrial processes. As a result of the new scheme is designed to bridge the gap seasonal performance factor (SPF) of at least amendments, the ground-source heat pump between the cost of fossil fuel heat 2.5; measurement of electrical input to (GSHP) technology will receive a tariff installations and renewable heat alternatives calculate SPF and provide quarterly meter increase. GSHPs will receive an increased through financial support for owners; a gap readings; ground-source heat pumps tariff of 8.7p/kWh of generated heat for the which often deterred individuals from capable of simultaneous heating and cooling first 1314 hours and then will receive 2.6p/ renewable heat options. will have to measure heat drawn from the kWh thereafter. RHI is the world’s first long-term financial ground and provide quarterly meter support programme for renewable heat. readings; ground-source heat pumps Implications for the food industry Anyone generating and using renewable capable of cooling must provide a capacity There is a large amount of heat that can be energy to heat theirheir bbuildingsuildings coucouldld bbenefitenefit vvaluealue basedbased on thethe heatingheating functionfunction only;only; inin recoveredrecovered ffromrom tthehe rerefrigerationfrige plant in the from RHI. By increasingreasing tthehe ggenerationeneration ooff addiadditiontion to usingusing naturallynaturally occurringoccurring energyenergy foodfood iindustry.ndustry. TToo hharnessarness this heat and heat from renewableable energy sourcesces instead create watewater at 65°C, a heheat pump could be of fossil fuels, thee RHI hhelpselps rereduceduce addedadded to thethe refrigerationrefrigeration system. From a greenhouse gas emissions and mmeeteet tartargetsgets freezer to a water chiller providingp air for reducing the eeffectsffects ooff cclimatelimate cchangehange cocconditioningnditioning to offices,offices, thethe principal is based in the UK. ono the factfact that a refrigerationrefrige system Key features of tthehe new popolicylicy fforor abaabsorbssorbs heatheat at a lowlo temperature and the non-domesticc scheme, thtthenen dischargesdischarges it tot the ambient at a published in late 2013, includedincluded anan wwarmerarmer temperature;temperat just not warm increase in supportort for renewable eenoughnough for practicalprac use. Which is CHP, large biomassass boilers (over(over whwwhereere tthehe hheateat pump comes in. 1MW), deep geothermal,othermal, ground A typical exampleexa of a heat source heat pumps,mps, solarsolar pump, includingincludin hot water buffer thermal and biogasgas combustion. tanks, pumps and distribution New support wasas introducedintroduced forfor ssystem,ystem, couldcould costc between air-water heat pumpsumps and £5£500-£600,000500-£600,000 dependingd on the commercial and industrialindustrial energy ccomplexityomplexity andand sizesiz of the facility. from waste. An evolvedevolved approach to EEvenven at £600,000,£600,000, a heat pump budget management,ment, usingusing improvedimproved systesystemm would a 2.6 yeary ROI. market intelligencece to allow crediblecredible OOfgemfgem estimates thatt the current growth rates acrossross thethe technologiestechnologgies scschemeheme willwill bebe retractedretrac by 1 April supported was highlighted,highlighted, whilst 22016,016, unlessunless a new budgetbud is approved for ensuring that thee schemescheme remainsremains ththee RHI funding.funding. AnyAny heatheat pump, however, affordable and achieveschieves value for moneymoney.. bought beforebefore this date willw be secured for The governmentent estimated that the policy 2200 years withwith the RHI non-domesticnon changes could incentivisencentivise arounaroundd 5,000 sscheme.cheme.

Feb 15 | Food Processing 22 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2222 229/01/20159/01/2015 12:5512:55 HEATING + VENTILATION PROCESS INSIGHT FEG install LEV system for UK food production company

DUST, VENTILATION AND FILTRATION extraction. This created a cost-effective and problems are common in food processing reliable solution from contaminant source to applications who must contend with the safe and efficient extraction. paramount importance of product quality, For their new ingredients feed and mixing environmental concerns and the health and requirements facility, the company took well-being of employees. On top of this, advantage of FEG’s expertise in CDM organic food production within the EU is (Construction, Design and Management). strictly regulated. EU rules apply to the With a project value of £1 million, FEG’s production of organic food and feed, and to involvement included heading a multi- the labelling and control of organic products. department project team, controlling project With demand for organic food product spend, assigning resources, controlling and increasing, major food retailers and In the ingredients feed area, FEG provided writing the Health & Safety File, supplier manufacturers are expanding their range. a full design, plan, installation and approval, control of contractors and issuing When a major UK food production commissioning service for a Local Exhaust permits. With overall responsibility for company looked to invest in their new Ventilation (LEV) system that provided an ensuring all building modifications, plant organic production facility for their biscuit and effective hood design, ductwork systems, modifications and new equipment met snack products, they looked to FEG Ltd to heat recovery and recirculation system to specification, FEG achieved production manage the project. ensure adequate ventilation and dust targets, within budget and timescale.

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2323 229/01/20159/01/2015 12:5512:55 SPOTLIGHT REGULATORY ISSUES Workplace incidents: are you prepared? Regardless of what industry you’re in, every business has to comply with regulations designed to reduce the risk of workplace incidents and the food sector is no different. But the old adage that accidents happen is no less true now, even with the correct procedures in place. So what should companies be looking to do, asks Philip Youdan, Partner at Cripps.

THE HEALTH AND SAFETY EXECUTIVE from management time, legal costs and request details of the questions to be put. (HSE) has reported that over 5,000 injuries penalties. Many offences can result in fines of This helps gain an understanding of the are registered with them from within the food up to £20,000 in the Magistrates Court and enforcement authority’s thinking and also and drink manufacturing industry each year. substantially in excess of this in the Crown gives the company the chance to ensure the That’s equivalent to roughly a quarter of all Court. Costs incurred will also include the right people attend. reported manufacturing injuries. HSE inspector’s time under their fee for The data from HSE shows that around intervention scheme. It’s important that Alternatives to attending 16% of these injuries are classed as major; businesses have an action plan for Declining an interview is not an offence, mainly caused by slips, falls from height or responding to interview requests and some of although inferences could be drawn in certain machinery and resulting in, for example, the key issues are highlighted here. circumstances. A company may provide a broken bones or hospitalisation. The balance, written response, as often health and safety most frequently caused by lifting and Initial steps incidents involve complicated technical The first step is obtaining legal advice once issues, and these can be difficult to address in they’ve received a request to attend an an interview setting. The person attending interview. There are a number of factors to may find it difficult to provide clear consider before deciding whether to attend explanations or may end up providing details the interview, and it’s quite reasonable to that could harm the company’s position. A notify the enforcement authority that, having written response gives the company the received the request, legal advice will be opportunity to explain its actions clearly sought before responding. without inadvertently incriminating itself; while In what capacity are you attending? also being viewed as assisting the HSE with When considering the request, ascertain their investigation. Sometimes this approach whether the director or manager attending an can be followed by an interview based on the interview is being asked to do so in his or her written answers. personal capacity or as a company representative. If attendance is being And finally requested in the person’s personal capacity, it In general, companies should adopt a isn’t generally sensible for the company cooperative stance in their communications handling, slips and trips, being struck by solicitor to represent them as their personal with any enforcement authority; however they objects, such as hand-knives or falling interests might differ from the company’s, should do so in a manner that protects their objects are described as over-3-day absence creating a conflict. own interests. The aim is to reduce the injuries. After an incident, the HSE will often prospect of enforcement action being taken need to investigate and may wish to interview Advance disclosure while being able to say to the Court that they the company’s directors and senior When properly considering a request to have cooperated, should prosecution follow. management. attend an interview, the advisor will want, as Being properly prepared for an interview is The way in which a company handles these far as possible, to receive advance disclosure only part of a full emergency plan. Other matters requests can have a major impact on the of the nature of the allegations being made to be considered include notifying insurers, approach taken by the HSE and whether a and the evidence obtained. If the interview is investigating the incident internally and dealing prosecution is pursued. There can be at a very early stage and there is no real with any press interest. The key is to have a significant consequences of a prosecution, disclosure to be made, it is often helpful to clear strategy for any possible outcome.

Feb 15 | Food Processing 24 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2424 229/01/20159/01/2015 12:5512:55 YOUR CUSTOMERS PREFER OIL-FREE

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2525 229/01/20159/01/2015 16:2716:27 PROCESS INSIGHT ENERGY MANAGEMENT Producing more for less? Energy management is a cost-effective strategy to save money and to act more responsibly as a business in the tough world of food processing. But are there ways to manage energy usage that perhaps food companies aren’t aware of?

THE FOOD AND DRINK INDUSTRY is the that there is much more potential for and lower production costs can translate to single largest manufacturing sector in the UK, savings,” says David Hilton, Managing improved profit margins. “In economic hard as well as being the fourth highest industrial Director of Vickers Energy Group, an energy times, those savings can be passed onto energy user. With energy consumption on management systems company. “It’s time for customers who increasingly demand more such a large scale, tackling the issue of businesses to develop an action plan that value,” says Badham. “This builds brand energy management can be daunting for addresses the changes that need to be loyalty for the long-term.” business owners and managers. Added to made.” this are the specific issues faced by the food More efficient energy management Government initiatives and drink industry, including volatile programmes are a key weapon for food and The Climate Change Act of 2007 introduced commodity prices, regulatory constraints for drink processors, but few are deploying them a number of initiatives targeted at businesses food safety, customer interest in to their full potential. “Electricity and gas are to help them reduce the UK’s carbon and sustainability, retailers and suppliers commodities that, like other commodities, greenhouse emissions by 80% by 2050. squeezing tighter margins and retailers come with a fluctuating price tag,” says “There’s pressure on business to act on their pushing to dictate product prices, as well as Richard Badham, Marketing Manager, corporate social responsibility from the consumers who want higher quality for less Schneider Electric. “Coping with this volatility government and from the increasing spend. is tenuous, as represented by a snapshot of demands of environmentally conscious “The pressure for improved efficiency the recent International Union of Food, consumers to understand where their continues to increase,” explains Andrew Agricultural, Hotel, Restaurant, Catering, produce comes from,” says Hilton. “It’s vital Todd, Head of Energy and Resource Tobacco and Allied Workers’ Association that companies are made aware of the Management at Verco, the sustainability and report. The report predicts grain prices will simple measures that can be taken to climate change consultancy. “The reasons rise by 40% by 2020, milk prices by 50% and address the issues and how they can are multifaceted; customers demanding more sunflower oil prices by 56%. While there is transform the efficiency of the business. It’s sustainable suppliers, businesses searching little that can be done about the price of never been more important for businesses to for controllable costs in the face of reduced energy, smart automation and monitoring of get on board by reducing energy usage, product margins and a need to mitigate plant manufacturing at each process phase particularly with the incentives and pressure against rapid energy price inflation. It would reduces the total amount of energy to consider corporate social responsibility.” be understandable to expect these aligned consumed, and that can make a big impact. The Global Industrial Energy Efficiency incentives, coupled with the fact that energy From process and machine control to Benchmarking report by the United Nations efficiency opportunities typically give a good electrical distribution, critical power and data has projected that by 2050, global industrial ROI, to make the case for energy efficiency centre control across multiple plant sites, energy use will increase by 50%. straightforward. However, following the energy management effectively lowers “Sustainable business practices that reduce recession and resulting competition for production costs which improves profit consumption of natural resources like energy capital, a short-term view persists in many margins.” are key efforts in environmental preservation,” organisations. In addition, a squeeze on With energy costs being one of the top explains Badham. “They are also important headcount over the past 10 years has left outgoings for businesses, Hilton believes it’s for food and drink processors because they many sites without dedicated energy key for companies to think outside the box directly tie to overall improved performance. management resources.” when it comes to new strategies to reduce Many in the industry are realising this fact, The Carbon Trust, independent experts any unnecessary waste within the processes. evidenced by a recent Deloitte study which working towards sustainability through “Negotiating energy costs with energy highlighted that 49% of food and drink CFOs carbon reduction, efficiency strategies and providers can be a simple and often effective see a significant link between sustainability commercialising low carbon technologies, way to start addressing the rising bills,” says performance and financial performance.” has identified energy management as one of Hilton. the three main areas to focus on to reduce Operational strategies that reduce energy Energy management strategies energy. “Effective energy management can usage mean that production is less “No two sites are the same,” says Hilton. reduce energy by 10 – 40%, which means dependent on moving commodity prices, “For this reason, companies need to look at

Feb 15 | Food Processing 26 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2626 229/01/20159/01/2015 12:5512:55 ENERGY MANAGEMENT PROCESS INSIGHT

their individual business and monitor specific money,” Hilton points out. “Some buildings Engage and empower the workforce needs. Starting the process of reducing use a single switch to control heating and “It’s important that staff have a energy consumption can be a daunting ventilation, which doesn’t allow variation comprehensive awareness and motivation for prospect. Many companies don’t know how across the different areas of the building. resource efficiency onsite,” says Cumberlege. to correctly analyse their energy consumption However, maintaining different areas “There are significant savings to be had or understand their bills. They may also not manually can be labour intensive and result in through wider staff engagement. Staff need have the resources to implement an analysis high costs. An energy management system to understand the goals, and to embed it into of what needs to be actioned in order to allows companies to control a huge range of the site’s culture to drive home the reduce consumption and reduce budgets.” areas in different ways, with one system to importance of resource savings for the Tom Cumberlege, Senior Consultant at monitor and regulate heating throughout the company. The most important thing about The Carbon Trust agrees. “The best and building, using weather predictions and installing any energy management system is most robust way to focus on energy sensors to maintain the correct to ensure staff have the appropriate skills to management issues is to focus on temperatures.” engage with the system. The system itself measurement to get a good idea of where The justification for heat integration can be used for reporting and validating on key energy hotspots are in the business. We projects is likely to be sensitive to process energy usage as well as to seek out more advise businesses to get an understanding of parameters and utility costs. opportunities for the site. Having the where energy is being consumed and appropriate skills to measure and monitor developing that understanding of what Creative solutions and target energy efficiency in factories is an processes across the site give rise to that As Todd points out, there is no silver bullet essential component of energy management energy consumption. It’s often an area that when it comes to successfully implementing that needs to be addressed.” gets overlooked and energy gets categorised an effective energy management system. Companies can go even further by as an operational cost that can’t be “There is a need to turn data into useful nominating departmental energy champions addressed, when in reality it’s an opportunity information, and then provide the correct to share responsibility. “The use of for food and drink processors to deliver information to the right people in good time,” noticeboards, posters and electronic significant financial savings with a very says Todd. “Meaningful targets need to be set dashboards can work well but the messaging favourable payback from one to three years and processes put into place to identify and needs regular reinforcement,” says Todd. with low cost capital investment.” follow up on variances in performance. Whilst “Energy reduction competitions can be a there is no short cut to energy management, great way to engage with and motivate staff.” You cannot manage what you cannot there are a number of initiatives and measure approaches that have been consistently seen Demystifying black box processes As important as it is to invest in a metering to deliver resultsesults at ffoodood processprocessinging ssites.”ites.” TheThe goodgood news isis thatthat tthere’shere’s stillstill a hugehuge and monitoring system for energy usage, it’s just as important to get information and act Improve aaccountabilityccountability upon it. “Companies should focus on “Energy managementanagement is more than just improving the efficiencies of priority areas compressedd air leak managementmanagement and steam onsite,” says Cumberlege. “Understanding, trap maintenancenance andand shouldn’tshouldn’t bebe thethe solesole checking and improving routine maintenance responsibilityty ofof thethe sitesite servicesservices manager,”manager,” is key. Looking at chillers and refrigeration on says Todd. “The ‘user pays’ concept is one site, for example, to explore whether old way of ensuringuring appropriate ownership of pipes need to be replaced or repaired or energy usage.ge. InsteadInstead ofof itit beingbeing thethe installing insulation upgrades. Looking at responsibilityty ofof one person, suchsuch as thethe whether they have a steam system to provide engineeringg manamanager,ger, heat distribution, making sure that energy is each departmenttment head not being wasted and ensuring steam holds a budgetdget anandd iiss distribution is adequately insulated is key.” recharged fforor theitheirr Heat recovery is essential in the food and energy use.. This can drink industry. Rather than waste heat, it be an effectivetive way to should be used to heat something else. ensure that process When predicting energy usage, many leads look aatt energy businesses ignore the varying temperatures cost objectivelyively when across different seasons and use one energy consideringg process setting for the building across the whole year, alterations.”” resulting in excessive energy waste during A prerequisiteuisite to this the summer months. “With large spaces and approach arere wide areas that need different temperatures, it can meter coveragerage anandd a be hard to maintain all of these effectively reliable reportingorting without wasting unnecessary energy and system.

www.fponthenet.net 27 FFoodood ProcessinProcessingg | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2727 229/01/20159/01/2015 12:5512:55 PROCESS INSIGHT ENERGY MANAGEMENT

opportunity in process optimisation and Top tips management in food processing; can control improvement and capital requirement Vickers Energy Group has 10 top tips for products be stored at a higher is likely to be lower. “Data availability and food processors to save energy. temperature? resource are typically the biggest barriers,” 1. Develop an environmental strategy for 7. Heat recovery: recycle heat waste and Todd explains. “A good place to look for your corporate social responsibility use it again for a more effective process savings is black box processes. Typically 2. Identify where the problems lie within on site complex by nature and often not looked at as production and address them directly 8. Continue to monitor and review long- long as a process parameter is being hit, 3. A free audit can be a simple, cost- term these systems can be very difficult to monitor effective way to understand more about 9. Don’t be afraid to tackle issues head on on an ongoing basis and are commonly your energy usage 10. Train staff and implement strategies recipe dependent. A good example in the 4. Install a sophisticated energy across the whole business. food processing industry of a system which is management system to centralise “Energy management programmes can worth interrogating is a clean-in-place (CIP) controls for a low-maintenance and also have a positive impact in areas of system. The use of advanced analytical effective way to address consumption regulatory requirements and the ever- techniques applied to high frequency data 5. Analyse your energy bills and challenge increasing cost of labour,” says Badham. over multiple cleans will almost always lead to any errors or complexities “The benefits are only as limited as a identified improvement opportunities.” 6. Refrigeration is key to energy company’s creativity in implementing them.”

IChemE calls for global action on water usage in food production

The Institution of Chemical Engineers (IChemE) to provide the water, food, medicines and energy “There are solutions, but these will require is pushing for coordinated action to reduce the to sustain our ever –growing population,” says political will, major investment and lifestyle amount of hidden water used in food and drink Andy Furlong, IChemE’s Director of Policy. “In changes,” Furlong continues. “Chemical production. Around 90% of all freshwater is used recent years and decades, we have seen how engineers are recommending that a global target by agriculture (70%) and industry (20%), leaving diffi cult it has been to agree and set targets to is set to reduce the amount of water used in food just 10% for domestic use. On average, each manage issues like climate change. Population production worldwide by 20%. In addition, a person consumes between 2,000 – 5,000 litres growth will throw up similar challenges and it combination of regulations and incentives should of water embedded in their food every day, or will have a direct impact on two of the building be introduced to require industry to monitor between 730,000 – 1.825 million litres annually. blocks for life; food and water. Estimates suggest their water usage, as well as rewarding them for And this is set to increase as the population that we will need to produce 60% more food using alternative and sustainable water supplies. grows and more people move towards a by 2050. Agriculture will need around 19% Revised planning frameworks and investment will Western-style diet, with water extraction more water to produce that extra food. It is be needed for the construction of new capacity, estimated to grow by clear that current production methods are infrastructure and appropriate technologies to over 50% to 6.9 billion unsustainable and there are genuine risks improve effi ciency of water management in food m3 annually. And while of food shortages, rising food prices, and drink production.” seven per cent of the droughts and social unrest for future “Education also has a role to ensure that world’s population live in generations unless we make more consumers understand better how their food water scare areas, by 2050 effi cient use of water. is produced to enable them to make informed this will escalate to two thirds choices,” Furlong concludes. “None of this will be of the world’s population. cheap or easy, but like the mitigation of climate “Chemical engineers provide change, it will be necessary to guarantee our many of the high level skills needed quality of life.”

Feb 15 | Food Processing 28 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2828 229/01/20159/01/2015 12:5512:55 SKILLS SPOTLIGHT One-stop solution to industry skills crisis? The impending and potentially devastating skills shortage that faces the food and drink industry will come as no great surprise to those in the sector. FoodStart, a new one-stop website hopes to offer UK-wide work experience options to those considering a career in the food industry.

ACCORDING TO A RECENT SURVEY from people. Students can search and apply for recruitment consultancy JAM, almost half of work experience through the FoodStart site the 750 respondents, who work in the food and therefore see for themselves the exciting and drink industry, said their company was career opportunities that the sector provides. struggling to find candidates with high-level The online platform will also enable students skills. Shift managers and product to record evidence from placements which development specialists were highlighted as they can use to demonstrate their interest in particularly scarce. And when asked what the sector for inclusion in their CVs – they thought the greatest risk to the UK food something that we hope will soon become and drink sector is over the next 10 years, the gold standard in recruitment.” 45% said the lack of young people emerging The service is free for both students and from the education system with the employers to use, and is funded by necessary skills for work in the industry. And sponsorship from a variety of food sector yet when they were questioned about businesses. Current sponsors include Adelie, adds Poole. “Anyone wishing to make a attracting new talent, 64% said they believed Barfoots, Food & Drink & Training Education donation will not only make a measurable that industry itself wasn’t doing enough to Council, Leatherhead Food Research, difference to young food enthusiasts, but will raise awareness of career opportunities. Campden BRI, More People, Cornelius, also be investing in their own future. All Raynors Sandwiches, DNV-GL, R Biopharm, FoodStart donations are recognised on the FoodStart Food Additives & Ingredients Association and FoodStart website.” According to the Institute of Food Science & Waitrose. Technology (IFST), who conducted their own “Sponsorship opportunities are ongoing,” Visit the website at www.foodstart.org.uk. research, food studies students are frustrated at the perceived lack of work experience opportunities. They also believe that a lack of understanding of career options is a barrier to Why we’re supporting FoodStart joining the food sector. Conversely, according Cornelius are an excellent way of introducing young to an IFST survey, 72% of employers “Cornelius supports FoodStart as part of people to the complex and fascinating identified work experience as a positive way our CSR charter and we are committed to processes in the food industry and R-Biopharm of accessing new talent, highlighting that contribute to the food industry in developing is very pleased to be able to give the FoodStart there is a clear disparity in the industry. healthy and nutritional balanced products,” says programme its full support.” IFST decided to join the growing number of Per Rehne, European Health & Food Business organisations attempting to tackle this Manager at Cornelius. “We also believe that Jamie Oliver, TV Chef problem by launching FoodStart. Designed to as a company we should take responsibility “We need people with all kinds of backgrounds bring together UK-wide work experience at for the education and development of the and skills working in food, and whether you’re next generation that will shape our industry. a genius or a hard grafter, I know fi rst hand that all levels, from school-based programmes to Cornelius also works with a number of this industry has never been more dynamic,” graduate placements and internships, universities to help students working on industry says Oliver. “This generation and the next will employers will be able to showcase their relevant projects and supports SMEs with make the biggest impact on the food industry opportunities and attract new talent. product development and innovation.” we’ve ever seen. “Food and drink manufacturing needs to “Right now, in the UK and around the world, have a single point of focus if it is to attract R-Biopharm this business is at the heart of some really students who are also looking at roles in “The food industry provides worthwhile and exciting innovations, and as so much of the automotive, aerospace and fulfi lling careers for millions of people in the industry is focused on doing the right thing telecommunications,” says IFST Chief UK and it is of the utmost importance that for farmers’, land, the planet and, of course, Executive Jon Poole. “FoodStart provides a we continue to attract youngsters who are consumers – it really is a wonderful time to single point to ensure that the food sector keen and willing to learn,” says Simon Bevis, be starting out. I can’t recommend FoodStart Managing Director at R-Biopharm. “Placements enough – it’s a brilliant idea.” has an increased visibility among young

www.fponthenet.net 29 Food Processing | Feb 15

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 2929 229/01/20159/01/2015 12:5512:55 Food Focus > ULMA’S NEW TFS THERMOFORMERS > ADM CELEBRATES FIVE YEARS OF COMMITMENT ULMA’S product manager, TO GHANA’S COCOA INDUSTRY AND LOCAL Alastair Cook, said: “The less COMMUNITIES downtime for cleaning means Cocoa and chocolate expert, more profi t for the customer. ADM Cocoa, is marking fi ve The TFS Thermoforming years of dedicated cocoa machines have been processing in the Ashanti designed so they are easily Region, with a continuation cleaned. Attention has been of the successful partnership given to the type of material with key stakeholders, such used in the construction, as the Ghana Cocoa Board, such as replacing some anodised aluminium components with stainless and a string of important local steel.” initiatives. Since opening the Developing packaging solutions worldwide, ULMA supplies world class cocoa processing thermoforming solutions to suit customers’ requirements. One of the facility in Kumasi in 2009, ADM has created over 250 jobs at its 75,000 country’s leading suppliers of packaging machinery and complete square metre purpose built site, which houses a bean warehouse, automated lines, ULMA’S thermoformers range from the TFS 200 to processing plant and fi nished goods’ warehouse. ADM has also TFS 700 skin, with the TFS 500 and TFS 600 as intermediate models. nurtured a local supplier network of more than 200 suppliers. A Packaging solutions offered by ULMA include vacuum bags to extend founding member of the World Cocoa Foundation, ADM has pioneered shelf life and packs with modifi ed atmosphere. numerous areas of social improvement across the region. ULMA PACKAGING LTD ADM INTERNATIONAL SÀRL 44 (0) 1909 506 504 www.ulmapackaging.co.uk [email protected]

> CARGILL REVEALS HOW 2015’S TOP FOOD > J & E HALL DIGITAL CONDENSING UNITS TRENDS TRANSLATE INTO COCOA AND INSTALLED AT FARM SHOP CHOCOLATE APPLICATIONS Three J & E Hall Series 5 From Clean to Clear Label’, ‘Good Fats, Good Digital Twin Scroll Commercial Carbs’ and ‘More in Store for Protein’ are just Condensing Units have been three food trends examined in the latest ‘T for installed in an extension to the Trends’ webinar presented by Cargill’s cocoa farm shop at the Woodlands and chocolate business. Nursery and Garden Centre in Leicestershire. With a capacity The webinar was co-presented by Cargill’s of up to 31kW, the new Series Brigitte Bayart, Senior Marketing Manager, 5 digital units are ideal for Chocolate, and Lu Ann Williams, Head of retail premises and are a Research at Innova Market Insights. proven packaged alternative “Through our unique T-model approach we to multi-compressor racks. combine broad food knowledge with deep The installer was the Jordon Group of Oldham. cocoa and chocolate expertise and apply Six cold stores, a dry storage area, an administrative area and staff the latest trends to the development of our ingredients. This in turn room form part of the extension. Fruit, vegetables, meat, and fi sh are provides our customers with the knowledge and ingredients they need stored ready for use in the farm shop and temperatures for the cold to create products to meet their consumers’ demands – and stand out stores range from -2°C to +4°C. A freezer room has to maintain a from the crowd”, said Bayart. temperature of -21°C. CARGILL J & E HALL LIMITED www.cargillcocoachocolate.com/innovations/driven-by-trends/index.html 01332 253400 www.jehall.com

> COLOUR CHANGE SYSTEM FOR CEREALS AND > FOOD SAFETY AND ALLERGENS SNACKS Allergen quantifi cation can be An innovative colour-change challenging. LGC, together with system for packs of assorted Manchester University, has extruded cereals and snacks developed a quality control material has been developed by Baker for detecting peanut allergen in Perkins. The ‘Spectrum’ food, with a blank material and technique extends Baker matrix material with peanut protein Perkins’ extrusion capability added at 10 ppm (mg kg-1). and cuts production costs. It These QC materials, the fi rst to be enables changeover between prepared like oral food challenge colour variations of an materials for diagnosing peanut extruded product to be made ‘on the run’ with minimal waste. allergies, have proven homogeneity and stability. Gill Holcombe, Head A typical application in a single pack in the cereals sector is mixed of Reference Materials Production at LGC said, “Reference materials fruit colours; in the snacks arena, matching the colour of vegetable- are key to improving reliability of allergen analysis results. Our emphasis fl avoured snacks such as carrot, beetroot, tomato, broccoli or peas. is on ‘Science for a safer world’; our new quality controls represent real progress in ensuring safer food for those with peanut allergy”. This skid-based system spells an end to the inconvenience and cost of cumbersome mixing and storage of different coloured snacks or LGC supplies reference materials to support measurement accuracy cereals, with its adverse impact on waste, hygiene and shelf life. and quality control in laboratories worldwide. BAKER PERKINS LGC 01733 283000 www.bakerperkins.com www.lgcstandards.com

Feb 15 | Food Processing 30 www.fponthenet.net

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 3030 330/01/20150/01/2015 16:2916:29 Food Focus > FOOD POISONING HAZARDS FROM CHICKEN > VEOLIA SERVES UP BIOGAS AT CANNINGTON DETECTED IN MINUTES COLD STORES The Food Standards Agency has Veolia has installed a 2MW highlighted the risk of Campylobacter biogas CHP, which adds to food poisoning from raw chicken four existing 324kW CHPs and made several recommendations successfully installed at for reducing the hazards associated Cannington Cold Stores’ with cross contamination. To 45,000 tonne Bridgwater site in help eradicate this risk, Hygiena Somerset. The biogas solution International have introduced the from Veolia, which is fuelled by CrossCheck rapid test system waste food, goes a signifi cant which can be used by anyone and way to helping the chilled food anywhere, with results provided in storage company improve its minutes. Detecting pathogens such as Campylobacter is a diffi cult, environmental impact and to achieve energy saving targets. The new skilled and expensive process giving results after several days. The 2MW biogas CHP at Cannington Cold Stores, supplied by Cogenco new CrossCheck simple rapid test specifi cally measures the presence Veolia’s package CHP team, will increase the generation of electricity of raw meat and fi sh residues giving results in 2 - 5 minutes. If raw by burning biogas. This is derived from waste food processed through meat residues are detected, there is a potential risk of food poisoning. an anaerobic digester. Surplus electricity is exported to the grid under CrossCheck is an integrated, self-contained test device that includes a Cannington Cold Stores’ Feed In Tariff (FITs). The excess heat from the swab for sample collection. CHPs feeds the digesters to run the biogas generation process. HYGIENA INTERNATIONAL LTD VEOLIA 01923 818821 www.hygiena.net www.veolia.co.uk

> BRC GLOBAL STANDARD FOR FOOD SAFETY > RAVENWOOD LINERLESS GO RUGGED FOR ISSUE 7 PROMPTS GLASSGUARD® WARNING PRO2PAC AGAINST LIGHTING COMPLACENCY Linerless labelling specialist Ravenwood GlassGuard® is keen to remind food manufacturers Packaging will be showcasing its not to overlook lighting while focusing attention ‘complete package’ of labelling on the new BRC Global Standard for Food Safety technology at Pro2Pac 2015 including Issue 7.Whilst there are no changes to lighting linerless labelling and the development requirements, safer lighting specialist GlassGuard® of the ultimate materials and adhesives is reiterating its message to food manufacturers to that produce seamless production lines. consider their lighting requirements, alongside the The company supplies the Comac 500 criteria changes. coating machine and a wide range of Last year the BRC reported Building Fabric (Section Nobac applicators capable of applying 4.4) and Glass, Brittle Plastic, Ceramics and sleeves in all formats varying from Similar Materials Control (Section 4.9.3) as leading C-wrap and full wraps, to packs for the failures in a list of leading non-conformity groups, chilled foods and convenience markets. prompting GlassGuard® to warn manufacturers New products include Slideable labels against complacency when it comes to lighting management. made from thicker materials to view the GlassGuard® subsequently welcomed the Guide to Lighting Best product inside and skin pack labelling to Practice for the BRC Global Standard for Food Safety, published by the reduce tray numbers and can include exceptionally bulky items. BRC to assist food manufacturers. GLASSGUARD RAVENWOOD UK 01842 763 752 www.glassguard.co.uk 01284 749144

> THE NEW SERIES 5 YTRON-Z IN-LINE HOMOGENISER

The YTRON-Z in-line homogeniser supplied by Ytron-Quadro to our customers. (UK) Limited has proved to be a great asset to the Dairygold Food The YTRON-Z gave Ingredients plant in Leeds. Dairygold has commented: us another tool to eradicate these “We are driven by innovation. Innovative products continue to occurrences and delight our customers and win awards so we have a constant speed up our process flow of projects both product & process focused fed through the without damaging the Dairygold joint Irish & UK based Innovation and Engineering team. functionality of the The YTRON-Z unit was identified as a possible product improver starch. after its benefits in yoghurt production were demonstrated.” “ The results were We booked a YTRON-Z for long term trials in our Leeds factory so conclusive that 2 and conducted exhaustive trials across the DFI product range. The YTRON-Z units were outcome was extremely positive. Our already high product quality ordered and installed in visually improved. Product was smoother and a ‘glossy’ effect was the two production lines seen across all products. The lower fat variants gained body too for packing bulk and and has now delivered what we feel is a “best-in-class” product. smaller Foodservice Starch is used in some products and the presence of un-hydrated size packs. starch molecules in finished product is clearly not acceptable

YTRON-QUADRO (UK) LIMITED +44 (0)1494 792898 www.ytron-quadro.co.uk

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33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 3131 330/01/20150/01/2015 16:3016:30 Food Focus > MORE IDEAS FOR READY MEALS > ALLERGENS IN CUMIN CAUSE PRODUCT RECALLS A number of product recalls in America and Canada have been linked to adulterated ground cumin which contains the potentially life- threatening allergens ground peanut and almond powders. In the UK a warning has been issued that the adulterant ingredient would present a serious health risk to people sensitive or allergic to the nuts. It is believed the contaminated cumin is of Indian origin, routed through Turkey on its way to America and, possibly, European markets. Third generation UK fl avours house Unbar Rothon immediately checked with its supplier who confi rmed there was neither peanut nor almond in the cumin it supplied. The BRC accredited supplier has been used by Unbar Rothon for many years without any reported incidences of allergen cross contamination. UNBAR ROTHON Its hugely successful range of ingredients for ready Tel: 01277 632211 meals manufacturers has been enhanced by Snowbird foods with the launch of two more exciting and innovative fully cooked and frozen products. Certain > BRITISH-BASED PUMP MANUFACTURER to deliver the sweet taste of success are Pork & Apple ENJOYS INTERNATIONAL SUCCESS Meatbites which feature 60% top quality British pork fl avoured with iconic Bramley apple plus onion, garlic The pioneering spirit characterising specialist pump manufacturer paste, wheat fl our, black pepper, ginger, nutmeg, Flotronic Pumps Limited’s approach to innovation and design has marjoram, parsley and sage. Its golden coating been driving their success in developing new markets overseas. contrasts with the darker hue of its new sister product, Flotronic, the only British-owned specialist manufacturer of air- Pork and Chorizo Meatbites, which delivers gentle heat. operated double-diaphragm pumps in the UK, has seen exports as Both meatbites weigh 8g. and the pork and chorizo a percentage of total sales rise from 15% in 2003 to 40% in 2013. variant boasts a meat content of over 90% which is 25% of exports go to Europe - but pumps are being sold worldwide accompanied by a complex mix of a dozen fl avourings. including the US and Canada (5%) and the Far East (2%) - with Both products are suitable for use as pizza toppings, the remaining 8% distributed to the Middle East, India, South America, South Africa and in wraps, with cheese gratins, pasta bakes and riced Australasia. The company is seeing particularly high overseas growth in pump sales into its based dishes and can also be added to soups. target Pharmaceutical, Food & Beverage, Chemical manufacture and Cosmetics markets. SNOWBIRD FOODS LTD FLOTRONIC PUMPS LIMITED 020 8805 9222 www.snowbirdfoods.co.uk www.fl otronicpumps.co.uk Products and Services

33837837 - FPFP FFeb15eb15 Edn.inddEdn.indd 3232 330/01/20150/01/2015 16:3016:30 BuyersGuide

BELTING (CONVEYORS) CONVEYORS HEAT EXCHANGERS

Moody Heat Exchangers (part of Moody Direct Limited) offer an on-site plate heat exchanger integrity testing service. We operate the UK’s most modern plate heat exchanger service centre for cleaning, dye-penetrant testing, and regasketing plates for all known brands of plate packs. We also offer a plate heat exchanger design & supply service. T 0800 666 397 E [email protected] W moodydirect.co.uk

BOILERS FLAVOUR (LIQUID AND POWDERS) HERBS & SPICE PRODUCTS

Growers and importers of fresh herbs. Suppliers of fresh cut, processed • Efficient steam boilers LTD. & frozen herbs to the food manufacturing industry. to reduce boiler FRESH PREPARED HERBS energy costs FROZEN HERBS • FRESH & FROZEN HEAT TREATED HERBS • PASTES & OILS ORGANIC ALSO AVAILABLE • Fully packaged FRUIT AND VEGETABLE JUICE boiler houses CONCENTRATES (LIQUID & POWDER) Tel : 01386 750734 Fax : 01386 750787 Email: [email protected] • Heat recovery www.reddeerherbs.co.uk boiler design LABELLING • Buy, Lease or Hire Tel: 01535 665225 www.byworth.co.uk

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NATURAL COLOURS SIEVES AND SEPARATORS

BOILERS

BYWORTH BOILERS www.byworth.co.uk KINGS BOILER HIRE www.kingsboilerhire.com

BOILERS/TANKS/CHIMNEYS PIPEWORK KINGS BOILER HIRE www.kingsboilerhire.com

COOKED VEGETABLES & PASTA

BEACON FOODS LTD www.beaconfoods.co.uk

COOKERS AND SMOKERS

NESS UK LTD www.ness.de

DRIVES TRAINING ABB DRIVES AND MOTORS www.abb.co.uk/energy Technical Training Solutions REFRIGERATED STORAGE The Industry Preferred Training Provider Operator Training Instrimentation Fluid Power FLOORING PLCs Electrical Motor drives Pneumatics Mechanical Working at height CONREN LTD www.conren.co.uk CUT YOUR BILLS Providing Practical Engineering 6,000 KG OF Skills Training For The Food Industry CARBON. IT’S AN MACHINE KNIVES CAMB MACHINE KNIVES OPEN AND SHUT CASE. www.camb-knives.co.uk T: 01634 731470 technicaltrainingsolutions.co.uk SMI's unique patented thermal insulation material, Tempro®, MOTORS is independently tested and Postgraduate Certificate,

proven to be the thinnest and Diploma or Master of Laws ABB DRIVES AND MOTORS most thermal efficient of its (LLM) in www.abb.co.uk kind in the world. That's why SMI's Cold-Stop® PROCESS HEAT curtains save customers millions of pounds on their energy costs Food Law WELWYN TOOL GROUP and slash their carbon emissions Course starts in September www.welwyntoolgroup.co.uk by more than 30% every year. www.informadl.com/FoodFPA If you'd like to cut your bills and your carbon Call: +44 (0) 20 3377 3622 REFRIGERATED STORAGE footprint, or to find out Email: [email protected] more about our range of SEYMOUR MANUFACTURING products, contact us on VIP Code: FKW12293FPA www.seymour-mi.com 01952 730630 or [email protected] • seymour-mi.com WEIGHING STORAGE TANKS & VESSELS/CHIMNEYS THE KING GROUP www.thekinggroup.co.uk

WASHING SYSTEMS ADVERTISE YOUR JEROS UK LTD LeadingLeading thethe wayway in loadload cellcell www.jeros.co.uk PRODUCTS AND andand processprocess weighing technologytechnology includingincluding: : WEIGHING SERVICES HERE • platform• platform scales scales • recipe• recipe systems systems APPLIED WEIGHING Contact Pennie Wood • dynamic• dynamic checkweighing checkweighing systems systems www.appliedweighing.co.uk Telephone:Telephone: 0118 0118 9469461900 1900 on 01732 359990 [email protected] www.sitefi ndonthenet.net www.appliedweighing.co.ukwww.appliedweighing.co.uk

Feb 15 | Food Processing 34 www.fponthenet.net

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